Woodward 721 User manual

Product Manual 02714
(Revision A)
Original Instructions
721 Digital Control
8280-133, 8280-134, 9906-118, 9906-119
Hardware Only
Hardware Manual

DEFINITIONS
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
DANGER—Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING—Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION—Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE—Indicates a hazard that could result in property damage only (including
damage to the control).
IMPORTANT—Designates an operating tip or maintenance suggestion.
The engine, turbine, or other type of prime mover should be equipped with an
overspeed shutdown device to protect against runaway or damage to the prime
mover with possible personal injury, loss of life, or property damage.
The overspeed shutdown device must be totally independent of the prime mover
control system. An overtemperature or overpressure shutdown device may also
be needed for safety, as appropriate.
Read this entire manual and all other publications pertaining to the work to be performed before
installing, operating, or servicing this equipment. Practice all plant and safety instructions and
precautions. Failure to follow instructions can cause personal injury and/or property damage.
This publication may have been revised or updated since this copy was produced. To verify that
you have the latest revision, be sure to check the publications page on the Woodward website:
www.woodward.com/publications
The current revision and distribution restriction of all publications are shown in manual 26311.
The latest version of most publications is available on the publications page. If your publication is
not there, please contact your customer service representative to get the latest copy.
Any unauthorized modifications to or use of this equipment outside its specified mechanical,
electrical, or other operating limits may cause personal injury and/or property damage, including
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.
To prevent damage to a control system that uses an alternator or batter
y
-charging
device, make sure the charging device is turned off before disconnecting the battery
from the system.
To prevent damage to electronic components 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.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken. Copyright © Woodward 1994
All Rights Reserved

Manual 02714 721 Digital Control Hardware Manual
Woodward i
Contents
ELECTROSTATIC DISCHARGE AWARENESS .................................................. II
CHAPTER 1. GENERAL INFORMATION...........................................................1
Introduction.............................................................................................................1
Application..............................................................................................................1
Control Options.......................................................................................................1
721 Digital Speed Control Accessories..................................................................2
CHAPTER 2. INSTALLATION..........................................................................5
Scope......................................................................................................................5
Unpacking...............................................................................................................5
Power Requirements..............................................................................................5
Location Considerations.........................................................................................5
Internal Jumpers.....................................................................................................6
Electrical Connections............................................................................................6
Installation Checkout Procedure ..........................................................................10
CHAPTER 3. ENTERING CONTROL SET POINTS...........................................12
Introduction...........................................................................................................12
Hand Held Programmer and Menus.....................................................................12
CHAPTER 4. FUNCTION BLOCK DIAGRAM...................................................15
CHAPTER 5. PRODUCT SUPPORT AND SERVICE OPTIONS...........................17
Product Support Options......................................................................................17
Product Service Options.......................................................................................17
Returning Equipment for Repair...........................................................................18
Replacement Parts...............................................................................................18
Engineering Services............................................................................................19
Contacting Woodward’s Support Organization ....................................................19
Technical Assistance............................................................................................20
721 CONTROL SPECIFICATIONS.................................................................21
Illustrations and Tables
Figure 1-1. 721 Digital Speed Control....................................................................3
Figure 1-2. Hand Held Programmer.......................................................................4
Figure 3-1. 721 Control Internal Jumpers...............................................................7
Figure 3-2. 721 I/O ...............................................................................................11
Figure 4-1. Hand Held Programmer Functions ....................................................14

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ii Woodward
Electrostatic Discharge Awareness
All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
1. Before doing maintenance on the electronic control, discharge the static
electricity on your body to ground by touching and holding a grounded metal
object (pipes, cabinets, equipment, etc.).
2. 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
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 board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
Do not touch any part of the PCB except the edges.
Do not touch the electrical conductors, the connectors, or the
components with conductive devices or with your hands.
When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
To prevent damage to electronic components 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.

Manual 02714 721 Digital Control Hardware Manual
Woodward 1
Chapter 1.
General Information
Introduction
This manual describes the Woodward 721 Digital Control hardware, 8280-133
(low voltage), 8280-134 (high voltage), 9906-118 (low voltage, marine type
approval), and 9906-119 (high voltage, marine type approval).
Application
The 721 Digital Control can be programmed to suit applications requiring two
magnetic pickups (MPUs) or proximity switches (such as for torsional filtering) as
the hardware includes two speed inputs. It also includes four analog inputs, three
analog outputs, eight discrete inputs and three discrete outputs, all of which can
be programmed to satisfy the application. The control can be used in load
sharing systems as it contains circuitry and connections to deal with this.
The 721 control (Figure 1-1) consists of a single printed circuit board in a sheet-
metal chassis. Connections are via three terminal strips and a 9-pin subminiature
D connector.
Control Options
The 721 control requires the following power supply input voltages, with 18 watts
as the nominal power consumption at rated voltage:
18–32 Vdc (24 Vdc nominal)
88–132 Vac 45–65 Hz (120 Vac nominal)
90–150 Vdc (125 Vdc nominal)
Discrete input voltages provide on/off command signals to the electronic control.
Each discrete input requires 10 mA at its 24 Vdc nominal voltage rating (for 24
volt switching logic).
Other control options are:
proximity switch input for speed signal frequencies below 100 Hz
tandem actuator outputs
The control may be used with either proximity switches or magnetic pickups. The
minimum frequency for steady state speed control is 7.5 Hz. For more
information see Control Specifications (inside back cover).

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721 Digital Speed Control Accessories
Hand Held Programmer (Figure 1-2), part number 9905-292, is used for adjusting
the 721 control. It plugs into the serial port of the control.
SPM-A Synchronizer, for synchronizing the generator phase to that of the power
bus. The synchronizer generates a close generator breaker signal to parallel the
generator with the power bus.
Power Output Sensor, for load sharing or droop operation in mechanical load
applications.
Real Power Sensor, for load sharing or droop-parallel generator applications.

Manual 02714 721 Digital Control Hardware Manual
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DIGITAL CONTROL
Figure 1-1. 721 Digital Speed Control

721 Digital Control Hardware Manual Manual 02714
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Figure 1-2. Hand Held Programmer

Manual 02714 721 Digital Control Hardware Manual
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Chapter 2.
Installation
Scope
This chapter contains general installation instructions for the 721 control. Power
requirements, environmental precautions, and location considerations are
included to help you determine the best location for the control. Additional
information includes unpacking instructions, electrical connections, and
installation checkout procedures.
Unpacking
Before handling the control, read page ii, Electrostatic Discharge Awareness. Be
careful when unpacking the electronic control. Check the control for signs of
damage such as bent panels, scratches, and loose or broken parts. If any
damage is found, immediately notify the shipper.
Power Requirements
The high-voltage versions of the 721 Digital Speed Control require a voltage
source of 88 to 132 Vac 45 to 65 Hz or 90 to 150 Vdc. The low-voltage versions
require a voltage source of 18 to 32 Vdc.
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 turned off or disconnected before
disconnecting the battery from the control.
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 devices, or devices which
produce electromagnetic interference
avoidance of vibration
selection of a location that will provide an operating temperature range of
–40 to +70 °C (–40 to +158 °F)
The control must NOT be mounted on the engine.

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Internal Jumpers
The 721 control has nine, two-position internal jumpers (JPR1 through JPR18)
located on the top of the printed circuit board. If it is necessary to change any
jumper to match your control requirements, and this suits the nature of the
software, be sure to read page ii, Electrostatic Discharge Awareness.
With the power off, remove the control cover. With your fingers or a small pair of
tweezers, carefully remove the appropriate jumper and replace it securely over
the proper two connectors (see Figure 3-1).
The jumper connections are listed:
JPR1 analog output #1 0–1 mA
JPR2 analog output #1 0–20 mA
JPR3 analog output #2 0–1 mA
JPR4 analog output #2 0–20 mA
JPR5 analog output #3 0–1 mA
JPR6 analog output #3 0–20 mA
JPR8 & JPR9 actuator output 0–200 mA, single
JPR8 & JPR10 actuator output 0–20 mA, single
JPR7 & JPR9 actuator output 0–160 mA, tandem
JPR11 & JPR15 speed sensor #1 proximity switch
JPR12 & JPR16 speed sensor #1 magnetic pickup
JPR13 & JPR17 speed sensor #2 proximity switch
JPR14 & JPR18 speed sensor #2 magnetic pickup
Electrical Connections
External wiring connections and shielding requirements for each installation are
shown in Chapter 5 of the software manual appropriate to the application.
Shielded Wiring
All shielded cable must be twisted conductor pairs. Do not attempt to tin the
braided shield. All signal lines should be shielded to prevent picking up stray
signals from adjacent equipment. Connect the shields to the nearest chassis
ground. Wire exposed beyond the shield should be as short as possible, not
exceeding 50 mm (2 inches). The other end of the shields must be left open and
insulated from any other conductor. DO NOT run shielded signal wires along with
other wires carrying large currents. See Woodward application note 50532, EMI
Control for Electronic Governing Systems, for more information.

Manual 02714 721 Digital Control Hardware Manual
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Figure 3-1. 721 Control Internal Jumpers

721 Digital Control Hardware Manual Manual 02714
8 Woodward
Where shielded cable is required, cut the cable to the desired length and prepare
the cable as instructed below.
1. Strip outer insulation from BOTH ENDS, exposing the braided or spiral
wrapped shield. DO NOT CUT THE SHIELD.
2. Using a sharp, pointed tool, carefully spread the strands of the shield.
3. Pull inner conductor(s) out of the shield. If the shield is the braided type,
twist it to prevent fraying.
4. Remove 6 mm (1/4 inch) of insulation from the inner conductors.
Installations with severe electromagnetic interference (EMI) may require
additional shielding precautions. Contact Woodward for more information.
Power Supply (Terminals 1/2)
Power supply output must be low impedance (for example, directly from
batteries). DO NOT power the control from high-voltage sources with resistors
and zener diodes in series with the control power input. The 721 control contains
a switching power supply which requires a current surge to start properly.
To prevent damage to the control, do not power a low-voltage control
from high-voltage sources, and do not power any control from high-
voltage sources 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. Connect the positive (line) to terminal 1 and negative
(common) to terminal 2. If the power source is a battery, be sure the system
includes an alternator or other battery-charging device.
If possible, do NOT turn off control power as part of a normal shutdown
procedure. Leave the control powered except for service of the system and
extended periods of disuse.
Do NOT apply power to the control at this time. Applying power may
damage the control.
To prevent damage to the engine, apply power to the 721 control at
least ten seconds prior to starting the engine. The control must have
time to do 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.

Manual 02714 721 Digital Control Hardware Manual
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Analog Outputs (#1, #2, & #3)
Use shielded twisted-pair wires to connect to terminals 9(+) & 10(–), 11(+) &
12(–) and 13(+) & 14(–). For an electrically isolated input device such as a 4 to
20 mA input analog meter, the shield should be grounded at the control end of
the cable. For input to other devices, use the recommendation of the device
manufacturer.
To prevent possible damage to the control or poor control
performance resulting from ground loop problems, we recommend
using current-loop isolators if the 721 control's analog inputs and
outputs must both be used with non-isolated devices. A number of
manufacturers offer 20 mA loop isolators. Consult Woodward for
further information.
Actuator Output (Terminals 15/16)
The actuator wires connect to terminals 15(+) and 16(–). Use shielded wires with
the shield connected to chassis at the control.
Speed Signal Inputs (Terminals 17/18 & 19/20)
Connect a magnetic pick-up (MPU) or proximity switch to terminals 17 and 18.
You may need to connect a second MPU/proximity switch to terminals 19 and 20
(see relevant application manual). Use shielded wire for all speed sensor
connections. Connect the shield to the chassis. Make sure the shield has
continuity the entire distance to the speed sensor, and make sure the shield is
insulated from all other conducting surfaces.
The number of gear teeth is used by the control to convert pulses
from the speed sensing device to engine rpm. To prevent possible
serious injury from an overspeeding engine, make sure the control is
properly programmed to convert the gear-tooth count into engine
rpm. Improper conversion could cause engine overspeed.
Aux Voltage Input (Load Sharing Lines; Terminals 21/22)
Connect the output of a Woodward Load Sensor, or another 721 control's load
sharing lines, to terminals 21(+) and 22(–). Use a shielded twisted-pair cable.
Wire the remainder of the load sensor in accordance with the wiring diagram for
the sensor used.
Discrete Inputs (Terminals 25–32)
Discrete inputs are the switch input commands to the 721 control. In low voltage
systems, or other systems where nominal 24 Vdc is available, the discrete inputs
should be powered by this external voltage.

721 Digital Control Hardware Manual Manual 02714
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If you are using the control-supplied aux voltage, which is recommended only for
high voltage systems where 24 Vdc is not available, jumper terminal 23 to
terminal 24. This connects the control's common to the discrete input common.
Terminal 15 then supplies power (approximately +21 Vdc) to the discrete inputs.
Since the aux voltage is not isolated from other control circuits, use only isolated
contacts (dry or signal voltage rated) for the discrete circuits. DO NOT POWER
ANY OTHER DEVICES WITH THE AUX VOLTAGE SOURCE.
If you are supplying the discrete input voltage (24 Vdc), connect the voltage
source negative (–) to terminal 24. Then run the voltage source positive (+) to the
appropriate switch or relay contact and then to the corresponding discrete input.
Analog Inputs (#1, #2, #3, & #4)
Use shielded twisted-pair cable to connect to terminals 36(+) & 37(–), 39(+) &
40(–), 42(+) & 43(–) and 45(+) & 46(–). Ensure that a jumper is installed between
relevant terminals (35 & 36 - #1, 38 & 39 - #2, 41 & 42 - #3, 44 & 45 - #4) for the
mA input. These inputs are not isolated from the other control inputs and outputs
(except the power supply input and the discrete inputs). If any other analog input
or output is used in a common ground system, an isolator must be installed. A
number of manufacturers offer 20 mA loop isolators. Consult Woodward for
further information.
Installation Checkout Procedure
With the installation complete, do the following checkout procedure before
beginning set point entry or initial start-up adjustments.
1. Visual inspection
A. Check the linkage between the actuator and fuel metering device for
looseness or binding. Refer to the appropriate actuator manual, and
Manual 25070, Electronic Governor Installation Guide, for additional
information on linkage.
To prevent possible serious injury from an overspeeding engine, the
actuator lever or stroke should be near but not at the minimum
position when the fuel valve or fuel rack is at the minimum fuel
delivery position.
B. Check for correct wiring in accordance with the plant wiring diagram,
(see relevant Application Manual).
C. Check for broken terminals and loose terminal screws.
D. Check the speed sensor(s) for visible damage. If the sensor is a
magnetic pickup, check the clearance between the gear and the
sensor, and adjust if necessary. Clearance should be between 0.25
and 1.25 mm (0.010 and 0.050 inch) at the closest point. Make sure the
gear runout does not exceed the pickup gap.

Manual 02714 721 Digital Control Hardware Manual
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2. Check for grounds
Check for grounds by measuring the resistance from all control terminals to
chassis. All terminals except terminals 2 and 24 should measure infinite
resistance (the resistance of terminals 2 and 24 depends on whether a
floating or grounded power source is used). If a resistance less than infinite
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.
Figure 3-2. 721 I/O

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Chapter 3.
Entering Control Set Points
Introduction
Due to the variety of installations, plus system and component tolerances, the
721 control must be tuned to each system for optimum performance.
This chapter contains information on how to enter control set points through the
control's menu system using the Hand Held Programmer.
An improperly calibrated control could cause an engine overspeed or
other damage to the engine. To prevent possible serious injury from
an overspeeding engine, read this entire procedure before starting
the engine.
Hand Held Programmer and Menus
The Hand Held Programmer is a hand-held computer terminal that gets its power
from the 721 control. The terminal connects to the RS-422 communication serial
port 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 information relating to the application. Pressing the 'ID' key
will change the display to show the part number of the software and version
letter.
The programmer screen is a four-line, backlighted LCD display. The display
permits you to look at two separate functions or menu items at the same time.
Use the “Up/Down Arrow” key to toggle between the two displayed items. The
BKSP and SPACE keys will scroll through the display to show the remainder of a
prompt if it is longer than the display screen's 18 characters.
The 721 has two sets of menus; the Service menus and the Configure menus.
The Service menus allow easy access and tuning while the engine is running.
The Configure menus may only be entered if the I/O is shutdown, and hence the
engine stopped.
Configure Menus
To access the Configure menus, the engine must be shutdown. Press the . key.
The display will show, 'To select configure, press enter'. Press the ENTER key
and the display will show, 'To shutdown I/O, press enter'. Press the ENTER key
and this will allow you into the Configure menus. Note: If the engine is running
during this process, it will be shutdown due to shutting down the I/O of the
control. To move between the menus use the and keys. To move through
the set points within a menu, use the and keys. Once within a menu, to
return to the menu header, press the ESC key.

Manual 02714 721 Digital Control Hardware Manual
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To leave the Configure menus press the ESC key. The set points will be
automatically saved when leaving Configure.
Service Menus
To access the Service menus press the key. To move between menus, and to
move through set points within menus follow the instructions as for the Configure
menus. Also to return to return to the menu header, or to leave Service, follow
the Configure instructions.
Adjusting Set Points
To adjust a set point, use the “Turtle Up” or the “Rabbit Up” keys to increase the
value, and the “Turtle Down” or “Rabbit Down” keys to decrease the value. The
“Rabbit Up” and “Rabbit Down” keys will make the rate of change faster than the
“Turtle Up” and “Turtle Down” keys. This is useful during initial setup 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.
This may only be done if the figure is within 10% of the existing
value.
To save set points at any time, use the SAVE key. This will transfer all new set
point values into the EEPROM memory. The EEPROM retains all set points
when power is removed from the control.
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 saved settings.
Hand Held Programmer Keys
The programmer keys do the following functions (see Figure 4-1):
(left arrow) Moves backward through Configure or Service, one
menu at a time.
(right arrow) Advances through Configure or Service, one menu at a
time.
(up/down arrow) Toggles between the two displayed items.
(up arrow) 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 set point value quickly (about
10 times faster than the turtle keys).

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– (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 Displays the 721 control part number and software
revision level.
ESC To return to menu header or to main screen.
SAVE Saves entered values (set points).
BKSP Scrolls left through line of display.
SPACE Scrolls right through line of display.
ENTER Used when entering exact values and accessing
Configure.
= (equals) For entering exact values (within 10%).
(decimal) To select Configure.
Figure 4-1. Hand Held Programmer Functions

Manual 02714 721 Digital Control Hardware Manual
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Chapter 4.
Function Block Diagram
This chapter provides a description of the how to use a function block diagram,
which can be found in the relevant application manual.
The function block diagram is a form of flow chart which has been designed
specifically for the application and is a representation of the software and it's
interface to the control hardware. It uses special symbols, some of which are
unique to Woodward; each symbol is identified and described in the first sheet of
the function block diagram. The function block diagram is drawn as a design aid
to act as an interface between the Woodward application engineer and the
customer in defining the control function. The third sheet of the diagram is a
complete overview of the control software.
The function block diagram is divided into separate categories, each representing
a different function of the software. Common categories used are:
ENGINE SPEED
SPEED REFERENCE
DROOP
KW LOAD
ACTUATOR DRIVER
SHUTDOWN
The adjustable parameters of the control can be identified in the function block
diagram by an S or a C within a circle, along with text explaining what the tunable
is. Those denoted by an S can be found in the Service menus, and those
denoted by a C will be found in the Configure menus (see Chapter 4). The name
of the category is found at the bottom of the page. Above this is written the name
of the Service or Configure menu under which any tunables in that category can
be found.
The diagram is made up of a combination of different blocks connected together.
Signal values into a block are depicted by an arrow, and logical inputs without an
arrow. Tie points are used to show blocks from different categories linked
together. Each tie point is repeated at the top of the page with the page numbers
of the categories to which it is connected. This allows quick location of
connections between categories.
Two vertical dashed lines on each page show the software/hardware interface,
the area in between the lines, detailing the application software. To the left of the
left line are the control inputs, whilst to the right of the right line, are the control
outputs.
The second page gives a list of the I/O functions dedicated to the application and
a list of functions causing shutdown.

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Example:
The speed inputs are shown to the left of the left dashed line, which represents
the hardware inputs. To the right of the right dashed line is an output to the
hardware, which in turn, is an output to the customer.
To enable the torsional filter:
Select Configure mode
Scroll left or right through each menu until the "SPEED" menu is located
Scroll down through menu. All Configure values found in the SPEED
category will be located in this menu, including the 'TORSIONAL FILTER' set
point
To adjust the filter value:
Select Service mode
Scroll left or right through each menu until the "SPEED" menu is located
Scroll down through menu. All Service values found in the SPEED category
will be located in this menu, including the 'FILTER VALUE' set point