Woodward 723PLUS User manual

Product Manual 02880
(Revision C)
Original Instructions
723PLUS Digital Speed Control for Single
Engine Marine Propulsion Applications
8280-419
Operation and Calibration 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 Out-of-date translations are marked with .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 02880 723PLUS/Single Engine Marine Propulsion
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
Hardware Options...................................................................................................3
Software Options....................................................................................................3
723PLUS Digital Speed Control Accessories.........................................................3
CHAPTER 2. INSTALLATION........................................................................12
Scope....................................................................................................................12
Unpacking.............................................................................................................12
Power Requirements............................................................................................12
Location Considerations.......................................................................................12
Internal Jumpers...................................................................................................13
Electrical Connections..........................................................................................13
Shielded Wiring ....................................................................................................13
Supply Input (Terminals 1/2) ................................................................................15
Relay Outputs (Terminals 3/4, 5/6, 7/8) ...............................................................16
RS-422 Communication Port (J1) ........................................................................16
Speed Signal Inputs #1 and #2 ............................................................................16
(Terminals 11/12 and 13/14) ................................................................................16
Analog Outputs #1 and #2 (Terminals 15/16 and 17/18).....................................18
Analog Output #3 (Terminals 19/20)....................................................................18
Analog Output #4 (Terminals 21/22)....................................................................19
LON #1 and LON #2 (Terminals 23—28).............................................................19
Discrete Inputs (Terminals 29—36)......................................................................19
Fuel Limit Shift (Input A; Terminal 29)..................................................................20
Alarm Reset (Input B; Terminal 30)......................................................................21
Speed Fail Override (Input C; Terminal 31) .........................................................21
2nd Dynamics (Input D; Terminal 32)...................................................................22
Raise Speed Contact (Input E; Terminal 33)........................................................22
Lower Speed Contact (Input F; Terminal 34).......................................................22
Remote Speed Reference Contacts.....................................................................22
(Input E; Terminal 33 and Input F; Terminal 34) ..................................................22
Rated Speed (Input G; Terminal 35)....................................................................23
Open to Run (Input H; Terminal 36).....................................................................23
Lube Oil Pressure Input (Signal Input #1; Terminals 42/43)................................23
Water Pressure Input (Signal Input #2; Terminals 45/46)....................................24
Air Manifold Pressure Input (Signal Input #3; Terminals 48/49)...........................25
Remote Speed Reference Input (Signal Input #4; Terminals 51/52) ...................25
Communication Port J2........................................................................................26
Installation Checkout Procedure ..........................................................................26
CHAPTER 3. STANDARD MENU ITEMS ........................................................28
Introduction...........................................................................................................28
Watch Window PC Interface.................................................................................28
723PLUS Marine SEP Control View ....................................................................29
Hand Held Programmer and Menus.....................................................................42
Hand Held Programmer Keys ..............................................................................43

723PLUS/Single Engine Marine Propulsion Manual 02880
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Contents
Service Menus......................................................................................................44
Configure Menus ..................................................................................................44
Adjusting Set Points .............................................................................................45
Configure Menu Descriptions...............................................................................45
Service Menu Descriptions...................................................................................52
1st Dynamics/2nd Dynamics Menu......................................................................53
Conclusion of Setup Procedures..........................................................................69
CHAPTER 4. INITIAL ADJUSTMENTS............................................................70
Introduction...........................................................................................................70
Start-up Adjustments............................................................................................70
Dynamic Adjustments...........................................................................................71
Alternative Dynamic Adjustments.........................................................................73
Based on the Zeigler-Nichols Method ..................................................................73
Setup ....................................................................................................................73
Gain, Reset, and Actuator Compensation Adjustments.......................................73
Gain, Window Width, and Gain Ratio Adjustments..............................................76
Gain Slope and Gain Break point Adjustments....................................................77
Torsional Adjustments..........................................................................................78
Fuel Limiters Adjustments....................................................................................79
Speed Adjustments ..............................................................................................79
Conclusion of Initial Adjustment Procedures........................................................80
CHAPTER 5. DESCRIPTION OF OPERATION..................................................81
General.................................................................................................................81
Speed Input ..........................................................................................................82
Torsional Filter Function.......................................................................................82
Speed Failures......................................................................................................82
Alarm Reset and Override....................................................................................83
Speed Reference and Ramps..............................................................................83
Dual Dynamics......................................................................................................84
Dual Gain Dynamics.............................................................................................85
Other Dynamics....................................................................................................85
Actuator Bump Function.......................................................................................85
Minimum Fuel Function........................................................................................85
Maximum Fuel Function.......................................................................................86
Start Limit Function...............................................................................................86
Fuel Limiting Function ..........................................................................................87
Actuator Function..................................................................................................88
Power-Up Diagnostics..........................................................................................88
CHAPTER 6. TROUBLESHOOTING ...............................................................89
General.................................................................................................................89
Troubleshooting Procedure..................................................................................89
Control Test and Calibration.................................................................................89
Discrete Inputs......................................................................................................90
Lube Oil Pressure Input........................................................................................90
Water Pressure Input............................................................................................91
Air Manifold Pressure Input..................................................................................91
Remote Speed Reference Input...........................................................................91
Analog Output #3..................................................................................................92
Speed Inputs.........................................................................................................92
Conclusion of Test and Calibration Procedures...................................................93

Manual 02880 723PLUS/Single Engine Marine Propulsion
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Contents
CHAPTER 7. PRODUCT SUPPORT AND SERVICE OPTIONS...........................94
Product Support Options......................................................................................94
Product Service Options.......................................................................................94
Returning Equipment for Repair...........................................................................95
Replacement Parts...............................................................................................95
Engineering Services............................................................................................96
Contacting Woodward’s Support Organization ....................................................96
Technical Assistance............................................................................................97
APPENDIX A. SERIAL COMMUNICATION PORT WIRING................................98
Grounding and Shielding......................................................................................99
APPENDIX B. PROGRAMMING CHECKLIST ................................................101
723PLUS CONTROL SPECIFICATIONS .....................................................109
Illustrations and Tables
Figure 1-1. Flexible Coupled Propeller...................................................................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. Vessel Wiring Diagram ........................................................................8
Figure 1-6. 723PLUS Block Diagram...................................................................10
Figure 1-7. Typical 723PLUS Connections..........................................................11
Figure 2-1. 723PLUS Control Internal Jumpers...................................................14
Figure 3-1. Hand Held Programmer Functions ....................................................43
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.........................................................................................60
Figure 5-1. Start Limit Function............................................................................86
Figure 5-2. Fuel Limit Break points ......................................................................87
Figure A-1. 723PLUS RS-232 Connections.........................................................98
Figure A-2. 723PLUS RS-422 Connections with Optional Termination at
Receiver...........................................................................................98
Figure A-3. RS-422 Terminator Locations............................................................99
Figure A-4. Preferred Multipoint Wiring Using Shielded Twisted-pair Cable with a
Separate Signal Ground Wire........................................................100
Figure A-5. Alternate Multipoint Wiring Using Shielded Twisted-pair Cable without
a Separate Signal Ground Wire.....................................................100

723PLUS/Single Engine Marine Propulsion Manual 02880
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 02880 723PLUS/Single Engine Marine Propulsion
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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/Single Engine Marine Propulsion Manual 02880
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Manual 02880 723PLUS/Single Engine Marine Propulsion
Woodward 1
Chapter 1.
General Information
Introduction
This manual describes the Woodward 723PLUS Digital Speed Control for Single
Engine Marine Propulsion Applications, for part number 8280-419.
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 Governor 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
The 723PLUS single engine marine control described in this manual controls the
speed and load of medium- and high-speed diesel reciprocating engines in
variable speed marine propulsion service, including those with flexible couplings.
The control includes inputs for two magnetic pickups (MPUs) or proximity
switches for speed sensing, an input for lube oil pressure, an input for water
pressure, an input for remote speed reference, and an input for air manifold
pressure to limit the fuel demand.
The control outputs include an actuator output, three configurable analog
outputs, and three relay outputs. The relay outputs are for engine trouble,
shutdown, and status indication. There are three communication ports on the
723PLUS control. One of these (J1) is dedicated to Watch Window, Standard PC
Interface, or a hand held programmer for software tuning. The other two
communication ports (J2 and J3) are configurable to either RS-232, RS-422, or
RS-485 communications. Port 2 (J2) is a spare (unused) port, configured for
Servlink. Port 3 (J3) is a spare (unused) unconfigured port.
In addition to these communication ports, there are two LON® * channels
available for further communications. In this control, the LON #1 and the LON #2
channel are not used. *—LON is a trademark of Echelon Corporation.
The 8280-419 single engine marine propulsion control is intended for use on
single engine, single propeller (variable or fixed pitch) propulsion systems. A
typical propulsion system is shown in Figure 1-1. The system is shown with a
flexible coupling between the engine and the propeller. Protection is provided to
the unit shown with the Fuel Limiters and special torsional detection and filtering
across the flexible coupling.

723PLUS/Single Engine Marine Propulsion Manual 02880
2 Woodward
Figure 1-1. Flexible Coupled Propeller
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.
The control system typically includes the following components:
a 723PLUS Digital Speed Control
one actuator to position the fuel metering device
an external power source
one or two speed-sensing devices
eight optional switch contacts to manage control functions
an optional lube oil pressure transducer
an optional water pressure transducer
an optional fuel limiting air manifold pressure transducer
three optional analog readout devices for display
two optional relay-driven alarms
Control Options
This manual describes the designed application of the 723PLUS marine control
system, with low voltage power supply and torsional filtering.
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 such as Raise Speed
and Lower Speed to the electronic control. Each discrete input requires 10 mA at
24 Vdc nominal voltage rating. The low voltage power supply may be used to
power these command signals (see Figure 1-7 for vessel wiring.)
Torsional filtering is provided on the 723PLUS control model described in this
manual. This filtering is specially designed to minimize the effects of flexible
coupling torsionals. This control provides exceptionally smooth steady-state
control which allows the control dynamics to be matched to the engine rather
than detuned to compensate for coupling torsionals. Removing the torsional
effects of the flexible coupling often provides a much longer life to the coupling.
This model can alarm and limit the fuel demand if unacceptably high torsional
levels occur.

Manual 02880 723PLUS/Single Engine Marine Propulsion
Woodward 3
These controls have a unique software function which allows the control
dynamics to respond only to changes in speed which can be corrected by
changing the amount of fuel to the engine. Variations in speed which are caused
by torque changes across a flexible coupling are ignored. By dampening the
dynamic response to these torque changes, the 723PLUS does not contribute to
the oscillations, and so the stress on the coupling is less. This damped response
occurs only when the instantaneous speed change is different between two
speed sensor inputs. Two separate speed sensors must be used for this
application to be effective (see Figure 1-7). In this case, a separate speed sensor
must be located on each side of the flexible coupling.
Hardware Options
The 723PLUS control has several hardware options available for signal inputs
and outputs. The inputs for the two speed sensors can be configured with
internal jumpers for either passive magnetic pickup units (MPUs) or active
proximity switches. The four signal inputs can be configured with external
jumpers for either milliamp or voltage sources. Analog Outputs #1 and #2 can be
configured with internal jumpers to source either 4 to 20 mA or 0 to 1 mA. Analog
Outputs #3 and #4 can be configured with internal jumpers to source either 0 to
200 mA or 0 to 20 mA. These options can be configured for each individual
application.
Software Options
In addition, there are several options available in the 723PLUS control software
which allow considerable flexibility for the application of the hardware. Along with
the typical adjustments for reference rates, limits, and dual dynamics, the
software allows for two speed sensing detection methods, a speed filter function,
an external fuel demand limit function, a start limit function, and a function to
“bump” the actuator to allow testing the dynamics. The software also allows
configuration of the two communication ports. One actuator output and both
analog outputs are software configurable to output one of several different
signals. All analog inputs and outputs are fully adjustable.
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 1-4 and 1-7.
Optional PC-based standard Interface Digital Control–723PLUS Marine SEP
Control View software (part number 8928-055) is a graphical user interface
product used for monitoring and adjusting software parameters of the
723PLUS/Process Control.

723PLUS/Single Engine Marine Propulsion Manual 02880
4 Woodward
Figure 1-2. 723PLUS Digital Speed Control

Manual 02880 723PLUS/Single Engine Marine Propulsion
Woodward 5
Figure 1-3. Watch Window Display

723PLUS/Single Engine Marine Propulsion Manual 02880
6 Woodward
Figure 1-4. Hand Held Programmer

Manual 02880 723PLUS/Single Engine Marine Propulsion
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723PLUS/Single Engine Marine Propulsion Manual 02880
8 Woodward
Figure 1-5. Vessel Wiring Diagram

Manual 02880 723PLUS/Single Engine Marine Propulsion
Woodward 9

723PLUS/Single Engine Marine Propulsion Manual 02880
10 Woodward
Figure 1-6. 723PLUS Block Diagram

Manual 02880 723PLUS/Single Engine Marine Propulsion
Woodward 11
Figure 1-7. Typical 723PLUS Connections

723PLUS/Single Engine Marine Propulsion Manual 02880
12 Woodward
Chapter 2.
Installation
Scope
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 page iv, Electrostatic Discharge Awareness. Be
careful when unpacking the electronic control. Check the control for signs of
damage such as bent panels, scratches, and loose or broken parts. If any
damage is found, immediately notify the shipper.
Power Requirements
The 723PLUS marine control requires a voltage source of 18 to 40 Vdc. The
input power source must be capable of supplying 40 W and 7 A.
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 provides an operating temperature range of
–40 to +70 °C (–40 to +158 °F).
The control must NOT be mounted on the engine.