Woodward 8909-051 User manual

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ProdProd

ucuc

t Manual 25t Manual 25

8080

(R(R

evisievisi

on on

D)D)

Original InstructionsOriginal Instructions

Governor Governor

TeTe

st Standst Stand

ModMod

el 8909el 8909

-05-05

1 (3 1 (3

HorHor

sepsep

owow

er / 2.2 er / 2.2

kW)kW)

ModMod

el 8909el 8909

-05-05

3 (5 3 (5

HorHor

sepsep

owow

er / 3.7 er / 3.7

kW)kW)

InstallatioInstallatio

n and Operan and Opera

tiotio

n Man Ma

nualnual

DEFINITIONSDEFINITIONS

This is the safety alert symbol. It This is the safety alert symbol. It

is used to alert is used to alert

you to potential personalyou to potential personal

injury hazards. Obey all safety messages that follow this symbol to injury hazards. Obey all safety messages that follow this symbol to

avoidavoid

possible injury or death.possible injury or death.



DANGERDANGER

—Indicates a hazardous situation which, if not avoided, —Indicates a hazardous situation which, if not avoided,

will result in deathwill result in death

or serious injury.or serious injury.



WARNINGWARNING

—Indicates a hazardous situation which, if not avoided, could result —Indicates a hazardous situation which, if not avoided, could result

inin

death or serious injury.death or serious injury.



CAUTIONCAUTION

—Indicates a hazardous situation which, if not avoided, could result —Indicates a hazardous situation which, if not avoided, could result

inin

minor or moderate injury.minor or moderate injury.



NOTICENOTICE

—Indicates a hazard that could result in —Indicates a hazard that could result in

property damage only (includingproperty damage only (including

damage to the control).damage to the control).



IMPORTANTIMPORTANT

—Designates an operating tip or maintenance suggestion.—Designates an operating tip or maintenance suggestion.

The eThe e

ngine, turbine, or other type of ngine, turbine, or other type of

prime mover shoulprime mover shoul

d be equipped with d be equipped with

anan

overspeeoverspee

d shutd shut

down device to down device to

protect against runaway or damage to the primeprotect against runaway or damage to the prime

mover with posmover with pos

sible personal injury, loss osible personal injury, loss o

f life, or property damagef life, or property damage

The oveThe ove

rspeed shutdown rspeed shutdown

device must be totally indevice must be totally in

depedepe

ndent of the prime mondent of the prime mo

verver

control control

system. An overtempesystem. An overtempe

rature or overpressure shutdowrature or overpressure shutdow

n device may alson device may also

be needed for safety, as approprbe needed for safety, as appropr

iate.iate.

ReRe

ad this entire manual and all other publications ad this entire manual and all other publications

pertaining to the work pertaining to the work

to be performed beforeto be performed before

installing, operating, or servicing thiinstalling, operating, or servicing thi

s equipment. Ps equipment. P

ractice all plant and safety instructions ractice all plant and safety instructions

andand

precautions. Faprecautions. Fa

ilure to foilure to fo

llow insllow ins

tructions tructions

can cause personal injury can cause personal injury

and/and/

or pror pr

operty damageoperty damage

This publication mThis publication m

ay have beay have be

en revised or upden revised or upd

ateate

d since thid since thi

s copy s copy

was produced. To verify thatwas produced. To verify that

you have the latest revision, be sure to cyou have the latest revision, be sure to c

heck theheck the

publications pagepublications page

on on

the Woodward website:the Woodward website:

www.woodward.com/publicationswww.woodward.com/publications

The current reThe current re

vision and distribvision and distrib

ution restriction oution restriction o

f all publications are shown in manualf all publications are shown in manual

2631126311

The laThe la

test version of test version of

most pubmost pub

lications is lications is

avaava

ilable on theilable on the

publications pagepublications page

. I. I

f your publif your publi

cation iscation is

not thnot th

ereere

, please contact your , please contact your

customer service rcustomer service r

epreseeprese

ntative to get the lntative to get the l

ateate

st cost co

py.py.

AnAn

y uy u

naunau

thth

oror

iziz

ed med m

odod

ifif

icic

atiati

onon

s ts t

o oo o

r ur u

se ose o

f tf t

hihi

s eqs eq

uiui

pmpm

enen

t ot o

utut

sisi

de ide i

ts ts

spsp

ecieci

fifi

ed med m

echech

aniani

calcal

electrical, or other operating limits may cause personal injury and/or property damage, includingelectrical, or other operating limits may cause personal injury and/or property damage, including

damadama

ge to the ge to the

equipmeequipme

nt. Any sunt. Any su

ch unch un

authorizeauthorize

d modifications: d modifications:

(i) constitute "misu(i) constitute "misu

se" se"

and/and/

oror

"negligence" within "negligence" within

the meathe mea

ning of ning of

the product wthe product w

arraarra

nty thereby excluding warranty coveragenty thereby excluding warranty coverage

for any for any

resulting damageresulting damage

, and (ii) invalida, and (ii) invalida

te product te product

certificacertifica

tions or tions or

listings.listings.

To prevent damaTo prevent dama

ge to a contrge to a contr

ol sysol sys

tem that uses an alternator or battery-chargingtem that uses an alternator or battery-charging

device, madevice, ma

ke sure the charging device is turnke sure the charging device is turn

ed off before disconned off before disconn

ecting the batteryecting the battery

from the sysfrom the sys

tem.tem.

To prevent damaTo prevent dama

ge to electronic coge to electronic co

mponents caused by impmponents caused by imp

roper handling, readroper handling, read

and observe the precautions in and observe the precautions in

Woodward manuaWoodward manua

8271582715

Guide for Handling andGuide for Handling and

Protection of Electronic Controls, Printed Circuit Boards, and ModulesProtection of Electronic Controls, Printed Circuit Boards, and Modules

Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward isWoodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is

believed to be correct and reliable. Hbelieved to be correct and reliable. H

owever, no responsibilowever, no responsibil

ity is assumed by Woodwity is assumed by Woodw

ard unless otherwise expresslyard unless otherwise expressly

undertaken.undertaken.

All All

RighRigh

ts Rests Res

ervederved

Manual Manual

258258

05 05

3 3

& &

5 5

HP HP

Governor Governor

Test Test

StandStand

Woodward iWoodward i

ContentsContents

HAPTERHAPTER

1.1.

ENERALENERAL

NFORMATIONNFORMATION

............................

... ...

Introduction ............................................................................................................. 1Introduction ............................................................................................................. 1

Description .............................................................................................................. 1Description .............................................................................................................. 1

Test Stand Features ............................................................................................... 1Test Stand Features ............................................................................................... 1

Test Stand ApplicatTest Stand Applicat

ions ions

................................

..................................

................................

....... .......

HAPTERHAPTER

2.2.

NSTALLATIONNSTALLATION

............................

..........................

............................

..... .....

Shipping .................................................................................................................. 5Shipping .................................................................................................................. 5

Receiving ................................................................................................................ 5Receiving ................................................................................................................ 5

LocatioLocatio

n Requiremenn Requiremen

ts ts

................................

..................................

....................................

...... ......

ElectricaElectrica

l l

ConnectiConnecti

ons ons

................................

..................................

................................

..................................

......... .........

Stop Clock (optional) .............................................................................................. 6Stop Clock (optional) .............................................................................................. 6

HydraulHydraul

ic Connectionic Connection

s s

..................................

....... .......

Accessories Accessories

..................

....................

..................

....................

..................

....................

..................

...... ......

HAPTERHAPTER

3.3.

PERATIONPERATION

........................

............................

......... .........

Test Stand Upper Cabinet ...................................................................................... 8Test Stand Upper Cabinet ...................................................................................... 8

Switches On The Back Panel ................................................................................. 8Switches On The Back Panel ................................................................................. 8

Governor FeedbaGovernor Feedba

ck ck

................................

..................................

................................

..................................

............ ............

1111

OperatoOperato

r Control Panel r Control Panel

................................

..................................

...... ......

1212

To Calibrate a Governor ....................................................................................... 13To Calibrate a Governor ....................................................................................... 13

Test Stand Jiggle Test Stand Jiggle

..............................

................................

..................................

................................

..................................

................................

. .

1515

Drive Boards Drive Boards

................................

....................................

..................................

... ...

1616

HAPTERHAPTER

4.4.

AA

CCESSORIESCCESSORIES

..........................

............................

..........................

............................

... ...

1717

Introduction ........................................................................................................... 17Introduction ........................................................................................................... 17

UniversaUniversa

l l

AccessorieAccessorie

s s

..............................

................................

..................................

................................

.......... ..........

1717

HAPTERHAPTER

5.5.

OVERNOROVERNOR

ONNECTIONONNECTION

NSTRUCTIONSNSTRUCTIONS

..........................

............................

.... 26.... 26

Adapter Plates and Adapter Plates and

Drives Drives

..................

....................

..................

....................

..................

. .

2626

Universal Connectors for Test .............................................................................. 26Universal Connectors for Test .............................................................................. 26

HAPTERHAPTER

6.6.

AINTENANCE ANDAINTENANCE AND

ROUBLESHOOTINGROUBLESHOOTING

......................................

.............. ..............

3939

Oil Strainer Oil Strainer

..............................

..................................

................................

..................................

......... .........

3939

Base Contents Base Contents

..............................

..................................

................................

..................................

... ...

3939

Oil Reservoir Oil Reservoir

................................

..................................

................................

..................................

..... .....

3939

Oil Oil

Heater....Heater....

..................................

....................................

..................................

... ...

4040

Cleaning the Table ............................................................................................... 41Cleaning the Table ............................................................................................... 41

Drive Motor Speed Reference .............................................................................. 41Drive Motor Speed Reference .............................................................................. 41

Removal of Drive Adapter and Seal ..................................................................... 41Removal of Drive Adapter and Seal ..................................................................... 41

ElectricaElectrica

l l

Circuits Circuits

................................

..................................

................................

..................................

................................

................ ................

4141

Fuses .................................................................................................................... 42Fuses .................................................................................................................... 42

Drive Motor Maintenance ..................................................................................... 43Drive Motor Maintenance ..................................................................................... 43

Vacuum Generator Vacuum Generator

..............................

..................................

................................

............. .............

4343

Oil Pressure Regulator ......................................................................................... 43Oil Pressure Regulator ......................................................................................... 43

Feedback Potentiometer ...................................................................................... 43Feedback Potentiometer ...................................................................................... 43

Oil Pump Rotation ................................................................................................ 44Oil Pump Rotation ................................................................................................ 44

HAPTERHAPTER

7.7.

EPLACEMENTEPLACEMENT

ARTSARTS

............................

... ...

5151

Parts Information Parts Information

................................

..................................

................................

..................................

................................

................ ................

5151

Governor

Test

Stand

Manual

258

ii Woodward

Contents

HAPTER

RODUCT

UPPORT AND

ERVICE

PTIONS

..............

.............

Product Support Options ......................................................................................

Product Service Options .......................................................................................

Returning Equipment for Repair ...........................................................................

Replacement Parts ...............................................................................................

Engineer

ing

Services

................

.................

..................

.......

Contacting

Woodward’s

Support

Organization ..................

..........

.........

..........

.....

Technical Assistance ............................................................................................

Manual

258

Governor

Test

Stand

Woodward iii

Illustr

ations and Ta

bles

Figure 1-1. All-Electric Test Stand .......................................................................... 2

Figure 2-1. Basic All-Electric Test Stand ................................................................ 4

Figure 2-2. Stop Clock Jumper ............................................................................... 7

Figure 3-1. Test Stand Back Panel ..........................

.................

..................

...........

Figure 3-2. Oil Controls on Side of Test Stand ..........

................

..........

Figure

3-3.

Typical Rotary

Output Connected

Feedback

.........

..........

.....

Figure

3-4.

Linear

Output

Connected

Feedback .

..........

.........

..........

......

Figure

3-5.

Downstroke

Output

Connected

Feedback

..........

.......

Figure 3-6. Operator Control Panel ...................................................................... 11

Figure

4-1.

Test

Stand

with Most

Options Installed

..........

.........

..........

.......

Figure 4-2. Variab

le DC Power Supply ...........................

.................

................

....

Figure

4-3.

Right-Angle Drive

with

EG-3

Actuator ................

..........

.........

Figure 4-4.

Multiplication Drive Assembly

with TG

Adapter and

Governor

..........

Figure

4-5.

Oil

Level

Control

Kit

Governor

........

..........

.........

..........

.........

Figure 4-6. PG Rail Switch Panel ......................................................................... 22

Figure

4-7.

Load

Control Indicator

PG Governor .................

.........

..........

........

Figure 4-8. Optional Air Pressure Layout ............................................................. 24

Figure

4-9.

Functional Drawing

Rail Switch

Panel

.........

..........

.........

Figure 5-1.

PG Power

Case Connections,

PG-PL Connections .........

..........

.......

Figure 5-2. PGA Connections .............................................................................. 29

Figure

5-3.

Lever,

Dial,

PG-PH Connections ......

.........

Figure

5-4.

Test

Stand

Connections

for

Governors .

.........

..........

.........

..........

Figure 5-5.

Test Stand

Connections for

SG, PSG and

TG Governors ................

Figure

5-6.

Test

Stand

Connections

for

EGB

Governors

.........

..........

........

Figure 5-7. Connections for

EGB and PG-200, -300,

and –500

Governors ........

Figure

5-8.

Test

Stand

Connections

for

Actuators

.........

..........

.........

....

Figure

5-9.

Adapters

Needed

for

Various

Governors

.........

..........

.........

..........

.....

Figure

5-10.

Chart

Matching

Adapters

Governors ..........

.........

..........

.........

.....

Figure

5-11.

Governor

Bases

(reference

for

Figure

5-10)

.........

..........

.........

........

Figure 6-1. Interior of Base ................................................................................... 40

Figure 6-2. Interior of Side Door ........................................................................... 40

Figure

6-3.

Drive

Adapter

and

Seal

Installation ..............

..........

.........

..........

........

Figure 6-4. Schematic of Oil Pressure System .................................................... 44

Figure 6-5

a. Interio

r of 3 HP Upper Pan

el Door

.................

................

.................

Figure

6-5b.

Interior

Upper

Panel

..........

.........

..........

.........

..........

Figure 6-5c.

Interior of

Back

Door

HP Test

Stand

.........

..........

.........

...

Figure

6-6.

Schematic of

Electric Test

Stand

.........

..........

.........

..........

........

Figure

6-7.

Wiring Layout

Electric Test

Stand

.........

..........

...

Figure 6-8. Schematic of 5 HP Test Stand ........................................................... 49

Figure 6-9

. Wiring Lay

out of 5 HP Test Sta

................

.................

....

Figure 7-1. Test Stand Cabinet ............................................................................ 53

Figure

7-2.

Test

Stand

Drive

and

Hydraulic

System ....

..........

.........

..........

Figure 7-3. Upper Cabinet Connections ............................................................... 56

Figure

7-4.

Inside

Upper Cabinet

Door .............

.........

..........

.........

..........

....

Figure 7-5. Operator Control Panel ...................................................................... 59

Figure 7-6. Back of Upper Panel .......................................................................... 60

Figure 7-7. PGE Governor Switch Kit ................................................................... 62

Figure 7-8

. Upper Cabinet Do

or for 5 HP Stand ..............................

................

....

Governor

Test

Stand

Manual

258

iv Woodward

Manual

258

Governor

Test

Stand

Woodward 11

Governor

edback

Feedback Potentiometer

A portable potenti

ometer, driven by a com

bination of a return sp

ring and

monofilament line, provides the feedback needed to calibrate and check a

governor. The test stand's universal output lever is attached to the output shaft of

the actuator or governor under test. The monofilament line is then attached to the

universal lever with the take-up spool either 20 degrees before the maximum

stop or 20 degrees in front of the

minimum stop. Figures 3-3, 3-4, and 3-5 show

methods of connecting the feedback system to various governor outputs.

Figure 3-3. Typical Rotary Output

Connected to Feedback

Figure 3-4. Linear Output Connected

to Feedback

Figure 3-5. Downstroke Output

Connected to Feedback

Figure 3-6. Operator Control Panel

Governor

Test

Stand

Manual

258

12 Woodward

Opera

tor

Control

nel

The Operator Control Panel, on the left-hand side of the test stand, provides the

switches and controls which are needed to test most governors.

A n

ber

es an

d c

need

ed t

o t

est

elec

accessories on PG R

ail governors are mount

ed in an Accessory

Panel on top of the Operator Control Panel. These switches are

described in Chapter 4 (Accessories).

Dire

ct A

cting/Re

verse Acting

witch

This switch is up (at Direct Acting) when the output shaft of the governor being

calibrated pulls the monofilament line from the feedback

spool on increase fuel.

This switch is down (at Reverse Acting) when the output shaft of the governor

being calibrated pulls the monofilament line from the feedback spool on decrease

fuel. The pulley on the

feedback potentiometer must turn counterclockwise to

increase when the switch is up and clockwise to increase when the switch is

down. When the lever switch is down, the pulley takes up line on

increased fuel.

Increase Speed, C

entering

This adjustment sets the drive speed of the test stand, clockwise for increased

speed and counterclockwise for reduced speed. Test stand drive speed is

adjusted to center the output of the governor at a

given governor speed setting.

The electric motor circuits are protected from

unintentional overloads by requiring

that this potentiometer always be at

the minimum (counterclockwise) setting

before the START button can activate

the drive circuit.

Increase Gain–Sensitivity

This potentiometer, turned counterclockwise, retards the rate of response

of the

test stand drive motor to

a speed change.

On initial operation, this potentiometer

should be set totally counterclockwise. After the test stand drive is set at the

desired speed, the Increase Gain–Sensitivity potentiometer should be

turned

clockwise until the governor being

tested loses stability. Response time can then

be set in the counterclockwise direction until governor stability is reached under

control of the feedback potentiometer connected to the governor output.

The response time set by

the Increase Gain-Sensitivity potentiometer is not

related to the ability of the governor to respond to speed

changes, but rather to

the ability of the

governor to operate with acceptable stability.

The sensitivity pot may be locked in a desired position. To lock the setting, turn

the button on the back of

the adjustment clockwise. To unlock, turn the button

counterclockwise.

Drive M

otor Butt

ons

(Black button is the START button, red

button is the STOP button.)

The electrical circuits in the test stand

automatically open the run circuits when

the stop switch is pushed in or when

an overload occurs. The run circuit is

always opened when the

forward-reverse switch is moved.

When the run circuit is opened, it cannot be

reinstated by the START button until

the Increase Speed–Centering potentiometer is turned counterclockwise to "0".

The START button likewise does not start the drive motor, as this must be done

by advancing the Increase

Speed-Centering potentiometer after the circuit is

energized by the START button.

Manual

258

Governor

Test

Stand

Woodward 13

When the motor is stopped by use of

the potentiometer, the run circuit does not

open, and restarting is

possible by adjusting the potentiometer.

Reversing the drive direction always opens

the drive circuit, and the

START

button must be used, even if the speed

adjusting potentiometer is at "0".

Drive Moto

r Direct

ion

(CW

CW)

When this two-position switch is "up"

(CW/clockwise) the drive shaft turns

clockwise. When this switch is "down"

(CCW/counterclo

ckwise), the drive shaft

turns counterclockwise.

If this switch is changed, it causes the motor circuit to open. The Centering

(speed-adjustment) potentiometer then has to be moved to the zero-speed

setting and the START button pushed before the motor can be restarted.

Load

The test stand is equipped with a control circuit which simulates load to an

engine. When the Load switch is held down, the

drive speed increases or

decreases by an amount determined by the setting of

the Load Potentiometer on

the operator control panel. With the speed change, the governor under

test

should call for a change in fuel setting with the test-stand drive responding to the

output of the portable feedback potentiometer. The load switch tests a governor's

ability to return to normal after a load transient. The feature is also used to test

droop settings.

To Ca

libr

ate a G

overnor

Select the drive adapter with the proper serration or keyway and the drive

coupling (if needed) for the test stand motor. Select the proper pilot adapter plate

to fit the governor base to the

stand. Clamp the governor to the stand and

adapter plate with the two hold-down clamps provided (see Chapter 5).

Attach the applicable

oil lines betw

een the governor and the test

stand. The valve

on the right-hand side of the test stand

is the oil fill connection. A second valve

on the side of the test stand

is optional and provides pressure oil to test certain

hydraulic options on governors. To fill a governor, first establish the desired oil

pressure (indicated on the Test Stand Oil Pressure Gauge) by adjusting the

pressure-regulating valve on the right-hand side of the test stand (10 to 30

psi /

70 to 210 kPa is normally adequate). Connect a

fill line to the governor and

adjust flow to the

governor with the fill valve.

Oil is drained through the slotted screen on the test stand

table, through an oil

return line to the side of the lower stand, or

through the governor drive. The oil

return line is generally preferred over the table drain because it allows return oil

to retain its heat, without heating

the table.

An optional oil l

evel control is avai

lable to allow hot

test stand oil t

o circulate

through governors with self-contained sumps, reducing the

warm-up time

required before testing the governor.

Oil from the oil level control

option supplies

the governor. The governor drain is then connected to the

oil return line or

opened onto the test stand table.

Manual

258

Governor

Test

Stand

Woodward 17

Chapt

er 4.

A

Introduction

Figure 4-1. Test Stand with Most Options Installed

Several accessories are available for the

Woodward Electric Test Stand. These

range from drive multipliers for testing high-speed

governors to special electrical

services to allow testing of electric so

lenoids and electric-hydraulic actuators.

Universal Accessories

Ai

r Pr

ess

e/Vacuu

m A

ess

ies

Many Electric Test Stands feature an

optional air pressure/vacuum accessory

panel. The air pressure system accepts a maximum of 200 psi (1380

kPa)

compressed air at a fitting on the upper back

of the control panel. A filter is

supplied at this fitting when the vacuum accessory is included on the stand.

Various gauges are available to provide the accuracy of measurement and size

of gauge needed by the

particular test conditions.

uges used in

the air pressure accessories can b

e damage

d by

pressures above the dial limit.