Application and Hardware Manual

Indian Railway Locomotive Electronic Control

System 8701-1349

Indian Railway

Manual B37818

WARNINGDANGER OF DEATH OR PERSONAL INJURY

WARNINGFOLLOW INSTRUCTIONS 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.

WARNINGOUT-OF-DATE PUBLICATION This publication may have been revised or updated since this copy was produced. To verify

that you have the latest revision, be sure to check the Woodward website:

www.woodward.com/pubs/current.pdf

The revision level is shown at the bottom of the front cover after the publication number. The

latest version of most publications is available at:

www.woodward.com/publications

If your publication is not there, please contact your customer service representative to get

the latest copy.

WARNINGOVERSPEED PROTECTION 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.

WARNINGPROPER 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.

CAUTIONPOSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY

CAUTIONBATTERY CHARGING 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.

CAUTIONELECTROSTATIC DISCHARGE 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.

IMPORTANT DEFINITIONS

A WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in damage to equipment or property.

A NOTE provides other helpful information that does not fall under the warning or caution categories.

RevisionsText changes are indicated by a black line alongside the text. Woodward Governor Company reserves the right to update any portion of this publication at any time. Information

provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is

assumed by Woodward Governor Company unless otherwise expressly undertaken.

Woodward 2006

All Rights Reserved

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Contents

REGULATORY COMPLIANCE ...................................................................... III

CHAPTER 1. GENERAL INFORMATION .......................................................... 1 Introduction ............................................................................................................ 1 Application ............................................................................................................. 1

CHAPTER 2. INSTALLATION ........................................................................ 3 Introduction ............................................................................................................ 3 Unpacking .............................................................................................................. 3 Power Requirements ............................................................................................. 3 Location Considerations ........................................................................................ 3 Introduction Installation Checkout Procedure ........................................................ 3

CHAPTER 3. SYSTEM WIRING DRAWINGS .................................................... 5 Introduction ............................................................................................................ 5

CHAPTER 4. SYSTEM HARDWARE DESCRIPTION ........................................ 11 Introduction .......................................................................................................... 11 733 Digital Control ............................................................................................... 12

Input/Output Arrangement ........................................................................... 13 Temperature Specifications ......................................................................... 13 733 Wiring Pin Out ....................................................................................... 13

PC Interface ......................................................................................................... 16 Using Watch Window ................................................................................... 16

Power Supply Module .......................................................................................... 20 Testing Power Supply Module: .................................................................... 20

Pressure Transducer ........................................................................................... 21 1. Boost Air Pressure Transducer: ............................................................... 21 2. Lube Oil Pressure Transducer: ................................................................ 21 3. Fuel Pressure Transducer: ...................................................................... 21

Load Control Potentiometer ................................................................................. 22 Procedure for testing LCP Module (No Load) .............................................. 23 Procedure for testing LCP Module (Load) ................................................... 23

Actuator Feedback Sensor (RVDT) ..................................................................... 25 Testing Procedure ........................................................................................ 25 Wiring Detail ................................................................................................. 25 Electrical Data .............................................................................................. 25 Mechanical Data .......................................................................................... 25 Environmental Data...................................................................................... 25

LCD Display ......................................................................................................... 27 Engine Main Parameters ............................................................................. 28 Engine More Parameters ............................................................................. 28 Shutdown and OST Status........................................................................... 29 ENGINE OVERSPEED STATUS ................................................................. 30 This parameter indicates the electrical or mechanical OST Switch position.30 Alarms History .............................................................................................. 30 Trending ....................................................................................................... 31

Data Logging ........................................................................................................ 32 Reset Counters ............................................................................................ 35

LEDs Indication on the Front Door ...................................................................... 35 Ready To Start ............................................................................................. 35 Shutdown ..................................................................................................... 35 OS Test ........................................................................................................ 35

Magnetic Speed Pickup ....................................................................................... 36 How to Mount Magnetic Pickup on the Cam Gear Cover ............................ 38 Magnetic Pickup Installation......................................................................... 39

UG-Actuator ......................................................................................................... 40 Terminal Shaft and Drive Shafts .................................................................. 40 Hydraulic Pump ............................................................................................ 40 Control Linkage ............................................................................................ 42

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Linkage Installation ....................................................................................... 43 Testing the functionality of MCBG Actuator on TEST Stand ........................ 44

CHAPTER 5. SYSTEM DESCRIPTION .......................................................... 47 Introduction ........................................................................................................... 47

Start-up Adjustments .................................................................................... 47 Procedure For Rack Calibration Procedure .................................................. 47

Overspeed Testing ............................................................................................... 49 Procedure for Testing Mechanical OST ....................................................... 49 Procedure for Testing Electronic OST .......................................................... 49

Adjustment of Various Engine Parameters .......................................................... 51 Notch wise engine speed .............................................................................. 51 Maximum permissible fuel rack at each notch ............................................. 52 Maximum Permissible Fuel Rack in Relation to Boost air Pressure ............ 53 PID Response ............................................................................................... 54 Load Control Timing From Max to Min. Field Position .................................. 55 Rack Calibration ........................................................................................... 56 Fuel Transmitter Calibration ......................................................................... 57

CHAPTER 6. TUNABLE ............................................................................. 59 Service Value List ................................................................................................. 59 Configure Value List ............................................................................................. 63 Service Tunable Description ................................................................................. 64 Configure Tunable Description ............................................................................. 72

CHAPTER 7. TROUBLESHOOTING .............................................................. 73

CHAPTER 8. SERVICE OPTIONS ................................................................ 77 Returning Equipment for Repair ........................................................................... 78 Replacement Parts ............................................................................................... 79 How to Contact Woodward ................................................................................... 79 Engineering Services ............................................................................................ 80 Technical Assistance ............................................................................................ 81

CONTROL SPECIFICATIONS ...................................................................... 83

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Regulatory Compliance Woodward Governor declares that this controlling device complies with the requirements of IEC571-1 as per the detail given by RDSO. NOTICE: This controlling device is intended to be put into service only upon incorporation into DLW locomotives.

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Electrostatic Discharge Awareness All electronic equipment is static-sensitive, some components more than others. To protect these components from static damage, you must take special precautions to minimize or eliminate electrostatic discharges. Follow these precautions when working with or near the control. 1. Before doing maintenance on the electronic control, discharge the static

electricity on your body to ground by touching and holding a grounded metal object (pipes, cabinets, equipment, etc.).

2. 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.

3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam

cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or folders, plastic bottles, and plastic ash trays) away from the control, the modules, and the work area as much as possible.

4. 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.

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Chapter 1.

General Information

Introduction This chapter describes the basic function of Woodward Indian Railway Locomotive Electronic Control (IRLEC) models 8701-1349.

Power Requirements

The control requires a voltage source of 18 to 75 Vdc.

Application This IRLEC controls the speed of locomotives in variable speed applications. The control includes inputs for a magnetic pickup (MPU) for monitoring speed, an input of boost air pressure, an input of lube oil pressure for LOP tripping, an input of fuel pressure for fuel pressure measurement and an input for fuel rack opening. The serial channels provide for various control interfaces. Port is switchable to be a Watch Window PC interface or a hand-held programmer port for monitoring and programming the IRLEC.

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Chapter 2.

Installation

Introduction This chapter contains general installation instructions for the IRLEC system.. Power requirements, environmental precautions, and location considerations are included to help you determine the best location for the control. Additional information includes unpacking instructions, electrical connections, and installation checkout procedures.

Unpacking

Before handling the control, read Chapter 2, Electrostatic Discharge Awareness. Be careful when unpacking the electronic control. Check the control for signs of damage such as bent panels, scratches, and loose or broken parts. If any damage is found, immediately notify the shipper.

Power Requirements

The control requires a voltage source of 18 to 75 Vdc.

Location Considerations

Consider these requirements when selecting the mounting location: adequate ventilation for cooling.

Space for servicing and repair. Protection from direct exposure to water or to a condensation-prone

environment. Protection from high-voltage or high-current devices, or devices which

produce electromagnetic interference. Selection of a location that will provide an operating temperature range of

40 to +70 C (40 to +158 F). The control must NOT be mounted on the engine.

Introduction Installation Checkout Procedure

With the installation complete as described in this chapter, do the following checkout procedure before beginning set point entry or initial start-up adjustments. Visual inspection

a. Check the linkage between the actuator and fuel-metering device for looseness or binding.

b. Check for correct wiring in accordance with the control wiring diagram, Figure 1-2.

c. Check for broken terminals and loose terminal screws. d. Check the speed sensor(s) for visible damage. If the sensor is a

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magnetic pickup, checks the clearance between the gear and the sensor, and adjusts if necessary. Clearance should be between 0.25 and 1.25 mm (0.010 and 0.050 inch) at the closest point. Make sure the gear run out does not exceed the pickup gap.

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Chapter 3.

System Wiring Drawings

Introduction This chapter gives the information about system wiring.

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Figure 3-1 IRLEC Functional Overview

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Figure 3-2 Cabinet General Arrangement

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Figure 3-3 Control Wiring Diagram

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Figure 3-4 UG-Actuator Wiring Diagram

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Figure 3-5 Interfacing Cables Detail

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Chapter 4.

System Hardware Description

Introduction This chapter gives information about the type of components used in the system (8701-1349). The IRLEC system includes:

A 733 Digital Control

ServLink Watch Window or a handheld terminal for adjusting control parameters

UG actuator to position the fuel metering

Power supply module

Magnetic pickup for speed sensing

72 Vdc Relay Module for desired notch position

Three pressure transducers for sensing LOP, FOP, BAP

Feedback Sensor for sensing engine fuel rack.

Load Control Potentiometer Module

LCD (Liquid Crystal Display) for data monitoring

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733 Digital Control

The 733 control uses a GAP programmable processing core that provides all the necessary functions in a single CPU. The below listed specifications give some insight to the processor capability relative to other Woodward controls. Processor type Motorola MPC565 Clock frequency 56 MHz Math support Floating point CPU Real time clock built into CPU RTC accuracy 1 Minute / month Flash memory 1 Mbytes RAM 512 Kbytes

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Input/Output Arrangement The standard I/O (input/output) for this product is:

Type of Input # of Inputs Options/Details DC Power Input

Power Input 1 1832 Vdc, protected from reverse polarity

Analog Inputs

Function Configurable Inputs 4 Current (420 mA)

MPU / Proximity Speed Sensor 2 10 25000 Hz (general purpose use) 106000 Hz (when used as fuel

injection

Speed input)

Analog Outputs

Actuator output 1 Current (either 420 mA or 20160 mA)

Function Configurable outputs 3 Current (420 mA)

Discrete Inputs

Configurable Switch, PWM, or Prox inputs 4 Switch to return pins to activate

Configurable Switch or Contact inputs 4 Switch to return pins to activate

Discrete Outputs

Configurable Relay Driver or PWM Outputs 4 Low side drivers

Communication Ports

Serial Ports 2 (1)RS-232, (1)RS-485

CAN Ports 3 (1)Isolated, (2)On-Engine use

Temperature Specifications The 733 control may be used in applications with an ambient temperature from

40 to +100 C (40 to +212F).

733 Wiring Pin Out

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Speed Inputs

MPU/Proximity 1 (+) G3 MPU/Proximity 2 (+) G1

MPU/Proximity 1 () F3 MPU/Proximity 2 () F1

MPU/Proximity 1 shield F2 MPU/Proximity 2 shield F2

Digital Inputs

Digital / PWM Input 1 E3 Digital / PWM Input 3 E1

Digital / PWM Input 2 E2 Digital / PWM Input 4 D3

Digital / PWM Return D2

Boolean Input 1 C3 Boolean Input 2 E1

Boolean Input 3 C1 Boolean Input 4 D3

Boolean Input Return B2

Analog Outputs

Analog Output 1 (+) B3 Analog Output 2 (+) A1

Analog Output 1 () A3 Analog Output 2 () A2

Actuator Outputs

Actuator Output 1 (+) H3 Actuator Output 2 (+) H1

Actuator Output 1 () G2 Actuator Output 2 () H2

Power Outputs

Proximity Power (+) D1

Proximity Power () D2

Digital Outputs

Digital / PWM Output 1 K3 Digital / PWM Output 3 K1

Digital / PWM Output 2 J3 Digital / PWM Output 4 J1

DO Circuit Power Input J2 Digital / PWM Output Return K2

Analog Inputs

Analog Input 1 (+) P2 Analog Input 3 (+) L1

Analog Input 1 () N3 Analog Input 3 () M2

Analog Input 2 (+) N1 Analog Input 4 (+) M3

Analog Input 2 () M1 Analog Input 4 () L3

Analog Input 1&2 Shield N2 Analog Input 3&4 Shield L2

Power Input

Power (+) Y3

Power () Y1

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CAN Communications

CAN 1 High S1

CAN 1 Low S3

CAN 1 Common T2

CAN 1 shield S2

CAN 2 High P3 CAN 3 High P1

CAN 2 Low R3 CAN 3 Low R1

CAN 2&3 shield R2 CAN 2&3 shield R2

RS-485 Communications

RS-485 (+) X3

RS-485 () X1 RS-485 Common Y2

RS-232/485 shield W2

Termination jumper (+) W3

Termination jumper () W1

RS-232 Communications

RS-232 TX T3

RS-232 RX T1

RS-232Common X2

RS-232/485 shield W2

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PC Interface The Woodward Watch Window can be used to interface with the ServLink Server, as a means for displaying the Service & Configure tunable/monitors, with the ability for tuning the parameters. Watch Window also offers the ability to upload the tunable parameters from the control, into a file, and also to download the parameters stored in the file, into a control (of the same type/application).

Using Watch Window

Here are brief instructions for using Watch Window in conjunction with Servlink to view the variables for your IRLEC on PC (Personal Computer). These instructions are meant to be introductory only. Full on-line help is available in each application. It is assumed that you already have ServLink and Watch Window installed. The default location can be found by clicking the START icon on the main menu bar and then clicking the PROGRAMS menu item. Look for an icon called WOODWARD WATCH WINDOW.

1. Make sure that all other programs that may access your computer

communication ports are shut down. 2. Get the right cable to talk from your PC to the control (5416-870). 3. Start the Servlink server and open a new file. Select the proper com port

for your PC, verify that POINT-TO-POINT communication mode is selected, verify that the baud rate is 115200.

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4. Select OK. If everything is working right, you should see an animated picture of a string of 1 and 0 flying from the control to the PC on your screen. You now have a network definition file whose default name is NET1.

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5. Start the watch window application. When watch window executes, you

will have a screen displaying three windows entitled Watch Window, Explorer, and Inspector.

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6. The explorer window will have two groups displayed, SERVICE and

CONFIGURE. Double clicking on either of these will expand them to show groups of values. Explorer is used only to locate a tunable or

monitor value. In order to change a value or monitor a value, you

must drag and drop a value from the explorer window into the

Inspector window. Once a value is displayed in the Inspector, you can see several blocks of information. The most important blocks for a tunable value are the FIELD and VALUE blocks. The FIELD block is used to identify a particular value, and the VALUE block display the current value of a variable. There are two types of values available in Watch Window. One is a monitor value, which is marked in the

INSPECTOR window with a pair of glasses. This mean it may only be looked at. The other value is read/write value, which is marked with a pencil. The read/write type may be modified using the up and down arrows in the value block.

The Inspector is used to monitor and edit variables available through the Servlink Server. The Inspector is composed of a set of tabbed sheets. Each sheet contains a grid (the grid shown in the following example is reduced - other fields headers are available to define which control a variable relates to, and if relevant, which category and block name. Each sheets tab is labeled with a user-definable name. The user has the ability to add and remove sheets using menu items and/or tool bar buttons in the Main Window. An icon to the left of the variable defines whether it is a monitor value, configure tunable or service tunable (or debug tunable if relevant) : Service Tunable : Monitor Value : Configure Tunable One or more variables can be selected using the mouse (left click) or keyboard (arrow keys).If the user wishes to select multiple variables, they can do so by performing one of these sequences:

Select a variable, hold down the shift key, and arrow up or down until all of the variables.

Click on a variable, hold down the shift key, and click on the last variable in the series that the user wishes to select.

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Power Supply Module

The Power Supply Module has a DC-to-DC converter and a battery charger circuit. The Specification of Power Supply Module is given below. Input Voltage Range: 18-75 Vdc Output Voltage: 24 Vdc Output Current: 6.26 Amps

Figure 4-4 Power Supply Module

Testing Power Supply Module: There is one terminal at the input (for 72 Vdc) and four terminals at the output. Out of four terminals, three terminals are for 24 Vdc and one terminal is for 5 Vdc. Connect 72 Vdc supply to the input terminal of the power supply module and measure the voltage across output terminal. If the output voltage is 23.5 to 24.5 Vdc at 24 Vdc terminal, and 5.0 Vdc at the 5 Vdc terminal, the supply module is healthy otherwise it is faulty.

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Pressure Transducer

Three pressure transducers are used.

1. Boost Air Pressure Transducer: Working Range: 0 to 5 Kg/cm

2

Signal Output: 420mA Supply Voltage: 830Vdc Accuracy 0.25% FS Operating Temperatures -40C to 125C Configuration: 2 wire

2. Lube Oil Pressure Transducer: Working Range: 0 to 10 Kg/cm

2

Signal Output: 420mA Supply Voltage: 830Vdc Accuracy 0.25% FS Operating Temperatures -40C to 125C Configuration: 2 wire

3. Fuel Pressure Transducer: Working Range: 0 to 10 Kg/cm

2

Signal Output: 420mA Supply Voltage: 830Vdc Accuracy 0.25% FS Operating Temperatures -40C to 125C Configuration: 2 wire

Figure 4-6 Pressure Transducer

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Load Control Potentiometer

In most governor applications, the primary function of the governor is to automatically maintain a specific engine speed under varying load conditions, by regulating the fuel supply to the engine. In the case of traction diesel engine governor, it has to basic functions to perform.

To maintain a desired engine speed at each notch, set by the drivers throttle handle.

To maintain constant power output of the engine at each notch speed.

Thus for each throttle setting (notch position), a constant engine speed and a predetermined fixed rate of fuel supply required. To satisfy both these conditions, the load on the engine must be adjusted by increasing or decreasing excitation of the traction generator as the locomotive operating conditions (track gradient, load of auxiliaries, etc.) vary. The governor thus performs the function of load control to maintain constant horsepower output of the engine at each speed setting. The voltage output of LCP (P/N: 1784-1063) varies from 24 Vdc to 68. The voltage at max field excitation is 24 Vdc. The voltage at min. field excitation is 68 Vdc. The voltage can be measured with the help of multimeter by connecting across terminals 29A (+) and 4(-). This voltage can be adjusted through a trim pot mounted on the PCB.

Figure 4-8 Load Control Potentiometer

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Procedure for testing LCP Module (No Load) 1. Connect 72 Vdc source across terminal 71(+) and 4(-). The output

voltage between wires 29A and 4 should be 24 Vdc. To vary this voltage 5%, adjust the trimpot on the base of PCB.

2. Switch ON the 4 20 mA source and apply 4 mA. The output voltage will be 24 Vdc.

3. Increase the 4 20 mA signal in steps of 4 mA and notice a corresponding change in the output voltage from 24 Vdc to 68 Vdc.

Procedure for testing LCP Module (Load)

1. Connect a 1K ohms/10 W power resistor between terminals IP (+) and IN (-). The output DC voltage should not vary more than 2 Vdc.

2. Similar testing as no load testing can be conducted now.

S.No. Current in mA Output Voltage (No

Load) Output Voltage (Load)

1. 2. 3. 4. 5. 6.

0 4 8 12 16 20

24.0 24.0 35.2 47.0 59.1 67.5

24.9 24.9 36.0 47.7 59.3 70.8

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72 VDC Relay

We use 72 VDC relay module (P/N: 1731-2082) having 5 relays (one spare) to sense notch position. The A notch signal coming from loco is connected to terminal 1(+), B notch signal to terminal 2(+), C notch signal to terminal 3(+) and D notch signal is connected to terminal 4(+). The Common terminal of all four relays is shorted together and connected to loco negative (4).

The potential free contact of each relay is connected to 733 control. The 24 Vdc +ve is connected to module terminals 16, 26, 36 and 46. The module terminal 15 is connected to 733 terminal #36, module terminal 25 is connected to 733 terminal #35, module terminal 35 is connected to 733 terminal #34 and module terminal 45 is connected to 733 terminal #33. For more detail see Figure1-3 (control wiring diagram).

Figure 4-9 Relay Module

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Actuator Feedback Sensor (RVDT)

The contact less sensor utilizes the orientation of a magnetic field for the determination of the measurement angle. Therefore, a magnet is attached to the sensor shaft, the magnetic field orientation is captured with an integrated circuit. An analogue output signal represents the calculated angle The housing is made of a special high-grade temperature-resistant plastic material. Fixings are in the form of elongated slots, which allow simplicity in mounting together with ease of mechanical adjustment. The transducer is not sensitive to either dirt or dampness. Electrical connections are made via a shielded cable with 3 lead wires, which is sealed into the housing.

Testing Procedure

a. Supply 5.0 +/- 0.2 Vdc to Pins D (+) and F (-) of 9 Pin Connector. b. Measure sensor output at Pins E (+) and F (-) to 4.25 - 4.45 Vdc at

minimum actuator terminal shaft position (Actuator terminal shaft can be moved with the help of Serrated Wrench).

c. Verify feedback sensor output is 0.44 - 0.84 Vdc at maximum actuator

terminal shaft position (Actuator terminal shaft can be moved with the help of Serrated Wrench). The terminal shaft can be bringing back to zero by giving some RPM from Test Stand Drive.

Verify that feedback sensor output voltage decreases uniformly as the actuator terminal shaft is moved from minimum to maximum position.

Wiring Detail Ground: green Voltage supply: brown Output signal: white

Electrical Data Operating voltage [VDC]: 5 0,5 Measuring range []: 30...180 (10-steps) Output signal [V]: 5,5...94,5% (ratiometric of supply voltage 5V 0,5V) Conductor length, bare, tinned [mm]: approx. 500 Conductor diameter [mm]: approx. 0,127

Mechanical Data Mounting: with 2 fillister-head screws M4 and washer Mechanical travel []: 360,continuous

Environmental Data Vibration: 5...2000 Hz / Amax=0,75 mm / amax=20 g Temperature range [C]: -40...+125 (supply voltage 5V) Mechanical life [movements]: > 50 x 10

6

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Figure 4-10 Feedback Sensor

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LCD Display A coloured LCD touch screen, display of reputed make is available on the front

panel of the controller unit and has a minimum of 6 of graphical display. The size of each character displayed on the screen is minimum 5mm. The brightness of the display is such that it is clearly visible under both day and night conditions from a distance of 2 meters. The main page of the display is as per RDSO given format. Alarm status is displayed at the bottom of the screen. Subsequent pages have different information about MCBG parameters and alarm logs etc.

POWER REQUIREMENTS: Power connection via removable three position terminal block. Supply Voltage: +24 VDC 20% Typical Power1: 8 W Maximum Power2: 14 W The LCD display has five programmed pages as per railway requirement and pressing buttons F1, F2, F3, F4 and F5 can access these pages individually.

When the governor is initially powered up, it will default to the Engine Main Parameters page. Here is what the display look like. The Main Engine Parameters Page can also be accessed while in any other page by pressing F1 button. Some buttons like NEXT, PREV, EXIT, ALARM, and TREND are also provided on the Display touch screen.

You can scroll display pages by pressing NEXT and PREV. Pressing ALARM

and TREND can directly access alarm History and Trending pages. You can come out from any page directly to main page i.e. Engine Main Parameters by pressing EXIT.

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The LCD display provides the following Information.

Engine Main Parameters The general format of the engine parameters displayed by Display is given below

The Engine Parameters Page provides the following information:

LOP: The lube oil pressure of the engine.

FOP: The fuel pressure of the engine.

BAP: The boost air pressure of the engine.

NOTCH: The notch position of the engine.

ENGINE SPPED: The actual speed of the engine.

FUEL RACK: The fuel rack opening of the engine.

LCP: The excitation position of the engine.

Engine More Parameters Pressing F2 button on the Display can access this page. The Engine More Parameters Page provides the following information:

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ENGINE MODE: This mode gives the following information.

NONE: This message will appear when the engine is ready to start.

SPPED IN CONTROL: This message will appear when the engine is running at Rated speed.

START FUEL LIMITER: This message indicates the maximum actuator opening during cranking.

BOOST AIR PRESSURE LIMIT: This message will appear when there is maximum allowable rack opening at any particular booster pressure (for more detail see fuel limiter curve).

RACK LIMIT ACTIVE: This message will appear when there is maximum allowable rack opening at any particular Notch.

ELECT. OVERSPEED ACTIVE: This message will appear when Electrical OST is selected through key switch provided on the door.

MECH. OVERSPEED ACTIVE: This message will appear when Mechanical OST is selected through key switch provided on the door.

ENGINE STOP: This message will appear when the engine is stopped normally (D Notch Shutdown)

ENGINE SPPED REF: This parameter indicates the speed reference at individual notch. ENGINE PEAK SPEED: This parameter gives the peak speed recorded by governor. The peak

speed can be reset any time by pressing the Reset button on the door. This parameter helps in knowing engine overspeed tripping during OST.

ACTUATOR OUTPUT: This parameter indicates Actuator opening in %.

LCP POSITION %: This parameter indicates LCP Position in %.

Shutdown and OST Status

Pressing F3 button on the Display can access this page. The Shutdown and OST Status Page provides the following information:

ENGINE SHUTDOWN STATUS This parameter indicates following engine shutdowns.

ENGINE OVERSPEED: The Engine will shutdown when the engine speed exceeds the engine electrical OST limit and this message will appear on the display

LOW LUBE OIL SHUTDOWN: The Engine will shutdown when the lube oil pressure is below the desired level and this message will appear on the display.

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SPEED SENSOR FAIL: The Engine will shutdown when the speed sensor fails and this message will appear on the display.

NORMAL SHUTDOWN (D NOTCH): The Engine will shutdown when there is normal shutdown (D Notch) and this message will appear on the display.

NO SHUTDOWN: This message will appear only when Engine is running well.

ENGINE OVERSPEED STATUS This parameter indicates the electrical or mechanical OST Switch position.

ELECTRICAL OST ACTIVE: This message will appear below the Engine Overspeed Status if OST Selector switch position is on Electrical OST.

MECHANICAL OST ACTIVE: This message will appear below the Engine Overspeed Status if OST Selector switch position is on Mechanical OST.

Alarms History Pressing F4 button on the Display can access this page. The Alarms History Page provides the following information:

Alarm History page provide alram history with date and time stamping. It indicates both generation and acknowledgement time of alarms. Alarms can be cleared by pressing Clear button. The list of alarms normally generated by Governor will be:

1. LUBE OIL SIGNAL FAULT: This signal fault will appear on the display when there is any wire break in Lube Oil Pressure Sensor

2. FUEL PRESSURE SIGNAL FAULT: This signal fault will appear on the display when there is any wire break in Fuel Pressure Sensor.

3. AIR MANIFOLD SIGNAL FAULT: This signal fault will appear on the display when there is any wire break in Boost Air Pressure Sensor.

4. ACT. FEEDBACK SENSOR FAULT: This signal fault will appear on the display when there is any wire break in Feedback Sensor (RVDT).

5. SPPED SENSOR FAULT: This signal fault will come on the display when there is any wire break or Magnetic Pick-up Failure.

6. ENGINE OVERSPEED TRIP: This alarm will appear when the engine shutdown due to Electrical Overspeed.

7. LOW LUBE OIL SHUTDOWN: This alarm will appear when the engine shutdown due to Low Lube Oil or Lube oil Signal Fault.

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Trending Pressing F5 button on the Display can access this page. The Trending provides the real time curve of Engine Speed.

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Data Logging The electronic governor has data logging facility. It uses CFM Card (1GB) to record alarm history and time spent on each notch for last 24 hours with date and time spent. When you connect a USB cable in between Display and PC, below window will appear on PC.

Double click on LOGS folder and the below window will appear on your PC.

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Double click on EVENTS folder if you want to check alarm history. The below window will appear.

Double click on the excel file and the alarm history with date and time stamp will appear on your PC in the form given below.

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Double click on NTCH_DLY folder if you want to check time spent on individual notch. The below window will appear.

Double click on the excel file and the cumulative time spent on each notch in seconds for last 24 hours with date and time stamp will appear on your PC in the form given below.

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Reset Counters Counters calculating time on 1

st to 8

th Notch can be reset any time through PC.

Set up communication between Governor and PC as per procedure mentioned on page 16. Now go to Service mode and drag menu NOTCH DELAY COUNTER RESET. Now select tunable RESET NOTCH 1 COUNTER to RESET NOTCH 8 COUNTER to reset desired counter.

LEDs Indication on the Front Door

Ready To Start This indication will appear on the control panel when the control system and the power supply module are okay.

Shutdown This indication will appear on the control panel when the control system is in shutdown mode.

OS Test This indication will appear on the control panel when the control system is in Overspeed test mode.

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Magnetic Speed Pickup

The magnetic speed pickup (MPU) is used to detect the speed of the prime mover. It is necessary when the prime mover drives something other than an alternator, and is often used where an alternator is driven directly by the prime mover and when a control signal is necessary before the alternator comes up to its proper output voltage. A speed sensor circuit, either a section on the governor amplifier chassis or a separate unit, is needed to convert the MPUs output signal to one usable by the governor amplifier. The magnetic pickup produces a voltage output when any magnetic material moves through the magnetic field at the end of the pickup. Since most engines and turbines have flywheels or other large gears made of magnetic material (usually iron or steel), magnetic pickups can usually be installed without adding attachments to gear or shaft. Nonmagnetic material such as aluminium, brass and some stainless steels, will not excite the magnetic pickup. The MPU makes use of a stray magnetic field and no provision for return magnetic circuits or paths is necessary. Any device which produces a dynamic discontinuity of magnetic material in the field of the pickup will produce an electrical voltage. Although gears are the normal devices measured by an MPU, other devices such as a vibrating surfaces, moving bar, crank, wheel spokes, or a steel head screw mounted on some moving surface will work equally well if surface speed and other factors are taken in account. The MPU may be excited by a keyway or slot in a wheel, there is likely to be an unwanted background signal due to varying density or eccentricity of the material. It is better to excite the MPU from a protrusion on the surface. This places the pickup at a relatively great distance from the materials between excitation periods and is likely to pick up stray signals. The output of a magnetic pickup is affected by three factors.

Voltage increases with increases of the surface speed of the monitored magnetic material.

Voltage decreases as the air gap between the magnetic pickup and the surface of the gear tooth is increased.

Voltage waveform is determined by the size and shape of the gear tooth in relation to the size and shape of the pole piece.

With any given speed and clearance conditions, a maximum power output will result when the field is filled with a relatively infinite mass of magnetic material at one instant and a complete absence of such material the next. A reasonable approach to these conditions exists when the cross-section of the exciting masses is equal to or greater than that of the pole piece, and the space between is equal to or greater than three rimes the diameter of the pole piece. As the magnetic pickup-gear relationship begins to deviate from the specifications listed above, the MPU output waveform may deteriorate to an unacceptable shape. Because the speed sensor detects zero-crossings, the waveform should cross zero only twice for each tooth (once going positive and once going negative)

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Figure 4-16 Magnetic Pickup Dimensions In above figure the optimum dimensions of A, B, C and F are given as they relate to D, the diameter of the pole piece of the magnetic pickup. The optimum relationship foe maximum output is as follows: A equal to or greater than D B equal to or greater than C C equal to or greater than three times D F equal to or greater than D

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Mount the magnetic pickup radially to the outside diameter of the desired gear either through a housing or on a rigid bracket. Make sure the gear is of magnetic material. The gap between the pickup and the outside diameter of the gear

should be set normally between 0.25 and 1.02 mm (0.010 and 0.040 ) at the

closest point [make sure the gear has less than 0.51 mm (0.020 ) diametric runout]. Since the signal strength is inversely proportional to gap distance, a

weak signal may be generated with more than 1.02 mm (0.040 ) gap. A shield of non-magnetic material may be installed between the gear and the pickup if necessary for physical shielding. Since the material spaces the pickup face farther from the gear, and since an electromagnetic force may be generated by enough to operate the speed signal circuit. Most electronic controls require a minimum output of 1.5 Vac (rms) from the magnetic speed pickup at the lowest controlling speed. Above figure shows the maximum air gap allowed for each surface speed and diametral pitch or gear module to produce this maximum required voltage.

MPU Hertz = No. Teeth x Gear RPM x Gear Ratio

60

Example: MPU Hertz = 120 Teeth x 1800 RPM x 1 60

MPU Hertz = 3600 Hertz

How to Mount Magnetic Pickup on the Cam Gear Cover With the prime mover shutdown, turn the pickup in until it just touches the outside diameter of the gear. One 360

0-turn counter clockwise will move the

pickup out 0.0555 inch (1.41 mm). Screw out the amount required for the desired gap. If possible, run the gear slowly through 360

0 rotation to check the

clearance of the pickup. When the gap is set, tighten the jam nut securely against the housing or bracket so the pickup cannot turn in or out. Repeat the procedure for the second MPU

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Magnetic Pickup Installation

Woodward MCBG system comprises of one magnetic pick up unit, which is installed on the cam gear cover. Two holes will need to be drilled on the cam gear cover. The location where the holes need to be drilled on the cam gear cover is shown on the drawing.

Figure 4-17 CAM Gear

Figure 4-18 Magnetic Pickup Mounted on CAM Gear Cover

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UG-Actuator

The UG-Actuator provides the muscle power required to control the engine fuel rack. It has a self-contained oil sump so a separate oil supply is not required. The UG-Actuator takes a given electrical input signal and converts it to a proportional hydraulic output-shaft position to control engine fuel flow. The standard UG-Actuator produces approximately 20J (15ft-lbs) of work over42 degrees of rotary output. The oil pump is the proven high-output gerator, designed to provide long life with minimal maintenance. The actuators electric to hydraulic transducer uses a Woodward built torque motor which converts the 20-160mA control signal to a given output position.

Terminal Shaft and Drive Shafts Terminal Shaft - .500-36 Serrated Drive Shaft 1.125-48 Serrated Work 15ft-lb

Hydraulic Pump The UG-Actuator is equipped with a Gerator pump. High speed and low speed pumps are available, depending on the drive speed from the engine. The pump uses oil from the self-contained UG-Actuator sump to provide 1172kPa (170 psi) internal operating pressure. The direction of rotation is selected by pump housing alignment. The pump operates in one direction only. The drive uses a maximum of 375 W (0.5hp). If the actuator oil pump is rotated in the wrong direction, oil pressure will not be generated in the actuator.

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Figure 4-19 UG Actuator

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Control Linkage The terminal shaft rotates 42 degrees. Use 2/3 of the total rotation between no load and full load. The additional overtravel should be split and used at both ends to provide maximum fuel when required and to assure shutdown at minimum-fuel actuator position.

!

WARNING

To prevent possible serious injury or loss of life, or damage to the engine, be sure to

allow sufficient overtravel at each end of the terminal shaft so the actuator can

shutdown the engine, and also give maximum fuel when required. Misadjusted

linkage could prevent the actuator from shutting down the engine.

Many control problems are related to the linkage between the actuator and the engine. Use only first-quality rod ends for the linkage, rod ends that will last under the nearly constant motion associated with precise control. The linkage must be stiff, not subject to engine-caused vibration. The linkage must be as light as possible and still maintain the attributes of stiffness. Linkage, which is too heavy, can damage the actuator as well as make it difficult to achieve steady control. Installed linkage must operate smoothly, be free of binding, and free of lost motion due to worn parts. If there is a collapsible member in the linkage, be sure it does not yield each time the actuator moves the linkage rapidly. Use a linear linkage. Linear linkage moves the fuel-setting shaft in direct proportion to the movement of the actuator output. Design the linkage so the power output of the engine is proportional to the position of the actuator output shaft.

Figure 4-20 Terminal Shaft Travel

a. Overtravel to insure prime mover stops are reached. b. No load to full travel normally 2/3 of full governor travel is

recommended. c. Travel required to accelerate the prime mover. d. Travel required to decelerate or shut down prime mover.

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Linkage Installation

Install the serrated lever (0.500-36 serrations) to the output shaft of the actuator (the serrations of both are matching). Install the link by fixing one end of the rod end with the hole in the serrated lever and tighten by M 12 allen bolt and nut with the spacer fitted on the bolt. Take the other end of the rod right through the hole of the oil drip pan as shown in the diagram and fix the other end of the rod end with the DLW spring lever clevis DLW P/L No. 10131670. Please note that machining of DLW spring lever clevis to 0.630-0.650 mm width is required to insert the other end of the rod end. Tighten the link by M 12 allen bolt and nut arrangement. Put the spacer with the bolt. Calibrate the linkage with zero fuel rack position with zero in actuator.

Figure 4-21 Linkage

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Testing the functionality of MCBG Actuator on TEST Stand The Woodward Actuator has following accessories, which needs to be checked.

a. UG Actuator b. Feedback Sensor c. LOP Sensor. d. FOP Sensor. e. BAP Sensor.

The following items are required to test the Actuator.

a. Woodward test Stand (8909-053). b. Current Source from 0 200mA. c. Voltage Regulated Power Supply range from 0 24 VDC. d. 24-ohm resistance. e. 9 Core Harness Connected one end with mating connector. f. 14 Core Harness Connected one end with mating connector. g. Multimeter. h. L-N Key Set. i. Serrated Wrench (30943)

Follow the procedure given below to test UG Actuator on Test stand. 1. Put the Actuator on the Woodward test stand (8909-053). The fitment of actuator on test stand will be same as PGEV fitment. You will get the reference from the picture given for actuator fitment. 2. Fill the actuator with specified oil up to the indicator. 3. Check the wiring of actuator and its accessories as per drawing. Feedback Sensor (9-pin connector; Ref. WD per Specification Report)

a. Starting with Sensor shaft mark down in Coupling slot and Coupling set screw at about 11 oclock position, adjust sensor mounting to align Sensor shaft to actuator terminal shaft so Coupling can be freely rotated without binding. Sensor shaft should stay centered in Coupling slot when rotated. The end of Sensor shaft must not touch the end of the actuator terminal shaft. [ ]

b. Supply 5.0 +/- 0.2 Vdc to Pins D (+) and F (-). Record ____________ Vdc.

c. Adjust feedback sensor output measured at Pins E (+) and F (-) to 4.25

4.45 Vdc at minimum actuator terminal shaft position. Record ______________ Vdc.

d. Verify feedback sensor output is 0.44 - 0.84 Vdc at maximum actuator

terminal shaft position. Record _______ Vdc. Record max. term. shaft angle _____ deg.

e. Verify that feedback sensor output voltage decreases uniformly as the

actuator terminal shaft is moved from minimum to maximum position. [ ]

f. Verify that hysteresis is acceptable by recording output voltage at 20 deg. terminal shaft rotation by first approaching from minimum and then approaching from maximum terminal shaft position. The voltage difference Vdc 1 ___ - Vdc 2 ___ should be less than 0.15 Vdc. ___. Re-adjust sensor mounting if necessary.

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g. Verify that setscrew on terminal shaft adapter and the two feedback sensor

clamp screws are tightened. [ ]

h. Record feedback sensor serial number. _________________________ 4. Pressure Transmitters (14-pin connector; Ref. WD per Specification Report)

a. For Boost Air Pressure transmitter, connect + 24 Vdc from power supply through a milliamp meter then to Pin F and connect power supply negative through a 240 ohm resistor then to Pin G; connect pressure source to BOP port (top/right).

1) Verify 3.80-4.20 mA at zero gage pressure.

Record__________mA

2) Verify 11.65-12.05 mA at 35.6 psig (2.5 Kg/cm2, 2.45 bar).

Record_______mA

3) Record transmitter serial number. _________________________

b. For Lube Oil Pressure transmitter, connect + 24 Vdc from power supply through a milliamp meter then to Pin H and connect power supply negative through a 240 ohm resistor then to Pin I; connect pressure source to LOP port (middle).

1) Verify 3.80-4.20 mA at zero gage pressure.

Record__________mA 2) Verify 19.49-19.89 mA at 142.2 psig (10.0 Kg/cm

2, 9.81 bar).

Record______mA 3) Record transmitter serial number. _________________________

c. For Fuel Oil Pressure transmitter, connect + 24 Vdc from power supply

through a milliamp meter then to Pin J and connect power supply negative through a 240 ohm resistor then to Pin K; connect pressure source to FOP port (bottom/left).

1) Verify 3.80-4.20 mA at zero gage pressure.

Record__________mA

2) Verify 19.49-19.89 mA at 71.1 psig (5.0 Kg/cm2, 4.90 bar).

Record_______mA

3) Record transmitter serial number. _________________________ 5. Verify magnetic pick up wiring is per wiring diagram on Spec. Report. [ ]

6. Actuator Output (connect through 9-pin connector A (+) and B (-)) a. Verify calibration in accordance with TSP-10245. [ ] b. Confirm shaft rotation at 20 mA ____(1-2 deg.) and at 160 mA ____(37-

40 deg.). 7. General a. Actuator is free of leaks. [ ] b. Verify there is no electrical conductivity (electrical short) between any

of the wired connector pins and the actuator housing (megger test). [ ]

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Chapter 5.

System Description

Introduction This chapter contains information on control calibration. It includes initial prestart-up and start-up settings and adjustments.

Start-up Adjustments

1. Complete the installation and connect all the interfacing cables between the Control and the Actuator.

2. Close the 72 Vdc Switch on the panel. Check the green Ready to Start indication appears on the front of panel.

3. Do the rack calibration.

Procedure For Rack Calibration Procedure Connect the Hand Held terminal or PC to the 9 pin communication port mounted on the door. Start as per process explained on page 16 (PC Interface). Bring fuel rack manually to min. position. Now see the FEEDBACK SENSOR VOLTS in the DISPLAY menu as shown in figure given below. Now go to CALIBRATION OF ANALOG I/O menu and enter the above seen voltage in RVDT VOLTS AT MIN RACK tunable. Now bring back fuel rack manually to max. position. Now again see the FEEDBACK SENSOR VOLTS in the DISPLAY menu. Now again go to CALIBRATION OF ANALOG I/O menu and enter the above seen voltage in RVDT VOLTS AT MAX RACK tunable. Now right click on Net1 (Dflt Control ID) and select SAVE VALUES to save all changes you made and then press ESC button to come out of the program. Crank the engine. Minimum voltage required from the speed sensor to operate the control is 1.0 Vrms. Well get this voltage when the engine runs above 85 rpm during cranking. Before cranking ensure that the speed setting lever is at Idle Notch. The engine will start running at Idle Speed.

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Overspeed Testing

Procedure for Testing Mechanical OST Put the Engine on 8

th Notch. Switch on the Mechanical OST Enable key switch

mounted on the control box door. Red LED mounted on the door will glow and Locomotive RPM will gradually move to the OST set point and hold there. In case mechanical OST not operating upto this rpm, shed staff should readjust engine mechanical OST and repeat the same procedure. In case mechanical OST fail to trip Loco, MCBG will issue shutdown command to locomotive at ten RPM above the mechanical OST setpoint. It is the second Electronic tripping from the MCBG which will work only when mechanical OST fail. Press F3 button on the display and Mechanical OST Active status will be displayed on the display as per picture given below.

Procedure for Testing Electronic OST Put the Locomotive on 8

th Notch. Switch on the OST key switch mounted on the

control box door in the Electrical OST position. Red LED mounted on the door will glow and Engine RPM will gradually move to Electrical OST set point. Once the RPM reaches to set point, governor will issue a shutdown command and a message (Engine Overspeed Shutdown) will appear in the display in

Shutdown and OST Page. At the same time governor will generate an alarm in the Alarm History Page with date and time stamping. Press F3 button on the display and Electrical OST Active status will be displayed on the display as per picture given below.

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Adjustment of Various Engine Parameters

Notch wise engine speed Do the communication with MCBG as per process explained on page 16 (PC Interface). Select the SPEED REF SETTING in Service menu and drag it on the right hand side (Inspector 1) as per picture given below. Now set the desires speed by clicking on up and down arrow. Any speed can be set. Now right click on Net1 (Dflt Control ID) and click on save values to save the changed parameters.

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Maximum permissible fuel rack at each notch Do the communication with MCBG as per process explained on page 16 (PC Interface). Select the MAX RACK LIMIT in Service menu and drag it on the right hand side (Inspector 1) as per picture given below. Now set the desires rack limit by clicking on up and down arrow. Now right click on Net1 (Dflt Control ID) and click on save values to save the changed parameters.

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Maximum Permissible Fuel Rack in Relation to Boost air

Pressure Do the communication with MCBG as per process explained on page 16 (PC Interface). Select the LIMITER SETTING in Service menu and drag it on the right hand side (Inspector 1) as per picture given below. Now set the desires fuel limit by clicking on up and down arrow. Now right click on Net1 (Dflt Control ID) and click on save values to save the changed parameters.

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PID Response Do the communication with MCBG as per process explained on page 16 (PC Interface). Select the SPEED PID ADJUSTMENT in Service menu and drag it on the right hand side (Inspector 1) as per picture given below. Now set the speed dynamics to remove hunting by clicking on up and down arrow. Now right click on Net1 (Dflt Control ID) and click on save values to save the changed parameters.

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Load Control Timing From Max to Min. Field Position Do the communication with MCBG as per process explained on page 16 (PC Interface). Select the LOAD REGULATION in service menu and drag it on the right hand side (Inspector 1) as per picture given below. Now set the load regulation timing by clicking on up and down arrow. Now right click on Net1 (Dflt Control ID) and click on save values to save the changed parameters.

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Rack Calibration Do the communication with MCBG as per process explained on page 16 (PC Interface). Select the CALIBRATION OF ANALOG I/O in Service menu and drag it on the right hand side (Inspector 1) as per picture given below. Now calibrate the engine rack as per rack calibration procedure explained on page 42. Now right click on Net1 (Dflt Control ID) and click on save values to save the changed parameters.

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Fuel Transmitter Calibration Do the communication with MCBG as per process explained on page 16 (PC Interface). Select the CALIBRATION OF ANALOG I/O in Service menu and drag it on the right hand side (Inspector 1) as per picture given below. Now calibrate the desired pressure sensor by changing its gain and offset. Now right click on Net1 (Dflt Control ID) and click on save values to save the changed parameters.

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Chapter 6.

Tunable

Service Value List

Service Prompt Default Range

Range Final Value

*SPEED REF SET*

IDLE/NOTCH 1 (rpm) 400 200 TO 1000 NOTCH 2 (rpm) 450 200 TO 1000 NOTCH 3 (rpm) 550 200 TO 1000 NOTCH 4 (rpm) 650 200 TO 1000 NOTCH 5 (rpm) 750 200 TO 1000 NOTCH 6 (rpm) 850 200 TO 1000 NOTCH 7 (rpm) 950 200 TO 1200 NOTCH 8 (rpm) 1050 500 TO 1300

*ALARM MONITOR*

SHUTDOWN MONITOR SPEED SENSOR FAULT MONITOR LOW LUBE OIL PRESSURE MONITOR LOW FUEL PRESSURE MONITOR

OVERSPEED MONITOR

ACT POS SIGNAL FAILURE MONITOR

LUBE OIL SIGNAL FAIL MONITOR

FUEL PRESS SIGNAL FAIL MONITOR

AIR BOX SIGNAL FAIL MONITOR

*CONTROL MODE* SPEED IN CONTROL MONITOR AIR BOX LIMITER IN CNTRL MONITOR ENGINE SHUTDOWN MONITOR

*CALIBRATION KEY* ENTER CAL PASSWARD 49 0 TO 999

*CALIBRATION ANALOG I/O*

AIR PRES SIGNAL OFFSET 0.00 -50.0 TO 50.0 AIR PRES SIGNAL SPAN 1.00 0.00 TO 3.00 LUBE OIL PRES SIGNL OFFSET 0.00 -30.0 TO 30.0 LUBE OIL PRES SIGNAL SPAN 1.00 0.00 TO 3.00 FUEL PRES SIGNAL OFFSET 0.00 -50.0 TO 50.0 FUEL PRES SIGNAL SPAN 1.00 0.00 TO 3.00 RVDT VOLTS AT MAX RACK 0.79 0.01 TO 5.00 MAX. RACK OPENNING (mm) 33.0 0.0 TO 35.0 RVDT VOLTS AT MIN RACK 4.18 0.01 TO 5.00 MIN RACK OPPENNING (mm) 0.0 0.0 TO 35.0 MAX. RACK OPENNING (mm) 33.0

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*DISPLAY* ACTUAL SPEED MONITOR SPEED REFERENCE MONITOR NOTCH POSITION MONITOR ACTUATOR OUTPUT MONITOR ACTUATOR FEEDBACK MONITOR BOOST AIR PRESS (bar) MONITOR LUBE OIL PRESS (bar) MONITOR LOAD BIAS % MONITOR FUEL PRESS (bar) MONITOR FEEDBK SENSR VOLTS MONITOR

*L/O PRESS MONITOR*

NOTCH1 TRIP DELAY 42.0 10.0 to 120.0 NOTCH2 TRIP DELAY 0.5 10.0 to 120.0 NOTCH3 TRIP DELAY 0.5 10.0 to 120.0 NOTCH4 TRIP DELAY 0.5 10.0 to 120.0 NOTCH5 TRIP DELAY 0.5 10.0 to 120.0 NOTCH6 TRIP DELAY 0.5 10.0 to 120.0 NOTCH7 TRIP DELAY 0.5 10.0 to 120.0 NOTCH8 TRIP DELAY 0.5 10.0 to 120.0 IDLE NTCH LUBE OIL REF. 1.1 0.0 to 5.0 8

TH NTCH LUBE OIL REF. 4.2 0.0 to 16.0

*MAX RACK LMT*

NOTCH 1 RACK (mm) 12.0 0.0 TO 35.0 NOTCH 2 RACK (mm) 15.0 0.0 TO 35.0 NOTCH 3 RACK (mm) 18.0 0.0 TO 35.0 NOTCH 4 RACK (mm) 21.0 0.0 TO 35.0 NOTCH 5 RACK (mm) 24.0 0.0 TO 35.0 NOTCH 6 RACK (mm) 27.0 0.0 TO 35.0 NOTCH 7 RACK (mm) 30.0 0.0 TO 35.0 NOTCH 8 RACK (mm) 33.0 0.0 TO 35.0

*ENGINE OST*

OST ENABLE FALSE TRUE TO FALSE OST RPM 1215.0 1100.0 TO 1300.0 OST FAIL TRIP RPM MONITOR

*TRIP SETTING*

OVERSPEED TRIP (rpm) 1205.0 1100.0 TO 1300.0 LOP TRIP BYPASS FALSE TRUE TO FALSE BAP TRIP BYPASS FALSE TRUE TO FALSE RACK LIMIT BYPASS FALSE TRUE TO FALSE

*SPEED PID ADJUSTMNT*

GAIN1 3.50 0.01 TO 20.0 IDLE GAIN 3.50 0.01 TO 20.0 RATED GAIN 4.50 0.01 TO 20.0

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RESET1 0.04 0.01 TO 20.0 IDLE RESET 0.04 0.01 TO 20.0 RATED RESET 0.10 0.01 TO 20.0 COMPE1 60.0 0.001 TO 100.0

IDLE COMPE 80.0 0.001 TO 100.0

RATED COMPE 80.0 0.001 TO 100.0

WINDOW WIDTH 5.0 0 TO 200

GAIN RATIO 1.0 1.0 TO 20.0

BAP LMT GAIN 0.50 0.01 TO 20.0 BAP LMT INT 0.02 0.01 TO 20.0

*SPEED REF RATES*

RAISE RATE (rpm/sec) 33.0 1.0 TO 1000.0 LOWER RATE (rpm/sec) 54.75 1.0 TO 1000.0 IDLE DROOP (rpm) 0.0 0.0 TO 500.0

*SPEED DROOP*

MIN LOAD ACTUATOR (%) 0.0 0.0 TO 100.0 MAX LOAD ACTUATOR (%) 100.0 0.0 TO 100.0 SPEED DROOP (%) 0.0 0.0 TO 15.0

*LOAD REGULATION*

SLOW LOAD CUT RATE 7.0 0.01 TO 15.00 FAST LOAD CUT RATE 8.0 0.01 TO 20.00 SLOW LOAD UP RATE 7.0 0.01 TO 20.00 FAST LOAD UP RATE 5.0 0.01 TO 10.00 SLOW RATE DEADBAND 5.0 2.0 TO 50.0 FAST RATE DEADBAND 2.0 5.0 TO 100.0 LOAD BIAS (%) MONITOR LCP ACTIVE MONITOR

*LIMITER SETTING*

START FUEL LIMITER 65 0 TO 100 BOOST AIR PRS (bar) P1 0.0 0.00 TO 30.00 BOOST AIR LMTR P1 ACT% 43.29 0.00 TO 100.00 BOOST AIR PRS (bar) P3 0.05 0.00 TO 30.00 BOOST AIR LMTR P3 ACT% 56.61 0.00 TO 100.00 BOOST AIR PRS (bar) P6 0.25 0.00 TO 30.00 BOOST AIR LMTR P6 ACT% 69.30 0.00 TO 100.00 BOOST AIR PRS (bar) P7 0.6 0.00 TO 30.00 BOOST AIR LMTR P7 ACT% 76.59 0.00 TO 100.00 BOOST AIR PRS (bar) P8 1.10 0.00 TO 30.00 BOOST AIR LMTR P8 ACT% 86.58 0.00 TO 100.00 BOOST AIR PRS (bar) P9 1.70 0.00 TO 30.00 BOOST AIR LMTR P9 ACT% 100.0 0.00 TO 110.00 BOOST AIR PRS (bar) P2 0.025 0.00 TO 30.00 BOOST AIR LMTR P2 ACT% 53.33 0.00 TO 100.00 BOOST AIR PRS (bar) P4 0.1 0.00 TO 30.00 BOOST AIR LMTR P4 ACT% 61.66 0.00 TO 100.00 BOOST AIR PRS (bar) P5 0.2 0.00 TO 30.00

BOOST AIR LMTR P5 ACT% 68.33 0.00 TO 100.00

*ACTUATOR SETTING*

DITHER Amp (map_p) 0.01 0.00 TO 20.00

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*NTCH DLY COUNTER RST*

RESET NOTCH 1 COUNTER FALSE TRUE TO FALSE RESET NOTCH 2 COUNTER FALSE TRUE TO FALSE RESET NOTCH 3 COUNTER FALSE TRUE TO FALSE RESET NOTCH 4 COUNTER FALSE TRUE TO FALSE RESET NOTCH 5 COUNTER FALSE TRUE TO FALSE RESET NOTCH 6 COUNTER FALSE TRUE TO FALSE RESET NOTCH 7 COUNTER FALSE TRUE TO FALSE RESET NOTCH 8 COUNTER FALSE TRUE TO FALSE

RESET ALL COUNTERS FALSE TRUE TO FALSE

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Configure Value List

SPEED CONTROL

NO OF TEETH SPEED SENSOR 1 GEAR RATIO SPEED SENSOR FAILED AT NO OF TEET SPEED SENSOR 2

SPEED SET FOR PID

IDLE 1 FOR GAIN 200 200 TO 1000 IDLE FOR GAIN 350 200 TO 1000 RATED FOR GAIN 1050 500 TO 1500 IDLE 1 FOR RESET 200 200 TO 1000 IDLE FOR RESET 350 200 TO 1000 RATED FOR RESET 1050 500 TO 1500 IDLE 1 FOR COMPENSATION 200 200 TO 1000 IDLE FOR COMPENSATION 350 200 TO 1000 RATED FOR COMPENSATION 1050 500 TO 1500

ACTUATOR DRIVER

USE ACTUATOR DITHER? FALSE TRUE TO FALSE

ACTUATOR MIN mA 20

ACTUATOR MAX mA 160

MISCELLANEOUS

EMG SHUTDOWN LATCH?

USE AUTO START MODE?

USE SPEED DROOP?

Manual B37818 IRLEC

64 Woodward

Service Tunable Description

* Speed Ref Setting * IDLE/NOTCH 1 (rpm)

Is the first notch rpm reference at which the prime mover has to run.

NOTCH 2 (rpm) Is the second notch rpm reference at which the prime mover has to run.

NOTCH 3 (rpm) Is the third notch rpm reference at which the prime mover has to run.

NOTCH 4 (rpm) Is the fourth notch rpm reference at which the prime mover has to run.

NOTCH 5 (rpm) Is the fifth notch rpm reference at which the prime mover has to run.

NOTCH 6 (rpm) Is the sixth notch rpm reference at which the prime mover has to run.

NOTCH 7 (rpm) Is the seventh notch rpm reference at which the prime mover has to run.

NOTCH 8 (rpm) Is the eighth notch rpm reference at which the prime mover has to run.

*Alarm Monitor*

SHUTDOWN If true, indicates control is in shutdown mode.

SPEED SENSOR FAULT If true, indicates speed is not sensed by magnetic pickup.

LOW LUBE OIL PRES. If true, indicates lube oil pressure is low at desired speed level.

LOW FUEL PRESSURE If true, indicates fuel pressure is low at desired speed level.

OVERSPEED If true, indicates control tripped due to overspeed.

ACT POS SIG FAILURE If true, indicates wire break or Feedback Sensor (RVDT) fail.

LUBE OIL SIGNAL FAIL If true, indicates wire break or Lube Oil Pressure Transducer fail.

FUEL SIGNAL FAILURE If true, indicates wire break or Fuel Pressure Transducer fail.

AIR BOX SIGNAL FAILURE If true, indicates wire break or Air Pressure Transducer fail.

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*Control Mode*

SPEED IN CONTROL If true, indicates control is running in speed control mode and no limiter is active.

AIR BOX LIM IN CONT If true, indicates Air Box Pressure Limiter limiting fuel rack.

SHUTDOWN ENGINE If true, indicates control is in shutdown mode.

*Calibration I/O*

AIR PRES SIGNAL OFFSET If