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
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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

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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

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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

UG40-DI Manual Manual B03575.C
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Manual B03575.C UG40-DI Manual
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1. GENERAL INFORMATION
1.1 Introduction
This manual is applicable to the UG40-DI Governor and describes its mechanical and
electrical installation, operation and set-up. It is arranged in ten chapters:
- GENERAL INFORMATION
- ESD PROTECTION AND HANDLING
- DESCRIPTION
- INSTALLATION
- GOVERNOR MECHANICAL OPERATION AND ADJUSTMENTS
- CALIBRATION OF THE DIGITAL INTERFACE
- ADJUSTMENT OF THE DIGITAL INTERFACE
- ALARMS, DIAGNOSTICS AND SERIAL COMMUNICATIONS
- TROUBLESHOOTING AND REPAIRS.
Mechanical operation and adjustment of the UG40-DI is similar to that for the UG40
mechanical governor.
1.2 Description
The UG40-DI is a mechanical-hydraulic governor with a digital interface for controlling diesel
engines. The UG40-DI uses a 250 PSI oil supply and is mechanically linked to the fuel racks.
The maximum travel of the output (terminal) shaft is 38°, and the recommended travel of the
output shaft is 25° from no load to full load (refer to Section 4.5 for more details).
Normally, the UG40-DI operates isochronously (constant speed) regardless of load on the
engine, except during operation as described in Chapter 3. DESCRIPTION.
Speed droop is incorporated in the UG40-DI to divide and balance load between units driving
the same shaft or paralleled in an electrical system.
A load limit control is also a standard feature on the UG40-DI. It limits the amount of fuel
supplied by restricting the travel of the governor output shaft. An indicator dial shows the
governor output shaft limit position.
The load limit control may also be used for manually shutting down the engine.
1.3 System Compliance
This equipment complies with the relevant industry specifications and regulations.
1.4 General Safety Precautions
Obey the following safety precautions when you install the unit:
- Obey all cautions or warnings given in the procedures.
- Never bypass or override machine safety devices.
- Always use sufficient personnel and/or lifting equipment to move the UG40-DI.
1.5 Notes, Warnings and Cautions
The following examples show how notes, warnings and cautions are used in this manual:
☞Notes are used in the text to provide useful information or hints. This is a note.

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!
WARNING
Warnings are used when a procedure or action is dangerous and injury or death
might occur. This is a warning.
!
CAUTION
Cautions are used when a procedure or action can cause damage to equipment. This is a
caution.
1.6 Identification Plate
The identification plate is installed on the front of the governor. It contains the following
information:
- Part Number
- Serial number
- Manufacturing date
- Speed range
- Customer part number (if applicable).
Always give the part number and serial number in any correspondence with Woodward.
1.7 Technical Data
Governor pressure 1724 kPa (250 psi)
Weight Approx. 50 kg (110 lbs)
Work capacity 78 J (57.5 ft-lb)
Drive power requirement 0.37 kW (0.5 hp)
Output 38º
Oil capacity 7 liters
Speed range 350 - 1050 rpm (low speed), 550 - 1300 rpm (high speed)
Start Fuel Limit Duration Adjustable from 0-20 sec
Operating Temperature Range -20 to 93°C (-4 to 200°F)
Storage Temperature Range -40 to 100°C (-40 to 212°F)
Vibration Qualification Test
Specification Woodward RV2 (0.1 G2/Hz Random, 10-2000 Hz, 12.8 Grms, 3 hr per axis).
Shock Qualification Test
Specification 40 G, 11 msec saw-tooth pulse
Humidity Qualification Test
Specification Woodward H2 (60°C, 95% RH, 5 days)
IP level IP54
Steady state speed band 0.25 % of rated speed (under normal operating conditions)
Speed setting linearity 1 % over full range
Speed setting bandwidth 0.5 Hz for full range step (4 to 20mA and 20 to 4mA)
Power supply 24 Vdc nominal (18 - 32 Vdc), 25 watts (fused by 3A, slow)
Shutdown power 18 - 31 Vdc, 12 watts
Alarm signal output 17-31 Vdc, 100 mA, sourcing only
Standard governer drive shaft 1.125” diameter shaft with 48 SAE serrations
Optional governer drive shaft 0.625” diameter shaft with keyway 0.187” wide x 0.094” deep x 1.500” long for
gear held by 0.625”-18 castle nut
Terminal (output) shaft 0.750” diameter with 48 SAE serrations
1.8 Software Versions
At power-up for one time, the yellow Mode LED indicates the UG40-DI software version
using long flash pulses for the integer digit, and short flash pulses for the decimal digits. The
differences between the software versions are as follows:

Manual B03575.C UG40-DI Manual
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Software
version Description Mode LED flash pulse
3.07 Start fuel limit time = fixed 10 seconds. I….I….I….l.l.l.l.l.l.l
3.08 Start fuel limit time = fixed 20 seconds. I….I….I….l.l.l.l.l.l.l.l
4.01 I….I….I….l….l.l
4.02 Alarm and diagnostics functions.
Start fuel limit time = adjustable 0 to 20 seconds. I….I….I….l….l.l.l
I = 1 flash of Mode LED
…. = pause between flash pulses

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Figure 1.1 Outline Drawing of UG40-DI Governor (sheet 1 of 2)