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 Out-of-date translations are marked with .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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Chapter 2.
Operating Procedures
Introduction
The following procedure is written to help you obtain the most use from your Portable Speed Loop Tester.
It covers the setup procedures for testing 2301/2301A Speed Loop controls, EGM controls, open loop
testing of EG and 2301 Load Sensing systems, and signal generator mode. This procedure is written with
the assumption that the control under test is in working condition.
Setup Procedures for 2301 and 2301A Controls
(Direct Acting Type)
See the appendixes for step-by-step procedures for the most common 2301A and 2301 models.
1. Before connecting the control under test to the tester, make the following settings:
LEVEL/NULL to dial setting 5.5
LOAD ADJ to 0
LOAD ON/LOAD OFF switch to LOAD OFF
ACTUATOR meter switch to (+)
REV/NORM switch to NORM
EGM/2301 switch to 2301
L.S.T. switch to position 1
2301/2301A to the position to match your actuator
2. Place the POWER switch in the ON position, and hold the START switch down for 5 seconds.
3. Hold the START switch in the down position, and use the RANGE adjust to set the MPU frequency
for 10 percent over rated speed. Maximum rated speed is determined from the specifications of the
control under test.
4. Set the ACCELERATION switch for one of the three rates. The acceleration is the percent-per-second
change of maximum MPU frequencywith a change of actuator input voltage from minimum to maximum
in one step. Select the setting which most nearlymatches the engine which thecontrol will operate.
5. Place the POWER switch in the OFF position.
6. Connect the control under test to the terminal strip of the tester. Use the plant wiring diagram for the
specific control under test. (See note for Reverse Actuator setting.)
If the control under test is designed to operate with a reverse-acting
actuator, place the REV/NORM switch in the REV position at step 6. In
step 8 of the procedure, adjust the LEVEL/NULL for 5.6 volts on the
ACTUATOR VOLTAGE meter. In step 9, set the LOAD ADJ for 2 Vdc on
the ACTUATOR VOLTAGE meter.
7. Place the POWER switch in the ON position. If the control under test has an active failsafe circuit,
hold down the START switch for about 5 seconds.
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8. When the control under test is controlling the speed of the tester, adjust the LEVEL/NULL for about 2
Vdc on the ACTUATOR meter.
9. Place the LOAD ON/LOAD OFF switch in the LOAD ON position and set the LOAD ADJ for about 5
Vdc on the ACTUATOR meter.
10. Adjust the control under test for the best stability and response of the system. The response is
observed by watching the ACTUATOR VOLTAGE meter and by turning the SPEAKER switch to the
ON position.
Setup Procedure for EGM Controls
1. Before connecting the control under test to the tester, make the following settings:
LEVEL/NULL to dial setting 1
LOAD ADJ to 0
LOAD ON/LOAD OFF switch to LOAD OFF
ACTUATOR meter switch to (–)
REV/NORM switch to NORM
EGM/2301 switch to 2301 (you will change this to EGM in step 7)
L.S.T. switch to position 1
2. Place the POWER switch in the ON position, and hold the START switch down for 5 seconds.
3. Hold the START switch in the down position, and use the RANGE adjust to set the MPU frequency
for 10 percent over rated speed.
4. Set the ACCELERATION switch for one of the three rates.
5. Place the POWER switch in the OFF position.
6. Connect the control under test to the terminal strip of the tester. Use the plant wiring diagram for the
specific control under test.
7. Place the EGM/2301 switch in the EGM position.
8. Turn on the power to the EGM control. Most EGM controls require either 115 Vac or 48 Vdc input
power. A separate power source is necessary.
9. Place thePOWER switch in the ON position. If the controlunder testhas afailsafecircuit activated,the
ACTUATORVOLTAGEmeterwillread about –8 volts.
10. To start the tester in the EGM mode, reset the EGM failsafe.
11. Set the desired null voltage with the LEVEL/NULL adjust.
12. Place the LOAD ADJ to dial setting 2. Place the LOAD ON/LOAD OFF switch in the LOAD ON
position. The actuator voltage will increase and then return to its original value. Place the LOAD
ON/LOAD OFF switch in the LOAD OFF position. The actuator voltage will decrease and again
return to its original value. Continue this while increasing the LOAD ADJ to obtain the maximum load
setting.
13. Adjust the control under test for the best stability and response of the system. The response is
observed by watching the ACTUATOR VOLTAGE meter and by listening to the speaker (SPEAKER
switch ON).
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Load Sensor Test Sequence
1. Place the POWER switch in the OFF position and the L.S.T. switch in position 1.
2. Connect the load sensor section of the control under test to the PT and CT terminals. The wires used
for the CT connections should be 1 mm² (18 AWG) or larger.
3. Place the L.S.T. switch in positions 2, 3, and 4. The tester will output the proper sequence of line-to-
line voltages and currents to test the control under test one phase at a time. The test sequence is
listed below:
L.S.T. Active
Position CT
1 OFF
2 A phase
3 B phase
4 C phase
4. P.T. voltages are on in L.S.T. switch positions 2, 3, and 4. The P.T. voltages are off in position 1. All
phases can carry 115 or 230 Vac, with the amount set with the order from the factory.
HIGH VOLTAGE—When the DANGEROUS VOLTAGES indicator is
on, potentially lethal voltages are present on the PT and CT
terminals. When the Load Sensor Test is not in use, return the L.S.T.
switch to position 1. Make sure the DANGEROUS VOLTAGES
indicator is off.
Signal Generator Mode
1. Place the POWER switch in the OFF position.
2. Disconnect the actuator + wire from the terminal strip. Make sure the loose wire does not come in
contact with any other wires.
3. Place the REV/NORM switch in the REV position.
4. Place the POWER switch in the ON position.
5. Adjust the RANGE to set the desired frequency.
6. Measure the signal outputs at the MPU terminals.
Wire Harness
A wire harness with 1 mm²/18 AWG wire and spade connectors should be constructed for use
with the tester. For convenience, the maximum wire length used in the harness should be about
60 cm/2 ft. A different color wire should be used throughout the harness, or at least the same
colors should be used only at opposite ends of the tester terminal strip
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Chapter 3.
Tester Performance Check
Required Instruments
Checking out the tester will require the following instruments to verify the operation of various parts of the
tester and to provide verification that meters are providing consistent and correct results of governor
readings.
DIGITAL VOLTMETER with RMS capability.
Fluke 8020 or equivalent
OSCILLOSCOPE with single wave capability.
CURRENT SOURCE 1 to 200 mA.
For calibration, must have known good dc current meter.
Performance Check
Initial Inspection
Open the suitcase and remove the power cord. Inspect the power cord, the tester box, and any other
equipment for obvious damage. Listen for rattling as the suitcase is tipped end to end and side to side.
Should there be any rattling, remove the test instrument from the suitcase by removing the four Phillips
head screws located along the top and bottom of the front panel. The test box should not rattle.
Power Connection
Set the power supply switch inside the test box to either 115 or 230 Vac, as needed by the availability of
electrical supply. Connect the power cord to the 50 or 60 Hz supply selected.
Newer testers do not have this switch. These units detect input
voltage and adjust automatically.
Test Box Setup
Initial Adjustment
Preset the tester as follows:
LEVEL/NULL 5.5
RANGE 10.0
LOAD ADJ 0.0
BIAS VOLTS 0.0
ACTUATOR +
LOAD ON/LOAD OFF OFF
ACCELERATION 100%/SEC
SPEAKER OFF
EGM/2301 2301
REV/NORM NORM
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SW1 DOWN
SW2 DOWN
2301/2301A 2301
L.S.T. 1
Test Box Setup Procedure
1. Turn on the power. The frequency counter should read less than 5 Hz after 5 seconds.
2. Measure the voltage from 24 V (–) to 24 V (+). It should read 24 Vdc ± 2.4 Vdc.
3. Measure the resistances for SW1 and SW2 on the terminal block as labeled. Resistances should
read infinity. Put both switches in the up position and repeat the procedure. The readings should now
be 0 ± 0.4 .
4. Measure the actuator resistance between ACT (–) and ACT (+). It should read 35 ± 2 .
5. Place a 250 load across the BIAS VOLTS jacks, with the BIAS VOLTS potentiometer at 0.0. The
voltage across the jacks should read –4.8 to –5.3 Vdc. With the BIAS VOLTS potentiometer at 10.0,
the voltage should read 4.8 to 5.3 Vdc. Return the BIAS VOLTS potentiometer to location 5.0.
6. Place the REV/NORM switch to REV. The frequency will increase to a value greater than 18 kHz.
Return the REV/NORM switch to NORM.
7. Turn the power off and connect a known good 2301 control with a rated speed of 4800 Hz to the
tester.
8. Turn the power on.
9. Press the START switch, the frequency will increase and the control should take command of the
tester. Adjust the control for stable operation at a rated speed of 4800 Hz. Connect an external
voltmeter across the actuator (ACT) connections, adjust the LEVEL/NULL for 2 ± 0.1 Vdc. The panel
meter on the tester must have the same reading as the external meter (2 ± 0.2 Vdc).
10. Put the ACTUATOR switch to (–). The panel meter should peg against the low end. Return the
switch to the (+) position.
11. Turn the LOAD ON/LOAD OFF switch ON and increase the LOAD ADJ. The ACTUATOR VOLTAGE
meter will show an increase in voltage. As the load is increased, the actuator voltage will reach a
maximum value (more than 7 Vdc but less than 10 Vdc). As the load is increased further, the
frequency will decrease and eventually go to zero (the engine will die). Return the LOAD ADJ to zero
and restart the tester. Now adjust the load for 5 Vdc on the panel meter, and turn the LOAD
ON/LOAD OFF switch OFF.
12. Turn the speaker on, there should be an audible sound. Turn the speaker off.
13. Measure the MPU voltage at the MPU terminals. It should be more than 2 Vrms.
14. a. With an ac voltmeter measure the line voltage at the ac power receptacle and record it on the
data sheet. With the L.S.T. switch in position 1, check all the PT outputs for 0 V. For the
remaining L.S.T. switch positions, measure the PT voltages and record them on the data sheet
as follows:
L.S.T.
Position Active PT Voltage
1 none none
2 A phase to B phase 110 V
3 B phase to C phase 110 V
4 C phase to A phase 0 V
All voltages are ±10 percent
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b. With the L.S.T. switch in position 1, check all CT positions for 0 V. For the remaining L.S.T.
positions, measure the CT voltages at the control according to the following:
L.S.T.
Position Active CT Voltage
1 none none
2 A phase 1.25 Vac
3 B phase 1.25 Vac
4 C phase 1.25 Vac
c. Verify that the DANGEROUS VOLTAGES indicator is on when the L.S.T. switch is in positions 2
through 4, and off in position 1.
d. With a control connected to the tester, put the L.S.T. switch in position 2. Adjust the control’s
LOAD GAIN VOLTAGE at the test point for 2.00 ± 0.1 Vdc. Positions 3 and 4 should read 2.00
± 0.2 Vdc at the test points.
15. Move the LINE VOLTAGE SELECT switch to the 220 V position and put the L.S.T. switch In position
2. Measure the A Phase to B Phase PT voltage. It should be 1/2 the line voltage reading taken in
step 14a. Return the L.S.T. to position 1. Return the LINE VOLTAGE SELECT switch to 115 V.
16. Turn off the power to the tester and remove the 2301 control. Attach an EGM control. Put the
EGM/2301 switch in the EGM position.
Connection on EGM
Function Terminal Board
External Number 1 (+)
Power Supply Number 2 (–)
Actuator Number 4 (–)
Number 5 (+)
200 Speed Number 6 (wiper)
Potentiometer Number 7 (ccw)
Number 8 (cw)
Magnetic Number 9
Pickup Number 10
17. Provide the power supply required by the particular EGM control (either 42 Vdc or 115 Vac). Turn on
the control and set the ACTUATOR VOLTAGE meter for 2 Vdc with the tester LEVEL/NULL
potentiometer. Turn the tester RANGE potentiometer in either direction and verify the speed changes
while the ACTUATOR VOLTAGE meter stays at 2 Vdc. (This presumes the EGM control attached to
the tester is in good running condition.) Set the speed to read 4800 Hz.
18. Put the ACTUATOR switch to (–) and adjust the LEVEL/NULL until the ACTUATOR VOLTAGE
meter reads –2 Vdc. Adjust the tester RANGE potentiometer in either direction and observe that the
speed changes while the actuator voltage stays at –2 Vdc. The speed should read 5200 Hz.
19. Turn the power off and remove the EGM from the tester. Return the EGM/2301 switch to 2301. Put
the ACCELERATION switch in the center 100%/SEC position. Turn the power on to the tester.
Select REV position on the REV/NORM switch and let the frequency rise. Adjust the range control
for 5000 Hz. Connect an oscilloscope to the MPU output terminals and adjust for a single cycle
across the screen. Move the tester REV/NORM switch to NORM and allow the frequency to drop to
0 Hz. Use a stop watch to measure the time it takes for the frequency to go from 0 to 5000 Hz when
switching from NORM to REV. The elapsed time should be 1 ± 0.2 second.
With the ACCELERATION switch at 50%/SEC, the elapsed time from 0 to 5000 Hz should be 2 ± 0.6
second.
With the ACCELERATION switch at 30%/SEC, the elapsed time from 0 to 5000 Hz should be 3 ± 0.8
second.
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Chapter 4.
Troubleshooting
Introduction
Most problems encountered when using the tester involve improper wiring of the tester to the control
being tested. Always check the complete wiring between the two units before making any changes in the
control or in the tester.
Problem Solving Hints
The following information is provided to aid in finding the solution to most simple problems involving the
tester. There are no adjustments inside the tester as it is mounted in the suitcase. Should the tester
malfunction, it must be returned to the factory for repair.
No Display
1. Possible loose power cord.
2. Possible tripped circuit breaker (push to reset; see Figure 1-1).
Governor Will Not Control
1. Possible incorrect connection between the governor and tester.
2. One or more switches incorrectly set.
3. Possible incorrect tester setup.
4. Possible governor defect. Confirm by checking a second governor, if practical.
Test Signal Fails
If any of the following signals or voltages is missing or is low, first carefully check the cable continuity. If
the cables check out, send the tester to the factory for repair.
1. 24 Vdc at governor.
2. CT voltage at the A terminal on the tester.
3. Voltage reading at the MPU terminals on the tester.
PTs Are Low or Show 0 Voltage
Possible mis-setting of the LINE VOLTAGE SELECT switch.
CTs Are Low or Show 0 Voltage
Possible mis-setting of the 2301/2301A switch.
Counter Does Not Read Correctly
No adjustments, send to the factory for repair.
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Manual 55011 Portable Speed Loop Tester
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Chapter 5.
Product Support and Service Options
Product Support Options
If you are experiencing problems with the installation, or unsatisfactory performance of a Woodward
product, the following options are available:
1. Consult the troubleshooting guide in the manual.
2. Contact the OE Manufacturer or Packager of your system.
3. Contact the Woodward Business Partner serving your area.
4. Contact Woodward technical assistance via email ([e-mail]) with
detailed information on the product, application, and symptoms. Your email will be forwarded to an
appropriate expert on the product and application to respond by telephone or return email.
5. If the issue cannot be resolved, you can select a further course of action to pursue based on the
available services listed in this chapter.
OEM or Packager Support: ManyWoodward controls and control devices are installed into the equipment
system and programmed byan Original Equipment Manufacturer (OEM) or Equipment Packager at their
factory. In some cases, the programming is password-protected by theOEM or packager, and they are the
bestsource for product service and support.Warrantyservice for Woodward products shipped with an
equipment system should also be handled through the OEM or Packager. Please review your equipment
system documentation for details.
Woodward Business Partner Support: Woodward works with and supports a global network of
independent business partners whose mission is to serve the users of Woodward controls, as described
here:
A Full-Service Distributor has the primary responsibility for sales, service, system integration
solutions, technical desk support, and aftermarket marketing of standard Woodward products within
a specific geographic area and market segment.
An Authorized Independent Service Facility (AISF) provides authorized service that includes repairs,
repair parts, and warrantyservice on Woodward's behalf. Service (not new unit sales) is an AISF's
primarymission.
A Recognized Engine Retrofitter (RER) is an independent company that does retrofits and
upgrades on reciprocating gas engines and dual-fuel conversions, and can provide the full line of
Woodward systems and components for the retrofits and overhauls, emission compliance upgrades,
long term service contracts, emergency repairs, etc.
A current list of Woodward Business Partners is available at www.woodward.com/directory.
Product Service Options
Depending on the type of product, the following options for servicing Woodward products may be
available through your local Full-Service Distributor or the OEM or Packager of the equipment system.
Replacement/Exchange (24-hour service)
Flat Rate Repair
Flat Rate Remanufacture
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Replacement/Exchange: Replacement/Exchange is a premium program designed for the user who is in
need of immediate service. It allows you to request and receive a like-new replacement unit in minimum
time (usually within 24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime.
This option allows you to call your Full-Service Distributor in the event of an unexpected outage, or in
advance of a scheduled outage, to request a replacement control unit. If the unit is available at the time of
the call, it can usually be shipped out within 24 hours. You replace your field control unit with the like-new
replacement and return the field unit to the Full-Service Distributor.
Flat Rate Repair: Flat Rate Repair is available for many of the standard mechanical products and some
of the electronic products in the field. This program offers you repair service for your products with the
advantage of knowing in advance what the cost will be.
Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat Rate Repair option, with
the exception that the unit will be returned to you in “like-new” condition. This option is applicable to
mechanical products only.
Returning Equipment for Repair
If a control (or any part of an electronic control) is to be returned for repair, please contact your Full-
Service Distributor in advance to obtain Return Authorization and shipping instructions.
When shipping the item(s), attach a tag with the following information:
return number;
name and location where the control is installed;
name and phone number of contact person;
complete Woodward part number(s) and serial number(s);
description of the problem;
instructions describing the desired type of repair.
Packing a Control
Use the following materials when returning a complete control:
protective caps on any connectors;
antistatic protective bags on all electronic modules;
packing materials that will not damage the surface of the unit;
at least 100 mm (4 inches) of tightly packed, industry-approved packing material;
a packing carton with double walls;
a strong tape around the outside of the carton for increased strength.
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.
Replacement Parts
When ordering replacement parts for controls, include the following information:
the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
the unit serial number, which is also on the nameplate.
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Woodward 18
Engineering Services
Woodward’s Full-Service Distributors offer various Engineering Services for our products. For these
services, you can contact the Distributor by telephone or by email.
Technical Support
Product Training
Field Service
Technical Support is available from your equipment system supplier, your local Full-Service Distributor,
or from many of Woodward’s worldwide locations, depending upon the product and application. This
service can assist you with technical questions or problem solving during the normal business hours of
the Woodward location you contact.
Product Training is available as standard classes at many Distributor locations. Customized classes are
also available, which can be tailored to your needs and held at one of our Distributor locations or at your
site. This training, conducted by experienced personnel, will assure that you will be able to maintain
system reliability and availability.
Field Service engineering on-site support is available, depending on the product and location, from one
of our Full-Service Distributors. The field engineers are experienced both on Woodward products as well
as on much of the non-Woodward equipment with which our products interface.
For information on these services, please contact one of the Full-Service Distributors listed at
www.woodward.com/directory.
Contacting Woodward’s Support Organization
For the name of your nearestWoodward Full-Service Distributor or service facility, please consult our
worldwide directory at www.woodward.com/directory, which also contains the most current product
support and contact information.
You can also contact the Woodward Customer Service Department at one of the following Woodward
facilities to obtain the address and phone number of the nearest facility at which you can obtain
information and service.
Products Used in
Electrical Power Systems
Facility ---------------Phone Number
Brazil -------------[phone]
China----------- [phone]
Germany:
Kempen----[phone]
Stuttgart - [phone]
India ---------------[phone]
Japan---------------[phone]
Korea---------------[phone]
Poland --------------[phone]
United States-----[phone]
Products Used in
Engine Systems
Facility ---------------Phone Number
Brazil -------------[phone]
China----------- [phone]
Germany ------ [phone]
India ---------------[phone]
Japan---------------[phone]
Korea---------------[phone]
The Netherlands--[phone]
United States-----[phone]
Products Used in Industrial
Turbomachinery Systems
Facility ---------------Phone Number
Brazil -------------[phone]
China----------- [phone]
India ---------------[phone]
Japan---------------[phone]
Korea---------------[phone]
The Netherlands--[phone]
Poland --------------[phone]
United States-----[phone]
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