Woodward 723PLUS User manual

Product Manual 26425
(Revision NEW)
Original Instructions
723PLUS Digital Control
Nile River Vessel Generator Control
Dredging International
8301-1146
Application 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 Out-of-date translations are marked with .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 2007
All Rights Reserved

Manual 26425 723PLUS Nile River Generator Control
Woodward i
Contents
WARNINGS AND NOTICES...........................................................................II
ELECTROSTATIC DISCHARGE AWARENESS ................................................III
CHAPTER 1. GENERAL INFORMATION......................................................... 1
Introduction.......................................................................................................... 1
System Compliance............................................................................................. 1
General Safety Precautions................................................................................. 1
Identification Plate ............................................................................................... 1
CHAPTER 2. SYSTEM DESCRIPTION ........................................................... 2
Introduction.......................................................................................................... 2
Speed Sensing .................................................................................................... 2
Speed Reference................................................................................................. 2
Droop / KW Control.............................................................................................. 3
Fuel Limiters ........................................................................................................ 3
Alarms.................................................................................................................. 3
CHAPTER 3. TUNABLES............................................................................. 4
Introduction.......................................................................................................... 4
Configure Mode Tunables ................................................................................... 4
Service Mode Tunables....................................................................................... 5
CHAPTER 4. HAND-HELD PROGRAMMER.................................................... 8
Hand-held Programmer and Menus.................................................................... 8
Adjusting Setpoints.............................................................................................. 9
Hand-Held Programmer Keys ............................................................................. 9
CHAPTER 5. CONTROL WIRING DIAGRAM................................................. 11
CHAPTER 6. FUNCTIONAL BLOCK DIAGRAM............................................. 18
CHAPTER 7. PRODUCT SUPPORT AND SERVICE OPTIONS......................... 21
Product Support Options ................................................................................... 21
Product Service Options.................................................................................... 21
Returning Equipment for Repair........................................................................ 22
Replacement Parts............................................................................................ 22
Engineering Services......................................................................................... 23
Contacting Woodward’s Support Organization.................................................. 23
Technical Assistance......................................................................................... 24
723PLUS HARDWARE MANUAL .............................................................. 25
Illustrations and Tables
Figure 4-1. Hand-held Programmer................................................................... 10

723PLUS Nile River Generator Control Manual 26425
ii 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 26425 723PLUS Nile River Generator Control
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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 Nile River Generator Control Manual 26425
iv Woodward

Manual 26425 723PLUS Nile River Generator Control
Woodward 1
Chapter 1.
General Information
Introduction
This manual is the functional description of Woodward 723PLUS Control
System 8301-1146. This 723PLUS control is made to Dredging International
specification as a generator control for the Nile River vessel.
723plus Digital Control 9906-619
GAP Diagram 5418-2825
Block Diagram 9971-1260
Plant Wiring 9971-1259
Use of this equipment by untrained or unqualified personnel could
result in damage to the control or the installation's equipment and
possible loss of life or personal injury. Make sure personnel using or
working on this equipment are correctly trained.
This manual covers only equipment which is manufactured by Woodward and does
not include operating instructions for the prime mover, or the driven devices or
processes. For information about other Woodward units used on the prime mover
please refer to the specific Woodward documentation supplied with each unit.
For specific operating information such as start-up, shutdown, and the prime
mover's response to signals from the Woodward control, refer to the prime
mover manufacturer's manual.
System Compliance
This system complies with the relevant industry specifications and regulations.
General Safety Precautions
Obey the following safety precautions when you install the unit:
Obey all cautions or warnings given in the procedures.
Never bypass or override machine safety devices.
Always use sufficient personnel and/or lifting equipment to move the cabinet.
Identification Plate
The identification plate is installed on the front of the plate in the upper right
corner. It contains the following information:
Part Number
Serial Number
Manufacturing Date
Weight
Customer Name
Customer
Power Supply Information
Always provide the model number and serial number in any correspondence
with Woodward.

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Chapter 2.
System Description
Introduction
The 723PLUS control for this application receives an analog speed setting
signal from an external system. The 723PLUS biases this speed reference for
synchronizing purposes, kW droop, and to make the kW base load control
possible.
Depending on the actual speed, the control will set maximum load setpoints that
will act as a torque limit curve.
Control functions include:
Speed sensing
Speed reference
Droop / KW Control
Speed Control
Fuel Limiters
Alarms
Speed Sensing
The speed sensing of the engine is done by one or two speed sensors. The
speed sensors can be proximity probes or magnetic pick-ups.
The influence of the engine firing frequencies is attenuated by a low pass filter.
Speed fault indication
The speed channels are continuously checked for speed sensor failures. A
failure is latched when the speed signal drops below 10 rpm or raises above
2000 rpm. The speed sensor fault detection is overridden during shutdown and
stays overridden for *10 seconds after Run is selected.
Because the 723PLUS does not act as speed control unit, a double failure of
the speed probes does not result in a major alarm. Each sensor can individual
be setup, in case of failure, as minor alarm or major alarm.
Speed Reference
On starts the control will run the engine on min speed and will ramp the speed
after a adjustable delay to rated. The speed reference can be adjusted by the
Raise and Lower contacts or the Remote Speed Reference. To select remote
speed reference both the raise and lower contact have to be made. On failure of
the remote reference signal the speed can be controlled by the raise and lower
contacts.
The speed reference can be adjusted between the Min. Speed Limit and Max.
Speed Limit (adjustable in Configure). The range of the remote speed reference
is determined by 4mA Rem. Ref. and 20mA Rem Ref. An analog input below
2 mA or above 22 mA will create an alarm.

Manual 26425 723PLUS Nile River Generator Control
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Droop / KW Control
Load sharing with other prime movers is done in droop. The main engine control
has this droop function already internally. For that reason, the droop amount in
the 723PLUS is set default to 0%. In case the kW droop must be activated, the
droop % must be set to the correct amount. In kW droop, the control uses the
load sensor input to calculate the droop. The load can be controlled with the
raise and lower or the remote speed setpoint.
If the load reference enable switch is closed, the control can act in kW control.
The range of the remote load reference is determined by the 4mA KW Ref and
the 20 mA KW Ref. An analog input below 2 mA or above 22 mA will create an
alarm on both the remote reference and the load sensor. An alarm of one or
both the inputs will disable the KW Control.
Shutdown
The shutdown function, when activated by the external Run/Stop contact, sends
a minimum Speed reference signal out. Also in the configure menu one can
select if the speed reference should go to minimum speed reference on the
event of a Major alarm.
Fuel Limiters
A four-point Speed / KW limiter is present to prevent overloading of the engine
dependable on speed. This will overrule the kW setpoint in case this demand
will be too much at the actual speed. An additional four-point curve is present to
allow a certain extra kW amount per speed setpoint. This can be used in case
the torque limit is too critical at certain speed setpoints! Always contact the
engine OEM for the correct settings.
Alarms
In this application the following I/O signals can cause an alarm:
Speed Probe # 1 input
Speed Probe # 2 input
Remote Speed Reference input
Load sensor input
Remote Load Reference input
These inputs have three types of alarms: no alarm, minor alarm, and major
alarm. In the configure mode the type of alarm can be chosen:
1 means no alarm
2 means minor alarm
3 means major alarm
The following failure will always give a major alarm:
Overspeed
The Overspeed Trip level can be adjusted in the configure mode.
A minor alarm will activate the minor alarm relay output. A major alarm will
create a shutdown and will activate the major alarm relay output. To reset an
alarm use the external reset.
The shutdown on major alarm can be adjusted to no shutdown on major alarm
(when mechanical backup and reverse acting is used)and the relay’s can be
adjusted to have NO or NC contacts.
The remote speed input and manifold pressure input can be adjusted as not
used. In that case the alarms are overridden and the manifold limiter is set at
maximum output.

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Chapter 3.
Tunables
Introduction
This chapter describes the parameters that can be tuned or monitored. Where
applicable, the nominal setting for each tunable is listed (the nominal values are
provided only as a guideline). The actual settings are obtained from the engine
manufacturer or determined during commissioning and should be noted in the
Actual column for future reference.
Refer to Chapter 4 (Hand-Held Programmer) for instructions about accessing
the tunables.
Configure Mode Tunables
** CONFIGURATION **
This menu is used to set the desired setpoints for the minimum and maximum
speed reference setpoints. Also Overspeed trip setpoint can be set.
Description Range Nominal
A
ctual
Min Speed RPM (0,2500) *800
Max Speed RPM (0,2500) *1900
Overspeed RPM (0,2500) *2000
** SET ALARMS **
This menu is used to configure the alarms for each specific parameter.
1= No Alarm
2= Minor Alarm
3= Major Alarm
It is selectable to go to minimum speed reference setpoint in case of major
alarm!
Description Nominal Range
A
ctual
Shtdwn on Maj Alarm? (TRUE,FALSE) *TRUE
MPU #1 Failed Alarm? (1,3) *2
MPU #2 Failed Alarm? (1,3) *2
Rem Spd Used? (TRUE,FALSE) *TRUE
Rem Spd Alm? (2,3) *2
Rem Load Used? (TRUE,FALSE) *TRUE
Rem Load Alm? (2,3) *2
KW Sensor Used (TRUE,FALSE) *TRUE
KW Sensor Alm? (2,3) *2
Major Alarm Relay NC ? (TRUE,FALSE) *TRUE
Minor Alarm Relay NC? (TRUE,FALSE) *TRUE

Manual 26425 723PLUS Nile River Generator Control
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Service Mode Tunables
** ALARMLOG **
This menu shows the active alarms and will only be visible in case of an alarm.
The first alarm will be logged and can be traced back!
Description Range Nominal Actual
First Alarm Monitor
Spd Probe #1 Fault Monitor
Spd Probe #2 Fault Monitor
Rmt Spd Ref Failed Monitor
Rem Ld Ref Failed Monitor
KW Trans Failed Monitor
Ovrspd Detected Monitor
Reset Fist Alarm? (TRUE,FALSE) *FALSE
** MONITOR ANALOG **
This menu shows the analog values as described in the parameter description.
No parameters can be tuned in this menu.
Description Range Nominal Actual
Engine Speed Monitor
Speed Reference Monitor
Spdref Before Bias Monitor
kW Limiter (kW) Monitor
Actual Load (kW) Monitor
Load Reference Input (kW) Monitor
SPM Input (rpm) Monitor
** MONITOR DISCRETE **
This menu shows the digital values as described in the parameter description.
No parameters can be tuned in this menu.
TRUE means, the input is active, FALSE when it is not active.
Description Range Nominal Actual
Run/Stop Contact Monitor
Reset Contact Monitor
Lower Contact Monitor
Raise Contact Monitor
Loadref Enbl Cntct Monitor
Synch Rate Contact Monitor
Breaker Contact Monitor
Release Rtd Contact Monitor
** MONITOR INPUTS **
This menu shows the analog values as described in the parameter description.
No parameters can be tuned in this menu.
Description Range Nominal Actual
Rem Spd Input /mA Monitor
Rem Load Input /mA Monitor
Load Sens Input /mA Monitor
SPM Input / rpm Monitor
Speed Probe #1 Monitor
Speed Probe #2 Monitor

723PLUS Nile River Generator Control Manual 26425
6 Woodward
** kW LIMITER **
This menu must be used to setup the kW Limiter. This is a four slope curve,
based on speed, that sets the maximum kW setpoint!
Additional an extra kW can be given to above mentioned curve. This also is a
four slope, speed dependant curve again!
Always request the correct info for these parameters from the engine OEM.
Description Range Nominal
A
ctual
KW Extra #1 (0.0, 1000,0) *0
KW Extra SPD #2 (0.0, 2500,0) *1600
KW Extra #2 (0.0, 1000,0) *0
KW Extra SPD #3 (0.0, 2500,0) *1700
KW Extra #3 (0.0, 1000,0) *0
KW Extra SPD #4 (0.0, 2500,0) *1800
KW Extra #4 (0.0, 1000,0) *0
** kW DROOP **
This menu is used to set the droop amount for the kW droop. Droop set to 0
means no droop!
Description Range Nominal
A
ctual
Droop % (0,10) *0
** SPEED SETTING **
This menu must be used to set the speed reference parameters as mentioned
in the description. Also the analog outputs can be configured in this menu!
Description Range Nominal
A
ctual
Rated Speed (0,2500) *1800
Lower Speed Rate (0,100) *15
Raise Speed Rate (0,100) *15
To Rated Rate (0,1000) *100
Synchro Rate (0,100) *2
4mA Rmt Reference (0,2500) *1500
20mA Rmt Reference (0,2500) *1830
Tacho at 4 mA Output (0,2500) *0
Tacho at 20 mA Output (0,2500) *2000
Speed Ref Out at 4 mA (0,2500) *1380
Speed Ref Out at 20 mA (0,2500) *1920
SPM Input –2 V = rpm (-100,100) *-2
SPM Input +2 V = rpm (-100,100) *2
** KW MENU **
This menu is used top set the kW transducer range and kW setpoint input for
the control. Also the deadband can be set with this menu. When load error is
within the deadband, the control will not bias anymore.
Description Range Nominal
A
ctual
KW Ref at 4 mA (0,10000) *0
KW Ref at 20 mA (0,10000) *1900
Maximum KW (0,10000) *1890
KW Load Sensor at 4 mA (0,10000) *0
KW Load Sensor at 20 mA (0,10000) *2127
KW Control Deadband (0,100) *10
** SPEED FILTER **
This menu must be used to set the speed filters of the speed sensor inputs. Too
much filtering will result in slow speed update.
Description Range Nominal
A
ctual
Speed Filter 1 (0.01,10.0) *0.04
Speed Filter 2 (0.01,10.0) *0.04

Manual 26425 723PLUS Nile River Generator Control
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** PORTSETTING **
This menu must be used to switch the J1 port from Handheld (2) into ServLink
(1) mode. Reboot of 723 will activate the handheld programmer mode again.
Description Range Nominal Actual
Set Download Mode (1,2) *2
Do not change the port setting. This function is only for trained
service personnel.

723PLUS Nile River Generator Control Manual 26425
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Chapter 4.
Hand-held Programmer
Hand-held Programmer and Menus
The Hand-held Programmer is a hand-held computer terminal that gets its
power from the Control. The terminal connects to the RS-422 communication
serial port on the control.
The programmer does a power-up self-test whenever it is plugged into the
control. When the self-test is complete, the screen displays two lines of
information. This is information relating to the application. Pressing the 'ID' key
changes the display to show the Woodward logo with the country name
("Woodward (NL)") and application name of the system. Press ‘ID’ again for the
software part number.
The programmer screen is a four-line, back lighted LCD display. The display
lets you 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 (an “@”
indicates the item in the active menu). Use the BKSP and SPACE keys to scroll
through the display to show the remainder of a prompt if it is longer than the
display screen's 18 characters.
The Control has three sets of menus: the Service menus, the Configure menus
and the Debug 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. The Debug menu allows access to
the GAP software.
Configure Menus
To access the Configure menus, the engine must be shutdown. Press the . key.
The display will show, 'To Enable 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 to get into the Configure menus.
If the engine is running, it will be shut down because the control’s
I/Os are disabled.
To move between the menus use the and keys. To move through the
setpoints within a menu use the and keys,. Once in a menu, press the
ESC key to return to the menu header.
To leave the Configure menus press the ESC key. The message 'Rebooting
Control' will appear. The setpoints are automatically saved when leaving
Configure.
Service Menus
To access the Service menus press the key. To move between menus, and
to move through setpoints within menus, follow the instructions as for the
Configure menus. Also to return to the menu header, or to leave Service, follow
the Configure instructions.

Manual 26425 723PLUS Nile River Generator Control
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Debug Menus
To access the Debug first press (solid square) after which the key should
be pressed. To move between category menus use the and keys, once in
the right category move through the GAP blocks by using the and keys.
Within a GAP block every output and tunable (*) input can been seen by using
the and keys.
A Tunable (*) can be changed by using the “Turtle Up” or the “Rabbit Up” keys
to increase the value, and the “Turtle Down” or “Rabbit Down” keys to decrease
the value (see also adjusting setpoints).
To return to the menu header press the key, or to leave Service, follow the
Configure instructions.
Adjusting Setpoints
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 set-up where
a value may need to be changed significantly. Where necessary, to select
TRUE, use either the “Turtle Up” or the “Rabbit Up” keys, and to select FALSE,
use the “Turtle Down” or “Rabbit Down” keys.
To obtain an exact value, press the “=“ key. Key in the required figure and press
ENTER.
This may only be done if the figure is within 10% of the existing
value.
To save setpoints at any time, use the SAVE key. This transfers all new setpoint
values into EEPROM memory. The EEPROM retains all setpoints when power
is removed from the control.
To prevent possible damage to the engine resulting from improper
control settings, make sure you save the setpoints before removing
power from the control. Failure to save the setpoints before
removing power from the control causes them to revert to the
previously saved settings.
Hand-Held Programmer Keys
The programmer keys have the following functions (see Figure 4-1):
(left arrow) Moves backward through Configure or Service, one
menu at a time.
(right arrow) Moves forward through Configure or Service, one menu
at a time.
(up/down arrow) Toggles between the two displayed items (the first
letter of the active menu item will blink).
(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.

723PLUS Nile River Generator Control Manual 26425
10 Woodward
(rabbit up) Increases the displayed set point value quickly (about
10 times faster than the turtle keys).
(rabbit down) Decreases the displayed set point value quickly (about
10 times faster than the turtle keys).
– (minus) Increases setpoint values by one step at a time.
+ (plus) Decreases setpoint values by one step at a time.
(solid square) Debug mode.
ID Displays the In-Pulse Woodward logo, application
name and software revision.
ESC To return to menu header or to main screen.
SAVE Saves entered values (set points).
BKSP Deletes last figure when entering exact values.
SPACE Not used.
ENTER Used when entering exact values and accessing
Configure.
= (equals) To enter exact values (within 10%).
(decimal) To select Configure.
Figure 4-1. Hand-held Programmer

Manual 26425 723PLUS Nile River Generator Control
Woodward 11
Chapter 5.
Control Wiring Diagram
This chapter contains the Control Wiring Diagram 9971-1259. Sheet one of the
drawing contains notes and additional information. The following sheets identify
the system cables and show their interconnections, and give the pin-out detail
of each cable connector.

723PLUS Nile River Generator Control Manual 26425
12 Woodward

Manual 26425 723PLUS Nile River Generator Control
Woodward 13

723PLUS Nile River Generator Control Manual 26425
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