Woodward 8280-464 User manual

Product Manual 02883
(Revision B)
Original Instructions
723PLUS Digital Speed Control for
Reciprocating Engines—Process Control
8280-464, 8280-465
Installation and Operation Manual

General
Precautions
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.
Revisions
This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, on the publications
page of the Woodward website:
www.woodward.com/publications
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.
Proper Use
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.
Translated
Publications
If the cover of this publication states "Translation of the Original Instructions"
please note:
The original source of this publication may have been updated since this
translation was made. Be sure to check manual 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.
Revisions—Changes in this publication since the last revision are indicated by a black line
alongside the text.
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 1998
All Rights Reserved

Manual 02883 723PLUS/Process Control
Woodward i
Contents
WARNINGS AND NOTICES........................................................................... IV
ELECTROSTATIC DISCHARGE AWARENESS ..................................................V
CHAPTER 1. GENERAL INFORMATION...........................................................1
Introduction.............................................................................................................1
Declaration of Incorporation ...................................................................................1
Application..............................................................................................................1
Control Options.......................................................................................................2
723PLUS Digital Speed Control Accessories.........................................................3
CHAPTER 2. INSTALLATION........................................................................10
Introduction...........................................................................................................10
Unpacking.............................................................................................................10
Power Requirements............................................................................................10
Location Considerations.......................................................................................10
Internal Jumpers...................................................................................................11
Electrical Connections..........................................................................................11
CHAPTER 3. ENTERING CONTROL SET POINTS...........................................25
Introduction...........................................................................................................25
Watch Window PC Interface.................................................................................25
723PLUS Control View.........................................................................................26
Hand Held Programmer and Menus.....................................................................39
Configuration Menu Descriptions.........................................................................42
Service Menu Descriptions...................................................................................54
CHAPTER 4. INITIAL ADJUSTMENTS ...........................................................86
Introduction...........................................................................................................86
Start-up Adjustments............................................................................................86
Dynamic Adjustments...........................................................................................87
Speed Adjustments ..............................................................................................89
Conclusion of Setup Procedures..........................................................................89
CHAPTER 5. DESCRIPTION OF OPERATION.................................................90
General.................................................................................................................90
Control Dynamics.................................................................................................90
Speed Input..........................................................................................................92
Torsional Filter Function.......................................................................................92
Notch Filter Function ............................................................................................93
Minimum Fuel Function........................................................................................93
Maximum Fuel Function.......................................................................................93
Start Limit Function...............................................................................................94
Fuel Limiting Function ..........................................................................................95
Actuator Function .................................................................................................96
Speed Failures .....................................................................................................96
Alarm Reset..........................................................................................................96
Speed and Process Reference and Ramps.........................................................97
Process Control..................................................................................................102
Droop..................................................................................................................104
Power-Up Diagnostics........................................................................................104
CHAPTER 6. TROUBLESHOOTING.............................................................105
General...............................................................................................................105
Troubleshooting Procedure................................................................................105
Control Test and Calibration...............................................................................105
Conclusion of Test and Calibration Procedures.................................................109

723PLUS/Process Control Manual 02883
ii Woodward
Contents
CHAPTER 7. PRODUCT SUPPORT AND SERVICE OPTIONS .........................110
Product Support Options....................................................................................110
Product Service Options.....................................................................................110
Returning Equipment for Repair.........................................................................111
Replacement Parts.............................................................................................111
Engineering Services..........................................................................................112
Contacting Woodward’s Support Organization ..................................................112
Technical Assistance..........................................................................................113
APPENDIX A. SERIAL COMMUNICATION PORT WIRING ..............................114
Grounding and Shielding....................................................................................116
APPENDIX B. LINKNET™I/O NETWORK....................................................117
Introduction.........................................................................................................117
Network Architecture ..........................................................................................117
Hardware............................................................................................................117
I/O Module Specifications...................................................................................117
Individual I/O Module Specifications...................................................................119
LINKnet I/O Module Descriptions.......................................................................119
Discrete Input Module.........................................................................................121
4–20 mA Input Module .......................................................................................123
Thermocouple Input Module...............................................................................125
RTD Input Module ..............................................................................................127
Relay Output Module..........................................................................................129
4–20 mA Output Module.....................................................................................131
Troubleshooting Flowchart.................................................................................135
Wiring and Proper Cable....................................................................................135
Cable Length and Number of LINKnet I/O Modules...........................................136
APPENDIX C. MODBUS SLAVE ADDRESS INFORMATION ............................137
Part Numbers 8280-464/-465.............................................................................137
APPENDIX D. PROGRAMMING CHECKLIST.................................................144
Configure Menus ................................................................................................144
Service Menus....................................................................................................147
APPENDIX E. MENU SUMMARY.................................................................161
Configure Menus ................................................................................................161
Service Menus....................................................................................................162
723PLUS CONTROL SPECIFICATIONS......................................................167

Manual 02883 723PLUS/Process Control
Woodward iii
Illustrations and Tables
Figure 1-1. Flexible Coupled Driven Load..............................................................2
Figure 1-2. 723PLUS Digital Speed Control...........................................................4
Figure 1-3. Watch Window Display ........................................................................5
Figure 1-4. Hand Held Programmer.......................................................................6
Figure 1-5. Typical 723PLUS Connections............................................................7
Figure 1-6a. Control Wiring Diagram......................................................................8
Figure 1-6b. Control Wiring Diagram......................................................................9
Figure 3-1. 723PLUS Control Internal Jumpers...................................................12
Figure 4-1. Hand Held Programmer Functions ....................................................42
Figure 4-2. Control Gain as a Function of Speed Error........................................59
Figure 4-3. Control Gain as a Function of Control Output....................................59
Figure 4-4. Typical Transient Response Curves..................................................60
Figure 4-5. Speed Filter........................................................................................61
Figure 4-6. Notch Filter.........................................................................................64
Figure 4-7. Start Limit Function............................................................................65
Figure 4-8. Torque Limit Curve ............................................................................69
Figure 4-9. Droop Curve.......................................................................................70
Figure 6-1. Simplified Block Diagram...................................................................92
Figure 6-2. Start Limit Function............................................................................94
Figure 6-3. Fuel Limit Breakpoints .......................................................................95
Figure 6-4. Remote Speed Reference .................................................................99
Figure 6-5. Droop Speed Setting........................................................................104
Figure A-1. 723PLUS RS-232 Connections.......................................................114
Figure A-2. 723PLUS RS-422 Connections with Optional Termination at
Receiver.........................................................................................114
Figure A-3. 723PLUS RS-485 Connections with Optional Termination.............115
Figure A-4. RS-422 Terminator Locations..........................................................115
Figure A-5. Preferred Multipoint Wiring Using Shielded Twisted-pair Cable with a
Separate Signal Ground Wire........................................................116
Figure A-6. Alternate Multipoint Wiring Using Shielded Twisted-pair Cable without
a Separate Signal Ground Wire.....................................................116
Figure B-1. LINKnet Relay Contacts..................................................................118
Figure B-2. Outline Drawing of I/O Module ........................................................120
Figure B-3. Discrete Input Module Block Diagram.............................................121
Figure B-4. Discrete Input Module Wiring Diagram............................................122
Figure B-5. 4–20 mA Input Module Block Diagram............................................123
Figure B-6. 4–20 mA Input Module Wiring Diagram ..........................................124
Figure B-7. Thermocouple Input Module Block Diagram...................................125
Figure B-8. Thermocouple Input Module Wiring Diagram..................................126
Figure B-9. RTD Input Module Block Diagram...................................................127
Figure B-10. RTD Input Module Wiring Diagram ...............................................128
Figure B-11. Relay Output Module Block Diagram............................................129
Figure B-12. Relay Output Module Wiring Diagram...........................................130
Figure B-13. 4–20 mA Output Module Block Diagram.......................................131
Figure B-14. 4–20 mA Output Module Wiring Diagram......................................132
Figure B-15a. Troubleshooting Flowchart (1 of 2)..............................................133
Figure B-15b. Troubleshooting Flowchart (2 of 2)..............................................134
Figure B-16. Direct Wired Network.....................................................................136
Figure B-17. Network Wired Via Stubs...............................................................136
Table 1-1. LINKnet Modules (Summary)................................................................3
Table 1-2. LINKnet Modules (Address)..................................................................3

723PLUS/Process Control Manual 02883
iv Woodward
Warnings and Notices
Important 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.
Overspeed /
Overtemperature /
Overpressure
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.
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 considered includes but is not
limited to:
Eye Protection
Hearing Protection
Hard Hat
Gloves
Safety Boots
Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.
Start-up
Be prepared to make an emergency shutdown when starting the
engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
Automotive
Applications
On- and off-highway Mobile Applications: Unless Woodward's control
functions as the supervisory control, customer should install a
system totally independent of the prime mover control system that
monitors for supervisory control of engine (and takes appropriate
action if supervisory control is lost) to protect against loss of engine
control with possible personal injury, loss of life, or property damage.

Manual 02883 723PLUS/Process Control
Woodward v
Battery Charging
Device
To prevent damage to a control system that uses an alternator or
battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.
Electrostatic Discharge Awareness
Electrostatic
Precautions
Electronic controls contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts:
Discharge body static before handling the control (with power to
the control turned off, contact a grounded surface and maintain
contact while handling the control).
Avoid all plastic, vinyl, and Styrofoam (except antistatic versions)
around printed circuit boards.
Do not touch the components or conductors on a printed circuit
board with your hands or with conductive devices.
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.
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
as possible because these do not store static electric charges as much as
synthetics.
2. 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.

723PLUS/Process Control Manual 02883
vi Woodward

Manual 02883 723PLUS/Process Control
Woodward 1
Chapter 1.
General Information
Introduction
This manual describes the Woodward 723PLUS Digital Industrial Speed/Process
Control, models 8280-464 (low voltage) and 8280-465 (high voltage).
Declaration of Incorporation
In accordance with the EMC Directive 89/336/EEC and its amendments, this
controlling device, manufactured by the Woodward Governor Company, is
applied solely as a component to be incorporated into an engine prime mover
system. Woodward declares that this controlling device complies with the
requirements of EN50081-2 and EN50082-2 when put into service per the
installation and operating instructions outlined in the product manual.
NOTICE: This controlling device is intended to be put into service only upon
incorporation into an engine prime mover system that itself has met the
requirements of the above Directive and bears the CE mark.
Application
This 723PLUS Digital Industrial Speed/Process Control controls the speed of
reciprocating engines in variable speed applications, including those with flexible
couplings (see Figure 1-1). The control includes inputs for two magnetic pickups
(MPUs) or proximity switches for monitoring flexible coupling torsionals, an input
for a remote speed setting, an input for output fuel limiting, an internal speed
reference for local control of speed, and two inputs for process control or
differential process control.
One LON®* channel can be used to support Woodward LINKnet input/output
nodes for monitoring and control functions. The other LON channel is not used.
*—LON is a trademark of Echelon Corporation.
The three serial channels provide for various control interfaces. Port J1 is
switchable to be a Watch Window PC interface or a hand-held programmer port
for monitoring and programming the 723PLUS control. Port J2 is a Watch
Window only port. Port J3 can interface to a Modbus®** master device such as a
Human/Machine Interface (HMI) to monitor the control and engine parameters
and to issue control commands.
**—Modbus is a trademark of Schneider Autiomation Inc.

723PLUS/Process Control Manual 02883
2 Woodward
The 723PLUS control system includes:
a 723PLUS Digital Speed Control
Servlink Watch Window (Figure 1-3) or a handheld terminal (Figure 1-4) for
adjusting control parameters
one or two proportional actuators to position the fuel metering
an external power source
one or two speed-sensing devices (two required for coupling torsional
filtering)
eight optional switch contacts to manage control functions
an optional fuel limiting transducer
three optional analog readout devices for display
three optional relay-driven alarms and status indicators
optional Modbus device for digital monitoring and control
optional LINKnet Modules to provide additional I/O paths for the Modbus
device
Figure 1-1. Flexible Coupled Driven Load
The 723PLUS control (Figure 1-2) consists of a single printed circuit board in a
sheet-metal chassis. Connections are via three terminal strips and three 9-pin
subminiature D connectors.
Control Options
Each 723PLUS control requires 40 W of power. A nominal current in-rush of 7 A
(low voltage) or 22 A (high voltage) is possible. Acceptable input voltage ranges
are:
low voltage—18 to 40 Vdc
high voltage—90 to 150 Vdc
Discrete input voltages provide on/off command signals to the electronic control,
such as Raise Speed, Lower Speed, etc. Each discrete input requires 10 mA at
its 24 Vdc nominal voltage rating (2210 load).
Other control options(On-board jumper configurations):
proximity switch input for speed signal frequencies below 1000 Hz
tandem actuator outputs
0–1 or 4–20 mA analog outputs
4–20 or 0–200 mA actuator outputs
Magnetic pickup inputs should only be used when operating speeds provide at
least 400 Hz magnetic pickup frequency.

Manual 02883 723PLUS/Process Control
Woodward 3
723PLUS Digital Speed Control Accessories
PC based Watch Window software (part number 8923-932) and a Hand Held
Programmer (part number 9907-205) are used for monitoring and adjusting
software parameters of the 723PLUS control, including the software options.
They plug into communication port J1 of the control. [Hand Held Programmer
part number 9905-292 can also be used.] See Figures 1-3 and 1-4.
Optional PC-based Control View software (part number 8928-056) is a graphical
user interface product used for monitoring and adjusting software parameters of
the 723PLUS/Process Control.
The two communication ports (J2 and J3) and the LON #1 data channel allow for
digital communications between external Modbus compatible devices, Servlink
devices, and Woodward LINKnet I/O modules. Port J2 is a dedicated port for
Servlink clients like Watch Window and Control View. The LON #1 channel has
been designated for use with up to 18 LINKnet modules. The inputs and outputs
of these modules can be read and controlled with Modbus compatible devices
connected to communication port J3. The number and types of LINKnet modules
available:
Total Module
Nodes Channels Network Part
Description Available Available Address Numbers
J Thermocouple In–Fail High OR 9905-966
J Thermocouple In–Fail Low 4 24 1, 2, 3, or 4 9905-967
100 Am RTD Input 3 18 5, 6, or 7 9905-970
4–20 mA Input 2 12 8 or 9 9905-968
Discrete Input 4 64 10, 11, 12, or 13 9905-971
Relay Output 4 32 14, 15, 16, or 17 9905-973
4–20 mA Output 1 6 18 9905-972
TOTAL 18 156
Table 1-1. LINKnet Modules (Summary)
Addr. Description Channels Notes
1J TC–Fail High 6
2J TC Input 6
3J TC Input 6
4J TC Input 6
5100 Am RTD Input 6
6100 Am RTD Input 6
7100 Am RTD Input 6
84–20 mA Input 6
94–20 mA Input 6
10 Discrete Input 16
11 Discrete Input 16
12 Discrete Input 16
13 Discrete Input 16
14 Relay Output 8
15 Relay Output 8
16 Relay Output 8
17 Relay Output 8
18 Analog Output 6
Total 156
Table 1-2. LINKnet Modules (Address)

723PLUS/Process Control Manual 02883
4 Woodward
Figure 1-2. 723PLUS Digital Speed Control

Manual 02883 723PLUS/Process Control
Woodward 5
Figure 1-3. Watch Window Display

723PLUS/Process Control Manual 02883
6 Woodward
Figure 1-4. Hand Held Programmer

Manual 02883 723PLUS/Process Control
Woodward 7
Figure 1-5. Typical 723PLUS Connections

723PLUS/Process Control Manual 02883
8 Woodward
Figure 1-6a. Control Wiring Diagram

Manual 02883 723PLUS/Process Control
Woodward 9
Figure 1-6b. Control Wiring Diagram

723PLUS/Process Control Manual 02883
10 Woodward
Chapter 2.
Installation
Introduction
This chapter contains general installation instructions for the 723PLUS 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 Electrostatic Discharge Awareness (p.iv). 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 723PLUS Digital Industrial Speed/Process
Control require a voltage source of 90 to 150 Vdc. The low-voltage versions
require a voltage source of 18 to 40 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.

Manual 02883 723PLUS/Process Control
Woodward 11
Internal Jumpers
The 723PLUS control has ten, two-position internal jumpers (JPR1 through
JPR20) located on the top of the printed circuit board. If you need to change any
jumper to match your control needs, be sure to read Electrostatic Discharge
Awareness (p.iv), before proceeding.
With the power off, remove the control cover. With a small pair of tweezers or
needle-nose pliers, carefully remove the appropriate jumper and replace it
securely over the proper two connectors (see Figure 3-1).
The following jumper options are available for these 723PLUS controls:
JPR10 analog output #1 0–1 mA
* JPR9 analog output #1 0–20 mA
JPR12 analog output #2 0–1 mA
* JPR11 analog output #2 0–20 mA
* JPR13 & JPR2 analog output #3 0–200 mA, single
JPR13 & JPR1 analog output #3 0–20 mA, single
& JPR14 & JPR2 analog output #3 0–160 mA, tandem
JPR15 & JPR3 analog output #4 0–200 mA, single
* JPR15 & JPR4 analog output #4 0–20 mA, single
& JPR16 & JPR3 analog 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
External wiring connections and shielding requirements for a typical 723PLUS
control installation are shown in Figure 1-5. The control wiring connections
(Figure 1-6) are explained in the rest of this chapter.
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 25 mm (1 inch). 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,
Interference Control in Electronic Governing Systems for more information.

723PLUS/Process Control Manual 02883
12 Woodward
Figure 3-1. 723PLUS Control Internal Jumpers