Woodward 723PLUS Original Instructions Manual Download

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Product Manual 02880

(Revision C)

Original Instructions

723PLUS Digital Speed Control for Single

Engine Marine Propulsion Applications

8280-419

Operation and Calibration Manual

Summary of Contents for 723PLUS

Page 1: ...Product Manual 02880 Revision C Original Instructions 723PLUS Digital Speed Control for Single Engine Marine Propulsion Applications 8280 419 Operation and Calibration Manual ...

Page 2: ...ncluding damage to the equipment Any 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 Translated Publications If the cover of this publication states Translation of the Original Instructions please note The original source...

Page 3: ...erminals 21 22 19 LON 1 and LON 2 Terminals 23 28 19 Discrete Inputs Terminals 29 36 19 Fuel Limit Shift Input A Terminal 29 20 Alarm Reset Input B Terminal 30 21 Speed Fail Override Input C Terminal 31 21 2nd Dynamics Input D Terminal 32 22 Raise Speed Contact Input E Terminal 33 22 Lower Speed Contact Input F Terminal 34 22 Remote Speed Reference Contacts 22 Input E Terminal 33 and Input F Termi...

Page 4: ...8 Fuel Limiters Adjustments 79 Speed Adjustments 79 Conclusion of Initial Adjustment Procedures 80 CHAPTER 5 DESCRIPTION OF OPERATION 81 General 81 Speed Input 82 Torsional Filter Function 82 Speed Failures 82 Alarm Reset and Override 83 Speed Reference and Ramps 83 Dual Dynamics 84 Dual Gain Dynamics 85 Other Dynamics 85 Actuator Bump Function 85 Minimum Fuel Function 85 Maximum Fuel Function 86 ...

Page 5: ...l Wiring Diagram 8 Figure 1 6 723PLUS Block Diagram 10 Figure 1 7 Typical 723PLUS Connections 11 Figure 2 1 723PLUS Control Internal Jumpers 14 Figure 3 1 Hand Held Programmer Functions 43 Figure 3 2 Control Gain as a Function of Speed Error 54 Figure 3 3 Control Gain as a Function of Control Output 54 Figure 3 4 Typical Transient Response Curves 55 Figure 3 5 Speed Filter 56 Figure 3 6 Notch Filt...

Page 6: ...the prime mover control system An overtemperature or overpressure shutdown device may also be needed for safety as appropriate Personal Protective Equipment The products described in this publication may present risks that could lead to personal injury loss of life or property damage Always wear the appropriate personal protective equipment PPE for the job at hand Equipment that should be consider...

Page 7: ...ents caused by improper handling read and observe the precautions in Woodward manual 82715 Guide for Handling and Protection of Electronic Controls Printed Circuit Boards and Modules Follow these precautions when working with or near the control 1 Avoid the build up of static electricity on your body by not wearing clothing made of synthetic materials Wear cotton or cotton blend materials as much ...

Page 8: ...723PLUS Single Engine Marine Propulsion Manual 02880 vi Woodward ...

Page 9: ...ic pickups MPUs or proximity switches for speed sensing an input for lube oil pressure an input for water pressure an input for remote speed reference and an input for air manifold pressure to limit the fuel demand The control outputs include an actuator output three configurable analog outputs and three relay outputs The relay outputs are for engine trouble shutdown and status indication There ar...

Page 10: ...control system with low voltage power supply and torsional filtering Each 723PLUS control requires 40 W of power A nominal current in rush of 7 A is possible Acceptable input voltage range is 18 to 40 Vdc Discrete input voltages provide on off command signals such as Raise Speed and Lower Speed to the electronic control Each discrete input requires 10 mA at 24 Vdc nominal voltage rating The low vo...

Page 11: ...and 4 can be configured with internal jumpers to source either 0 to 200 mA or 0 to 20 mA These options can be configured for each individual application Software Options In addition there are several options available in the 723PLUS control software which allow considerable flexibility for the application of the hardware Along with the typical adjustments for reference rates limits and dual dynami...

Page 12: ...723PLUS Single Engine Marine Propulsion Manual 02880 4 Woodward Figure 1 2 723PLUS Digital Speed Control ...

Page 13: ...Manual 02880 723PLUS Single Engine Marine Propulsion Woodward 5 Figure 1 3 Watch Window Display ...

Page 14: ...723PLUS Single Engine Marine Propulsion Manual 02880 6 Woodward Figure 1 4 Hand Held Programmer ...

Page 15: ...Manual 02880 723PLUS Single Engine Marine Propulsion Woodward 7 ...

Page 16: ...723PLUS Single Engine Marine Propulsion Manual 02880 8 Woodward Figure 1 5 Vessel Wiring Diagram ...

Page 17: ...Manual 02880 723PLUS Single Engine Marine Propulsion Woodward 9 ...

Page 18: ...723PLUS Single Engine Marine Propulsion Manual 02880 10 Woodward Figure 1 6 723PLUS Block Diagram ...

Page 19: ...Manual 02880 723PLUS Single Engine Marine Propulsion Woodward 11 Figure 1 7 Typical 723PLUS Connections ...

Page 20: ...e source of 18 to 40 Vdc The input power source must be capable of supplying 40 W and 7 A To prevent damage to the control do not exceed the input voltage range If a battery is used for operating power an alternator or other battery charging device is necessary to maintain a stable supply voltage To prevent damage to the control make sure that the alternator or other battery charging device is tur...

Page 21: ...alog output 4 0 160 mA tandem JPR5 JPR17 speed sensor 1 proximity switch JPR6 JPR18 speed sensor 1 magnetic pickup JPR7 JPR20 speed sensor 2 proximity switch JPR8 JPR19 speed sensor 2 magnetic pickup default jumper settings tandem outputs are designed to supply a maximum of 160 mA into two actuators connected in series Electrical Connections The vessel wiring connections are shown in Figure 1 5 Th...

Page 22: ...723PLUS Single Engine Marine Propulsion Manual 02880 14 Woodward Figure 2 1 723PLUS Control Internal Jumpers ...

Page 23: ...ains a switching power supply which requires a current surge to start properly To prevent damage to the control do not use a high voltage power source and do not use a high voltage source with resistors and zener diodes in series with the power input Run the power leads directly from the power source to the control DO NOT POWER OTHER DEVICES WITH LEADS COMMON TO THE CONTROL Avoid long wire lengths...

Page 24: ...d without being cleared and reset The state of the contact can be configured as either close on alarm or open on alarm If power to the control is lost the contact will open The relay contact on terminals 7 8 for Relay Output 3 is used when indication conditions are to be used by other devices in the application The relay changes state if any configured indication condition has occurred without bei...

Page 25: ...to 15 000 Hz An analog speed detection method is also available in the software The analog speed detection can filter out frequency changes caused by the cylinder firing frequency This filter allows the control loop to better respond to real engine speed changes if the firing frequency is within the bandwidth of the control loop The analog detection method is capable of receiving input frequencies...

Page 26: ... configured for 0 to 1 mA Use shielded twisted pair wires For electrically isolated devices such as 4 to 20 mA analog meters the shield should be grounded at the control end of the cable For input to other devices use the recommendation of the device manufacturer Analog Output 3 Terminals 19 20 Analog Output 3 provides a dedicated current signal to a single actuator or two actuators connected in s...

Page 27: ... 4 is factory set for 4 to 20 mA representing the fuel demand default range is 0 100 Note that the Actuator Position selection can be used to allow Analog Output 4 to have an actuator signal identical to Analog Output 3 Analog Output 4 can be connected to a second standard Woodward actuator by changing the hardware configuration to 0 to 200 mA Software settings must be changed if the hardware is c...

Page 28: ... the 723PLUS control Remove the factory installed jumper between terminal 37 and terminal 38 when using external discrete input power As an alternative the discrete inputs may be powered by the internal 24 Vdc Discrete Input Power source at terminal 39 This source is capable of supplying 100 mA at a voltage level of 24 Vdc Connect the internal 24 Vdc voltage source positive from terminal 39 to the...

Page 29: ... signal is too low to be detected Note that most starting designs crank the engine fast enough to allow the speed signal to be detected by the control For these designs the override command is not needed and this input can be left disconnected When the external switch or relay contacts are closed discrete input in the TRUE state the control overrides the shutdown associated with losing the speed s...

Page 30: ...overspeed When the external switch or relay contacts are closed discrete input in the TRUE state the control raises the speed reference Raise is limited to the software adjusted maximum speed limit With the contacts open discrete input in the FALSE state the control stops raising the speed reference Lower Speed Contact Input F Terminal 34 The input switch or relay contact used to activate the Lowe...

Page 31: ...mmediately decreasing the fuel demand to zero When the switch or relay contacts are open discrete input in the FALSE state the Minimum Fuel Function is increased to 100 percent When the switch or relay contacts are closed discrete input in the TRUE state the Minimum Fuel Function immediately pulls the fuel demand to zero The Open to Run command is the preferred means for a normal shutdown of the e...

Page 32: ...ows engine shutdown protection or alarm protection or both to be provided Water pressure is displayed in software adjustable engineering units on the hand held programmer and may be re transmitted by configuration through one of the analog outputs to an external device meter recorder etc Default engineering units setting is 0 100 psig Engine trouble alarm and shutdown are also displayed on the han...

Page 33: ... pressure fuel limit and causes a Status Indication alarm The fuel limit removal and Status Indication alarm remain until the failure is repaired Remote Speed Reference Input Signal Input 4 Terminals 51 52 Connect a Remote Speed Reference transmitter to Signal Input 4 The input signal must be an isolated high quality signal This signal input allows remote speed reference set point changes and by c...

Page 34: ...e default data value is ATE0Q150 1 D0 Installation Checkout Procedure With the installation complete as described in this chapter do the following checkout procedure before beginning set point entry Chapters 3 and 4 or initial start up adjustments Chapter 5 1 Visual inspection A Check the linkage between the actuator and fuel metering device for looseness or binding Refer to the appropriate actuat...

Page 35: ...als to chassis All terminals should measure infinite resistance the resistance of terminals 2 and 37 depends on whether a floating or grounded power source is used If a resistance less than infinity is obtained remove the connections from each terminal one at a time until the resistance is infinite Check the line that was removed last to locate the fault ...

Page 36: ... An inspector provides a window for real time monitoring and editing of all control Configuration and Service Menu parameters and values Custom inspectors can easily be created and saved Each window can display up to 28 lines of monitoring and tuning parameters without scrolling The number with scrolling is unlimited Two windows can be open simultaneously to display up to 56 parameters without scr...

Page 37: ...n noisy environments When using port J1 with Watch Window or Control View place a jumper across terminals 9 and 10 This tells the control that a computer is connected to J1 When using the Hand Held Programmer remove the jumper Port J2 is configured for RS 232 and requires a widely available 9 pin null modem cable This cable should be available at most computer or electronics stores It does not mat...

Page 38: ...Switch to Configuration Mode box then press or click Configuration Mode Close window click to cancel Show Service Values This will bring the service values to the top so they can be adjusted If the control is in configure mode then the values can be adjusted by any amount within their allowed maximum and minimum ranges The within 10 of their value rule does not apply in configure mode Show Configu...

Page 39: ...o move to another screen Click the appropriate tab The arrows in the upper right hand corner if applicable are used to scroll to other tabs that may be hidden Some screens when opened such as Monitor will display additional tabs to sub screens Clicking these tabs will move you into the sub screens A quick means of moving directly to another screen or sub screen from any screen is to right click an...

Page 40: ...display of the Fuel Limiter In Control Bar graph display of all Fuel Limiters on the fuel demand LSS Bus Sub tabs for the Fuel Limiter Settings Torque Limit Curve and AMP Limit Curve Fuel Limiter Curve sub tab is shown open Two sets of raise lower arrows accompany each tunable value The hollow arrows produce slow turtle set point changes and the solid arrows produce fast rabbit set point changes V...

Page 41: ...ith raise lower arrows for all fuel limiters Right clicking on a gauge panel will bring up a different quick menu This quick menu will appear when you right click on a gauge or a group of gauges that has a changeable range There are always multiple quick options and a manual option If the program is set to save settings on close then new gauge settings will automatically be saved when the program ...

Page 42: ...uge settings Save to EEPROM will save all configuration and service tunables in the 723PLUS EEPROM Load Config File will load settings from a saved Configuration File into the 723PLUS EEPROM overwriting all previous values The control must be in configure mode to perform this function Save As Config File will dump all settings from the 723PLUS controller EEPROM into a Configuration File To prevent...

Page 43: ...urves are available for both viewing the curve graph and changing curve set points The above screen shows that the Torque Limit curve is a 2D curve with five break points It is set to limit torque by limiting maximum fuel demand at various engine speeds A digital display of the present x curve input and y curve output values in engineering units is included Y in this example is the fuel limit as a...

Page 44: ...clicking on a break point and selecting properties pops up a Point Adjustment window for that point as shown below Adjustments to both the x and y break point values can be made as described earlier by using the turtle and rabbit arrows or by typing in values and pressing the key for the selected point All break points of all curves can be adjusted in this manner from the curve graph screens ...

Page 45: ...epresentation of data as it changes over time This is especially useful when tuning an engine and different fluctuations need to be seen and dealt with analytically Here is an example showing some analog inputs as well as a static value The Available Trends are listed below with the items they contain Speed Dynamics Engine Speed rpm Speed Ref rpm Fuel Demand Remote Speed Ref rpm Torsional Level rp...

Page 46: ...d by right clicking on the graph and selecting Max and Min Values and then selecting Reset All Max and Min Auto Update Will pause and unpause the graph motion as well as pause and unpause logging Auto Save Settings If checked this will automatically save all settings as they are changed Copy to Clipboard Copies the whole graph axes graph window descriptions and values to the clipboard so that it c...

Page 47: ...0 22 37 622 72 23 0 05 0 12 0 05 0 16 00 22 37 772 72 23 0 05 0 12 0 05 0 16 00 22 37 923 72 23 0 10 0 06 0 05 0 16 00 22 38 7372 23 0 10 0 06 0 05 0 16 00 22 38 223 72 23 0 12 0 06 0 11 0 06 00 22 38 373 72 23 0 12 0 06 0 05 0 15 00 22 38 524 72 23 0 13 0 06 0 11 0 06 00 22 38 674 72 23 0 12 0 06 0 11 0 06 00 22 38 824 72 23 0 12 0 06 0 11 0 06 00 22 38 974 72 23 0 13 0 06 0 11 0 06 Log Status Th...

Page 48: ...Maximum These values are used to scale the data in the graph window Change these values to zoom in or out on a particular region for a given Pen Show Time Top Bottom This option toggles whether the time passed is written to the graph window as well as if it is written to the top or bottom of the graph Show Grid Toggles whether the grid is drawn or not X Grid Tics This controls how many lines are d...

Page 49: ...hen it is written to the graph window if show time is enabled Enable Logging Enables or disables logging Log Time Toggles whether or not the time stamp is placed with every data set in the log file If a simple relational log is needed it is not useful to log the time However if you need to generate scatter plot or perform more complex data analysis then a time stamp is necessary Log File Name The ...

Page 50: ...trol When the self test is complete the screen displays two lines of information about the application Press the ID key to display the part number and revision level of the software in the control Refer to this number and revision level in any correspondence with Woodward Governor Company write this information in the Programming Checklist in the Appendix The programmer screen is a four line backl...

Page 51: ...rrow Moves backward through each menu one step at a time Down Arrow Advances through each menu one step at a time Selects Service from Main Screen Turtle Up Increases the displayed set point value slowly Turtle 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 ...

Page 52: ...epeatedly until you stop pressing the key Moving Around Within a Menu Items within a menu are arranged vertically To enter a menu from a menu title use the Down Arrow key To move through the items within a menu use the Down Arrow and Up Arrow keys If you press the Down Arrow or Up Arrow keys continually you will cycle through all the menu items repeatedly until you stop pressing the key Leaving a ...

Page 53: ...a running engine DO NOT hold the keys down to adjust set points Instead make short taps on the keys The 723PLUS is storing your input commands at a higher rate than can be seen on the hand held terminal If you hold the keys down the 723PLUS will appear to coast beyond the last value seen on the hand held at the time you release the button To save set points at any time use the SAVE key This transf...

Page 54: ...ER is set TRUE USE NOTCH FILTER Enables disables a Notch Filter on the speed input s Set TRUE to enable the notch filter and disable the torsional filter Set to FALSE to disable the notch filter and permit the torsional filter to be enabled USE AIR MAN LIMIT Allows the ENABLE AMP FUEL LMT to be active The Air Manifold Pressure Fuel Limit is not active when set to FALSE even if ENABLE AMP FUEL LMT ...

Page 55: ...PD 2 TEETH and DSPD 2 TEETH are the same value The number of gear teeth is used by the control to convert pulses from the speed sensing device to engine rpm Make sure the control is properly programmed to convert the gear tooth count into engine rpm Improper conversion could cause engine overspeed CFIG INDICATION This menu allows configuring which conditions are seen as status indications and the ...

Page 56: ...LAY time Alarm is bypassed when speed is below the SD BYPASS SPEED and is armed when speed is above the SD BYPASS SPEED for the SD BYPASS time HIGH TORSION LEVEL Alarms when the torsional level exceeds the TORS LVL SETPT for longer than the HI TORSION DLY time SPEED SWITCH ALM Alarms when engine speed is above a programmable SPD SW PICKUP setting Alarm clears when engine speed is below a programma...

Page 57: ...nfiguring the function of the Status Indication Relay Output 2 ENERGIZE FOR STATUS Set TRUE to energize Status Indication Relay and close Output 2 contact on configured status conditions Set FALSE to de energize Status Indication Relay and open Output 2 contact on configured status conditions Default is TRUE SPD SW PICKUP Set speed rpm at which the SPEED SWITCH picks up on increasing speed to indi...

Page 58: ...onds to wait before the TORSIONAL ALARM is issued after the torsional vibration level exceeds the TORS LVL SETPT ENERGIZE FOR ALARM Set TRUE to energize Engine Trouble Relay and close Output 3 contact on configured alarm conditions Set FALSE to de energize Engine Trouble Relay and open Output 3 contact on configured alarm conditions Default is TRUE SHUTDOWN SETUP This menu allows configuring the S...

Page 59: ...utput 1 contact on configured shutdown conditions Set FALSE to de energize Shutdown Relay and open Output 1 contact on configured shutdown conditions Default is TRUE CFIG COMMUNICATION This menu configures Communication Port J2 PORT 2 Address Determines the optional Servlink address from 1 to 247 for Port J2 CFIG ANALOG OUTPUTS This menu allows configuring the two analog outputs and the two actuat...

Page 60: ...ng power from the control causes them to revert to the previously saved settings Service Menu Descriptions The following describes the Service menus The listing below shows the menu title in large BOLD type The title is followed by the separate menu items A complete listing of the menu titles and menu items can be found in the Appendix The listing shows the minimum value of the item the maximum va...

Page 61: ...s in conjunction with the Window Width and Gain adjustments by multiplying the Gain set point by the Gain Ratio when the speed error is greater than the Window Width This makes the control dynamics fast enough to minimize engine speed overshoot on start up and to reduce the magnitude of speed error when loads are changing This allows a lower gain at steady state for better stability and reduced st...

Page 62: ...723PLUS Single Engine Marine Propulsion Manual 02880 54 Woodward Figure 3 2 Control Gain as a Function of Speed Error Figure 3 3 Control Gain as a Function of Control Output ...

Page 63: ...Manual 02880 723PLUS Single Engine Marine Propulsion Woodward 55 Figure 3 4 Typical Transient Response Curves ...

Page 64: ...transient performance may worsen As the filter frequency is increased steady state stability worsens but transient performance may improve If the calculated firing frequency is greater that 15 9 Hz then disable the filter SPEED SETTING MENU ENABLE SPEED FILTER to FALSE 9 BUMP ACT allows you to test your dynamics settings by temporarily applying a decreased fuel demand transient to stimulate a cont...

Page 65: ...ypically used to electrically limit the amount of fuel to prevent overfueling SHIFT FUEL LMT FD This sets the Fuel Demand increase to be added to all fuel limits when the Fuel Limit Shift discrete input is true Limit is increased only for the SHIFT DURATION time setting SHIFT DURATION SEC This sets the duration in seconds of the SHIFT FUEL LMT when the Fuel Limit Shift discrete input is true The F...

Page 66: ...irst break point It may be set less than the start fuel limit and still allow the start fuel limit to function TQ LMT INPUT B RPM This sets the second break point of the TLC It should be adjusted to the rpm which represents the second break point FUEL LIMIT B FD This sets the maximum fuel demand at the second break point TQ LMT INPUT C RPM This sets the third break point of the TLC It should be ad...

Page 67: ... fuel demand at the fifth break point TORSIONAL FILTER Torsional filter adjustments are the settings that affect the control s ability to react to flexible coupling torsionals See Initial Adjustments in Chapter 4 for a more detailed description of the adjustments for the Torsional Filter A Notch Filter is also provided with this control as an alternate filtering means for single speed sensor appli...

Page 68: ...hey deviate A value of 0 50 causes both inputs to be weighted equally A higher value uses more of the engine speed input and less of the load side speed input Conversely a lower value uses less of the engine speed input and more of the load side speed input TORS SCALE RT RPM This sets the value of torsional vibration as a rated engine rpm which equals the full scale 100 torsional vibration level D...

Page 69: ...is less than the alarm set point curve The curve has four break points The input break points units are in RPM The Water Pressure set points are in tunable engineering units SPEED INPUT A RPM This sets the first break point of the WASC It should be adjusted to the engine rpm which represents the first break point The set point below this point is extrapolated from this point and the SPEED INPUT B ...

Page 70: ...e WATER SD SETPOINT Curve WSDSC for the WATER LOW PR SD which triggers shutdown when the water pressure input is less than the shutdown set point curve The curve has four break points The input break points units are in rpm The Water Pressure set points are in tunable engineering units SPEED INPUT A RPM This sets the first break point of the WSDSC It should be adjusted to the engine rpm which repr...

Page 71: ...Vdc WATER PRESS 4 mA EU Enter the input pressure from the water pressure sensing device in preferred units psi kPa bar etc at 4 mA If a voltage sensing device is provided enter the input pressure at 1 Vdc WATER PRESS 20 mA EU Enter the input pressure from the water pressure sensing device in preferred units psi kPa bar etc at 20 mA If a voltage sensing device is provided enter the input pressure a...

Page 72: ...he span value should be adjusted so that the maximum input or output provides the correct display value The display values of the inputs can be read in the DISPLAY ANALOG I O menu The input currents should be monitored with a milliamp meter in series with the source or from the source itself The display values of the outputs can also be read in the DISPLAY ANALOG I O menu The Actuator Output is ei...

Page 73: ... of the C discrete input D 2ND DYNAMICS This shows the state of the D discrete input E RAISE SPEED This shows the state of the E discrete input F LOWER SPEED This shows the state of the F discrete input G RATED SPEED This shows the state of the G discrete input H CLOSE TO STOP This shows the state of the H discrete input SHUTDOWN DO1 This shows the state of Relay Output 1 A TRUE indicates the rela...

Page 74: ...been applied SPEED SWITCH Display shows TRUE when the Speed Switch has been triggered Display shows FALSE when the Speed Switch is reset OIL XMTR FAIL Display shows TRUE when the Oil Pressure Transmitter input on Signal Input 1 has failed WATER XMTR FAIL Display shows TRUE when the Water Pressure Transmitter input on Signal Input 2 has failed AIR MANF XMTR FAIL Display shows TRUE when the Air Mani...

Page 75: ...e TRUE then FALSE to reset all configured alarms and shutdowns DISPLAY SHUTDOWN This menu is for display only It displays the configured shutdowns in the 723PLUS control Any shutdowns which are TRUE cause Relay Output 1 Shutdown to activate and the Alarm 1 LED to illuminate It also shows which configured shutdown occurred first FIRST SHUTDOWN This integer indicates which of the shutdowns occurred ...

Page 76: ...y shows TRUE when the speed sensor 1 input is active as the primary input for speed control The primary input is in control in single speed sensor applications and assumes control if the secondary input fails in a two speed sensor input application SPEED SENSOR 2 ACTIVE Display shows TRUE when the speed sensor 2 input is active as the primary input for speed control The primary input is in control...

Page 77: ...S Marine SEP Control View interface or Watch Window for later download This can be very useful if a replacement control is necessary or for start up of another similar unit Power down the control for about 10 seconds Restore power and verify that all set points are as recorded To prevent possible damage to the engine resulting from improper control settings make sure you save the set points before...

Page 78: ...of the control are on 3 Check the speed sensor Minimum voltage required from the speed sensor to operate the control is 1 5 Vrms measured at cranking speed or the lowest controlling speed For this test measure the voltage while cranking with the speed sensor connected to the control Before cranking be sure to prevent the engine from starting At 5 of rated speed and 1 0 Vrms the failed speed sensin...

Page 79: ...dynamics 2nd Dynamics contact open Use the 1st Dynamics Menu to set the 1st dynamics if changes are needed Then repeat the adjustments for 2nd dynamics 2nd Dynamics contact closed Use the 2nd Dynamics Menu to set the 2nd dynamics if changes are needed 1 No Load Adjustments Do this adjustment without load applied Slowly increase the Gain set point until the engine becomes slightly unstable then red...

Page 80: ... set point slightly and reduce the Gain set point see Figure 3 4 The use of negative Gain Slope should be considered carefully Low gain at high fuel levels results in poor load rejection response and possible overspeed To prevent possible serious injury from an overspeeding engine the maximum fuel limit must be set near the full load output current demand to prevent excessive integrator windup and...

Page 81: ...are likely to adjust the gain a little bit too far and go into an unstable condition When that happens you will see the engine start to run away and approach overspeed or stall The reason the dynamic settings are copied from 1st dynamics to 2nd dynamics is to allow you to quickly switch to settings that can control the engine and keep it from running away or dying We recommend you use either a jum...

Page 82: ... 1st dynamics Keep slightly adjusting the gain up or down until you find the setting that gives you the point of marginal stability When you are there the oscillations will neither decrease nor increase in amplitude If you can maintain a constant amplitude for 30 seconds to a minute you have found the point If the oscillations die out your gain is too low If they keep getting bigger your gain is t...

Page 83: ...e overshoot 17 This usually concludes the dynamic adjustment for one set of dynamics These settings are typically robust Overly aggressive adjustments should be avoided if possible The Reset and Compensation settings produced by this procedure are normally not changed Increases to the Gain may produce some improvement in the load transient response however Window Width and Gain Ratio to be describ...

Page 84: ...to obtain optimum transient response settings The step that increases Gain may be skipped in favor of Window Width and Gain Ratio adjustments only 20 This trace shows the transient response with the Gain Ratio and Window Width disabled In this example Gain is 1 235 Reset is 0 28 and Compensation is 0 88 Load step is 15 21 This trace shows results of just increasing Gain from 1 235 to 3 0 Gain Rati...

Page 85: ...h the highest Gain Ratio without going unstable If the Gain Ratio setting that causes severe instability is known then the final setting should not be more than half of this amount 24 Eventually a point is reached where no further improvement is possible The fuel demand overshoot should be minimal Reduce the Gain or Gain Ratio as needed to reduce the fuel demand overshoot Gain Slope and Gain Break...

Page 86: ...t can be found by bumping the system using the Actuator Bump function in the dynamics menu Be prepared to move the system away from the torsional point if it goes unstable Bump the system at several different speeds and loads If the system remains stable slightly increase the dynamic Gain and again bump the system at several different speeds and loads At some point a torsional oscillation may begi...

Page 87: ...anking The final adjustment should be made on a cold day when the normal starting Fuel Demand is insufficient to start the engine Increase the Start Ramp Rate if necessary to achieve satisfactory starts 3 Maximum Fuel Limit sets the maximum Fuel Demand Adjust so that all loads and transients can be satisfactorily assumed by the genset Note that very hot days may require more fuel for the engine to...

Page 88: ...y useful if a replacement control is necessary or for start up of another similar unit Power down the control for about 10 seconds Restore power and verify that all set points are as recorded 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 power ...

Page 89: ...ensionless value based on percentage of required fuel where 0 percent generally represents no fuel and 100 percent represents maximum fuel The fuel demand is supplied to the actuator function to produce an actuator current The actuator current is supplied to the actuator which controls the fuel delivery system The speed sensors contain a special tracking filter designed for reciprocating engines w...

Page 90: ...nstantaneous change in speed of the generator to be different from the instantaneous change in speed of the engine The difference between these two values is referred to as the torsional level A high torsional level can cause the governor to over respond to load and speed changes which can make the entire system unstable Without torsional filtering this would force the closed loop dynamics to be d...

Page 91: ...ich is used for the speed reference Remote is selected as long as the Raise Speed and Lower Speed contacts are both closed This section describes the operation of the speed reference and ramp functions and their relation to each other Read this section carefully to be sure your sequencing provides the proper operating modes The control provides idle lower limit rated and raise limit set points acc...

Page 92: ...e mA input the current speed reference is raised or lowered at the rate determined by the raise or lower rate to bring the speed reference into agreement with the remote speed reference The remote reference will not increase speed over the raise limit or lower it below the lower limit When in remote mode Raise and Lower Speed contacts both closed if the remote input goes below 2 mA 0 5 Vdc the spe...

Page 93: ...ump Function The Actuator Bump Function is a software activated means of momentarily decreasing the fuel demand It is used to determine how well the 723PLUS control is controlling the engine and generator The function bumps the actuator with a consistent change in output This change causes engine speed to vary which causes a response from the PID The response can be varied using the appropriate dy...

Page 94: ...of rated speed the Start Limit Function is momentarily triggered to immediately limit the fuel demand to a software adjustable start fuel limit The start ramp begins increasing the fuel demand at a software adjustable rate shortly after the start fuel limit is triggered The rate can be set to zero to eliminate the start ramp function When engine speed reaches 95 of the speed reference and the PID ...

Page 95: ...justable five break point curves based on each signal The display value of the input signal can be scaled according to the engineering units desired The output used for fuel demand limiting is in percent The limiting value is linear from set point to set point as shown in Figure 5 2 The functions are enabled when the engine speed first reaches 95 percent of the speed reference They then remains en...

Page 96: ...als of 20 to 160 mA to travel from minimum position to maximum position or 160 to 20 mA to travel from minimum position to maximum position on reverse acting systems The fuel demand is scaled from 0 to 100 percent for an output of 0 to 200 mA or 200 to 0 mA if Reverse Acting is selected This results in a fuel demand with a value of ten percent when the actuator is effectively at minimum for either...

Page 97: ...accordance with the instructions in Chapter 3 Verify that correct voltage and polarity are applied to the control Verify that the programmer does its power up test if applicable Be sure the jumper between terminals 9 and 10 is removed to use the Hand Held Programmer do NOT remove the jumper to use Watch Window or the Marine Control Standard PC Interface Failure to do the power up test indicates th...

Page 98: ...ge from TRUE to FALSE when the contact is closed and opened the control has failed and should be replaced 2 Repeat for all the discrete inputs Verify the proper voltage exists at the terminal the proper LED illuminates and the proper status appears in the Display I O menu Lube Oil Pressure Input The following tests verify the function of the Lube Oil Pressure Input Signal Input 1 1 Connect a 4 to ...

Page 99: ...ion of the Air Manifold Pressure Input Signal Input 3 1 Connect a 4 to 20 mA or 1 to 5 Vdc source to terminals 48 and 49 If a mA source is used assure the jumper is installed across terminals 47 and 48 Connect a voltmeter across terminals 48 and 49 Optionally a mA meter may be installed in series with the 4 to 20 mA source 2 Set the source for 5 0 Vdc 20 mA on the meter Select Display Analog I O o...

Page 100: ...nected across the output when an actuator is connected The correct output currents must be computed using the voltage measured and the input resistance of the actuator 3 Select the CFIG OPTION menu on the Hand Held Programmer the Marine Control Standard PC Interface or Watch Window and set the item Use REV ACTUATOR to FALSE Select the FUEL LIMITERS menu and set item START FUEL LIMIT to 100 FD then...

Page 101: ...efer to Help if you need help Power down the control for about 10 seconds Restore power and verify that all set points are as recorded 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 power from the control causes them to revert to the previously ...

Page 102: ...m should also be handled through the OEM or Packager Please review your equipment system documentation for details Woodward Business Partner Support Woodward works with and supports a global network of independent business partners whose mission is to serve the users of Woodward controls as described here A Full Service Distributor has the primary responsibility for sales service system integratio...

Page 103: ...ion This option is applicable to mechanical products only Returning Equipment for Repair If a control or any part of an electronic control is to be returned for repair please contact your Full Service Distributor in advance to obtain Return Authorization and shipping instructions When shipping the item s attach a tag with the following information return number name and location where the control ...

Page 104: ...or information on these services please contact one of the Full Service Distributors listed at www woodward com directory Contacting Woodward s Support Organization For the name of your nearest Woodward Full Service Distributor or service facility please consult our worldwide directory published at www woodward com directory You can also contact the Woodward Customer Service Department at one of t...

Page 105: ...nders Type of Fuel gas gaseous diesel dual fuel etc Power Output Rating Application power generation marine etc Control Governor Information Control Governor 1 Woodward Part Number Rev Letter Control Description or Governor Type Serial Number Control Governor 2 Woodward Part Number Rev Letter Control Description or Governor Type Serial Number Control Governor 3 Woodward Part Number Rev Letter Cont...

Page 106: ...cations The default setting is RS 232 The RS 232 connections are shown in Figure A 1 The maximum distance from the PC to the 723PLUS control is 15 m 50 ft Figure A 1 723PLUS RS 232 Connections The RS 422 connections are shown in Figure A 2 The maximum distance from the PC to the 723PLUS control is 1219 m 4000 ft Figure A 2 723PLUS RS 422 Connections with Optional Termination at Receiver ...

Page 107: ...oltage between either receiver input and circuit ground must be less than 10 V There is one termination resistor network for each port located on the 723PLUS board Connection to this resistor network is made through the 9 pin connectors on pins 6 and 9 Grounding and Shielding The RS 422 specifications state that a ground wire is needed if there is no other ground path between units The preferred m...

Page 108: ...erred Multipoint Wiring Using Shielded Twisted pair Cable with a Separate Signal Ground Wire The SG signal ground connection is not required if signal ground is unavailable Figure A 5 Alternate Multipoint Wiring Using Shielded Twisted pair Cable without a Separate Signal Ground Wire ...

Page 109: ...OPTION USE REV ACTUATOR FALSE USE 2nd DYNAMICS TRUE DYNAMICS 1 CONSTANT FALSE USE TORSION FILTER TRUE USE AIR MAN LIMIT TRUE USE TORQ LIMIT TRUE RESET ALM ON CLEAR TRUE NON LATCH ALM DOUT3 FALSE CFIG SPEED CONTROL RATED SPEED RPM 1200 1 2100 ASPD 1 TEETH 16 16 500 ASPD 1 MAX FREQ Hz 5000 10 17500 ASPD 2 TEETH 16 16 500 ASPD 2 MAX FREQ Hz 5000 10 17500 REVERSE ACTING FALSE DSPD 1 TEETH 16 16 500 DS...

Page 110: ...T 99 0 0 0 1000 0 ALARM SETUP OIL PRESS DELAY SEC 10 0 0 0 10800 0 HI FUEL DEMND SETPT FD 100 0 0 0 100 0 HI FUEL DEMND DELAY SEC 10 0 0 0 10800 0 HI SPEED SETPT RPM 1320 0 0 0 2500 0 HI SPEED DELAY SEC 0 2 0 0 10800 0 WATER PR DELAY SEC 10 0 0 0 10800 0 TORS LVL SETPT RPM 25 0 0 0 2500 0 HI TORSION DLY SECS 10 0 0 0 10800 0 ENERGIZE FOR ALARM TRUE SHUTDOWN SETUP SHUTDOWN ACTUATOR TRUE OIL PRESS D...

Page 111: ...MP BUMP ENABLE FALSE ACT BUMP LEVEL FD 1 0 0 0 100 0 ACT BUMP DURATN SEC 0 1 0 01 2 0 FUEL LIMITERS START FUEL LMT FD 10 0 0 0 100 0 START RAMP RATE FD S 2 0 0 0 1000 0 MAX FUEL LIMIT FD 100 0 0 0 100 0 SHIFT FUEL LMT FD 10 0 0 0 100 0 SHIFT DURATION SEC 10 0 0 0 20 0 SPEED SETTING RAISE SPEED LMT RPM 1300 1 2100 LOWER SPEED LMT RPM 600 1 2100 IDLE SPEED RPM 750 1 2100 ACCEL RAMP TIME SEC 8 0 0 0 ...

Page 112: ... 0 32000 0 SPEED INPUT B RPM 250 0 0 0 2200 0 WAT ALM SETPT B EU 10 0 32000 0 32000 0 SPEED INPUT C RPM 500 0 0 0 2200 0 WAT ALM SETPT C EU 20 0 32000 0 32000 0 SPEED INPUT D RPM 750 0 0 0 2200 0 WAT ALM SETPT D EU 30 0 32000 0 32000 0 OIL ALM SETPOINT SPEED INPUT A RPM 0 0 0 0 2200 0 OIL ALM SETPT A EU 0 0 32000 0 32000 0 SPEED INPUT B RPM 250 0 0 0 2200 0 OIL ALM SETPT B EU 10 0 32000 0 32000 0 ...

Page 113: ...ENGR 0 0 30000 0 30000 0 ACTUATOR OUT 2 MAX ENGR 100 0 30000 0 30000 0 AO FILTER Hz 20 0 0 01 20 0 I O CALIBRATION OIL PR OFFSET AI1 0 0 200 0 200 0 OIL PRESS SPAN AI1 100 0 50 0 200 0 OIL PR READ VLT AI1 FALSE WTR PR OFFSET AI2 0 0 200 0 200 0 WATER PRESS SPAN AI2 100 0 50 0 200 0 WTR PR READ VLT AI2 FALSE AMP OFFSET AI3 0 0 200 0 200 0 AIR MAN PR SPAN AI3 100 0 50 0 200 0 AIR MP READ VLT AI3 FAL...

Page 114: ...XMTR FAIL WATER XMTR FAIL AIR MAN XMTR FAIL LOAD SWITCH DISPLAY ENG TROUBLE FIRST ALARM 1 SPEED 1FAIL 2 SPEED 2 FAIL 3 SPD 1AND 2 FAIL 4 REM SPD XMTR FAIL 5 OIL LOW PR ALM 6 HI FUEL DEMND ALM 7 HI SPEED ALARM 8 WATER LOW PR ALM 9 TORSIONAL ALARM 10 SPEED SWITCH 11 LOAD SWITCH ALARM RESET DISPLAY SHUTDOWN FIRST SHUTDOWN 1 SPEED 1FAIL 2 SPEED 2 FAIL 3 SPD 1AND 2 FAIL 4 REM SPD XMTR FAIL 5 OIL LOW PR...

Page 115: ...lsion Woodward 107 ACTUATOR SHUTDOWN TORSNL FILTR ACTIVE DISPLAY MENU ENGINE SPEED RPM SPEED REF RPM FUEL DEMAND OIL PRESSURE EU WATER PRESS EU AIR MANF PRESS EU REMOTE SPD REF RPM TORQUE LIMIT FD AMP FUEL LIMIT FD TORSNL LIMIT FD TORSIONL LEVEL RPM ...

Page 116: ...723PLUS Single Engine Marine Propulsion Manual 02880 108 Woodward ...

Page 117: ...40 Vdc Common Mode Rejection 1 0 of full scale Accuracy 1 0 of full scale Analog Outputs 0 1 or 4 20 mA 2 Analog Output 0 1 mA or 4 20 mA max 600 load Accuracy 0 5 of full scale Analog Outputs 0 20 or 0 200 mA 2 Analog Output 0 20 mA max 600 load or 0 200 mA max 70 load Accuracy 0 5 of full scale Relay Contact Outputs 3 Contact Ratings 2 0 A resistive 28 Vdc 0 5 A resistive 125 Vdc Environment Ope...

Page 118: ...ast Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 Fax 1 970 498 3058 Email and Website www woodward com Woodward has company owned plants subsidiaries and branches as well as authorized distributors and other authorized service and sales facilities throughout the world Complete address phone fax email information for all locations is available on our website 2012 10 Colorado ...

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