EPG
EPG
EPG
(Revision J, 8/2002)
Original 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.
General
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 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, 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
Translated translation was made. Be sure to check manual 26311 , Revision Status &
Publications Distribution Restrictions of Woodward Technical Publications, 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 Out-of-date translations are marked with .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.
RevisionsChanges in this publication since the last revision are indicated by a black line
alongside the text.
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 82329
Copyright Woodward 1984
All Rights Reserved
Manual 82329
Contents
WARNINGS AND NOTICES ............................................................................ II
ELECTROSTATIC DISCHARGE AWARENESS ..................................................III
CHAPTER 1. GENERAL INFORMATION ........................................................... 1
Introduction .............................................................................................................1
Associated Publications..........................................................................................1
EPG Models ...........................................................................................................1
CHAPTER 2. INSTALLATION AND TROUBLESHOOTING ................................... 6
Installation ..............................................................................................................6
Installation Check and Troubleshooting .................................................................8
CHAPTER 3. PRODUCT SUPPORT AND SERVICE OPTIONS ........................... 12
Product Support Options ......................................................................................12
Product Service Options .......................................................................................12
Returning Equipment for Repair ...........................................................................13
Replacement Parts ...............................................................................................13
Engineering Services............................................................................................14
Contacting Woodwards Support Organization ....................................................14
Technical Assistance ............................................................................................15
DECLARATIONS ......................................................................................... 17
Woodward
Manual 82329
Overspeed /
Overtemperature /
Overpressure
Personal Protective
Equipment
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
Automotive
Applications
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Battery Charging
Device
Electrostatic
Precautions
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
Each Woodward Electrically Powered Governor (EPG) system includes three
basic parts:
A magnetic pickup (MPU) which senses engine speed from an enginedriven gear.
A speed control which receives the speed signal from the MPU, compares it
to a reference signal, and generates a control signal which the control sends
to the actuator.
An actuator which receives the signal from the control and positions its
output shaft according to this signal. The output shaft is linked to the fuel
control.
There are two EPG models:
The isochronous speed control, which is available with start-fuel limit or dual
dynamics;
The droop speed control, which includes a load sensor and provides droop
control for generator sets.
Different actuator sizes are available for different work output requirements.
Models are available for either 12 or 24 volt systems.
Associated Publications
Manual
82313
25070
82510
82493
82327
82476
Title
Generator Load Sensor
Electronic Control Installation Guide
Magnetic Pickups & Proximity Switches for Electronic Controls
Isochronous EPG
EPG with Droop
Ramp Generator
Product
Spec.
04106
82314
Title
EPG Electrically Powered Governors
Generator Load Sensor
EPG Models
Model
512
524
1712
1724
Woodward
Battery
Voltage
1016 V
2032 V
1016 V
2032 V
Work
Output
0.7 J (0.5 ft-lb)
1.0 J (0.75 ft-lb)
1.6 J (1.2 ft-lb)
2.3 J (1.7 ft-lb)
512/524 Actuator
Manual 82329
1712/1724 Actuator
Control
MOUNTING SCREWS
0.250-20 (inch) thread. Minimum mounting screw engagement should be 9.5 mm (0.375
inch). Torque screws to 911 Nm (80100 lb-in).
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1.
2.
3.
4.
5.
6.
7.
8.
Shielded wires to be twisted pairs or twisted 3-conductor, grounded at one end only.
4 or 2 mm (12 or 14 AWG) stranded wire, must be as short as possible. Total of
distance from battery to control, and from control to actuator, to be as short as
possible (see maximum length in chart).
See EPG Models above for source voltages.
Open for minimum fuel. Do not use either the minimum fuel option, or disconnect the
actuator leads, or disconnect the power to the control as part of any emergency stop
sequence.
For positive ground systems, switch and fuse to be located in series with battery ()
and terminal 2. Positive (+) terminal becomes chassis ground. Leads from battery to
terminals 1 and 2 must be direct and not pass through distribution points.
Approximate speed change with trim potentiometer:
2.5% using a 1 k potentiometer
5% using a 2 k potentiometer
About one second ramp time per 50 F. Capacitor specification: 200 F maximum,
15 W minimum, less than 30 Adc leakage current over temperature range.
Idle range about 25% to 200% of rated, using 50 k potentiometer. For fixed idle,
calculate the value of the resistor:
R = 17 k
9.
10.
11.
12.
13.
14.
15.
Speed
1 )
( Rated
Idle Speed
Woodward
Actuator
15 ft (4.6 m)
25 ft (7.6 m)
Battery
15 ft (4.6 m)
25 ft (7.6 m)
Manual 82329
Chapter 2.
Installation and Troubleshooting
Installation
Speed Control
The speed control box should be mounted on the control panel, often on the
same skid as the engine. It is not designed for installation on the engine. Provide
space for adjustment, wiring access, and ventilation. Choose a location that
protects the control from being bumped and that the wiring harness will reach.
The installation should allow for adequate air circulation to the control box and
have an ambient temperature of 40 to +75 C (40 to +167 F).
Actuator
Install the actuator solidly, and install a linkage with the correct configuration to
provide an almost linear relationship between change of actuator position and
change in engine power output. In most cases use about 2/3 of the actuator
rotation between minimum and maximum fuel. The engine fuel control usually
provides the minimum and maximum stops. The minimum and maximum stops
on the actuator may be used, if necessary (see Figure 2-1). If the actuator is
controlling the speed-setting shaft of a mechanical governor, use the actuator
stops to limit the travel of the linkage. Set the minimum stop for 5% below rated
speed at no load, and set the maximum stop for rated speed plus 3% more than
the droop of the governor. The actuator is designed to operated in ambient
temperatures of 40 to +82 C (40 to +180 F). Installation should avoid sources
of excessive heat.
Do not pressure wash sealed bearingsyou may force dirt inside
them, shortening their life. If the actuator is exposed to weather,
mount it with the clockwise end higher, if possible.
Electrical Connections
Connect the system as shown in the appropriate wiring diagram (Figures 1-2,
1-3, 1-4). See the appropriate manual for wiring of accessories. Connect the
speed control to system ground.
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Shields
Use twisted-pair, shielded wire where the wiring diagram shows. Each shield
must be grounded only at the end nearest the control. Do not ground both ends
of a shield. Tie all shields to the same ground point. When passing a shield
through a terminal block, connect the shield to its own terminal. Do not ground
the shield at the terminal block. Do not solder to braided shields.
Damage to the speed control will occur if the battery is disconnected
while the alternator or battery charging device is energized and
connected to the control.
2.
Magnetic Pickup:
Correctly adjusted?
Tight?
Resistance of 50350 ?
3.
4.
Turn the governor power on: (Do not start the engine or turbine.)
Fuse OK?
Actuator shaft settles in minimum fuel position?
5.
Battery Voltage:
10 to 16 Vdc for model 512, 1712?
20 to 32 Vdc for model 524, 1724?
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7.
Set the RATED speed pot fully counterclockwise (to minimum speed
setting).
8.
9.
MPU voltage between terminals 5 and 6 at least 1.5 Vrms while cranking?
(For small gears, it may be necessary to decrease the MPU clearance). Do
not decrease below 0.25 mm (.010 inches).
Actuator should go to maximum fuel position when the starter turns engine
or turbine. (If applicable, Start Fuel Limit must be fully clockwise.)
When the engine or turbine starts and comes to speed, the actuator arm
should move toward minimum-fuel position.
11. Adjust the GAIN pot to the stable region between low-frequency and highfrequency oscillation.
12. If there is a low-frequency oscillation which does not stop when the GAIN
pot is adjusted, turn the STABILITY pot slightly clockwise and try the GAIN
pot adjustment again. Continue adjusting the STABILITY pot slightly
clockwise, then readjusting the GAIN pot, until the engine runs at a steady
speed.
If there is a high-frequency oscillation which will not stop, even when the
GAIN pot is fully counterclockwise, adjust the STABILITY pot slightly
counterclockwise until the high-frequency oscillation stops.
Speed Settings
13. Adjust the RATED SPEED pot for the desired rated speed.
14. Set the IDLE SPEED pot for the desired idle speed.
15. Close the IDLE/RATED switch.
16. Adjust transient response. Simulate a transient by manually bumping the
linkage.
To decrease settling time (may increase ringing) after a transient, turn the
GAIN pot clockwise slightly, then turn the STABILITY pot as required to
eliminate oscillation and to obtain desired response. Repeat if necessary.
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To decrease ringing (will increase settling time) after a transient, turn the
GAIN pot counterclockwise slightly, then turn the STABILITY pot as required
to eliminate oscillation and obtain desired response. Repeat if necessary.
17. Select alternate dynamics and alternate fuel, if applicable. Repeat this step
as necessary.
This completes the check of units without droop. For units with droop, do the
following additional steps.
2.
Adjust the RATED SPEED pot for rated speed with no load.
3.
4.
Rated Speed -
Example 1:
The generator set is a 60 Hz unit with an isolated load. If the desired droop
is 5% and the generator set can be run at 100% load, then the speed at full
load would be 57 Hz.
Example 2:
It is again desired to set the droop of the same generator set to 5%, but this
time the generator set cannot be run at 100% load. The generator set is
therefore run at 50% load and the speed (in step 3) would be 58.5 Hz.
Example 3:
The generator set is a 60 Hz unit that will be paralleled with an infinite bus. If
the desired droop is 5% and the generator set can be run at 100% load, the
speed at which the generator is run (in step 2) would be 63 Hz.
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Example 4:
It is again desired to set the droop of the same generator set to 5%, but this
time the generator set cannot be run at 100% load. It has been decided to
run the generator set at 50% load, so the speed (in step 2) at which the
generator set is run would be 61.5 Hz. In step 7, the DROOP pot is then
turned counterclockwise only until the load is 50%.
Paralleled with Infinite Bus:
1.
2.
Rated Speed -
3.
4.
5.
6.
7.
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Chapter 3.
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
(EngineHelpDesk@Woodward.com) 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: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service 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:
Woodward
Manual 82329
return number;
Packing a Control
Use the following materials when returning a complete control:
packing materials that will not damage the surface of the unit;
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:
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Manual 82329
Engineering Services
Woodwards 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 Woodwards 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 nonWoodward 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.
Products Used In
Electrical Power Systems
Products Used In
Engine Systems
Products Used In
Industrial Turbomachinery
Systems
For the most current product support and contact information, please visit our
website directory at www.woodward.com/directory.
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Manual 82329
Technical Assistance
If you need to contact technical assistance, you will need to provide the following information.
Please write it down here before contacting the Engine OEM, the Packager, a Woodward
Business Partner, or the Woodward factory:
General
Your Name
Site Location
Phone Number
Fax Number
Control/Governor Information
Control/Governor #1
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Control/Governor #2
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Control/Governor #3
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Symptoms
Description
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.
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Woodward
Declarations