Woodward UG40 Guide

B03575.C
UG40 GOVERNOR WITH DIGITAL INTERFACE (UG40-DI)
Software versions 3.07/3.08/4.01/4.02
INSTALLATION AND COMMISSIONING MANUAL

!
WARNING
Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment. Practice all plant
and safety instructions and precautions. Failure to follow instructions can cause
personal injury and/or property damage.
!
WARNING
The engine, turbine, or other type of prime mover should be equipped with an
overspeed (overtemperature, or overpressure, where applicable) shutdown device(s),
that operates totally independently of the prime mover control device(s) to protect
against runaway or damage to the engine, turbine, or other type of prime mover with
possible personal injury or loss of life should the mechanical-hydraulic governor(s) or
electric control(s), the actuator(s), fuel control(s), the driving mechanism(s), the
linkage(s), or the controlled device(s) fail.
!
CAUTION
To prevent damage to a control system that uses an alternator or battery-charging device,
make sure the charging device is turned off before disconnecting the battery from the system.
!
CAUTION
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.
• When not installed in a control, modules should be kept in a protective antistatic bag.
☞Revisions in this manual are marked by a vertical line in the margin.
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.
© Woodward, 2001
All Rights Reserved

Manual B03575.C UG40-DI Manual
Woodward i
Table of Contents
1. GENERAL INFORMATION......................................................................................................1
1.1 INTRODUCTION............................................................................................................................1
1.2 DESCRIPTION..............................................................................................................................1
1.3 SYSTEM COMPLIANCE .................................................................................................................1
1.4 GENERAL SAFETY PRECAUTIONS .................................................................................................1
1.5 NOTES, WARNINGS AND CAUTIONS..............................................................................................1
1.6 IDENTIFICATION PLATE.................................................................................................................2
1.7 TECHNICAL DATA ........................................................................................................................2
1.8 SOFTWARE VERSIONS .................................................................................................................2
2. ESD PROTECTION AND HANDLING.....................................................................................6
3. DESCRIPTION..........................................................................................................................7
3.1 INTRODUCTION............................................................................................................................7
3.2 DI CONTROL PANEL AND GOVERNOR DIAL PLATE.........................................................................7
3.3 MECHANICAL GOVERNOR.............................................................................................................7
3.3.1 Introduction...................................................................................................................7
3.3.2 Component description ................................................................................................7
3.3.3 Operation of the UG40-DI Mechanical Part .............................................................. 12
3.4 DIGITAL INTERFACE .................................................................................................................. 14
3.4.1 Introduction................................................................................................................ 14
3.4.2 Component Description............................................................................................. 15
3.4.3 Operation................................................................................................................... 15
4. INSTALLATION..................................................................................................................... 16
4.1 INTRODUCTION......................................................................................................................... 16
4.2 INSTALLATION REQUIREMENTS.................................................................................................. 16
4.3 UNPACKING.............................................................................................................................. 16
4.4 STORAGE................................................................................................................................. 16
4.5 MOUNTING THE GOVERNOR ...................................................................................................... 16
4.6 LINKAGE ATTACHMENTS ........................................................................................................... 17
4.7 OIL SUPPLY ............................................................................................................................. 18
4.8 ELECTRICAL CONNECTIONS ...................................................................................................... 21
5. GOVERNOR MECHANICAL OPERATION AND ADJUSTMENTS ..................................... 22
5.1 INTRODUCTION......................................................................................................................... 22
5.2 CHECK THE MAXIMUM SPEED SETTING...................................................................................... 22
5.3 INITIAL OPERATION FOR A NEW GOVERNOR – MECHANICAL ....................................................... 22
5.3.1 Adjustments............................................................................................................... 22
5.3.2 Compensation Adjustments ...................................................................................... 22
5.4 READING SETTINGS FROM MECHANICAL GOVERNOR ON THE ENGINE.......................................... 24
5.4.1 Procedure.................................................................................................................. 24
6. CALIBRATION OF THE DIGITAL INTERFACE................................................................... 25
6.1 INTRODUCTION......................................................................................................................... 25
6.1.1 Calibration on test bench........................................................................................... 25
6.1.2 Calibration on engine ................................................................................................ 25
6.2 FUNCTIONS OF UG40-DI DURING CALIBRATION......................................................................... 25
6.2.1 Introduction................................................................................................................ 25
6.2.2 Explanation of the UG40-DI panel during calibration................................................ 25
6.3 CALIBRATION ON TEST BENCH .................................................................................................. 27
6.3.1 Procedure.................................................................................................................. 27
6.4 CALIBRATION ON ENGINE.......................................................................................................... 28
6.4.1 Procedure.................................................................................................................. 28
6.5 CALIBRATION FLOW CHART....................................................................................................... 28

UG40-DI Manual Manual B03575.C
ii Woodward
7. ADJUSTMENT OF THE DIGITAL INTERFACE ...................................................................31
7.1 INTRODUCTION .........................................................................................................................31
7.1.1 Adjustment.................................................................................................................31
7.1.2 Fine tuning.................................................................................................................31
7.2 FUNCTIONS OF UG40-DI DURING ADJUSTMENT......................................................................... 31
7.2.1 Introduction................................................................................................................31
7.2.2 Explanation of the UG40-DI panel during calibration and adjustment ......................31
7.2.3 Displaying values on the Dial Panel speed setting knob and speed indicator..........34
7.3 ADJUSTMENT............................................................................................................................34
7.3.1 Procedure..................................................................................................................35
7.4 FINE-TUNING............................................................................................................................35
7.4.1 Procedure..................................................................................................................35
7.5 ADJUSTMENT FLOW CHART.......................................................................................................35
7.6 FINE-TUNING FLOW CHARTS.....................................................................................................41
7.6.1 Speed Setting fine-tuning..........................................................................................41
7.6.2 Fuel limit fine tuning...................................................................................................42
7.6.3 Clutch fuel limit fine tuning.........................................................................................43
8. ALARMS, DIAGNOSTICS AND SERIAL COMMUNICATIONS...........................................44
8.1 INTRODUCTION .........................................................................................................................44
8.1.1 Alarm indication and operation..................................................................................44
8.1.2 Serial interface........................................................................................................... 44
8.2 UG40-DI ALARM INDICATION AND OPERATION........................................................................... 44
8.2.1 Introduction................................................................................................................44
8.2.2 Explanation of the UG40-DI panel for alarms and diagnostics .................................44
8.2.3 Alarm flash codes...................................................................................................... 45
8.3 UG40-DI SERIAL INTERFACE ....................................................................................................46
8.3.1 Serial link with PC - alarm page ................................................................................46
8.3.2 Serial link with PC - parameter page.........................................................................46
8.3.3 Serial link with PC - uploading software.................................................................... 47
9. TROUBLESHOOTING AND REPAIRS.................................................................................49
9.1 INTRODUCTION .........................................................................................................................49
9.2 TROUBLESHOOTING (MECHANICAL AND ELECTRICAL) .................................................................49
9.2.1 Preliminary inspection ...............................................................................................49
9.2.2 Oil ..............................................................................................................................50
9.2.3 Compensating adjustment and needle valve ............................................................50
9.3 TROUBLESHOOTING CHART.......................................................................................................50
9.3.1 Definitions.................................................................................................................. 50
9.3.2 Trouble-shooting chart...............................................................................................51
9.4 GOVERNOR FIELD REPAIRS.......................................................................................................55
9.4.1 Removal of governor from engine.............................................................................55
9.5 RETURNING THE UG40-DI TO WOODWARD................................................................................56

Manual B03575.C UG40-DI Manual
Woodward iii
Table of Figures
FIGURE 1.1 OUTLINE DRAWING OF UG40-DI GOVERNOR.......................................................................4
FIGURE 3.1 DI CONTROL PANEL AND GOVERNOR DIAL PLATE................................................................7
FIGURE 3.2 SCHEMATIC DIAGRAM OF THE UG40-DI ..............................................................................9
FIGURE 4.1 RECOMMENDED OUTPUT SHAFT TRAVEL ADJUSTMENT...................................................... 17
FIGURE 4.2 OIL CHART...................................................................................................................... 19
FIGURE 4.3 OIL DRAIN PLUG.............................................................................................................. 20
FIGURE 4.4 UG40-DI ELECTRICAL CONNECTIONS.............................................................................. 21
FIGURE 8.1 EXAMPLE ALARM AND DIAGNOSTICS PAGE ....................................................................... 46
FIGURE 8.2 EXAMPLE UG40-DI PARAMETERS PAGE .......................................................................... 47
FIGURE 8.3 TYPICAL TERMINAL PROGRAM UPLOAD MESSAGES........................................................... 48
FIGURE 8.4 CHECKSUM FAILED MESSAGE .......................................................................................... 48