Installation and Operation Manual: UG-8/UG-40 Governors
Installation and Operation Manual: UG-8/UG-40 Governors
Installation and Operation Manual: UG-8/UG-40 Governors
UG-8/UG-40 Governors
Manual 03047B
WARNING
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.
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.
CAUTION
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.
IMPORTANT DEFINITIONS
WARNING—indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
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 1993
All Rights Reserved
Manual 03047 UG 4–20 mA Speed Setting System
Contents
Illustrations
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UG 4–20 mA Speed Setting System Manual 03047
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.
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:
• 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
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 03047 UG 4–20 mA Speed Setting System
Chapter 1.
General Information
Introduction
This manual contains information on installation, operation, adjustment, and
troubleshooting for the 4–20 mA speed setting system for UG-8/UG-40
governors. The manual does not describe the operation of the UG-8D/UG-40D
(dial) governors. For complete operation of the UG dial governors, see manual
03040.
Description
The speed setting system consists of an electronic control amplifier which
accepts the 4–20 mA signal and drives a stepper motor, which is mounted on the
cover of the UGD governor. This unit in turn rotates the speeder rod which sets
the speed of the UGD governor. Chapter 4 contains a detailed description of
operation. The control amplifier is housed in a small cast aluminum case (see
Figure 1-3). The stepper motor and the feedback potentiometer are mounted in
the aluminum cover which is part of the UGD governor (see Figures 1-1 and 1-2).
Applications
The speed setting system is designed around a UGD type of governor to enable
its speed to be set from a remote location using a 4–20 mA current loop.
Its principal aim is to meet the need for remote control of engine speed in marine
applications using milliamp signals instead of the more traditional pneumatic
pressure signal. It can, however, be used in other situations where a UGD
governor is applicable.
Reference Publications
The following publications contain additional product and installation information
relating to this system.
Manual Title
03040 UG Dial Governor
03013 Shutdown Solenoid for UG Governors
25071 Oils for Hydraulic Controls
36052 Magnetic Speed Pickup for PG and UG Governors
36684 Booster Servomotor
56103 UG Dial Repair
Product
Spec. Title
03029 UG-8 Governor
03048 UG MAS Governor with Milliamp Speed Setting
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Chapter 2.
Installation
Introduction
The milliamp speed setting consists of two items: the electronic control and the
cover assembly. The electronic control is contained in a separate box from the
UG governor. The cover assembly mounts on top of the UG governor. This
chapter covers mounting, connecting, and power requirements for these items.
Unpacking
Before handling the electronic control, read the electrostatic discharge
awareness information on page ii. Check all items for damage or for loose or
broken parts. If any damage is found, notify the shipper immediately.
Power Requirements
The electronic control requires a voltage source of 18 to 40 Vdc for operating
power. If a battery is used for operating power, an alternator or other battery-
charging device is necessary to maintain a stable supply voltage.
CAUTION
To prevent damage to the control, make sure that the alternator or other
battery-charging device is turned off or disconnected before disconnecting
the battery from the control.
Location Considerations
Consider these requirements when selecting the mounting location for the
electronic control unit:
• 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
• Avoidance of vibration
• Selection of a location that will provide an operating temperature range of
–40 to +85 °C (–40 to +185 °F).
The control must NOT be mounted on the engine, but as close to the UG
governor as possible. Try to avoid connections in excess of 10 m (33 ft).
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Manual 03047 UG 4–20 mA Speed Setting System
Electrical Connections
External wiring connections and shielding requirements for a typical control
installation are shown in the plant wiring diagram (Figure 1-4). These wiring
connections and shielding requirements are explained in the balance of this
section.
Shielded Wiring
All shielded cable must be twisted conductor pairs. Do not attempt to tin (solder)
the braided shield. All signal lines should be shielded to prevent picking up stray
signals from adjacent equipment. Connect the shields to the control terminals as
shown in Figures 1-3 and 1-4. Wire exposed beyond the shield should be as
short as possible, not exceeding 50 mm (2 inches). The other end of the shields
must be left open and insulated from any other conductor. Do not run shielded
signal wires with other wires carrying large currents.
Where shielded cable is required, cut the cable to the desired length and prepare
the cable as instructed below:
1. Strip outer insulation from BOTH ENDS, exposing the braided or spiral
wrapped shield. DO NOT CUT THE SHIELD.
2. Using a sharp, pointed tool, carefully spread the strands of the shield.
3. Pull inner conductor(s) out of the shield. If shield is the braided type, twist to
prevent fraying.
Power Supply
Connect the 24 volt power supply leads to terminals 1 and 2 of the control
amplifier, positive to terminal 1, as shown in Figure 1-4.
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Stepper Motor
A total of five wires are required between the control and the stepper motor.
Each wire should be 0.8 mm² (18 AWG) or larger. The cable can be a five-core
screened cable or separate one- or two-core screened cable. Shielding is
optional, but if used, all screens must be terminated at the control amplifier end
only. The connections between the amplifier and the governor pins are:
Pin Terminal
A to 7
B to 6
C to 4
D to 5
E to 3
Feedback Potentiometer
The feedback potentiometer must be wired to the amplifier using screened one-,
two-, or three-core cable. Each wire should be 0.3 mm² (22 AWG) or larger. All
screens must be terminated at the control amplifier end only. The connections
between the amplifier and the governor pins are:
Pin Terminal
F to 13
G to 12
H to 11
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Manual 03047 UG 4–20 mA Speed Setting System
Chapter 3.
Operation and Adjustment
Normal Operation
Once the milliamp speed setting system has been properly connected, the
engine may be started, stopped, and controlled according to the engine
operators instructions. The milliamp system is self starting on engine cranking,
provided the nominal 24 volt supply is switched on to the control amplifier.
In the event of a fault in the control amplifier or loss of its 24 volt supply, the
governor will continue to run at the last speed level. The speed can then be
changed by turning the manual speed setting knob on the front panel of the
governor.
When installing or first starting a milliamp speed setting system, follow the
procedures in this chapter.
Initial Start-up
The speed setting system (consisting of a UG governor and a driver amplifier)
should be adjusted on the engine to the required speed range and ramp speeds.
If the system is already adjusted and only needs to be checked for proper
operation, skip the Initial Setup and Control Adjustments sections and follow the
Starting Procedure section.
When the system is not yet adjusted or a replacement control amplifier has been
installed, skip the Initial Setup section and follow the Control Adjustments and
Starting Procedure sections.
Where replacement items have been fitted in the UG governor assembly (such
as new cover assembly, potentiometer, or stepper motor), begin with the Initial
Setup section and continue through the end of the chapter.
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Initial Setup
Where replacement items have been fitted in the UG governor assembly (such
as new cover assembly, potentiometer, or stepper motor), follow this procedure
and the remaining sections of the chapter.
4. Run the engine at the middle of the required speed range by rotating the
manual speeds setting knob.
5. Mount the cover on the governor while keeping the shaft of the stepper
motor and the speed setting knob on the governor at the positions just
determined in steps 3 and 4.
6. Connect the driver to the governor as shown in the plant wiring diagram
(Figure 1-4).
Control Adjustments
In order to achieve the best results, follow the order of adjustments as given in
this section.
If the required speed ranges cannot be achieved with the potentiometer ranges
of the control amplifier, try resistance values other than 3.2 kΩ.
Set the mechanical endstops out of the way by turning them about five turns
counterclockwise (see Figure 1-1 for the location of the mechanical endstops).
Set the input signal to 4 mA and adjust the IDLE SPEED pot for the desired
minimum controlled speed.
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Manual 03047 UG 4–20 mA Speed Setting System
Set the input signal to 20 mA and adjust the RATED SPEED pot for the desired
maximum controlled speed.
Repeat the Idle Speed and Rated Speed Adjustments until no further adjustment
is necessary.
Mechanical Endstops
The mechanical endstops limit the speed range in case of failure of the milliamp
speed setting system in order to protect the engine from running at speeds either
too low or too high.
1. Run the engine at 25 rpm below the normal idle speed. Rotate the left
mechanical endstop clockwise until it hits the speed indicator gear. Lock the
screw with the lock nut.
2. Run the engine at 25 rpm above the normal rated speed. Rotate the right
mechanical endstop clockwise until it hits the speed indicator gear. Lock the
screw with the lock nut.
NOTE
If the motor and the coupling are connected incorrectly, the motor will not
stop, but the speed setting will not be changed.
Be sure that the stepper motor does not hit against the endstop under
normal operation within the 4 to 20 mA range.
1. Run the engine at rated speed using the milliamp speed setting system.
3. Rotate the MINOR ALARM pot until the speed of the engine is at the
required level.
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Ramp Rates
The UP RATE and DOWN RATE pots set the minimum time period in which the
engine can go from idle to rated and from rated to idle. Rotating the pot
counterclockwise will make the engine react more quickly, and rotating the pot
clockwise will make the engine react more slowly.
Starting Procedure
Before starting the engine, apply power to the control amplifier (terminals 1 and
2).
The following adjustments can only be made with the engine running under the
control of the UG governor as described below.
WARNING
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.
4. Verify that the engine speed is under control of the UG governor by raising
and lowering the mechanical speed setting knob on the UG governor. Set
the engine speed to the idle speed level.
6. Restore the 24 Vdc supply to the control amplifier. The engine should now
run at the adjusted low speed level.
7. Set the remote signal to 20 mA. The engine should now run at the adjusted
high speed level.
If the above steps have been completed successfully, the engine is ready for
normal operation with the milliamp speed setting system.
If the milliamp levels do not correspond with the demanded speed levels, repeat
the procedures under the Control Adjustments section.
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Manual 03047 UG 4–20 mA Speed Setting System
Chapter 4.
Description of Operation
The system consists of a UG governor fitted with a special cover and a separate
driver (Figures 1-1 and 1-2).
The cover includes a stepper motor that is connected directly to the speeder
screw in the governor. On top of the stepper motor, the position of the motor
shaft is measured with a potentiometer connected with a worm and gear.
In operation, the driver compares the milliamp input signal with the voltage signal
derived from the potentiometer and runs the stepper motor to the position in
which the milliamp signal corresponds with the feedback signal. This results in a
speed setting proportional to the milliamp signal.
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Chapter 5.
Troubleshooting
Indicated Faults
The following fault conditions will result in a system malfunction:
• dc power supply below 18 Vdc
• break in connection to the potentiometer
• failure of the potentiometer or loss of supply to the pot
• open circuit of the stepper motor or break in connection to the motor
If a problem or failure of the milliamp speed setting system is detected, stop the
engine and do the following tests:
2. If the supply voltage is good, remove the connection from terminals 11 and
13, and measure the voltage between these terminals. The voltage should
be 5.0 Vdc. If the voltage is wrong, replace the driver. Check the resistance
of the feedback pot (10 kΩ) connected to pins F, G, and H of the governor.
4. If no fault has been found, measure the resistance over the following pins:
A–E, B–E, C–E, and D–E of the governor. These should all be between 1.3
and 1.7 Ω. If not, the stepper motor or the stepper motor wires are broken.
5. If no fault can be determined by the previous steps, return the control unit to
Woodward for further investigation/repair.
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Manual 03047 UG 4–20 mA Speed Setting System
Fault Chart
This table lists some of the possible fault symptoms and their causes and
remedies.
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Chapter 6.
Service Options
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).
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.]
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CAUTION
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.
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UG 4–20 mA Speed Setting System Manual 03047
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.
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.
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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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
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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
Control/Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:
Serial Number
Serial Number
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.
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Declarations
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.
05/3/F