Installation and Operation Manual

Ramp Generator and Signal Converter

8271-083
for EGM and 2301 Controls

Manual 82359
 WARNINGS
FOLLOW 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.

OUT-OF-DATE PUBLICATION—This publication may have been revised or updated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.

OVERSPEED 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.

CAUTIONS
BATTERY 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.

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

CAUTION—indicates a potentially hazardous situation which, if not avoided, could

result in damage to equipment.

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

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 1987
All Rights Reserved
Manual 82359 Ramp Generator and Signal Converter

Contents

ELECTROSTATIC DISCHARGE AWARENESS .................................................. II

CHAPTER 1. DESCRIPTION........................................................................... 1
CHAPTER 2. INSTALLATION.......................................................................... 2
Unpacking...............................................................................................................2
Location Considerations.........................................................................................2
Mounting the Control ..............................................................................................2
Electrical Connections............................................................................................2
CHAPTER 3. ADJUSTMENTS ......................................................................... 5
CHAPTER 4. TROUBLESHOOTING ................................................................. 6
Initial Troubleshooting ............................................................................................6
Static Test...............................................................................................................6
CHAPTER 5. SERVICE OPTIONS ................................................................... 9
Product Service Options.........................................................................................9
Returning Equipment for Repair...........................................................................10
Replacement Parts ...............................................................................................11
How to Contact Woodward...................................................................................11
Engineering Services ...........................................................................................12
Technical Assistance............................................................................................13

Illustrations and Tables

Figure 1-1. System Drawing...................................................................................1

Figure 2-1. Outline Drawing ...................................................................................3
Figure 2-2. Plant Wiring Diagram ...........................................................................4

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Ramp Generator and Signal Converter Manual 82359

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.

CAUTION—ELECTROSTATIC DISCHARGE
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.

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Manual 82359 Ramp Generator and Signal Converter

Chapter 1.
Description

The 8271-083/8271-083A Ramp Generator and Signal Converter combines the

functions of a ramp generator and a signal converter in one control. It serves as
an interface between a 4–20 or 10–50 mA signal from a current source used to
set speeds and a Woodward EGM or 2301 electronic speed control.

Model 8271-083 is the 10–50 mA configuration, and model 8271-083A is the

4–20 mA configuration.

When functioning as a ramp generator, the control facilitates the acceleration of

a prime mover at a uniform rate.

As a signal converter, the control converts a mA input signal to a signal that is

usable by the EGM or 2301 to control speeds.

The ramp generator/signal converter uses a low signal select bus (LSS) to
choose either the ramp generator signal or the signal converter signal—
whichever calls for the lesser amount of fuel—to output to the summing point of
the control amplifier. The LSS, therefore, prevents the control from
simultaneously working in ramp generator mode and in signal converter mode.

Figure 1-1 shows how the ramp generator/signal converter works in the system.

Figure 1-1. System Drawing

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Ramp Generator and Signal Converter Manual 82359

Chapter 2.
Installation

Unpacking
Be careful when unpacking the ramp generator/signal converter. Check it for
signs of damage, including bent or dented panels, scratches, and loose and/or
broken parts. If you find any damage, notify the shipper immediately.

Location Considerations
When selecting a location to mount the ramp generator/signal converter,
consider the following:
• The control must operate within a temperature range of –50 to +150 °F (–46
to +66 °C).
• Protect the control from direct exposure to water or a condensation-prone
environment.
• Provide adequate ventilation for cooling. Shield the control from radiant heat
sources.
• Do not install the control near high-voltage or high-current devices.
• Allow adequate space around the control for servicing.
• Electrically ground the control for proper shielding.

Mounting the Control

You can mount the ramp generator/signal converter in any position that allows
adequate ventilation and room for servicing.

Mount the ramp generator/signal converter as shown in the outline drawing

(Figure 2-1).

Electrical Connections
Wire all input and output connections for the ramp generator/ signal converter as
shown in the plant wiring diagram (Figure 2-2).

Power Supply
Connect the 36 ±3 Vdc power supply to terminals 1 (+) and 2 (–).

Ramp Switch
Connect the ramp switch to terminals 3 and 4. Close the switch to accelerate to
rated speed, and open it to decelerate to idle.

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Manual 82359 Ramp Generator and Signal Converter

Signal Converter Input

Connect the 10–50 mA (8271-083) or 4–20 mA (8271-083A) current input to
terminals 5 (–) and 6 (+).

Speed Control Signal

If you’re using an EGM, connect its speed-setting line to terminal 7 (±). If your
speed control is a 2301, connect the speed-setting line to terminal 8 (±).

Connect the EGM or 2301 signal common to terminal 5.

Jumper Connections
For 8271-083 (10–50 mA configuration), connect a jumper to terminals 10 and
11. For 8271-083A (4–20 mA configuration), connect a jumper to terminals 9 and
10.

Figure 2-1. Outline Drawing

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Ramp Generator and Signal Converter Manual 82359

Figure 2-2. Plant Wiring Diagram

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 Manual 82359 Ramp Generator and Signal Converter

Chapter 3.
Adjustments

There are four potentiometers on the ramp generator/signal converter chassis.

Make any necessary pre-start-up adjustments as follows:

WARNING—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.

Potentiometer Mode Function

RAMP SLOPE Ramp Generator Sets the time the prime mover accelerates from idle to rated
speed.

CAUTION
Having the RAMP SLOPE potentiometer past mid-position
counterclockwise causes negative ramping. This will not
allow the prime mover to increase speed.

To ensure positive ramping, work this potentiometer from mid-

position (12.5 turns from either end) to fully clockwise. Turn the
potentiometer clockwise to decrease ramp time from 2 minutes to
3 seconds.
IDLE Ramp Generator Sets the idle speed.

To increase idle, turn the potentiometer clockwise.

CONVERTER GAIN Signal Converter Sets the output voltage for the maximum current input, which sets
(Slope) the maximum speed. (If the control is reverse-acting, it sets the
minimum speed.)

Turn the potentiometer clockwise to increase gain.

NOTE
CONVERTER GAIN and CONVERTER ZERO are not
independent adjustments. Alternate adjusting GAIN and
ZERO until they are both satisfactory.
CONVERTER ZERO Signal Converter Sets the output voltage for the minimum current input, which sets
(Level) the minimum speed. (If the control is reverse-acting, it sets the
maximum speed.)

To increase zero, turn the potentiometer clockwise.

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Ramp Generator and Signal Converter Manual 82359

Chapter 4.
Troubleshooting

Initial Troubleshooting
If you suspect problems with the ramp generator/signal converter:
• Use the plant wiring diagram (Figure 2-2) to verify all the wiring inputs to,
and outputs from, the control.
• Make sure the input current to the ramp generator/signal converter is 10–50
mA (8271-083) or 4–20 mA (8271-083A). Verify the proper jumper is in
place for the input used.
• Remove the ramp switch wires to terminals 3 and 4. The speed should
decrease to idle. Using the speed-setting potentiometer on the EGM or
2301, slowly accelerate and decelerate the prime mover. If the speed does
not follow the speed setting, check the speed control. If the speed does
increase with the speed setting, perform the following Static Test.

If you’re still having problems after performing the following test, contact
Woodward for assistance.

NOTE
Perform the following Static Test after the ramp generator/signal converter
has been correctly installed on your prime mover.

WARNING—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.

Static Test
Resistance Test
1. Make sure there are no external wiring connections to the ramp
generator/signal converter during this test.

2. Using a volt-ohmmeter (Simpson 270 or equivalent) selected to a minimum

scale of R x 10K, measure the resistance from each terminal to the chassis.
The reading at each terminal should be infinity.

If you’re using a digital meter, the reading should be 100 MΩ or greater.

3. Verify the following resistance values:

Terminal to Terminal Resistance

5 11 51.1 ±1 Ω
9 11 75.0 ±1 Ω
7 TP1 30 kΩ ±600 Ω
5 TP2 0.0 Ω
6 9 0.0 Ω

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Manual 82359 Ramp Generator and Signal Converter

Bench Test Setup

1. Connect a 36 ±3 Vdc power supply to terminals 1 (+) and 2 (–).

2. Connect a normally open ramp switch to terminals 3 and 4.

3. For 8271-083 (10–50 mA configuration), connect a jumper to terminals 10

and 11. For 8271-083A (4–20 mA configuration), connect a jumper to
terminals 9 and 10.

4. Connect a 10–50 mA (8271-083) or 4–20 mA (8271-083A) dc current

source to terminals 5 (–) and 6 (+). Also connect a 10–50 mA or 4–20 mA
meter in series with this current source.

5. Connect a dc voltmeter across TP1 and TP2, with TP2 as common.

6. Each potentiometer on the chassis can turn more than 25 turns. (These
potentiometers have an internal slip clutch and will not be damaged by
overtravel.) Set each potentiometer as follows:

Potentiometer Setting
RAMP SLOPE Fully clockwise, 25 turns
IDLE Mid-position, 12.5 turns from either end
CONVERTER ZERO Mid-position, 12.5 turns from either end
CONVERTER GAIN Fully clockwise, 25 turns

Static Test

NOTE
This is a static test, performed for troubleshooting purposes only. You must
adjust gain, zero, and idle for the speed range of your prime mover.

1. Perform the preceding Bench Test Setup. Power up the control, then the
test equipment.

2. Make sure the ramp switch across terminals 3 and 4 is open.

3. Adjust the input current signal to its maximum rated input: 50 mA

(8271-083) or 20 mA (8271-083A) across terminals 5 and 6. The output
should be 1 ±1 V.

4. Adjust the IDLE potentiometer for 1 V at TP1 and TP2 (common).

5. Lower the input to 5 mA. There should be no voltage change at either TP1
or TP2.

6. Return the input to the maximum rated input.

7. Close the ramp switch at terminals 3 and 4. The voltage reading across TP1
and TP2 should ramp from idle voltage to a positive maximum of 17 ±1 Vdc.
If there is no ramp or if the ramp is negative, adjust RAMP SLOPE
clockwise.

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Ramp Generator and Signal Converter Manual 82359
8. Alternate opening (and closing) the ramp switch while adjusting the RAMP
SLOPE potentiometer to verify the ramp time from minimum to maximum
voltage.

With the switch closed, make sure the fast ramp rate is 3 ±1 seconds.
Adjust RAMP SLOPE clockwise if it is not. For the slow ramp rate, adjust
RAMP SLOPE counterclockwise until the voltage starts to decrease.
Readjust RAMP SLOPE until the voltage just starts to increase.

Open the ramp switch at terminals 3 and 4. The voltage should drop to 1 ±1
V.

Close the switch; the ramp time to maximum voltage should be 2 minutes or
longer.

Adjust the RAMP SLOPE potentiometer to set your desired ramp time from
idle to rated.

NOTE
CONVERTER GAIN and CONVERTER ZERO are not independent
adjustments. Alternate adjusting GAIN and ZERO until they are both
satisfactory.

9. Adjust CONVERTER GAIN to be 10.5 Vdc with your maximum rate input
signal: 50 mA (8271-083) or 20 mA (8271-083A).

10. Adjust the input current signal to the minimum rated signal at terminals 5
and 6: 10 mA (8271-083) or 4 mA (8271-083A).

Adjust CONVERTER ZERO to 0.5 ±0.05 Vdc at TP1 and TP2.

Set the input current back to your maximum rated input current; readjust
CONVERTER GAIN to 10.5 Vdc.

Repeat step 10 as necessary, until both gain and zero are where you want
them.

11. Open the ramp switch at terminals 3 and 4.

12. Close the ramp switch; allow the voltage to ramp to 10.5 Vdc.

13. Reverse the polarity of the input current. The output polarity should reverse.

14. Turn off power to, then remove, the test equipment. This completes the
Static Test.

NOTE
Set the actual speeds of your primer mover by adjusting the IDLE,
CONVERTER GAIN, and CONVERTER ZERO potentiometers on your prime
mover while it is running.

8 Woodward
Manual 82359 Ramp Generator and Signal Converter

Chapter 5.
Service Options

Product Service Options

The following factory options are available for servicing Woodward equipment,
based on the standard Woodward Product and Service Warranty (5-01-1205)
that is in effect at the time the product is purchased from Woodward or the
service is performed:
• Replacement/Exchange (24-hour service)
• Flat Rate Repair
• Flat Rate Remanufacture

If you are experiencing problems with installation or unsatisfactory performance

of an installed system, the following options are available:
• Consult the troubleshooting guide in the manual.
• Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In most cases, your problem
can be resolved over the phone. If not, you can select which course of
action you wish to pursue based on the available services listed in this
section.

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 is also a flat rate structured program and
includes the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205).

This option allows you to call 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 Woodward facility as explained below (see “Returning Equipment
for Repair” later in this chapter).

Charges for the Replacement/Exchange service are based on a flat rate plus
shipping expenses. You are invoiced the flat rate replacement/exchange charge
plus a core charge at the time the replacement unit is shipped. If the core (field
unit) is returned to Woodward within 60 days, Woodward will issue a credit for
the core charge. [The core charge is the average difference between the flat rate
replacement/exchange charge and the current list price of a new unit.]

Return Shipment Authorization Label. To ensure prompt receipt of the core,

and avoid additional charges, the package must be properly marked. A return
authorization label is included with every Replacement/Exchange unit that leaves
Woodward. The core should be repackaged and the return authorization label
affixed to the outside of the package. Without the authorization label, receipt of
the returned core could be delayed and cause additional charges to be applied.

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Ramp Generator and Signal Converter Manual 82359

Flat Rate Repair

Flat Rate Repair is available for the majority of standard 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. All repair work carries the standard
Woodward service warranty (Woodward Product and Service Warranty
5-01-1205) on replaced parts and labor.

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 and carry
with it the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205). 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 to Woodward for
repair, please contact Woodward in advance to obtain a Return Authorization
Number. When shipping the item(s), attach a tag with the following information:
• 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.

CAUTION—ELECTROSTATIC DISCHARGE
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.

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.

10 Woodward
Manual 82359 Ramp Generator and Signal Converter

Return Authorization Number

When returning equipment to Woodward, please telephone and ask for the
Customer Service Department [1 (800) 523-2831 in North America or
+1 (970) 482-5811]. They will help expedite the processing of your order through
our distributors or local service facility. To expedite the repair process, contact
Woodward in advance to obtain a Return Authorization Number, and arrange for
issue of a purchase order for the item(s) to be repaired. No work can be started
until a purchase order is received.

NOTE
We highly recommend that you make arrangement in advance for return
shipments. Contact a Woodward customer service representative at
1 (800) 523-2831 in North America or +1 (970) 482-5811 for instructions and
for a Return Authorization Number.

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.

How to Contact Woodward

In North America use the following address when shipping or corresponding:
Woodward Governor Company
PO Box 1519
1000 East Drake Rd
Fort Collins CO 80522-1519, USA

Telephone—+1 (970) 482-5811 (24 hours a day)

Toll-free Phone (in North America)—1 (800) 523-2831
Fax—+1 (970) 498-3058

For assistance outside North America, call one of the following international
Woodward facilities to obtain the address and phone number of the facility
nearest your location where you will be able to get information and service.

Facility Phone Number

Brazil +55 (19) 3708 4800
India +91 (129) 230 7111
Japan +81 (476) 93-4661
The Netherlands +31 (23) 5661111

You can also contact the Woodward Customer Service Department or consult
our worldwide directory on Woodward’s website (www.woodward.com) for the
name of your nearest Woodward distributor or service facility.

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Ramp Generator and Signal Converter Manual 82359

Engineering Services
Woodward Industrial Controls Engineering Services offers the following after-
sales support for Woodward products. For these services, you can contact us by
telephone, by email, or through the Woodward website.

• Technical Support
• Product Training
• Field Service

Contact information:
Telephone—+1 (970) 482-5811
Toll-free Phone (in North America)—1 (800) 523-2831
Email—icinfo@woodward.com
Website—www.woodward.com

Technical Support is available through our many worldwide locations or our

authorized distributors, depending upon the product. This service can assist you
with technical questions or problem solving during normal business hours.
Emergency assistance is also available during non-business hours by phoning
our toll-free number and stating the urgency of your problem. For technical
support, please contact us via telephone, email us, or use our website and
reference Customer Services and then Technical Support.

Product Training is available at many of our worldwide locations (standard

classes). We also offer customized classes, which can be tailored to your needs
and can be held at one of our locations or at your site. This training, conducted
by experienced personnel, will assure that you will be able to maintain system
reliability and availability. For information concerning training, please contact us
via telephone, email us, or use our website and reference Customer Services
and then Product Training.

Field Service engineering on-site support is available, depending on the product

and location, from one of our many worldwide locations or from one of our
authorized 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 field service engineering assistance, please contact us
via telephone, email us, or use our website and reference Customer Services
and then Technical Support.

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 Manual 82359 Ramp Generator and Signal Converter

Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:

General
Your Name
Site Location
Phone Number
Fax Number

Prime Mover Information

Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, gaseous, steam, etc)
Rating
Application

Control/Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number
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.

Woodward 13
Ramp Generator and Signal Converter Manual 82359

14 Woodward
 We appreciate your comments about the content of our publications.
Send comments to: icinfo@woodward.com
Please include the manual number from the front cover of this publication.

PO Box 1519, Fort Collins CO 80522-1519, USA

1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811 • Fax +1 (970) 498-3058
Email and Website—www.woodward.com

Woodward has company-owned plants, subsidiaries, and branches,

as well as authorized distributors and other authorized service and sales facilities throughout the world.
Complete address / phone / fax / email information for all locations is available on our website.

06/3/F