Woodward 723PLUS User manual

Technical Manual 26482
(Revision D)
Original Instructions
723PLUS Digital Marine Control
Woodward Part Number 8280-1109
Two-Engine Redundant LON Torque Sharing
Marine Propulsion Application
Installation and Operation Manual

General
Precautions
Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions.
Failure to follow instructions can cause personal injury and/or property damage.
Revisions
This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, on the publications
page of the Woodward website:
www.woodward.com/publications
The latest version of most publications is available on the publications page. If
your publication is not there, please contact your customer service representative
to get the latest copy.
Proper Use
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifications or listings.
Translated
Publications
If the cover of this publication states "Translation of the Original Instructions"
please note:
The original source of this publication may have been updated since this
translation was made. Be sure to check manual 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.
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 2008
All Rights Reserved

Manual 26482 723PLUS Digital Marine Control
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Contents
WARNINGS AND NOTICES........................................................................... IV
ELECTROSTATIC DISCHARGE AWARENESS ..................................................V
REGULATORY COMPLIANCE ....................................................................... VI
CHAPTER 1. GENERAL INFORMATION...........................................................1
Introduction.............................................................................................................1
Application ..............................................................................................................1
Control Options.......................................................................................................2
723PLUS Digital Speed Control Accessories.........................................................3
CHAPTER 2. INSTALLATION........................................................................12
Introduction...........................................................................................................12
Unpacking.............................................................................................................12
Power Requirements ............................................................................................12
Location Considerations .......................................................................................12
Specific Marine Installation Requirements ...........................................................13
Internal Jumpers...................................................................................................13
Electrical Connections ..........................................................................................15
Installation Checkout Procedure ..........................................................................24
CHAPTER 3. DESCRIPTION OF OPERATION.................................................25
Introduction...........................................................................................................25
Speed Control.......................................................................................................25
Torque Sharing.....................................................................................................32
CHAPTER 4. SERVICE AND CONFIGURE MENUS..........................................33
Watch Window and Servlink Software .................................................................33
Hand Held Programmer........................................................................................33
Menus ...................................................................................................................34
Servlink / Watch Window PC Interface.................................................................37
Configure Menus ..................................................................................................45
Service Menus......................................................................................................50
CHAPTER 5. I/O VERIFICATION AND CALIBRATION......................................65
Introduction...........................................................................................................65
I/O Verification ......................................................................................................65
I/O Calibration.......................................................................................................70
Engine Start-up.....................................................................................................74
Conclusion............................................................................................................80
Quick Calibration Check .......................................................................................80
CHAPTER 6. FAULTS AND TROUBLESHOOTING...........................................83
Introduction...........................................................................................................83
Major Alarm and Minor Alarm...............................................................................83
Both Speed Sensors Failed..................................................................................83
CPU Watchdog Fault............................................................................................83
POWER SUPPLY OK LED...................................................................................83
Alarm Delay Time .................................................................................................84
Alarm/Fault Resets ...............................................................................................84
Speed Sensor 1 & 2 Fault ....................................................................................84
Overspeed Trip.....................................................................................................85
Remote Speed Input Fault....................................................................................85
Torque Sensor Input Fault....................................................................................85
PID at Low Level Fault .........................................................................................86
Troubleshooting Procedure ..................................................................................86

723PLUS Digital Marine Control Manual 26482
ii Woodward
Contents
CHAPTER 7. PRODUCT SUPPORT AND SERVICE OPTIONS ...........................93
Product Support Options ......................................................................................93
Product Service Options.......................................................................................93
Returning Equipment for Repair ...........................................................................94
Replacement Parts ...............................................................................................94
Engineering Services............................................................................................95
Contacting Woodward’s Support Organization ....................................................95
Technical Assistance............................................................................................96
APPENDIX A. SERIAL COMMUNICATION PORT WIRING ................................97
Grounding and Shielding ......................................................................................99
APPENDIX B. PROGRAMMING CHECKLIST.................................................100
APPENDIX C. MENU SUMMARY.................................................................106
Configure Menus ................................................................................................106
Service Menus ....................................................................................................107
723PLUS CONTROL SPECIFICATIONS......................................................108
DECLARATIONS .......................................................................................109

Manual 26482 723PLUS Digital Marine Control
Woodward iii
Illustrations and Tables
Figure 1-1. 723PLUS Digital Speed Control...........................................................4
Figure 1-2. 723PLUS Marine Torque Sharing System...........................................5
Figure 1-3. Functional Block Diagram ....................................................................7
Figure 1-4. Control Wiring Diagram........................................................................9
Figure 1-5. System Wiring Overview....................................................................10
Figure 1-6. Hand Held Programmer .....................................................................11
Figure 2-1. 723PLUS Control Internal Jumpers ...................................................14
Figure 3-1. Speed Sensor Roll-off Filter...............................................................26
Figure 3-2. Speed Reference ...............................................................................29
Figure 4-1. Hand Held Programmer Functions ....................................................36
Figure 4-2. Service and Configure Headers.........................................................37
Figure 4-3. Speed Filter........................................................................................56
Figure 4-4. Gain Slope .........................................................................................58
Figure 4-5. Gain Window......................................................................................58
Figure 4-6. Typical Transient Response Curves ..................................................59
Figure 5-1. Analog Output Calibration Example...................................................72
Figure 5-2. Start Fuel Limit...................................................................................74
Figure 5-3. Gain Slope .........................................................................................77
Figure 5-4. Speed and Load-Sharing Control Loops ...........................................81
Figure A-1. 723PLUS RS-232 Connections .........................................................97
Figure A-2. 723PLUS RS-422 Connections with Optional Termination at
Receiver...........................................................................................97
Figure A-3. 723PLUS RS-485 Connections with Optional Termination...............98
Figure A-4. RS-422 Terminator Locations............................................................98
Figure A-5. Preferred Multipoint Wiring Using Shielded Twisted-pair Cable with a
Separate Signal Ground Wire..........................................................99
Figure A-6. Alternate Multipoint Wiring Using Shielded Twisted-pair Cable without
a Separate Signal Ground Wire.......................................................99
Table 6-1. Troubleshooting Procedure.................................................................87

723PLUS Digital Marine Control Manual 26482
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 26482 723PLUS Digital Marine Control
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Battery Charging
Device
To prevent damage to a control system that uses an alternator or
battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.
Electrostatic Discharge Awareness
Electrostatic
Precautions
Electronic controls contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts:
Discharge body static before handling the control (with power to
the control turned off, contact a grounded surface and maintain
contact while handling the control).
Avoid all plastic, vinyl, and Styrofoam (except antistatic versions)
around printed circuit boards.
Do not touch the components or conductors on a printed circuit
board with your hands or with conductive devices.
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
Follow these precautions when working with or near the control.
1. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
2. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
Do not touch any part of the PCB except the edges.
Do not touch the electrical conductors, the connectors, or the
components with conductive devices or with your hands.
When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.

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vi Woodward
Regulatory Compliance
European Compliance for CE Mark
EMC Directive Declared to 2004/108/EC COUNCIL DIRECTIVE of 15
December 2004 on the approximation of the laws of
the Member States relating to electromagnetic
compatibility and all applicable amendments.
This controlling device, manufactured by Woodward, is applied solely as a
component to be incorporated into a larger, prime mover, system. Woodward
declares that this controlling device complies with the EMC Directive
requirements when put into service per the installation and operating instructions
outlined the product manual. All wiring must also follow the wiring and shielding
requirements given in the specific, separate, software manual.
This controlling device is intended to be put into service only upon
incorporation into a prime mover system that itself has met the
requirements of the above Directive and bears the CE mark.
Low Voltage Directive Declared to 2006/95/EC COUNCIL DIRECTIVE of 12
December 2006 on the harmonization of the laws of
Member States relating to electrical equipment
designed for use within certain voltage limits.
North American Compliance
UL UL Listed for Class I, Division 2, Groups A, B, C, and
D, T4A at 70 °C ambient for use in the United States
and Canada: UL File E120143.
These listings are limited to those units bearing the UL
or DEMKO agency identifications.
EXPLOSION HAZARD—Do not connect or disconnect while circuit is
live unless area is known to be non-hazardous.
Substitution of components may impair suitability for Class I,
Division 2 or Zone 2 applications.
RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher
tant que l’installation est sous tension, sauf en cas
l’ambiance est décidément non dangereuse.
La substitution de composants peut rendre ce matériel
inacceptable pour les emplacements de Classe I, Division 2
ou Zone 2.
Installation wiring must be in accordance with Class I, Division 2
wiring methods in Article 501–4(b) of the NEC, and in accordance
with the authority having jurisdiction.
All peripheral equipment must be suitable for the location in which
used.

Manual 26482 723PLUS Digital Marine Control
Woodward vii
Safety Related Installation Limitations
Wiring must be in accordance with North American Class I, Division 2 wiring
methods as applicable, and in accordance with the authority having
jurisdiction.
Field wiring must be suitable for at least 75 °C for operating ambient
temperatures expected to exceed 50 °C.
A fixed wiring installation is required.
Do not connect more than one main power supply to any one fuse or circuit
breaker.
Connect ground screw to earth ground (see Figures 1-1a, 1-1b).
Marine Type Approval Compliance
American Bureau of 2007 Steel Vessel Rules 1-1-4/7.7, 4-2-1/7.3,
Shipping (ABS) 4-2-1/7.5.1, 4-9-3/17, 4-9-7/13, 4-9-2/11.7 & 4-9-4/23
(Low Voltage Models only)
Bureau Veritas (BV) Certified for Environmental Category EC Code: 33
Certified for use on AUT-UMS, AUT-CSS, AUT-PORT
and AUT-IMS Classed Vessels
Det Norske Veritas Certified for Marine Applications, Temperature Class
(DNV) B, Humidity Class A, Vibration Class B, EMC Class A,
and Enclosure Class B per DNV Rules for Ships Pt. 4,
Ch. 9 Control and Monitoring Systems and Pt. 4, Ch.’s
2 & 3, Rotating Machinery
Germanischer Lloyd Environmental Category C; EMC2 per Type Tests Part
(GL) 2, Edition 2003: Regulations for the Use of Computer
and Computer on Board
Lloyd’s Register LR Type Approval Test Specification No. 1:1996 for
(LR) Environmental Categories ENV1, ENV2, and ENV3
Nippon Kaiji Kyokai Rules Ch. 1, Part 7, of Guidance for the approval and
(NKK) Type approval of materials and equipment for marine
use and relevant Society’s Rules (Low Voltage Models
only)
Registro Italiano RINA Rules for the Classification of Ships – Part C
Navale (RINA) Machinery, Systems and Fire Protection – Ch. 3, Sect.
6, Tab. 1.

723PLUS Digital Marine Control Manual 26482
viii Woodward

Manual 26482 723PLUS Digital Marine Control
Woodward 1
Chapter 1.
General Information
Introduction
This manual describes the Woodward 723PLUS Digital Marine Speed Control for
two-engine mechanical torque sharing with using LonWorks®* communications,
Application
The 723PLUS Digital Marine Speed Control is designed to control clutching
functions and to regulate the speed and load of diesel engines in dual-engine
marine applications that require mechanical torque sharing. The applications
include mechanically combined two-engine operation for main propulsion,
including those with flexible couplings (see Figure 1-2).
Features include:
Clutch control and permissive logic
Soft loading and unloading
Mechanical torque sharing by matching torque sensor inputs
Advanced speed-sensing algorithms
Firing torsional filtering
Start fuel limiting
Torque sensor failure mode which retains torque sharing
Single-throttle operation for both engines during clutched operation
Redundant control LON®* communication
Watch Window communications port
*—LON and LonWorks are trademarks of Echelon Corporation
Inputs include:
Two magnetic pickups (MPUs) or proximity switches for sensing engine
speed, capable of providing redundant speed signals
1–5 Vdc remote speed-setting input
4–20 mA torque sensor input
1–5 Vdc remote speed input
Eight discrete inputs (contact inputs) for Run/Stop, Clutch Request, Clutch
Position, Maneuvering Speed, and Alarm Reset.
Redundant Control LON channels to perform mechanical torque sharing and
communicate essential control status to the mating control for proper
clutching and loading operations.

723PLUS Digital Marine Control Manual 26482
2 Woodward
Outputs include:
Two 4–20 mA outputs which are set for: engine speed and rack position.
One 0–200 mA actuator output compatible with most Woodward actuators
One relay output for clutch permissive/close contact out
Two Alarm relay outputs: each is user-configurable for normally open/
closed contact output. There are status choices to choose among for these
two alarms.
Three serial ports. Port J1 is switchable to be a Watch Window PC interface
or a hand-held programmer port for monitoring and programming the
723PLUS control. Ports J2 and J3 are Watch Window only ports.
The 723PLUS control provides multiple functions including speed governing,
mechanical torque sharing, clutching/de-clutching control logic, speed matching
during clutching, and soft engine loading/unloading. Each engine requires a
723PLUS control along with the associated I/O connections, transducers, and
accessories (see Figure 1-2).
The 723PLUS control uses a master/slave relationship during clutching and
torque sharing operations. The master unit is the first unit to close its clutch. The
slave unit is the last unit to close its clutch. The primary function of the 723PLUS
control is speed control. Once the engines are clutched together, the primary
function becomes torque sharing, utilizing the master control's speed reference
for both engines. The engine clutching/torque sharing process, which begins with
closure of the Clutch Request discrete input, includes matching (synchronizing)
the engine speeds and then giving a clutch permissive command. Once clutched,
the engine is soft-loaded until the engines' torques are balanced. The engines
will maintain equal torques (torque sharing) during clutched operation. During a
de-clutching operation, the de-clutching engine is soft unloaded and, a de-clutch-
command is given when the engine is at the unload trip level. This is a simplified
description. For a more detailed description, see Chapter 3, Description of
Operation.
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. The 723PLUS control should be located in a
protected location. See Woodward manual 02877, 723PLUS Digital Control
Hardware, for installation details.
Control Options
Each 723PLUS control requires 40 W of power. A nominal in-rush current 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 Run/Stop, De-Clutch Request, 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 400 Hz
0–1 or 4–20 mA analog outputs
4–20 or 0–200 mA actuator outputs
Magnetic pickup inputs should provide at least a 400 Hz frequency at minimum
operating speed.

Manual 26482 723PLUS Digital Marine Control
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723PLUS Digital Speed Control Accessories
PC based Watch Window software (part number 8923-932) or a Hand Held
Programmer (part number 9907-205) are used for adjusting software parameters
of the 723PLUS control, including the software options. The RS-232/RS-422
download cable (part number 5416-870) or Hand Held Programmer plug into
communication port J1 of the control. Hand Held Programmer part number 9905-
292 can also be used. See Figure 1-6.
As an alternate, an RS-232 cable (part number 5416-614) may be plugged into
communication port J2 of the control to use the PC based Watch Window
software (see manual 26007 Getting Started for using the Watch Window
software).

723PLUS Digital Marine Control Manual 26482
4 Woodward
Figure 1-1. 723PLUS Digital Speed Control

Manual 26482 723PLUS Digital Marine Control
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Figure 1-2. 723PLUS Marine Torque Sharing System

723PLUS Digital Marine Control Manual 26482
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Manual 26482 723PLUS Digital Marine Control
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Figure 1-3. Functional Block Diagram

723PLUS Digital Marine Control Manual 26482
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Manual 26482 723PLUS Digital Marine Control
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Figure 1-4. Control Wiring Diagram

723PLUS Digital Marine Control Manual 26482
10 Woodward
Figure 1-5. System Wiring Overview