Woodward 8909-555 User manual

Product Manual 55011
(Revision J, 05/2019)
Original Instructions
Portable Speed Loop Tester
with Load Sensor
8909-555 for 2301/2301A/EGM
Installation and Operation Manual
Released

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 Out-of-date translations are marked with .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 55011
Copyright © Woodward, Inc. 1999-2019
All Rights Reserved
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Contents
WARNINGS AND NOTICES...........................................................................2
ELECTROSTATIC DISCHARGE AWARENESS .................................................3
CHAPTER 1. GENERAL INFORMATION..........................................................4
Introduction.............................................................................................................4
Tester Functions ....................................................................................................4
Principles of Operation...........................................................................................4
CHAPTER 2. OPERATING PROCEDURES ......................................................9
CHAPTER 3. TESTER PERFORMANCE CHECK ............................................12
Required Instruments...........................................................................................12
Performance Check .............................................................................................12
Test Box Setup.....................................................................................................12
CHAPTER 4. TROUBLESHOOTING..............................................................15
Introduction...........................................................................................................15
Problem Solving Hints..........................................................................................15
CHAPTER 5. PRODUCT SUPPORT AND SERVICE OPTIONS..........................16
Product Support Options......................................................................................16
Product Service Options ......................................................................................16
Returning Equipment for Repair ..........................................................................17
Replacement Parts...............................................................................................17
Engineering Services ...........................................................................................18
Contacting Woodward’s Support Organization....................................................18
Technical Assistance ...........................................................................................19
APPENDIX 1. FUNCTIONAL TEST FOR 2301 MODEL 8270-973....................21
APPENDIX 2. FUNCTIONAL TEST FOR 2301 MODEL 8271-444....................23
APPENDIX 3. FUNCTIONAL TEST FOR 2301 MODELS 8271-308/-442/-467/-500/-652/-706 25
APPENDIX 4. FUNCTIONAL TEST FOR 2301A REVERSE-ACTING MODELS 8270-290/-291/-293 27
APPENDIX 5. FUNCTIONAL TEST FOR 2301A DIRECT-ACTING MODELS 8272-268/-287/-288/-289 31
APPENDIX 6. FUNCTIONAL TEST FOR 2301A HIGH-VOLTAGE REVERSE-ACTING MODEL 9905-03135
APPENDIX 7. FUNCTIONAL TEST FOR 2301A 24 VDC REVERSE-ACTING MODEL 9905-133 39
APPENDIX 8. FUNCTIONAL TEST FOR 2301A 24 VDC DIRECT-ACTING MODEL 9905-131 43
TESTER SPECIFICATIONS .........................................................................47
REVISION HISTORY ..................................................................................48
Illustrations and Tables
Figure 1-1. Suitcase Tester Control Panel.............................................................7
Figure 1-2. Suitcase Tester Block Diagram...........................................................8
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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.
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.
External wiring connections for reverse-acting controls are identical
to those for direct-acting controls.
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Chapter 1.
General Information
Introduction
The Woodward 8909-555 portable speed loop tester (suitcase tester) provides a convenient engine-and-
actuator simulator needed to test and adjust 2301, 2301A, and EGM Woodward governors.
The tester provides both static and closed loop speed tests as well as test facilities for Load Sensor
portions of the 2301 systems.
The tester can adequately test most functions of the governor system as well as many system
accessories. It will not provide final adjustment of gain and stability, since these must be matched exactly
to the engine to be controlled.
Tester Functions
The tester provides the following specific functions to check out a 2301, 2301A, or EGM governor system:
Simulates proportional or integrating actuators.
Produces an MPU (magnetic pickup) signal to a governor under test.
Simulates engine load to increase required actuator voltage or upset the null voltage.
Provides three different rates of simulated engine response.
Accommodates testing of direct- and reverse-acting 2301 controls.
Simulates potential transformer (PT) and current transformer (CT) to test Load Sensor capabilities.
Provides bias voltage power supply to simulate paralleling, synchronizing, and biasing inputs to the
control under test.
Has a speaker to simulate engine noise.
Has a start function to overcome an activated failsafe circuit in the control under test.
Has an actuator voltage meter to measure the voltage across the 35 resistor used to simulate an
actuator.
Provides a signal generator mode of operation to allow the checking of switch points or control set
points.
Has a digital frequency meter for the exact setting of speed or closed-loop operating frequency.
Has a 24 Vdc power supply to power the control under test.
Principles of Operation
The suitcase tester (Figure 1-1) has been created to provide a convenient way to certify operation of
2301, 2301A, and EGM controls prior to placing them on an engine. The tester also provides a means of
presetting the gain and stability settings on the controls, although final adjustment must be made on the
engine. Four potentiometers are mounted on the test plate to allow the operator to provide critical
simulated voltages or resistances to the control under test. A digital meter provides a frequency readout
of the simulated MPU reading.
Special testing equipment included in the kit is an engine start schedule and a response ramp which
provides a realistic simulation of an engine in the acceleration mode.
Convenient switches allow the operator to use the tester on either direct- or reverse-acting controls. An
actuator Response Amplifier can be switched to test either the proportional 2301 system or the integrating
EGM systems.
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The 2301/2301A switch permits changing the PT functions in the tester to fit either a 2301 or a 2301A
governor.
Block Diagram
The block diagram (Figure 1-2) offers a concise picture of the tester operation. Starting with the actuator
input from the control, the tester adds an adjustable level or null signal, then further modifies the signal in
the load adjust and engine response areas before sending an adjusted MPU signal back to the control
being tested. Meters provide readings of the actuator operation signal from the control and of the digital
frequency being sent to the control.
Separate portions of the block diagram indicate the adjustable bias voltage source and the two special
switch signals provided by the tester.
Another area of the block diagram shows the input and power-supply signals as well at the load sensor
transformer which allows testing the load sensing circuits in a control.
Actuator Input Amplifier
The input amplifier receives the 0 to 160 mA signal from the 2301/2301A control, or the ± voltage signal
from the EGM control, and converts it into a voltage usable throughout the tester. The tester uses a 35 
resistor to simulate the actuator coil, and a 0 to 10 Vdc meter to monitor the voltage across this resistor.
The 35 resistance may not exactly match the resistance of the actuator used, in which case the tester
will provide an adequate assurance that the control will operate, but will not allow absolute final
adjustment of the control in advance of engine control.
The Actuator Meter ± switch is used to test the output driver of an EGM control. Again, the 35 
resistance may not exactly match the actual control loop.
Actuator Response Amplifier
The LEVEL/NULL potentiometer (10-turn) on the front panel adds a signal to the actuator voltage
received by the tester. In the 2301/2301A modes, the potentiometer sets the amount of actuator voltage
needed to cause the tester to output an MPU signal. In the EGM mode, the null voltage is set with the
potentiometer. The 2301/EGM switch changes the tester response to proportional in the 2301 location
and integrating in the EGM location.
The 2301/2301A switch selects the tester function when the 2301/EGM switch is set in the 2301 position.
The EGM position provides EGM functions when the other switch is in either position.
The response of the amplifier in either mode is about 100 ms (0.1 seconds).
Direct- or Reverse-Acting
Moving the REV/NORM switch to the NORM position causes the tester to react to an actuator signal
which varies from a low mA position for a minimum-fuel supply to a maximum signal for a maximum-fuel
supply. A reverse-acting actuator requires a maximum signal for minimum-fuel position and a minimum
signal for a maximum-fuel position. When the switch is in the REV position, the tester reacts to this type of
reverse-acting signal. The 2301, 2301A, and EGM controls can be reverse acting. Reverse-acting
controls are used in systems which go to maximum fuel should the electrical control fail. Direct-acting
systems go to minimum fuel should the electrical system fail.
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Engine Start Amplifier
The START switch adds a positive signal to the input signal for as long as it is held in the START
position. This allows controls with a failsafe feature to start operation. After the start period, the signal is
removed from the system, allowing normal closed-loop operation of the control.
Engine Load
A simulated load is provided through a combination of the LOAD ADJUST potentiometer (10-turn) and the
LOAD ON/OFF switch. The potentiometer adjusts the amount of load which is simulated. The ON/OFF
switch permits adding or subtracting the simulated load instantly to or from the control loop, testing the
control's ability to be stable and to react to load swings.
The LOAD ADJ potentiometer produces a voltage that reduces the amount of actuator signal that the
tester uses to set the MPU signal generator.
Engine Response Amplifier
The ACCELERATION switch slows the response of the tester to a change in actuator signal from the
control. In the upper position, the response is slowed at 30 percent per second. At the lower position, the
response is slowed at 50 percent per second. In the center position, the switch sets fast speed response
to a change in actuator signal. The response rates will not exactly equal the response of any given
engine, so the gain and stability settings on the control will have to be set to the exact positions after the
engine is running.
Range Adjustment
The RANGE potentiometer (10-turn) is used to set the tester for the maximum MPU frequency desired.
The MPU frequency is displayed on the digital frequency meter and is scaled in Hertz. The range
adjustment is set with the control running in closed loop.
Speaker
A small speaker in the tester provides an audible translation of the frequency of the MPU simulation. The
audible signal allows tuning the control “by ear”. This is particularly valuable when establishing stability
and response settings on the control. The speaker may be turned off, if desired.
Power Supply to the Control Under Test
The 35 V terminal strip outputs are used to power the control under test when its requirements do not
exceed a maximum of 1 A. If the output terminals are shorted, the circuit breaker will trip, but will not
cause permanent damage to the power supply. Power is not provided for EGM controls which require 117
Vac or 48 Vdc. All portions of the tester are electronically protected by a circuit breaker (Figure 1-1). After
correcting the cause of the trip, reset the circuit breaker by pushing it in.
Switches SW1 and SW2
These miscellaneous function switches can be wired to the control under test to simulate requirements
such as input from shutdowns, overcurrent warnings, or other discrete inputs to the control being tested.
Load Sensor Test Sequence
Current transformer currents are selected, one phase at a time, by the L.S.T. rotary switch. The number 1
position on the switch is off, with the other three positions establishing a comparable phase in the current
portions of the control. The CT current is 5 A, but in some conditions this may vary slightly. To all tester
voltages to be transmitted to the control without change, use 1 mm² (18 AWG) wire and keep the lead
from the test to the control under 600 mm (2 ft) in length.
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Only one leg may be tested at a time because of the limited voltage input to the tester. If all three legs test
correctly, the system should be compatible when connected to a three-phase system.
HIGH VOLTAGE—The PT terminals can contain lethal voltages. When
the DANGEROUS VOLTAGES indicator is on, voltages of up to 220
Vac are present at the PT output terminals. PT voltages are "ON" in
L.S.T. positions 2 through 4 and "OFF" in position 1.
Bias Voltage Supply
The ±5 Vdc supply is available through the pin jacks on the front panel of the tester. When the BIAS
VOLTS potentiometer's adjust-counting dial is on 5, the output is zero volts. For a positive voltage, turn
the dial clockwise. The setting of 10 equals +5 volts. For a negative voltage, turn the dial
counterclockwise from 5. The setting of 0 equals –5 volts. The BIAS VOLTAGE pot is connected only to
the banana plug and does not affect tester operation.
Figure 1-1. Suitcase Tester Control Panel
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Figure 1-2. Suitcase Tester Block Diagram
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