Woodward 723PLUS User manual

Installation and Operation Manual
723PLUS Digital Speed Control
for Reciprocating Engines—
Analog Load Sharing
8280-414, 8280-415, 8280-480, 8280-481
Manual 02879 (Revision A)

WARNING—DANGER OF DEATH OR PERSONAL INJURY
WARNING—FOLLOW INSTRUCTIONS
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.
WARNING—OUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify
that you have the latest revision, be sure to check the Woodward website:
www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The
latest version of most publications is available at:
www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get
the latest copy.
WARNING—OVERSPEED PROTECTION
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.
WARNING—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.
CAUTION—POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY
CAUTION—BATTERY CHARGING
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.
CAUTION—ELECTROSTATIC DISCHARGE
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.
IMPORTANT DEFINITIONS
• A WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
• A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in
damage to equipment or property.
• A NOTE provides other helpful information that does not fall under the warning or caution
categories.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information
provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is
assumed by Woodward Governor Company unless otherwise expressly undertaken.
© Woodward 1999
All Rights Reserved

Manual 02879 723PLUS/Analog Load Sharing
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Contents
CHAPTER 1. GENERAL INFORMATION...........................................................1
Introduction.............................................................................................................1
Declaration of Incorporation...................................................................................1
Application..............................................................................................................1
Control Options.......................................................................................................2
723PLUS Digital Speed Control Accessories ........................................................3
CHAPTER 2. ELECTROSTATIC DISCHARGE AWARENESS.............................11
CHAPTER 3. INSTALLATION........................................................................12
Introduction...........................................................................................................12
Unpacking.............................................................................................................12
Power Requirements............................................................................................12
Location Considerations.......................................................................................12
Internal Jumpers...................................................................................................13
Electrical Connections..........................................................................................13
Installation Checkout Procedure ..........................................................................26
CHAPTER 4. ENTERING CONTROL SET POINTS ..........................................28
Introduction...........................................................................................................28
Watch Window PC Interface ................................................................................28
723PLUS Analog Load Sharing Control View......................................................30
System Requirements.......................................................................................30
Control Modes......................................................................................................31
Hand Held Programmer and Menus ....................................................................43
Configuration Menu Descriptions.........................................................................46
Service Menu Descriptions...................................................................................56
CHAPTER 5. INITIAL ADJUSTMENTS ...........................................................84
Introduction...........................................................................................................84
Start-up Adjustments............................................................................................84
Dynamic Adjustments...........................................................................................85
Speed Adjustments ..............................................................................................87
Torsional Adjustments..........................................................................................88
Conclusion of Setup Procedures..........................................................................89
CHAPTER 6. DESCRIPTION OF OPERATION.................................................90
General.................................................................................................................90
Fuel Control..........................................................................................................91
Control Dynamics.................................................................................................91
Speed Input..........................................................................................................93
Torsional Filter Function.......................................................................................96
Minimum Fuel Function........................................................................................97
Maximum Fuel Function.......................................................................................98
Start Limit Function...............................................................................................98
Fuel Limiting Function ..........................................................................................99
Actuator Function .................................................................................................99
Speed Failures ...................................................................................................100
Alarm Reset........................................................................................................100
Speed/Load Reference and Ramps...................................................................100
Speed Reference and Ramp Functions.............................................................101
Load Reference and Ramp Functions ...............................................................102
Load Control.......................................................................................................104
Power System Management Concepts..............................................................108
Power-Up Diagnostics........................................................................................113

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Contents
CHAPTER 7. TROUBLESHOOTING .............................................................114
General.............................................................................................................. 114
Troubleshooting Procedure............................................................................... 114
Control Test and Calibration.............................................................................. 114
Conclusion of Test and Calibration Procedures................................................ 117
CHAPTER 8. SERVICE OPTIONS................................................................118
Product Service Options.................................................................................... 118
Returning Equipment for Repair........................................................................ 119
Replacement Parts............................................................................................ 120
How to Contact Woodward................................................................................ 120
Engineering Services......................................................................................... 121
Technical Assistance......................................................................................... 122
APPENDIX A. SERIAL COMMUNICATION PORT WIRING ..............................123
Grounding and Shielding................................................................................... 125
APPENDIX B. LINKNET®I/O NETWORK.....................................................126
Introduction........................................................................................................ 126
Network Architecture......................................................................................... 126
Hardware........................................................................................................... 126
I/O Module Specifications.................................................................................. 126
Individual I/O Module Specifications ................................................................. 128
LinkNet I/O Module Descriptions....................................................................... 128
Discrete Input Module........................................................................................ 130
4–20 mA Input Module ...................................................................................... 132
Thermocouple Input Module.............................................................................. 134
RTD Input Module ............................................................................................. 136
Relay Output Module......................................................................................... 138
4–20 mA Output Module.................................................................................... 140
Troubleshooting Flowchart................................................................................ 144
Wiring and Proper Cable................................................................................... 144
Cable Length and Number of LinkNet I/O Modules .......................................... 145
APPENDIX C. MODBUS SLAVE ADDRESS INFORMATION ............................146
Part Numbers 8280-414/-415/-480/-481........................................................... 146
APPENDIX D. PROGRAMMING CHECKLIST.................................................151
APPENDIX E. MENU SUMMARY.................................................................164
Configure Menus............................................................................................... 164
Service Menus................................................................................................... 165
723PLUS CONTROL SPECIFICATIONS......................................................169

Manual 02879 723PLUS/Analog Load Sharing
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Illustrations and Tables
Figure 1-1. Flexible Coupled Generator Set ..........................................................2
Figure 1-2. 723PLUS Digital Speed Control ..........................................................5
Figure 1-3. Watch Window Display........................................................................6
Figure 1-4. Hand Held Programmer.......................................................................7
Figure 1-5a. Control Wiring Diagram .....................................................................8
Figure 1-5b. Control Wiring Diagram (Notes).........................................................9
Figure 1-6. Typical 723PLUS Connections..........................................................10
Figure 3-1. 723PLUS Control Internal Jumpers...................................................14
Figure 4-1. Hand Held Programmer Functions....................................................46
Figure 4-2. Control Gain as a Function of Speed Error .......................................60
Figure 4-3. Control Gain as a Function of Control Output ...................................60
Figure 4-4. Typical Transient Response Curves..................................................61
Figure 4-5. Speed Filter........................................................................................62
Figure 4-6. Start Limit Function............................................................................66
Figure 4-7. Torque Limit Curve ............................................................................69
Figure 6-1. Simplified Block Diagram...................................................................92
Figure 6-2a. Detailed Block Diagram ...................................................................94
Figure 6-2b. Detailed Block Diagram ...................................................................95
Figure 6-3. Notch Filter.........................................................................................97
Figure 6-4. Start Limit Function............................................................................98
Figure 6-5. Fuel Limit Breakpoints .......................................................................99
Figure 6-6. Remote Speed Reference ...............................................................102
Figure 6-7. Paralleling System...........................................................................109
Figure 6-8. Droop Mode.....................................................................................110
Figure 6-9. Isochronous Mode ...........................................................................111
Figure 6-10. Droop/Isochronous Load Sharing..................................................112
Figure 6-11. Isochronous Load Sharing.............................................................112
Figure 6-12. Isochronous Base Load on an Isolated Bus..................................112
Figure A-1. 723PLUS RS-232 Connections.......................................................123
Figure A-2. 723PLUS RS-422 Connections with Optional Termination at
Receiver.........................................................................................123
Figure A-3. 723PLUS RS-485 Connections with Optional Termination.............124
Figure A-4. RS-422 Terminator Locations .........................................................124
Figure A-5. Preferred Multipoint Wiring Using Shielded Twisted-pair Cable with a
Separate Signal Ground Wire........................................................125
Figure A-6. Alternate Multipoint Wiring Using Shielded Twisted-pair Cable
without a Separate Signal Ground Wire........................................125
Figure B-1. LinkNet Relay Contacts...................................................................127
Figure B-2. Outline Drawing of I/O Module........................................................129
Figure B-3. Discrete Input Module Block Diagram.............................................130
Figure B-4. Discrete Input Module Wiring Diagram ...........................................131
Figure B-5. 4–20 mA Input Module Block Diagram............................................132
Figure B-6. 4–20 mA Input Module Wiring Diagram ..........................................133
Figure B-7. Thermocouple Input Module Block Diagram...................................134
Figure B-8. Thermocouple Input Module Wiring Diagram..................................135
Figure B-9. RTD Input Module Block Diagram...................................................136
Figure B-10. RTD Input Module Wiring Diagram ...............................................137
Figure B-11. Relay Output Module Block Diagram............................................138
Figure B-12. Relay Output Module Wiring Diagram...........................................139
Figure B-13. 4–20 mA Output Module Block Diagram.......................................140
Figure B-14. 4–20 mA Output Module Wiring Diagram .....................................141
Figure B-15a. Troubleshooting Flowchart (1 of 2) .............................................142
Figure B-15b. Troubleshooting Flowchart (2 of 2) .............................................143

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Illustrations and Tables
Figure B-16. Direct Wired Network.................................................................... 145
Figure B-17. Network Wired Via Stubs.............................................................. 145
Table 1-1. LinkNet Modules (Summary).................................................................3
Table 1-2. LinkNet Modules (Address)...................................................................4
Table 6-1. Description of Discrete Inputs While in Load Control ...................... 107
Table 6-2. Droop/Isoch Mode Selection............................................................ 108

Manual 02879 723PLUS/Analog Load Sharing
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Chapter 1.
General Information
Introduction
This manual describes the Woodward 723PLUS Analog Load Sharing Digital
Speed Control, models 8280-414 (low voltage), 8280-415 (high voltage),
8280-480 (low voltage, low speed), and 8280-481 (high voltage, low speed). The
low speed versions are for engines rated at 130 rpm or less.
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
This 723PLUS Digital Speed Control controls the speed and load of reciprocating
engines in generator set service, including those with flexible couplings (see
Figure 1-1). The control includes inputs for two magnetic pickups (MPUs) or
proximity switches for monitoring flexible coupling torsionals, an input for a kW
sensor, an input for a synchronizer, an input for a remote speed or load setting,
an input for output fuel limiting, and an internal speed reference for local control
of speed. The control outputs include an actuator output, three configurable
analog outputs, and three relay outputs. The relay outputs are for a shutdown, an
alarm, and to open the generator breaker after unloading the generator.
Connections for analog load sharing via an internal relay are also provided.
These controls can be used with other Woodward controls and accessories
which use standard analog load sharing.
LON channel #1 can be used to support Woodward LinkNet®input/output nodes
for monitoring functions. LON channel #2 is not used.
The three serial channels provide for various control interfaces. Port J1 is
switchable to be a Watch Window PC interface or a hand-held programmer port
for monitoring and programming the 723PLUS control. Port J2 is a Watch
Window only port. Port J3 can interface to a Modbus®* master device such as a
Human/Machine Interface (HMI) to monitor the control and engine parameters
and to issue control commands. *—Modbus is a trademark of Modicon, Inc.

723PLUS/Analog Load Sharing Manual 02879
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A typical 723PLUS control system is shown in Figure 1-6. The system shown is a
genset with a flexible coupling between the engine and the generator. The
generator is connected (along with other gensets) to an infinite bus and a plant
load. While the utility is present, the on-line units will run in baseload or kW
droop. The load can be controlled by the Remote Load Setpoint device. If the
utility tie-line is lost, the on-line gensets will isochronously load share to control
the system frequency as the system load changes. Off-line units can be brought
on-line at any time with the SPM-A synchronizer. Protection is provided to the
unit shown with the External Fuel Limiter and special torsional detection and
filtering across the flexible coupling.
The 723PLUS control system includes:
• a 723PLUS Digital Speed Control
• ServLink Watch Window (Figure 1-3) or a hand held terminal (Figure 1-4)
• one or two proportional actuators to position the fuel metering
• an external power source
• one or two speed-sensing devices (two required for coupling torsional
filtering)
• eight optional switch contacts to manage control functions
• an optional synchronizing device
• an optional fuel limiting transducer
• three optional analog readout devices for display
• two optional relay-driven alarms and shutdowns
• 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 1-2) consists of a single printed circuit board in a
sheet-metal chassis. Connections are via three terminal strips and three 9-pin
subminiature D connectors.
Control Options
Each 723PLUS control requires 40 W of power. A nominal current in-rush of 7 A
(low voltage) or 22 A (high voltage) is possible. Acceptable input voltage ranges
are:
• low voltage—18 to 40 Vdc
• high voltage—90 to 150 Vdc
Figure 1-1. Flexible Coupled Generator Set

Manual 02879 723PLUS/Analog Load Sharing
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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 Ωload).
Other control options (on-board jumper configurations):
• proximity switch input for speed signal frequencies below 1000 Hz
• tandem actuator outputs
• 0–1 or 4–20 mA analog outputs
• 4–20 or 0–200 mA actuator outputs
Magnetic pickup inputs should only be used when operating speeds provide at
least 400 Hz magnetic pickup frequency.
723PLUS Digital Speed Control Accessories
PC-based Watch Window Software (part number 8923-932) and a Hand Held
Programmer (part number 9907-205) are used for monitoring and adjusting
software parameters of the 723PLUS control, including the software options.
They plug into communication port J1 of the control. [Hand Held Programmer
part number 9905-292 can also be used.] See Figures 1-3 and 1-4.
A kW feedback device such as the Woodward Real Power Sensor (RPS) or
commercial kW transducer can be used to provide the 723 control with a signal
representing generator load. The generator load signal is used for a variety of
automatic loading functions within the control. This signal is also required for
baseloading against the grid or load sharing with other units. Signal Input #1 has
been dedicated for this purpose.
An analog Speed and Phase Matching Synchronizer such as the Woodward
SPM-A can be used to allow automatic synchronizing of the engine generator.
Signal Input #2 has been dedicated to this purpose.
The two communication ports (J2 and J3) and the LON #1 data channel allow for
digital communications between external Modbus compatible devices, ServLink
devices, and Woodward LinkNet I/O modules. Port J2 is a dedicated port for
ServLink clients like Watch Window and Control View. The LON #1 channel has
been designated for use with up to 9 LinkNet modules. The inputs and outputs of
these modules can be read and controlled with Modbus compatible devices
connected to communication port J3. The number and types of LinkNet modules
available:
Total Module
Nodes Channels Network Part
Description Available Available Address Numbers
J Thermocouple In–Fail High OR 9905-966
J Thermocouple In–
Fail Low 4 24 1, 2, 3, or 4 9905-967
100 ΩAm 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)

723PLUS/Analog Load Sharing Manual 02879
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Addr. Description Channels Notes
1J TC–Fail High 6
2J TC Input 6
3J TC Input 6
4J TC Input 6
5100 ΩAm RTD Input 6
64–20 mA Input 6
7Discrete Input 16
8Relay Output 8
9Analog Output 6
Total 66
Table 1-2. LinkNet Modules (Address)

Manual 02879 723PLUS/Analog Load Sharing
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Figure 1-2. 723PLUS Digital Speed Control

723PLUS/Analog Load Sharing Manual 02879
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Figure 1-3. Watch Window Display

Manual 02879 723PLUS/Analog Load Sharing
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Figure 1-4. Hand Held Programmer

723PLUS/Analog Load Sharing Manual 02879
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Figure 1-5a. Control Wiring Diagram

Manual 02879 723PLUS/Analog Load Sharing
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Figure 1-5b. Control Wiring Diagram (Notes)

723PLUS/Analog Load Sharing Manual 02879
10 Woodward
Figure 1-6. Typical 723PLUS Connections

Manual 02879 723PLUS/Analog Load Sharing
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Chapter 2.
Electrostatic Discharge Awareness
All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
1. Before doing maintenance on the electronic control, discharge the static
electricity on your body to ground by touching and holding a grounded metal
object (pipes, cabinets, equipment, etc.).
2. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam
cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.
4. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
•Do not touch any part of the PCB except the edges.
•Do not touch the electrical conductors, the connectors, or the
components with conductive devices or with your hands.
•When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
CAUTION—ELECTROSTATIC DISCHARGE
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.

723PLUS/Analog Load Sharing Manual 02879
12 Woodward
Chapter 3.
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 Chapter 2, Electrostatic Discharge Awareness.
Be careful when unpacking the electronic control. Check the control for signs of
damage such as bent panels, scratches, and loose or broken parts. If any
damage is found, immediately notify the shipper.
Power Requirements
The high-voltage versions of the 723PLUS Digital Speed Control require a
voltage source of 90 to 150 Vdc. The low-voltage versions require a voltage
source of 18 to 40 Vdc.
CAUTION—INPUT VOLTAGE
To prevent damage to the control, do not exceed the input voltage range.
NOTE
If a battery is used for operating power, an alternator or other battery-
charging device is necessary to maintain a stable supply voltage.
CAUTION—BATTERY
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 02879 723PLUS/Analog Load Sharing
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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 Chapter 2, Electrostatic
Discharge Awareness, before proceeding.
With the power off, remove the control cover. With a small pair of tweezers or
needle-nose pliers, carefully remove the appropriate jumper and replace it
securely over the proper two connectors (see Figure 3-1).
The following jumper options are available for these 723PLUS controls:
JPR10 analog output #1 0–1 mA
* JPR9 analog output #1 0–20 mA
JPR12 analog output #2 0–1 mA
* JPR11 analog output #2 0–20 mA
* JPR13 & JPR2 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 1-6. 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/Analog Load Sharing Manual 02879
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Figure 3-1. 723PLUS Control Internal Jumpers