Woodward PGA-EG 200 User manual

Product Manual 54065
(Revision NEW)
Original Instructions
PGA-EG, PGG-EG, PGM-EG 200/300/500
Governor/Actuator
Installation Manual

General
Precautions
Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions.
Failure to follow instructions can cause personal injury and/or property damage.
Revisions
This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, on the publications
page of the Woodward website:
www.woodward.com/publications
The latest version of most publications is available on the publications page. If
your publication is not there, please contact your customer service representative
to get the latest copy.
Proper Use
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifications or listings.
Translated
Publications
If the cover of this publication states "Translation of the Original Instructions"
please note:
The original source of this publication may have been updated since this
translation was made. Be sure to check manual 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.
Revisions—Changes in this publication since the last revision are indicated by a black line
alongside the text.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken. Copyright © Woodward 1986
All Rights Reserved

Manual 54065 PGA-EG, PGG-EG, PGM-EG Installation
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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.

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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.

Manual 54065 PGA-EG, PGG-EG, PGM-EG Installation
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PGA-EG, PGG-EG, PGM-EG
Governor/Actuator Installation
Introduction
Receiving, storage, and installation requirements for the PGA-EG, PGG-EG, and
PGM-EG 200/300/500 ft-lb (271/407/678 J) governor/actuators are covered in
this manual. Hereafter, these units will be referred to as PG-EG
governor/actuators.
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.
Be careful when handling and installing the governor/actuator. Do not hit the
drive shaft and output shaft. Rough handling can cause damage to seals, parts,
and adjustments.
Receiving
The PG-EG governor/actuator has been calibrated at the factory to exact
specifications, then drained of oil. A light film of oil covers the internal parts to
help prevent rust. Calibration or internal cleaning is not needed before installation
and operation.
Installation Requirements
See outline drawings, Figures 2A and 2B, for the following:
Location of hydraulic and electrical connections
Location of optional mode select valve
Hydraulic fitting sizes
Output and drive shaft dimensions
Maintain clearance for removal and servicing of the governor. The governor oil
drain should be easily accessible.
Installation
Install the PG-EG governor/actuator on the engine accessory drive pad. A gasket
may be used between the governor and the mounting pad. The drive shaft must
slip into the accessory drive or mating coupling without force. Be careful not to
push the drive shaft into the governor. Improper alignment or too tight a fit
between any of the parts can result in part wear or seizure. This can also cause
jiggle in the governor output.

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Damage to the drive shaft, drive shaft seal, or other parts of the
governor may occur if the governor is dropped or set on the drive
shaft or drive coupling.
Fuel System Linkage
Align and install the linkage between the fuel system and the governor/actuator.
Refer to Figure 1, Recommended Output Shaft Travel. The linkage must move
freely and not have excessive backlash. Use approximately 2/3 governor output
travel (26 degrees) between idle and full fuel. Permit enough overtravel so the
governor can cause complete shutdown and give full fuel at full load.
Figure 1. Recommended Output Shaft Travel
Many governors include an optional compensation cutoff, and since this option
cannot be seen without disassembly of the governor, the following notice must be
observed:
Because the optional compensation-cutoff region is near the
minimum fuel position, it is necessary to adjust the governor output
linkage to use no less than 5 degrees travel between zero- and idle-
fuel positions on the governor.
Hydraulic And Electrical Connections
Refer to Figures 2A and 2B, Outline of PG-EG Governor! Actuator, and make all
required hydraulic connections. Refer to the wiring diagram provided with the unit
for conformation of the mating electrical connections. The plant wiring diagram
included with the electronic control will provide other details about electrical
connections.

Manual 54065 PGA-EG, PGG-EG, PGM-EG Installation
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Figure 2A. Outline Drawing of the PG-EG Governor/Actuator

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Figure 2B. Outline Drawing of the PG-EG Governor/Actuator

Manual 54065 PGA-EG, PGG-EG, PGM-EG Installation
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Booster Servomotor
Make all hydraulic Connections from the booster to the PG-EG governor/actuator
(refer to manual 36684, Booster Servomotor). The booster servomotor assists
the internal pump during starting. It provides a rapid increase in oil pressure
which results in a rapid movement of the terminal shaft towards maximum. Refer
to Figures 2A and 2B, Outline of the PG-EG Governor/Actuator, and make the
connections from the booster outlets. Governor fuel position during start-up can
be limited by the fuel limiter (if available) or the stroke-limit screw on the booster.
Heat Exchanger
Make all hydraulic connections from the heat exchanger to the governor. Refer to
Figures 2A and 2B, Outline of the PG-EG Governor/Actuator and to manual
36641, Governor Oil Heat Exchanger. The heat exchanger should be installed as
close as possible to the governor. Install it below the governor’s oil level to
prevent trapping air in the system. Plumbing between the heat exchanger and
the governor must not restrict flow.
Oil Specifications
The same type and grade of oil used in the prime mover can be used in the
governor if it meets heat and viscosity requirements.
Oil contamination is the major cause of governor/actuator troubles.
Use only new oil to fill the governor/actuator. Containers used for
filling the actuator must be clean and should be rinsed with a light
grade of the same oil before use.
The PG-EG oil supply is self-contained. Sump capacity is about 7 US quarts (6.6
L). Fill the sump through the dip-stick port. It may be necessary to add oil after
the governor is first started to restore oil to the proper level on the dipstick.
Proper level is between the “ADD” and “FULL” marks. Check the oil level with the
governor running. Oil will splash from the test location during major governor
transients.
When using a booster servomotor or heat exchanger, be sure that oil
lines, booster, and the heat exchanger are full of oil before starting
the prime mover.
Whenever the PG-EG is filled, always check the oil level after starting, when the
unit is at rated speed, and at normal operating temperature. If the oil level is high,
oil should be drained. If the dipstick shows low level, add new, clean oil.
Refer to Woodward manual 25071, Oils for Hydraulic Controls, for more
information on selection of oils for use in hydraulic actuators (governors). Proper
selection of the oil used in the actuator is necessary for the best governor
performance and maximum service life. The oil should have a minimum tendency
to foam or retain air, form sludge, or deposit varnish. It should protect actuator
parts from corrosion and not be detrimental to oil seals or paint.

PGA-EG, PGG-EG, PGM-EG Installation Manual 54065
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The oil viscosity index should be within the range of 100 to 300 SUS (Saybolt
Universal Seconds) at governor operating temperature. Only oils of the grade
specified for a particular temperature range should be used.
The recommended continuous operating temperature of the oil is 140 to 200 °F
(60 to 98 °C). Measure the temperature of the governor or actuator through the
dipstick port while the PG-EG is running in a steady-state condition.
Do not put the temperature probe too deeply into the port or the
probe, the PG-EG, or both may be damaged.
Figure 3 shows the viscosity of oils at the different operating temperatures.
Operating the governor with oil which does not fall in the acceptable operating
range on the chart can cause erratic governor operation and possible damage to
the governor.
Figure 3. Viscosity and Operating Temperature of Oils
Initial Operation
Before the first start-up of the governor/actuator, be sure that all of the previous
steps have been done and are correct.
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.

Manual 54065 PGA-EG, PGG-EG, PGM-EG Installation
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Adjustments to the Ballhead Governor
Use the optional “Mode Select Valve” (see Figure 2) to set to the “PG Mode”
position to start the engine under control of the ballhead governor.
The valve can be set to “PG Mode” by appropriate electric, pneumatic, or manual
means:
Electrical—Can be either energize (24 Vdc, 0.87 A) or de-energize to set
PG Mode. See specification sheet for your application.
Pneumatic—60 to 75 psi (414 to 517 kPa) sets PG Mode.
Manual—Set knob to PG Mode.
If the Mode Select option is not included on the governor, the PG-EG can be put
under ballhead operation by running the electrical side to maximum, either
through the electrical governor control, or by simulating a maximum signal at the
electrical connection. (Most PG-EGs are “reverse acting” and an absence of any
electrical control signal will place the ballhead in control.)
Before Start-up
1. Set the compensation needle valve to 1/8 turn open from the fully closed
(clockwise) position.
2. Assure the ballhead speed setting is at the idle condition (manual speed set
to idle, pneumatic speed signal at minimum speed).
To Adjust the Compensation Needle Valve after Start up:
1. With the prime mover operating at IDLE speed, open the compensation
needle valve until the governor begins to hunt. Let the governor hunt for
several minutes to remove trapped air in the hydraulic circuits. DO NOT
allow a level of hunting which would cause damage to the prime mover.
It maybe necessary to upset the governor speed momentarily to
cause the governor to hunt. (A rapid fluctuation in the speed setting
of the PG-EG will usually accomplish this upset.)
2. Close the compensation needle valve slowly until hunting just stops. Do not
close the needle valve completely. To prevent slow governor response,
keep the needle valve open as far as possible. The needle valve setting can
be from 1/16 to 2 turns open.
3. Check the stability of the governor output by disturbing the governor speed
setting. The compensation adjustment is satisfactory when the governor
returns to speed with only a small overshoot or undershoot. Once the
needle valve adjustment is correct, it is not necessary to change the setting
unless there is a change in oil viscosity. Additional adjustment may be
necessary if stability problems exist at full speed-full load conditions

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Adjustments to the Electric Actuator
1. The PG ballhead speed setting must be set higher than the electronic-speed
setting for electric actuator operation. If so equipped, the Mode Select Valve
must be set for the EG Mode.
2. Refer to the operation manual for the specific electronic control used to set
gain, stability, and speed reference.
To select the EG Mode on the optional Mode Select Valve:
Electric—0 Vdc or 24 Vdc (0.67 A) depending on the specified
requirements for your unit.
Pneumatic—0 psi (0 kPa).
Manual—Set the knob to “EG Mode”.
Pressure
The following minimum oil pump pressures should be present at operating
speed:
PG-EG 200 200 psi (1379 kPa)
PG-EG 300 360 psi (2482 kPa)
PG-EG 500 280 psi (1931 kPa)
To check the internal pressure attach a pressure gauge in the .562-18 straight-
thread port indicated as oil from booster outlet Number 1 in Figure 2B.

Manual 54065 PGA-EG, PGG-EG, PGM-EG Installation
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