Woodward PG-EG User manual

Product Manual 36637
(Revision G, 8/2014)
Original Instructions
PG-EG
Integral EG Actuator for PG Governors
Installation and Operation Manual

General
Precautions
Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions.
Failure to follow instructions can cause personal injury and/or property damage.
Revisions
This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26455, Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, on
the publications page of the Woodward website:
www.woodward.com/publications
The latest version of most publications is available on the publications page. If
your publication is not there, please contact your customer service representative
to get the latest copy.
Proper Use
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifications or listings.
Translated
Publications
If the cover of this publication states "Translation of the Original Instructions"
please note:
The original source of this publication may have been updated since this
translation was made. Be sure to check manual 26455, Customer Publication
Cross Reference and Revision Status & Distribution Restrictions, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.
Revisions—Changes in this publication since the last revision are indicated by a black line
alongside the text.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken. Manual 36637
Copyright © Woodward 1995–2014
All Rights Reserved

Manual 36637 PG-EG Integral EG Actuator for PG Governors
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Contents
REGULATORY COMPLIANCE ........................................................................ II
WARNINGS AND NOTICES............................................................................III
ELECTROSTATIC DISCHARGE AWARENESS ................................................. IV
CHAPTER 1. GENERAL INFORMATION...........................................................1
Introduction.............................................................................................................1
Description..............................................................................................................1
Reverse or Direct Acting.........................................................................................1
Vibration Resistance...............................................................................................1
CHAPTER 2. INSTALLATION..........................................................................6
Introduction.............................................................................................................6
Initial Operation ......................................................................................................6
Receiving................................................................................................................6
Storage...................................................................................................................7
Mounting Requirements .........................................................................................7
Linkage...................................................................................................................7
Electrical and Hydraulic Connections.....................................................................8
Clearances .............................................................................................................9
Governor Oil...........................................................................................................9
Oil Problems...........................................................................................................9
Governor Oil Service............................................................................................10
CHAPTER 3. PRINCIPLES OF OPERATION ...................................................12
Flapper Nozzle System ........................................................................................12
Torque-motor System...........................................................................................12
Direct and Reverse Acting....................................................................................13
CHAPTER 4. OPERATION AND ADJUSTMENTS.............................................17
Introduction...........................................................................................................17
Centering Adjustment...........................................................................................17
Adjustment of the Anti-rotation Device.................................................................18
Mode Select Valve and Mode Indicating Switch ..................................................18
Parts List for Figure 4-1........................................................................................19
Parts List for Figure 4-2........................................................................................21
Maintenance.........................................................................................................23
Applications..........................................................................................................23
Parts List for Figure 4-3........................................................................................24
CHAPTER 5. PRODUCT SUPPORT AND SERVICE OPTIONS...........................25
Product Support Options......................................................................................25
Product Service Options.......................................................................................25
Returning Equipment for Repair...........................................................................26
Replacement Parts...............................................................................................26
Engineering Services............................................................................................27
Contacting Woodward’s Support Organization ....................................................27
Technical Assistance............................................................................................28
REVISION HISTORY....................................................................................29
DECLARATIONS.........................................................................................30

PG-EG Integral EG Actuator for PG Governors Manual 36637
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Illustrations and Tables
Figure 1-1. PG-EG Actuator Connections..............................................................2
Figure 1-2. PGA/PGG-EG Governor Connections (without mode select block)....3
Figure 1-3. PGA/PGG-EG Governor Connections (with mode select block).........4
Figure 1-4. PGA-EG 200/300 Outline Drawing ......................................................5
Figure 2-1. Governor Travel...................................................................................8
Figure 3-1. Schematic of Pilot Valve and Pressure Regulator Section................11
Figure 3-2. PG-EG Schematic, without Mode Select Valve.................................13
Figure 3-3. PG-EG Schematic, with Mode Select Valve, Controlling on PG .......14
Figure 3-4. PG-EG Schematic, with Mode Select Valve, Controlling on EG .......15
Figure 3-5. EG Actuator Schematic, No Ballhead Backup...................................16
Figure 4-1. Torque Motor Exploded View.............................................................19
Figure 4-2. Mode Select Block Exploded View ....................................................20
Figure 4-3. Assembly and Tubing Exploded View................................................24
Regulatory Compliance
Other European Compliance:
Compliance with the following European Directives or standards does not qualify
this product for application of the CE Marking:
Machinery Directive: Compliant as partly completed machinery with
Directive 2006/42/EC of the European Parliament
and the Council of 17 May 2006 on machinery.
Special Conditions for Safe Use:
Field wiring must be suitable for at least 95 °C.
Compliance with the Machinery Directive 2006/42/EC noise measurement and
mitigation requirements is the responsibility of the manufacturer of the machinery
into which this product is incorporated.

Manual 36637 PG-EG Integral EG Actuator for PG Governors
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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.

PG-EG Integral EG Actuator for PG Governors Manual 36637
iv Woodward
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.

Manual 36637 PG-EG Integral EG Actuator for PG Governors
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Chapter 1.
General Information
Introduction
This manual contains information about the Woodward Integral EG Actuator for
PG governors as an add-on unit:
to form the PG-EG actuator (no ballhead) or
to create a ballhead backup governor (PGA-EG or PGG-EG) from the PGA
or PGG governor.
In this manual, PG-EG refers to any of these three governor types.
This manual covers the EG, governor components affected by the EG, and
information pertaining to the PG-EG. For more general governor information,
refer to the PGA governor manual (36604) or the PGG governor manual (36627).
Description
The EG is an electro-hydraulically controlled actuator that accepts a (0 to 200)
mA signal, and outputs on a standard PG servo proportional to the mA signal.
Reverse or Direct Acting
The actuator is available for use with either direct- or reverse-acting electronic
controls. Direct-acting units assume an increasing fuel as the current level
increases. Reverse-acting units assume a decreasing fuel position as the current
level increases.
Reverse-acting EG actuators are normally used on ballhead governors to provide
an automatic ballhead back-up in case the electrical control signal is lost or
interrupted.
Direct-acting EG actuators will cause shutdown if the electrical current to the
actuator is lost or interrupted.
Direct-acting Reverse-acting
Fuel Rack Position (0.050 to 0.950) inches TR (0.050 to 0.950) inches TR
Control Current (20 to 160) mA (160 to 20) mA
Vibration Resistance
The EG actuator is in itself resistant against vibration due to the torque motor
beam being mass-stabilized in all three axes. As a consequence, vibrations have
minimal influence on the position of the beam.

PG-EG Integral EG Actuator for PG Governors Manual 36637
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Figure 1-1. PG-EG Actuator Connections

Manual 36637 PG-EG Integral EG Actuator for PG Governors
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Figure 1-2. PGA/PGG-EG Governor Connections (without mode select block)

PG-EG Integral EG Actuator for PG Governors Manual 36637
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Figure 1-3. PGA/PGG-EG Governor Connections (with mode select block)

Manual 36637 PG-EG Integral EG Actuator for PG Governors
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Figure 1-4. PGA-EG 200/300 Outline Drawing

PG-EG Integral EG Actuator for PG Governors Manual 36637
6 Woodward
Chapter 2.
Installation
Introduction
This chapter describes receiving, storage, and installation requirements for the
actuator.
Due to typical noise levels in turbine or engine environments,
hearing protection should be worn when working on or around the
actuator.
The surface of this product can become hot enough or cold enough
to be a hazard. Use protective gear for product handling in these
circumstances. Temperature ratings are included in the specification
section of this manual.
Use of a predicted minimum fuel shutdown procedure is highly
recommended. Failure to comply with this recommendation can
cause personal injury and/or property damage.
Use care while handling and installing the actuator. Be particularly
careful to avoid striking the drive shaft, terminal shaft, or the
electrical connector. Abuse can damage seals, internal parts, and
factory adjustments. Do not set the actuator on its drive shaft.
External fire protection is not provided in the scope of this product. It
is the responsibility of the user to satisfy any applicable
requirements for their system.
Initial Operation
Before initial operation of the engine equipped with this actuator, read
all of this installation chapter. Make sure that all installation steps have
been correctly accomplished and all linkages are secured and properly
attached. Carefully review the direction of rotation for the actuator oil
pump.
Receiving
Your PG governor is shipped from the factory bolted to a wooden platform in a
vertical position. After being tested at the factory, the governor is drained of oil.
This leaves a light film of oil covering the internal parts, preventing rust. No
internal cleaning is required.
Use care in handling the governor. Be particularly careful to avoid
striking the drive shaft. Do not drop or rest the governor on its drive
shaft. Such treatment could damage the gears and bearings in the
governor oil pump.

Manual 36637 PG-EG Integral EG Actuator for PG Governors
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Most PG governors lift from an eye-bolt threaded into a 0.375-16 (inch) hole in
the center of the cover. PG-200, PG-300, and PG-500 governors must be lifted
with a sling. Some PG governors have split covers which need to be lifted with a
sling as well.
Storage
The governor may be stored for up to a year as received from the factory. Store
the governor in a vertical position. Fill completely with oil if extended storage is
necessary.
Mounting Requirements
A gasket must be used between the governor and the accessory mounting pad.
A 0.81 mm (0.032 inch) thick gasket is recommended for this purpose. The
gasket is used to absorb imperfections between the governor base and the
mounting pad, and to avoid oil leakage between the governor and the drive
portion of the engine.
Install the governor square on the accessory pad, using the correct length of
coupling between the governor and the drive. Make sure the driveshaft does not
bind, and that there is no excessive side load on the driveshaft assembly. Make
sure the coupling is tight, and do not use force when installing the drive shaft into
the coupling. The governor must be installed in a vertical position.
A rough or non-concentric drive can prevent smooth governor operation and
shorten governor life. The drive should be as smooth as possible. Poor drive
dynamics can damage governor seals and bearings.
Rotation direction is factory set for some governors. Damage will
result if the governor is installed on a drive which rotates in the
wrong direction. Specifications for individual governors indicate if
the unit has been plugged to limit rotation to one direction only.
Many PG governors are equipped with check valves in the pump,
allowing rotation in both clockwise and counterclockwise directions.
Linkage
Align the linkage from the governor to the fuel pumps or valves to eliminate
binding and excessive backlash. The relationship of governor/terminal shaft
angular position to the fuel control position must be adjusted in accordance with
the engine manufacturer's specifications. The linkage must not limit the
governor's ability to call for maximum fuel or to shut down the engine.
Linkage must not give during major transients and must not be so heavy that it
hinders accurate governor response. Linkage must be designed to resist wear.
Linkage is responsible for many apparent “governor problems”, and proper
design and installation of the linkage between the governor output and the
engine is extremely important.

PG-EG Integral EG Actuator for PG Governors Manual 36637
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The fuel-control linkage must be adjusted so at least 15 % of the governor travel
(output) from minimum position has been used when the fuel control is at idle no-
load (A and D; see Figure 2-1). This minimum setting is required due to the
location of the compensation cut-off port (if so equipped).
Use as much of the governor output travel as possible. Stability is greatly
improved with the use of maximum governor travel. Design linkage so governor
output and resultant power output of the engine are nearly linear.
Figure 2-1. Governor Travel
Electrical and Hydraulic Connections
Make the pneumatic (if applicable), hydraulic, and electrical connections required
for the particular governor. Refer to Figures 1-1 through 1-3.
Most governors are equipped with an oil spray to reduce or prevent vibration-
induced damage to the torque-motor assembly.
All governors have hydraulic connections for a heat exchanger which allows oil to
be circulated to an external cooler to ensure that the governor oil temperature
remains between 71 °C and 93 °C (160 °F and 200 °F) under all operating
conditions. In case a heat exchanger is used on a governor also equipped with
an oil spray, extra attention is required. Since the spray tube is located at the
same height as the oil-to-cooler connection on the governor’s power case, these
two connections are hydraulically linked. This means that the oil spray will no
longer function when combined with a cooler, since the oil will follow the path
with the least resistance. In order to prevent this, we recommend adding an
orifice to the oil-to-cooler line exactly where it leaves the power case to ensure
enough flow of oil is going to the oil spray.
Standard electrical connections are made to the four-pin connector on the side of
the column (see figures). Optionally, the EG actuator may be wired to the
connector on the receiver bracket through an internal mounting bracket.

Manual 36637 PG-EG Integral EG Actuator for PG Governors
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Instead of a connector, the governor may be equipped with a flying lead, leaving
the governor on the side of the column. This option is used mostly on governors
in a high-vibration environment.
Clearances
Leave adequate clearance to connect the linkage, to fill the governor with oil, and
to remove the cover (if necessary).
Governor Oil
Governor oil must have lubricating and hydraulic properties. The oil must have a
viscosity index that allows it to perform over the operating temperature range of
the governor. The oil must have additives that allow it to remain stable and
predictable over the operating temperature range of the governor. The oil used in
the governor must be compatible with the nitrile, polyacrylic, and fluorocarbon
seals used in the governor.
Many oils and synthetic lubricating fluids used in the engines controlled by PG
governors meet these specifications. When possible use the same grade and
weight of oil used in the engine. Information in this manual is intended to be used
only in the selection of the governor lubricating oil, not for selecting engine lube
oil. USE ONLY NEW, CLEAN OIL. DO NOT USE USED ENGINE OIL IN THE
GOVERNOR.
Woodward governors and actuators are designed to give stable operation with
oils which provide 50 to 3000 SUS (Saybolt Universal Seconds) of viscosity
throughout the operating temperature range. Ideally the viscosity at the normal
operating temperature should be between 100 and 300 SUS. Poor governor
response or instability is often an indication that the oil being used is too thick or
too thin.
For more detailed information on the choice of governor oil, refer to manual
25071, Oils for Hydraulic Controls.
The recommended oil temperature for continuous governor operation is
(60 to 93) °C / (140 to 200) °F. Measure the oil temperature of the governor or
actuator on the outside lower part of the power case. The actual oil temperature
will be about 6 °C (10 °F) higher. The governor is designed to operate in ambient
temperatures of (29 to 93) °C / (20 to 200) °F.
Oil Problems
A filter is located between the oil pump and the control pilot valve of the EG
actuator. Should this filter become clogged, it can seriously hinder the ability of
the actuator to control, even on the mechanical ballhead side. Take extra care
with the PG to be sure that oil is clean and that it does not deteriorate due to
heat.

PG-EG Integral EG Actuator for PG Governors Manual 36637
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Excessive component wear or seizure in a governor indicates the possibility of
insufficient lubrication caused by:
An oil that flows slowly when it's cold or at start-up;
High or low governor oil level;
Restrictions in oil lines to boosters or heat exchangers;
Contaminated oil (usually caused by dirty oil containers used when
transferring oil to the governor);
A governor exposed to heating and cooling cycles, creating condensation of
water in the oil;
Oil not suitable for the operating conditions.
Operating a governor continuously beyond the high-limit temperature of the oil
will result in oil oxidation. This is identified by varnish or sludge deposits on
governor parts. To reduce oil oxidation, lower the oil operating temperature with a
heat exchanger or other means, or change to an oil more oxidation resistant at
the operating temperature.
PG-governors operating with internal oil-pressures in excess of 1655 kPa
(240 psi) often require a heat exchanger to protect the oil from damage.
Many governor problems are the result of improper selection or
improper maintenance of governor oil. The governor should be
serviced on a routine schedule. Develop the schedule with
consideration to the governor operating temperature and the
cleanliness of the atmosphere in which the governor operates.
A loss of stable governor control and possible engine overspeed
may result if oil viscosity exceeds the 50 to 3000 SUS range.
Governor Oil Service
Replace the governor oil if it is contaminated or if it is suspected of causing
governor problems. Drain the oil while it is still hot and agitated. Flush the
governor with kerosene or an equivalent solvent. If drain time is insufficient for
the solvent to completely drain or evaporate, flush with the same grade and
weight of oil which will be used to refill the governor. Discard the oil used to flush
out the solvent.
To avoid contamination of the governor, the replacement oil must be free of dirt,
water, or other foreign material. Use clean containers to store and transfer oil.
Refer persistent or recurring oil problems to an oil specialist.
After the oil is selected, fill the governor with new, clean oil, in the volumes listed
here: Type 12/29/58 (1.4 L / 1.5 qt), Type 200/300 (6.2 L / 6.5 qt), Type 500
(6.6 L / 7.0 qt).
While the engine is not running, fill the governor to the maximum level indication.
During normal operation, this level should not drop below the minimum level. Do
not add oil when operating the governor.

Manual 36637 PG-EG Integral EG Actuator for PG Governors
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PG-EG 200, 300, and 500 cases must be filled in two stages. Fill with about
4 liters/quarts before starting, then add the amount needed to bring the oil up to
operating levels after start-up. On these governors, there is an oil level dipstick
inside the fill port cap. On newer types, a small sight gauge glass has been
added onto the terminal shaft housing. Always use the dipstick for accurate oil
level readings. All other PG-EGs have an oil filler cup in the cover and a special
long oil gauge glass on the power case.
To prevent contamination of the flapper nozzle system, an oil filter has been fitted
to the oil feed line going to the EG actuator. Check this filter every time the oil is
changed, and clean if necessary.
Figure 3-1. Schematic of Pilot Valve and Pressure Regulator Section

PG-EG Integral EG Actuator for PG Governors Manual 36637
12 Woodward
Chapter 3.
Principles of Operation
Flapper Nozzle System
The flapper nozzle system is basically a hydraulic amplifier which converts the
torque motor beam position through the pilot valve into a servo position. Pump
pressure oil is supplied to the interior of the pilot valve and lowered by the
pressure regulating valve into the regulated pressure at 690 kPa (100 psi). This
flow of 690 kPa oil is then directed onto the bottom of the control land and
through a dropping orifice (giving the pilot valve control pressure) to the top of the
same control land but with a larger surface. At the same time, pilot valve control
pressure oil is directed through a nozzle and sprays onto the bottom of the torque
motor beam (acting as the flapper).
The balance of these hydraulic pressures and forces positions the pilot valve in
the bushing and causes the pilot valve to follow the position of the torque motor
beam. To center the pilot valve in the bushing in steady state, the gap between
the flapper (the torque motor beam) and the nozzle is adjustable by means of the
center adjustment.
The control land of the pilot valve, balanced between the regulated pressure
below and the pilot valve control pressure above, provides a hydraulic
amplification of the position of the torque-motor beam. This permits accurate
positioning of the plunger in the bushing without having the bushing rotate to
eliminate static friction as is necessary in the mechanical pilot valve system.
Torque-motor System
The torque-motor system consists of an electromagnetic coil and a beam. On top
of the beam, an armature is mounted which is placed into the electromagnetic
field of the coil. The beam itself is suspended by a torsion spring, allowing a
small degree of rotation of the beam around the center of the torsion spring but
no translations.
The torque-motor beam is balanced between the restoring spring, the level-
adjust spring, and the torque from the torque-motor. With the system in steady
state, the pilot valve of the flapper nozzle system is centered and the servo is
stationary.
By changing the current to the coil, the amount of torque on the armature
changes, and thus the torque on the torque-motor beam. This will change the
gap between the beam and the pilot valve, cause the pilot valve to follow the
movement of the beam, and allow oil to flow to or from the servo. The resultant
change in servo position causes the restoring lever to load or unload the
restoring spring, and thus restores the equilibrium of the torque-motor beam at
the new current level. The torque motor beam resumes its original position, and
the gap between the beam and the pilot valve will be restored to its original size
with the pilot valve centered.

Manual 36637 PG-EG Integral EG Actuator for PG Governors
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Direct and Reverse Acting
The same set of springs may be set for either a direct- or reverse-acting actuator.
The only difference is the level to which the level-adjust spring is set, and the
wires to the torque-motor which are reversed.
Figure 3-2. PG-EG Schematic, without Mode Select Valve

PG-EG Integral EG Actuator for PG Governors Manual 36637
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Figure 3-3. PG-EG Schematic, with Mode Select Valve, Controlling on PG