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Woodward 721 Operation And Calibration Manual Download Page 11

Manual 26004 

 

721DSC for Marine Propulsion Application 

Woodward

  

7

 

 

 

 

CAUTION

 

To prevent damage to the control, make sure that the alternator or other 
battery-charging device is turned off or disconnected before 

disconnecting the battery from the control.

 

 

 

 

 

CAUTION

 

To prevent damage to the engine, apply power to the 721 control at least 

15 seconds prior to starting the engine. The control must have time to 
complete its power up diagnostics and become operational. Do not start 
the engine unless the green POWER AND CPU OK indicator on the 721 
control cover comes on, because test failure turns off the output of the 
control.

 

 

 

Summary of Contents for 721

Page 1: ...A COM REM JPR FOR 5 VDC REM JPR FOR 5 VDC REM JPR FOR 5 VDC SIGNAL INPUT 2 SIGNAL INPUT 3 SIGNAL INPUT 4 18 40VDC 18W SUPPLY INPUT C NO RELAY OUTPUT 1 C NO RELAY OUTPUT 1 C NO RELAY OUTPUT 1 ANALOG OUTPUT 1 ANALOG OUTPUT 2 ANALOG OUTPUT 3 ACTUATOR OUTPUT SPEED SENSOR INPUT 1 SPEED SENSOR INPUT 2 LOAD SHARING LINES POWER AND CPU OK ALARM 1 ALARM 2 CONTACT POWER RATING 2 0 AMP RESISTIVE 28VDC 0 1 AM...

Page 2: ... such unauthorized modifications i constitute misuse and or negligence within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage and ii invalidate product certifications or listings CAUTION POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY CAUTION BATTERY CHARGING To prevent damage to a control system that uses an alternator or battery charging device make sure...

Page 3: ...rmation Introduction 1 Application 1 721ControlAccessories 1 Chapter2 ElectrostaticDischargeAwareness Summary 3 GeneralInformation 3 Chapter3 Installation Scope 5 Unpacking 5 Locationconsideration 5 ElectricalConnection 6 PowerRequirement 6 Chapter4 DescriptionofOperation General 9 ControlDynamics 9 SpeedReference 10 LoadTransfer 10 FuelLimit 11 MonitoringControl 11 Chapter5 EnteringControlSetPoin...

Page 4: ...arms 29 Chapter7 MajorAlarmandMinorAlarm MajorAlarm 35 MinorAlarm 35 721DSCSpecification insidebackcover ILLUSTRATIONSAND TABLES Fig1 HandHeldProgrammerFunctions 16 Fig2 TypicalTransientResponseCurve 31 Fig3 ControlGainasaFunctionofSpeedError 32 Fig4 ControlGainasaFunctionofControlOutput 32 Fig5 SpeedFilter 33 Fig6 T orqueFuelLimitCurve 33 SetPointRecordSheets 37 FunctionBlockDiagram AppendixP1 Co...

Page 5: ...hangeable pitch propeller control This control has two sets of control dynamics which the operator can switch to get most suitable engine operation either when only the propeller shaft is driven or when both the propeller shaft and the generator are driven Normally generators are operated in isolation However this control has a load transfer mode to enable parallel operation in order to transfer t...

Page 6: ...721DSC for Marine PropulsionApplication Manual 26004 Woodward 2 ...

Page 7: ...erials as much as possible because these do not store static electric charges as much as synthetics 3 Keep plastic vinyl and styrofoam materials such as plastic or styrofoam cups cup holders cigarette packages cellophane wrappers vinyl books or folders plastic bottles and plastic ash trays away from the control the modules and the work area as much as possible 4 Do not remove the printed circuit b...

Page 8: ...721DSC for Marine PropulsionApplication Manual 26004 Woodward 4 ...

Page 9: ...of damage such as bent panels scratches and loose or broken parts If any damage is found immediately notify the shipper Location Considerations Consider these requirements when selecting the mounting location adequate ventilation for cooling space for servicing and repair protection from direct exposure to water or to a condensation prone environment protection from high voltage or high current de...

Page 10: ...pplication note 50532 Interference Control in Electronic Governing Systems for more information Power Requirement The 721 control requires the following power supply input voltages with 18 watts as the nominal power consumption at rated voltage 18 40 Vdc 24 Vdc or 32 Vdc nominal Discrete input voltages provide on off command signals like RUN STOP or IDLE START to the electronic control Each discre...

Page 11: ...isconnecting the battery from the control CAUTION To prevent damage to the engine apply power to the 721 control at least 15 seconds prior to starting the engine The control must have time to complete its power up diagnostics and become operational Do not start the engine unless the green POWER AND CPU OK indicator on the 721 control cover comes on because test failure turns off the output of the ...

Page 12: ...721DSC for Marine PropulsionApplication Manual 26004 Woodward 8 ...

Page 13: ...outputs provide a major alarm a minor alarm and the load transferring indication Control Dynamics The control algorithms used in the 721 control are designed specifically for reciprocating engine applications To provide better transient performance the control can be operated automatically with two gain settings depending on engine speed error speed error is the difference between the speed settin...

Page 14: ...ED SPEED set point and stay there But the Raise Speed contact and Lower Speed contact are enable while the engine is synchronizing for parallel operation or performing Load Transfer The Speed Reference returns to RATED SPEED automatically after Load Transfer finished Load Transfer This engine control system does not provide parallel operation in isochronous mode but it can make two engine generato...

Page 15: ...Limit is the maximum percent actuator output during normal engine operation This limit should normally be set just above the output at full load Monitoring Control 721DSC s analog input signals analog output signals and present discrete inputs status can be monitored using the hand held programmer Three 4 20mA outputs are provided for monitoring Engine rpm Speed Reference and Rack Position Actuato...

Page 16: ...721DSC for Marine PropulsionApplication Manual 26004 Woodward 12 ...

Page 17: ...on the control terminal J1 To connect the terminal slightly loosen the right hand screw in the cover over J1 and rotate the cover clockwise to expose the 9 pin connector Then firmly seat the connector on the terminal into J1 The programmer does a power up self test whenever it is plugged into the control When the self test is complete the screen will display two lines of information This is inform...

Page 18: ...ss the ENTER key and this will allow you into the Configure menus NOTE If the engine is running during this process it will be shut down due to shutting down the I O of the control To move between the menus use the W and X keys To move through the set points within a menu use the S and T keys Once within a menu to return to the menu header press the ESC key To exit the Configure menus press the ES...

Page 19: ...eys This is useful during initial set up where a value may need to be changed significantly Where necessary to select TRUE use either the Turtle Up or the Rabbit Up keys and to select FALSE use the Turtle Down or Rabbit Down keys To obtain an exact value press the key Key in the required figure and press ENTER NOTE This may be done only if the figure is within 10 of the existing value To save set ...

Page 20: ...rtle down Decreases the displayed set point value slowly rabbit up Increases the displayed set point value quickly about 10 times faster than the turtle keys rabbit down Decreases the displayed set point value quickly about 10 times faster than the turtle keys minus Increases set point values by one step at a time plus Decreases set point values by one step at a time solid square Not used ID Displ...

Page 21: ...Manual 26004 721DSC for Marine PropulsionApplication Woodward 17 Figure 1 Hand Held Programmer Functions ...

Page 22: ...S Display 1 1 Engine Speed rpm 2 Speed Reference rpm 3 Generator Load KW 4 Actuator Output 5 Fuel Limit Output Dynamics 1 1 Idle Prop Gain1 0 001 50 0 1 0 2 Rated Prop Gain1 0 001 50 0 1 0 3 Integrator Rate1 0 1 50 0 2 0 sec 4 Derivative Ratio1 1 0 100 0 5 0 5 Window Width1 1 0 50 0 10 0 rpm 6 Gain Ratio1 0 1 10 0 1 0 7 Gain Break Point 10 0 100 0 30 0 8 Gain Slope 0 1 10 0 1 0 9 Speed Filter 20 0...

Page 23: ...at 20mA 200 1000 540 rpm 11 Tach at 4mAOutput 0 0 1000 0 0 rpm 12 Tach at 20mAOutput 0 0 1000 600 rpm 13 Speed Set at 4mAOutput 0 0 1000 0 0 rpm 14 Speed Set at 20mAOutput 0 0 1000 600 rpm KW Setting 1 Rated KW 100 10000 1280 KW 2 20mAKW Load Input 100 10000 1500 KW 3 KW Droop Set 0 0 10 0 5 0 Fuel Limit 1 Start Fuel Limit 10 0 100 0 10 0 2 Torque Lmt P1 rpm 200 800 300 rpm 3 Torque Lmt P1 10 0 10...

Page 24: ...tact H Status 13 MajorAlarm Ry Status 14 MinorAlarm Ry Status 15 Transfer Mode Ry Status 16 1 LED Status 17 2 LED Status Alarms 1 MinorAlarm 2 MajorAlarm 3 No1 MPU Failure 4 No2 MPU Failure 5 KW Signal Fail 6 Spd Set Signal Fail 7 Fault Reset FALSE TRUE FALSE CAUTION To prevent possible damage to the engine resulting from improper control settings make sure you save the set points before removing ...

Page 25: ...back up governor for example Woodward EGB or PGA EG is required for reverse acting applications 2 No 1 Gear Teeth Set this to the number of teeth or holes on the speed sensing gear for speed sensor 1 If the speed sensing gear is not rotating at the same speed as the crankshaft this is the number of gear teeth that will pass the speed sensor in one complete engine revolution 3 No 1 Max Hz This is t...

Page 26: ...cy at Raise Limit Otherwise the 721 control may not control the engine 7 Normal Opn Minr Alm Ry This set point determines the operating mode of Minor Alarm relay Set the set point to TRUE if this relay is used as normally open Set the set point to FALSE if this relay is normally closed If it was set to TRUE the relay will be closed when a minor alarm happens 8 Normal Opn Mjr Alm Ry This set point ...

Page 27: ... output limited by the current fuel limit is shown Dynamics 1 Tune the control dynamics for stable engine operation and most suitable transient performance This 721 control has two sets of dynamics The dynamics used in the 721 control are selected with an external contact input See figure 2 for tuning Prop Gain traditional Gain in Woodward controls and Integrator Rate traditional Reset in Woodward...

Page 28: ...en loads are changing This allows a lower gain at steady state for better stability and reduced steady state actuator linkage movement 7 Gain Breakpoint 1 Gain Breakpoint sets the percent output above which the Gain Slope becomes effective It should usually be set just above the minimum load output See figure 4 The Gain Breakpoint adjustment is common to both sets of dynamics 8 Gain Slope 1 Gain S...

Page 29: ...s set point to 5 for ordinary applications 5 Window Width 2 Window Width is the magnitude in rpm of a speed error at which the control automatically switches to fast response The control does not use the absolute value of speed error but anticipated speed error to make this switch This method provides for quick switching to the high gain value when an offspeed occurs and early switching to the low...

Page 30: ... Transfer Rate is the speed raise lower rate which is used for generator load transfer or for generator synchronization This speed change rate is selected automatically when the engine is operated in the KW droop mode Normally the speed change rate of Load Transfer Rate is less than that of Raise Lower Rate 7 Spd Set at 4mA Spd Set at 4mA is the speed reference when the remote speed setting input ...

Page 31: ...s from no load to full load The actual droop is dependent on linkage adjustment and stroke For example 5 droop gives a real droop of 2 5 if the control output changes 50 from no load to full load Fuel Limit Fuel Limiters limit the actuator output current from the control 1 Start Fuel Limit Start Fuel Limit sets the maximum actuator output current for starting the engine Set this set point to the f...

Page 32: ...Speed Signal 1 displays the speed signal input to speed signal input channel 1 2 Speed Signal 2 Speed Signal 2 displays the speed signal input to speed signal input channel 2 3 KW Signal Input KW Signal Input displays the input signal from the KW transducer in percent 4 Spd Set Input mA Spd Set Input mA displays the external remote speed setting input signal in mA 5 Contact A Status Contact A Stat...

Page 33: ...t open or closed 15 Transfer Mode Ry Status Transfer Mode Ry Status indicates if the engine is transferring load or not open or closed 16 1 LED Status 1 LED Status displays the status of 1 LED on or off 17 2 LED Status 2 LED Status displays the status of 2 LED on or off Alarms These are menus to monitor fault status 1 Minor Alarm Minor Alarm displays TRUE if the control has detected any minor alar...

Page 34: ... have completed the adjustments save the set points by pressing the SAVE key Disconnect the Hand Held Programmer from the control Close the cover over J1 and retighten the retaining screw CAUTION To prevent possible damage to the engine resulting from improper control settings make sure you save the set points before removing power from the control Failure to save the set points before removing po...

Page 35: ...Manual 26004 721DSC for Marine PropulsionApplication Woodward 31 Figure 2 Typical Transient Response Curve ...

Page 36: ...NxGAINRATIO WINDOWWIDTH WINDOWWIDTH GAIN LOWGAINREGION 0 0 SPEEDERROR RPM Figure 3 Control Gain as a Function of Speed Error CONTROLGAIN GAINSLOPE GAIN ADJUSTMENT GAINSLOPE ADJUSTMENT GAIN GAINBREAKPOINT ADJUSTMENT GAINBREAKPOINT 50 100 CONTROLOUTPUTCURRENT Figure 4 Control Gain as a Function of Control Output ...

Page 37: ...40 0 Filter Cutoff 20 Hz Figure 5 Speed Filter Actuator output Torque Lmt P4 100 Torque Lmt P4 rpm Max Lmt Torque Lmt P3 75 Torque Lmt P3 rpm Torque Lmt P2 50 Torque Lmt P2 rpm Torque Lmt P1 Torque Lmt P1 rpm 300 400 460 520 Engine Speed RPM Figure 6 Torque Fuel Limit Curve ...

Page 38: ...721DSC for Marine PropulsionApplication Manual 26004 Woodward 34 ...

Page 39: ... cause a major alarm is Both speed sensors failed CAUTION The 721 control will not activate a major alarm even on an actuator internal open circuit However an actuator internal open circuit will cause engine shutdown consequently both speed sensors will fail for engine stalls This will then cause the 721 control to activate a major alarm Minor Alarm If the 721 control detects a minor alarm it will...

Page 40: ...721DSC for Marine PropulsionApplication Manual 26004 Woodward 36 ...

Page 41: ...____ 7 Normal Opn MinrAlm Ry FALSE TRUE FALSE _________ 8 Normal Opn MjrAlm Ry FALSE TRUE FALSE _________ S S1 Display 1 1 Engine Speed _________ 2 Speed Reference _________ 3 Generator Load _________ 4 Actuator Output _________ 5 Fuel Limit Output _________ S S2 Dynamics 1 1 Idle Prop Gain1 1 0 0 001 50 0 _________ 2 Rated Prop Gain1 1 0 0 001 50 0 _________ 3 Integrator Rate1 2 0 0 1 50 0 ______...

Page 42: ... _________ 4 Raise Limit 572 0 300 0 1000 0 _________ 5 Raise Lower Rate 1 0 0 1 100 0 _________ 6 Load Transfer Rate 1 0 0 1 100 0 _________ 7 Spd Set at 4mA 350 0 200 0 1000 0 _________ 8 Spd Set at BP mA 8 0 4 0 20 0 _________ 9 Spd Set at BP RPM 350 0 200 0 1000 0 _________ 10 Spd Set at 20mA 540 0 200 0 1000 0 _________ 11 Tach at 4mAOutput 0 0 0 0 1000 0 _________ 12 Tach at 20mAOutput 600 0...

Page 43: ...0 0 800 0 _________ 9 Torque Lmt P4 87 0 10 0 100 0 _________ 10 Maximum Fuel Limit 87 0 10 0 100 0 _________ S S7 Display 2 1 Speed Signal 1 _________ 2 Speed Signal 2 _________ 3 Kw Signal Input _________ 4 Spd Set Input mA _________ 5 ContactAStatus _________ 6 Contact B Status _________ 7 Contact C Status _________ 8 Contact D Status _________ 9 Contact E Status _________ 10 Contact F Status _...

Page 44: ...n Manual 26004 Woodward 40 S S8 Alarms 1 MinorAlarm _________ 2 MajorAlarm _________ 3 No1 MPU Failure _________ 4 No2 MPU Failure _________ 5 KW Signal Fail _________ 6 Spd Set Signal Fail _________ 7 Fault Reset FALSE TRUE FALSE _________ ...

Page 45: ...Appendix P1 ...

Page 46: ...Appendix P2 ...

Page 47: ...Appendix P3 ...

Page 48: ...Appendix P4 ...

Page 49: ...Appendix P5 ...

Page 50: ...Appendix P6 ...

Page 51: ...sition Output 4 20 mA Relay Outputs Load Transferring Major Alarm Minor Alarm Programmer Serial Port RS 422 9 pin D connector 1200 baud full duplex Ambient Operating Temperature 40 to 70 C 40 to 158 F Storage Temperature 55 to 105 C 67 to 221 F Humidity 95 at 38 C EMI RFI Susceptibility US MIL STD 461C Parts 5 9 Humidity US MIL STD 810D Method 507 2 Procedure III Mechanical Vibration 24 2000 Hz sw...

Page 52: ...from the front cover of this publication PO Box 1519 Fort Collins CO 80522 1519 USA 1000 East Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 Fax 1 970 498 3058 Email and Website www woodward com Woodwardhascompany ownedplants subsidiaries andbranches aswellasauthorizeddistributorsandotherauthorizedserviceandsalesfacilitiesthroughouttheworld Completeaddress phone fax emailinformationfora...

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