Woodward EPG 512 User manual

Product Manual 35162
(Revision -, 11/2019)
Original Instructions
EPG Electrically Powered Governors
with Single Phase Droop
RoHS Compliant
Models 512/524 and 1712/1724
UL Listed E97763
Installation and Operation Manual
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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 Out-of-date translations are marked with .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—A bold, black line alongside the text identifies changes in this publication since the
last revision.
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 35162
Copyright © Woodward, Inc. 2019
All Rights Reserved
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Manual 35162 EPG Governors with Single Phase Droop RoHS Compliant
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Contents
WARNINGS AND NOTICES............................................................................ 3
ELECTROSTATIC DISCHARGE AWARENESS.................................................. 4
CHAPTER 1. GENERAL INFORMATION .......................................................... 5
Application..............................................................................................................5
Part Number Selection ...........................................................................................5
Reference...............................................................................................................6
CHAPTER 2. INSTALLATION,CHECK,AND CALIBRATION............................... 7
General...................................................................................................................7
Speed Control Mounting.........................................................................................7
Actuator Mounting and Linkage..............................................................................7
Install Magnetic Pickup...........................................................................................8
CHAPTER 3. OPERATION........................................................................... 19
CHAPTER 4. DESCRIPTION ........................................................................ 20
Speed Control Applications..................................................................................20
Paralleled Generator Applications........................................................................23
CHAPTER 5. TROUBLESHOOTING............................................................... 24
CHAPTER 6PRODUCT 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
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Illustrations and Tables
Figure 1-1. Basic EPG System...............................................................................6
Figure 2-1. Typical Installation Kit..........................................................................8
Figure 2-2. Outline Drawing of EPG Speed Control...............................................9
Figure 2-3. Outline Drawing of EPG Actuators.......................................................9
Figure 2-4. Linear Linkage....................................................................................10
Figure 2-5. Carburetor Compensating Linkage at Minimum Fuel........................10
Figure 2-6. Carburetor Compensating Linkage at Maximum Fuel.......................10
Figure 2-7. Typical EPG (with droop) Wiring Diagram.........................................12
Figure 2-8. Droop Definition .................................................................................16
Figure 2-9. Correct and Incorrect Wiring to Battery..............................................17
Figure 2-10. Starting and Transient Response Curves........................................18
Figure 4-1a. EPG Block Schematic Diagram (standard)......................................21
Figure 4-1b. EPG Block Schematic Diagram.......................................................22
Figure 4-2. Actuator Schematic............................................................................23
Table 1-1. Part Number Selection Chart................................................................5
Table 2-1. Maximum Wiring Length Chart............................................................11
Table 2-2. Switch and Fuse Requirements Chart ................................................11
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Warnings and Notices
Important Definitions
This is the safety alert symbol 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.
Lockout/Tagout
LOTO
Ensure that personnel are fully trained on LOTO procedures prior to
attempting to replace or service an EPG on a “live” running engine.
All safety protective systems (overspeed, over temperature,
overpressure, etc.) must be in proper operational condition prior to
the start or operation of a running engine. Personnel should be
equipped with appropriate personal protective equipment to
minimize the potential for injury due to release of hot hydraulic
fluids, exposure to hot surfaces and/or moving parts, or any moving
parts that may be activated and are located in the area of control of
the EPG.
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.
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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.
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.
External wiring connections for reverse-acting controls are identical
to those for direct-acting controls.
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Chapter 1.
General Information
Application
This manual covers only the part numbers of the system
components that are listed in the Part Number Selection Chart.
Contact Woodward or your authorized dealer or distributor for
information about other part numbers or applications.
The Model 1712/1724 and Model 512/524 Electrically Powered Governors (EPGs) are used to control the
speed of diesel, gas, and gasoline engines. They also can control the speed of gas turbines. Installation
of EPG actuators is simple because they require neither mechanical drive nor hydraulic supply.
These controls are intended for prime mover with generator loads. The advantage of these units is that
the DROOP circuitry is in the speed control.
An Electrically Powered Governor is a three-component system. A magnetic pickup, speed control, and
actuator are required.
A battery charger must be used to keep the battery charged. Maximum steady-state-current consumption
is 4 amps for the 12-volt model, and 3 amps for the 24-volt model.
Part Number Selection
Use EPG Model 1712/512 for operation in 12-volt systems. Use the Model 1724/524 for use in 24-volt
systems.
Additionally, speed controls are available for four ranges of magnetic pickup frequencies. These speed
controls are available for diesel engines and gas turbines or for gasoline and gas engines. Actuators have
a double ended output shaft for either clockwise (cw) or counterclockwise (ccw) rotation to increase fuel.
Speed controls and actuators must be compatible. Select compatible EPG controls and actuators from
Table 1-1.
Table 1-1. Part Number Selection Chart
For Use with
Prime Mover Type
System
Battery
Voltage
Single Phase Droop Control
Actuator
Part
Number
Speed Range (Hz) Required
750 to
1500
1500 to
3000
3000 to
6000
6000 to
12 000
Diesel and Gas
Turbine
24
8290-216*
8256-032
(*) These part numbers are EU directive compliant.
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Reference
These publications are available on the Woodward website (www.woodward.com).
Catalog 52122, Woodward Product Line Catalog
Product Specification 04106, EPG Electrically Powered Governors
Manual 25070, Electronic Control Installation Guide
Manual 82510, Magnetic Pickups and Proximity Switches for Electronic Controls
Figure 1-1. Basic EPG System
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Chapter 2.
Installation, Check, and Calibration
General
Custom installation kits, including actuator-mounting hardware, linkage, and actuator wiring harness are
available for some specific engines. Contact Woodward or your authorized dealer or distributor for more
information.
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.
Speed Control Mounting
The speed control is designed to operate within a temperature range of –40 to +75 °C (–40 to +167 °F).
Mount the control in a location with space for adjustment and wiring access. If mounted on the prime
mover, do not expose the speed control to sources of radiant heat, such as exhaust manifolds or
turbochargers. Also choose a protected location so the control won’t be damaged when moving the prime
mover or when equipment is moving nearby. Mount the control close to the actuator and battery to meet
the wire length requirements. Allow for adequate ventilation.
Actuator Mounting and Linkage
Actuator location must allow installation of a suitable linkage. The actuators are designed to operate
within a temperature range of –40 to +82 °C (–40 to +180 °F). Do not expose the actuator to sources of
excessive heat.
Match the actuator’s direction of rotation for increased fuel with the fuel control’s direction of rotation for
increased fuel by choosing a suitable linkage.
If you are using a Woodward-supplied installation kit, follow its instructions and skip over Linkage
Compatibility. Begin again with Installing the Magnetic Pickup.
Sealed bearings should not be pressure-washed. If the actuator is exposed to weather, mount it with the
clockwise end higher, if your installation allows it.
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Figure 2-1. Typical Installation Kit
Linkage Compatibility
Also match linkage to the fuel control. Use a linear linkage as shown in Figure
2-4 unless the prime mover has a carburetor or other nonlinear fuel control. See Figures 2-5 and 2-6 for a
carburetor compensating linkage. Contact Woodward if a linkage different from those shown is required.
Incorrect linearity matching can cause stable operation at some fuel settings but oscillation at other fuel
settings.
Manually stroke the fuel control linkage from stop to stop as if the actuator were moving it. The linkage
must move freely, without friction and without backlash. Lubricate or replace linkage or fuel control parts
as required.
Mount the actuator and install a suitable linkage.
A return spring is included in the actuator. Woodward recommends minimizing the external return force.
(Low-force return springs that may be located in an engine’s valve cover usually don’t affect EPG
performance.)
Make sure the actuator is capable of moving the fuel control to maximum and minimum limits. Let the fuel
control limit actuator travel. Set the linkage so the actuator is just above minimum when the fuel control is
at its minimum stop and, except for Detroit Diesel engines, just below maximum when the fuel control is at
its maximum stop. It is recommended that Woodward installation kits be used.
Use good rod-end connectors. The link connecting the actuator lever to the fuel-control lever must not be
so long that it flexes when the prime mover is running.
Install Magnetic Pickup
Mount the magnetic pickup (MPU) through a housing or rigid bracket. Make sure the sensed gear is
sensitive to magnetic fields The gap between the pickup and the outside diameter of the gear should be
set to approximately 1.02 mm (0.040 inch) at the closest point (radial runout). Using the pickup with small
gears may require spacing as close as 0.25 mm (0.010 inch).
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