Woodward 723PLUS User manual

Product Manual 26043
(Revision B, 7/2008)
Original Instructions
723PLUS Digital Speed Control for
Reciprocating Engines—
Performance Control ‘598’
8280-598
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 26455, Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, 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 26455, Customer Publication
Cross Reference and Revision Status & Distribution Restrictions, 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 Out-of-date translations are marked with .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. Manual 26043
Copyright © Woodward 1999–2008
All Rights Reserved

Manual 26043 723PLUS Performance Control ‘598’
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.........................................................2
CHAPTER 2. INSTALLATION........................................................................10
Introduction...........................................................................................................10
Unpacking.............................................................................................................10
Power Requirements............................................................................................10
Location Considerations.......................................................................................10
Internal Jumpers...................................................................................................11
Electrical Connections..........................................................................................11
Installation Checkout Procedure ..........................................................................23
CHAPTER 3. ENTERING CONTROL SET POINTS...........................................24
Introduction...........................................................................................................24
Watch Window Generic PC Interface...................................................................24
723PLUS Performance Control ‘598’ Control View..............................................25
Hand Held Programmer and Menus.....................................................................39
Configuration Menu Descriptions.........................................................................42
Service Menu Descriptions...................................................................................52
CHAPTER 4. INITIAL ADJUSTMENTS ...........................................................85
Introduction...........................................................................................................85
Start-up Adjustments............................................................................................85
Speed Control Dynamic Adjustments...................................................................86
Air/Fuel Ratio Dynamic Adjustments....................................................................88
Turbo Assist Dynamic Adjustments......................................................................88
Speed Adjustments ..............................................................................................89
Conclusion of Setup Procedures..........................................................................90
CHAPTER 5. DESCRIPTION OF OPERATION.................................................91
General.................................................................................................................91
Speed Control Dynamics......................................................................................93
Speed Input..........................................................................................................93
Minimum Fuel Function........................................................................................93
Maximum Fuel Function.......................................................................................94
Start Limit Function...............................................................................................94
Fuel Limiting Function ..........................................................................................95
Actuator Function .................................................................................................95
Speed Failures .....................................................................................................95
Alarm Reset..........................................................................................................96
Speed Reference and Ramps..............................................................................96
Air/Fuel Ratio Reference......................................................................................98
Ignition Timing Reference...................................................................................100
Turbocharger Air Assist Control .........................................................................102
Power-Up Diagnostics........................................................................................102

723PLUS Performance Control ‘598’ Manual 26043
ii Woodward
Contents
CHAPTER 6. TROUBLESHOOTING .............................................................103
General...............................................................................................................103
Troubleshooting Procedure................................................................................103
Control Test and Calibration...............................................................................103
Conclusion of Test and Calibration Procedures.................................................107
CHAPTER 7. PRODUCT SUPPORT AND SERVICE OPTIONS .........................108
Product Support Options....................................................................................108
Product Service Options.....................................................................................108
Returning Equipment for Repair.........................................................................109
Replacement Parts.............................................................................................109
Engineering Services..........................................................................................110
Contacting Woodward’s Support Organization ..................................................110
Technical Assistance..........................................................................................111
APPENDIX A. SERIAL COMMUNICATION PORT WIRING ..............................112
Grounding and Shielding....................................................................................114
APPENDIX B. LINKNET®I/O NETWORK.....................................................115
Introduction.........................................................................................................115
Network Architecture ..........................................................................................115
Hardware............................................................................................................115
I/O Module Specifications...................................................................................115
Individual I/O Module Specifications...................................................................117
LinkNet I/O Module Descriptions........................................................................117
Discrete Input Module.........................................................................................119
4–20 mA Input Module .......................................................................................121
Thermocouple Input Module...............................................................................123
RTD Input Module ..............................................................................................125
Relay Output Module..........................................................................................127
4–20 mA Output Module.....................................................................................129
Troubleshooting Flowchart.................................................................................133
Wiring and Proper Cable....................................................................................133
Cable Length and Number of LinkNet I/O Modules............................................134
APPENDIX C. MODBUS SLAVE ADDRESS INFORMATION ............................135
Part Number 8280-598.......................................................................................135
APPENDIX D. PROGRAMMING CHECKLIST.................................................144
723PLUS CONTROL SPECIFICATIONS......................................................159

Manual 26043 723PLUS Performance Control ‘598’
Woodward iii
Illustrations and Tables
Figure 1-1. 723PLUS Digital Speed Control...........................................................4
Figure 1-2. Watch Window Display ........................................................................5
Figure 1-3. Hand Held Programmer.......................................................................6
Figure 1-4. Typical 723PLUS Connections............................................................7
Figure 1-5a. Control Wiring Diagram......................................................................8
Figure 1-5b. Control Wiring Diagram......................................................................9
Figure 2-1. 723PLUS Control Internal Jumpers...................................................12
Figure 3-1. Hand Held Programmer Functions ....................................................42
Figure 3-2. Control Gain as a Function of Speed Error........................................54
Figure 3-3. Control Gain as a Function of Control Output....................................54
Figure 3-4. Typical Transient Response Curves..................................................55
Figure 3-5. Speed Filter........................................................................................56
Figure 3-6. Notch Filter.........................................................................................56
Figure 3-7. Start Limit Function............................................................................59
Figure 3-8. Fuel Limit Breakpoints .......................................................................62
Figure 4-1. Assist Air Demand..............................................................................89
Figure 5-1. Simplified Block Diagram...................................................................92
Figure 5-2. Start Limit Function............................................................................94
Figure 5-3. Fuel Limit Breakpoints .......................................................................95
Figure 5-4. Remote Speed Reference .................................................................98
Figure A-1. 723PLUS RS-232 Connections.......................................................112
Figure A-2. 723PLUS RS-422 Connections with Optional Termination at
Receiver.........................................................................................112
Figure A-3. 723PLUS RS-485 Connections with Optional Termination.............113
Figure A-4. RS-422 Terminator Locations..........................................................113
Figure A-5. Preferred Multipoint Wiring Using Shielded Twisted-pair Cable with a
Separate Signal Ground Wire........................................................114
Figure A-6. Alternate Multipoint Wiring Using Shielded Twisted-pair Cable without
a Separate Signal Ground Wire.....................................................114
Figure B-1. LinkNet Relay Contacts...................................................................116
Figure B-2. Outline Drawing of I/O Module ........................................................118
Figure B-3. Discrete Input Module Block Diagram.............................................119
Figure B-4. Discrete Input Module Wiring Diagram............................................120
Figure B-5. 4–20 mA Input Module Block Diagram............................................121
Figure B-6. 4–20 mA Input Module Wiring Diagram ..........................................122
Figure B-7. Thermocouple Input Module Block Diagram...................................123
Figure B-8. Thermocouple Input Module Wiring Diagram..................................124
Figure B-9. RTD Input Module Block Diagram...................................................125
Figure B-10. RTD Input Module Wiring Diagram ...............................................126
Figure B-11. Relay Output Module Block Diagram............................................127
Figure B-12. Relay Output Module Wiring Diagram...........................................128
Figure B-13. 4–20 mA Output Module Block Diagram.......................................129
Figure B-14. 4–20 mA Output Module Wiring Diagram......................................130
Figure B-15a. Troubleshooting Flowchart (1 of 2)..............................................131
Figure B-15b. Troubleshooting Flowchart (2 of 2)..............................................132
Figure B-16. Direct Wired Network.....................................................................134
Figure B-17. Network Wired Via Stubs...............................................................134
Table 1-1. LinkNet Modules (Summary).................................................................3
Table 1-2. LinkNet Modules (Address)...................................................................3

723PLUS Performance Control ‘598’ Manual 26043
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 26043 723PLUS Performance Control ‘598’
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 Performance Control ‘598’ Manual 26043
vi Woodward

Manual 26043 723PLUS Performance Control ‘598’
Woodward 1
Chapter 1.
General Information
Introduction
This manual describes the Woodward 723PLUS Digital Industrial Speed/
Performance Control ‘598’, model 8280-598 (low 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/Performance Control ‘598’ controls the
speed, air/fuel ratio, and ignition timing of reciprocating engines in variable speed
applications. The control includes inputs for two magnetic pickups (MPUs) or
proximity switches for monitoring engine and turbocharger speed (or redundant
engine speed sensing), a notch filter to attenuate the effect of flexible coupling
torsionals, an input for a remote speed setting, inputs for air manifold pressure,
fuel gas header pressure, and air manifold temperature and an internal speed
reference for local control of speed.
One LON®* channel can be used to support Woodward LinkNet®input/output
nodes for monitoring functions. The other LON channel is not used.
The two serial channels can interface to a Modbus®** master device such as a
Human/Machine Interface (HMI) to monitor the control and engine parameters.
*—LON is a trademark of Echelon Corporation.
**—Modbus is a trademark of Schneider Automation Inc.

723PLUS Performance Control ‘598’ Manual 26043
2 Woodward
The 723PLUS control system includes:
a 723PLUS Digital Speed, Air/Fuel Ratio and Ignition Timing Control
ServLink Watch Window (Figure 1-2) or an optional hand held terminal
(Figure 1-3) for adjusting control parameters
one proportional actuator output to position the fuel metering end device
one proportional actuator output to position the air/fuel ratio end device
one analog output to control the ignition timer setting
an external power source
one or two speed-sensing devices (two engine or one engine and one turbo)
eight optional switch contacts to manage control functions
one analog output for configurable turbocharger air assist PID control or
display indication
two optional relay-driven alarm and shutdown indicators
one optional relay-driven automatic turbocharger air assist control
optional Modbus devices for digital monitoring and control
optional LinkNet modules to provide additional I/O paths for the Modbus
devices
The 723PLUS control (Figure 1-1) 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
is possible. Acceptable input voltage range is 18 to 40 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 W load).
Other control options (on-board jumper configurations):
proximity switch input for speed signal frequencies below 1000 Hz
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.
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 adjusting software parameters
of the 723PLUS control, including the software options. The PC cable or Hand
Held Programmer plug into communication port J1 of the control (see manual
26007 Getting Started for using the Watch Window software). [Hand Held
Programmer part number 9905-292 can also be used.] See Figures 1-2 and 1-3.
Optional Performance Control ‘598’ Control View software (part number
8928-060) is a graphical user interface PC-based product used for monitoring
and adjusting software parameters of the 723PLUS/Performance Control ‘598’.

Manual 26043 723PLUS Performance Control ‘598’
Woodward 3
The two communication ports (J2 and J3) and the LON # 1 data channel allow for
digital communications between external Modbus compatible devices and
Woodward LinkNet I/O modules. Up to 9 LinkNet modules have been designated
for use and can be connected to the LON # 1 channel. The inputs and outputs of
these modules can be read and controlled with Modbus compatible devices
connected to communication ports J2 and 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 9905-966
OR
J Thermocouple In–Fail Low 4 24 1, 2, 3, or 4 9905-967
100 Am RTD Input 1 6 5 9905-970
4–20 mA Input 1 6 6 9905-968
Discrete Input 1 16 7 9905-971
Relay Output 1 8 8 9905-973
4–20 mA Output 1 6 9 9905-972
TOTAL 9 66
Table 1-1. LinkNet Modules (Summary)
Addr. Description Channels Notes
1 J TC–Fail High 6
2 J TC Input 6
3 J TC Input 6
4 J TC Input 6
5 100 Am RTD Input 6
6 4–20 mA Input 6
7 Discrete Input 16
8 Relay Output 8
9 Analog Output 6
Total 66
Table 1-2. LinkNet Modules (Address)

723PLUS Performance Control ‘598’ Manual 26043
4 Woodward
Figure 1-1. 723PLUS Digital Speed Control

Manual 26043 723PLUS Performance Control ‘598’
Woodward 5
Figure 1-2. Watch Window Display

723PLUS Performance Control ‘598’ Manual 26043
6 Woodward
Figure 1-3. Hand Held Programmer

Manual 26043 723PLUS Performance Control ‘598’
Woodward 7
Figure 1-4. Typical 723PLUS Connections

723PLUS Performance Control ‘598’ Manual 26043
8 Woodward
Figure 1-5a. Control Wiring Diagram

Manual 26043 723PLUS Performance Control ‘598’
Woodward 9
Figure 1-5b. Control Wiring Diagram

723PLUS Performance Control ‘598’ Manual 26043
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 low voltage version of the 723PLUS Digital Speed/Performance Control ‘598’
requires 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 26043 723PLUS Performance Control ‘598’
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 2-1).
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 actuator output #1 0–200 mA, single
JPR13 & JPR1 actuator output #1 0–20 mA, single
& JPR14 & JPR2 actuator output #1 0–160 mA, tandem
JPR15 & JPR3 actuator output #2 0–200 mA, single
* JPR15 & JPR4 actuator output #2 0–20 mA, single
& JPR16 & JPR3 actuator output #2 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 1-4. The control wiring connections
(Figure 1-5) 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 Performance Control ‘598’ Manual 26043
12 Woodward
Figure 2-1. 723PLUS Control Internal Jumpers
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 braided
shield.
3. Pull inner conductor(s) out of the shield. If the shield is the braided type,
twist it to prevent fraying.