Manual 82510

(Revision R)
Original Instructions

Magnetic Pickups and Proximity Switches

for Electronic Controls

Reference Manual
 This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
 DANGER—Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
DEFINITIONS  WARNING—Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
 CAUTION—Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
 NOTICE—Indicates a hazard that could result in property damage only (including
damage to the control).
 IMPORTANT—Designates an operating tip or maintenance suggestion.

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.

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.

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 publications page on the Woodward website:
www.woodward.com/searchpublications.aspx
The current revision of all publications is shown in file "current.pdf".

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.

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.

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.

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.

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.
© Woodward 1969
All Rights Reserved
Manual 82510 Magnetic Pickups and Proximity Switches

Magnetic Pickups and Proximity Switches

for Electronic Controls

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.

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 MPU’s 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 a gear or shaft. Nonmagnetic materials, such as aluminum, 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 surface, moving bar, crank, wheel spokes, or a
steel screw head mounted on some moving surface will work equally well if
surface speed and other factors are taken into account. The MPU may be excited
by a keyway or slot in a wheel, but 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 it is less likely
to pick up stray signals.

The output voltage 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 times the diameter of the pole piece (see Figure 1).

Woodward 1
Magnetic Pickups and Proximity Switches Manual 82510

Figure 1. Magnetic Pickup Dimensions

In Figure 1, 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 for 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

2 Woodward
Manual 82
2510 Mag
gnetic Pickup
ps and Proxim
mity Switche
es
As
s the magnetic pickup-gear relationship begins to devviate from thee
pecifications listed above, the
sp t MPU outp put waveform may deteriorrate to an
un
nacceptable shape.
s Becausse the speed sensor deteccts zero-crosssings, the
wa
aveform shou uld cross zero
o only twice fo
or each tooth (once going positive
p and
on
nce going neg gative, see Fig
gure 2).

Figure 2. Magnetic
M Pickkup Output Waveforms
W

MPU Installa
ation
Th
he magnetic pickup
p is available in short or long stand
dard models, a standard
me
etric model, hazardous
h dutty models, annd explosion-pproof models,, including
CS
SA/ATEX app proved models (see Figure e 3 for dimenssions and partt numbers).

Mo ount the magnetic pickup radially

r to the
e outside diam
meter of the de esired gear,
eitther through a housing or ono a rigid bracket. Make su ure the gear is of magneticc
ma aterial. The gap between the
t pickup and d the outside diameter of the
t gear
sh
hould be set normally
n between 0.25 mm m and 1.02 mm m (0.010” and d 0.040") at thhe
clo
osest point [mmake sure the e gear has lesss than 0.51 mm
m (0.020") diametric
d
runout]. Since the
t signal streength is inverssely proportio
onal to gap distance, a
weeak signal ma ay be generatted with more e than 1.02 mm m (0.040") gaap. A shield of
no
on-magnetic material
m may be installed between
b the gear
g and the pickup
p if
ne
ecessary for physical
p shieldding. Since th paces the pickup face
his material sp
farrther from the
e gear, and since an electro omagnetic force may be generated by
ed
ddy currents in n the shielding material, make
m sure the signal level iss still high
en
nough to operrate the speed d signal circuit.

Mo
ost electronicc controls requuire a minimu 1 Vac (rms) from the
um output of 1.5
ma
agnetic speed d. Figures 4 and 5 show the
d pickup at the lowest conttrolling speed e
ma
aximum air ga ap allowed foor each surfacce speed and diametral pitcch or gear
mo
odule to produce this minim mum required d voltage.

Woodward
d 3
Magnetic Pickups and Proximity Switches Manual 82510

Figure 3a. MPU Models

The surface speed in meters per second (m/s) or inches per second (IPS) is
related to revolutions per minute (rpm) by the following:
rpm x π x gear diameter
Surface Speed =
60

The diametral pitch for the gear is obtained by the formula:

number of teeth + 2
Diametral Pitch =
gear diameter (inches)

The gear module is obtained by the formula:

gear diameter (mm)
Gear Module =
number of teeth + 2

4 Woodward
Manual 82510 Magnetic Pickups and Proximity Switches

Figure 3b. CSA/ATEX Models

The standard magnetic pickup may be used with a gear with a diametral pitch
coarser than 8 (gear module 3.2), but the output will not be increased. Gears with
a finer diametral pitch than 8 (gear module 3.2) may be used with a
corresponding decrease in output voltage. A diametral pitch of 20 (gear module
1.27) is the finest that may be used with this pickup without two teeth appearing
over the pole piece at the same time. When adjusting the clearance between the
pickup pole piece and the gear, adjust the pickup so the output voltage is a
minimum of 1.5 Vac (rms) at the lowest speed.

If you cannot measure the gap directly, it can be determined in the following
manner.

Woodward 5
Magn
netic Pickups
s and Proximity Switches Manual 82510

F
Figure 4. Max ble Signals for Most
ximum Air Gap Allowed to Provide Usab
Electronic Co
ontrols

With the
t prime mov ver shut down n, turn the picckup in until itt just touches the
outsid
de diameter ofo the gear. If the
t pickup ha as a 5/8-18 thread, one 360 0° turn
w move the pickup out 0.0555 inch (1..41 mm). The
countterclockwise will e metric
pickupp will move 1.5 mm per turrn. If the picku up has a 3/4-20 mounting thread, the
pickupp will move out 0.050 inch (1.27 mm) pe er turn. Screww out the amo ount
requirred for the desired gap. If possible,
p run the gear slow wly through 36 60° rotation
to che
eck the clearaance of the pickup. When the t gap is sett, tighten the jam nut
securrely against th
he housing or bracket so th he pickup can nnot turn in orr out.

6 Woodward
Manual 82
2510 Mag
gnetic Pickup
ps and Proxim
mity Switche
es

Figure
F 5. Maxximum Air Gap Allowed to Provide 1.5 Vac
V (rms) on EGM Control

Thhe standard models

m of pickkups, including the metric model,
m require
e mating
co
onnector number MS-3106A-10SL-4S. These T connecctors are not furnished
f with
h
e pickups, but may be orde
the ered if desired
d. The hazarddous duty andd explosion-
prooof models ha
ave leads attaached to the pickups, and the heads ha ave 1/2"
fem
male pipe thre alling conduit or pipe.
eads for insta

Woodward
d 7
Magnetic Pickups and Proximity Switches Manual 82510

Troubleshooting Magnetic Pickups

Disconnect the pickup leads. Check between leads with an ohmmeter for
resistance as listed below. Check between the pickup case and leads with an
ohmmeter for near infinity resistance. Start the prime mover and control speed
manually or block the throttle. Check pickup leads with a high-impedance ac
voltmeter for 10 to 20 Vac (rms). Reconnect the pickup and check at the speed
sensor input terminals for a minimum 1.5 Vac (rms) at the lowest controlling
speed. Check the pickup and gear clearance if voltage is low.

MPU Resistance List

Long Standard Model 250 Ω max
Extra Long Standard Model 250 Ω max
Short Standard Model 220 Ω max
Standard Metric Model 250 Ω max
Conduit Model 114 to 140 Ω
Explosion Proof Model 165 to 225 Ω

Inspect for physical damage. Replace pickup if faulty.

8 Woodward
Manual 82510 Magnetic Pickups and Proximity Switches

Proximity Switches
Large engines usually have a larger air gap between the speed sensor probe and
the monitored gear than smaller engines. This is necessary because of the
relatively large runout of the monitored gear in a large engine. The monitored
gears on large engines usually also have a slower surface speed. Because of
either, or both, of these conditions, a magnetic pickup may not perform
satisfactorily on a large engine. A proximity switch (zero velocity pickup) will,
however, operate well on large engines because of its abilities to operate with a
large air gap and at low surface speeds.

The output of these pickups depends solely on the position of the gear tooth (or
similar ferrous discontinuity) and not the velocity at which the gear tooth passes
the sensing end of the pickup.

When wired as a “sinking” type proximity switch, the output is normally zero.
When a gear tooth is within the sensing range of the proximity switch, the output
of the switch goes “high” (nearly equal to the supply voltage). After the tooth has
passed, the output switches back to zero volts until another tooth comes into
position. Typical wiring for a “sinking” type proximity switch is shown in Figure 7.

When wired as a “source” type proximity switch, the output is normally “high”
(nearly equal to the supply voltage). When a gear tooth is within the sensing
range of this proximity switch, the switch output goes to zero volts. After the tooth
has passed, the output switches back to nearly the supply voltage until another
tooth comes into position. Typical wiring for a “source” type proximity switch is
shown in Figure 8.

The on-off nature of the output of a proximity switch produces a square wave
which is compatible with nearly all Woodward speed sensors and will directly
replace the signal from a magnetic pickup as a speed sensor input.

Proximity Switch Features

As long as the air gap between the sensor end of the proximity switch and the
gear being monitored does not exceed the sensing range of a particular proximity
switch, changing the air gap will not change the output voltage. The duty cycle of
the signal from the proximity switch varies with the air gap, but this does not
change the reference signals produced in the Woodward control.

For proper operation there cannot be more than one tooth in the sensing field of
a proximity switch. (The distance between the teeth must be greater than the size
of the sensing field.)

Types of Proximity Switches

Two different sizes of proximity switch are available from Woodward:

1. A proximity switch with a fairly narrow sensing field, suitable for medium size
gears with a tooth size from diametral pitch 8 to 12 (gear module 3 to 2).
This switch can be mounted flush with the mounting plate with an air gap up
to 5.00 mm (0.197 inch).

Woodward 9
Magn
netic Pickups
s and Proximity Switches Manual 82510
2. A proximity sw
witch with a wide
w sensing field
f is availab
ble for large gears
g
w
where a wide air gap (maxximum of 10 mm/0.4
m i necessary. This
inch) is
s
sensor requirees larger gear sizes for pro
oper operation n and should be used
f gears large
for er than diameetral pitch 12 (gear module e 2.1). There must
m be a
3 mm (1.1 in
30 nch) radius cle
earance of me etal around thhe front of the
e sensor
a mounting
and g bracket.

Some
S Woodw ward controls s have less than
t o dc impedance. In
300 Ω of
these cases the
t probe ma ay be damag ged by excesss current wh
hen the
engine
e is stopped. To preevent this poossible damaage, a 300 Ω, 2 W
resistor
r shouuld be installed in series with the probe.

Prox
ximity Swittch Power Supply
mity switches
Proxim s provided by Woodward re equire an exte
ernal power supply
s of a
single
e dc voltage, usually
u 24 volts. This may be from the same
s supply source
s as
power for the contrrol system. Th
he maximum current rating g for these pro
oximity
switch
hes is 80 mA,, but actual cu
urrent is less and dependeent on the exteernal load.

The
T red plasttic cap on top of the prox ximity switch
h is an integrral part
o the device, not a loose
of e shipping co over. The pro
oximity switcch can
be
b damaged beyond repa air if an attem
mpt is made to
t remove th he cap.

Figure 6. Air Gaps for Ra

adial and Axia
al Sensing Prroximity Switcches

Chec
cking Prox
ximity Swittch Operattion
To ch
heck the opera ation of a proxximity switch,, a load resisttance must be
e placed
across the terminaals from whichh the speed co ontrol speed sensor was re emoved.
An osscilloscope maay provide addequate load resistance.

10 Woodward
Manual 82
2510 Mag
gnetic Pickup
ps and Proxim
mity Switche
es

Prroximity Sw
witch Wirin
ng
Th
he proximity switches
s suppplied by Wood dward are wireed for a “sinkking” type
ou
utput. Figure 7 shows a typ
pical wiring meethod. Other proximity swiitches, not
su
upplied by Wooodward, are wired dc “sou urce”. Figure 8 shows a typ pical dc sourcce
wiring method. AC proximityy switches aree seldom used d with Woodw ward controls..

Figure 7. Suggested
d Wiring for a “Sinking” Typ
pe Proximity Switch
S

Figure 8. Suggested
d Wiring for a “Source” Typ
pe Proximity Switch
S

Woodward
d 1
11
Magnetic Pickups and Proximity Switches Manual 82510

Using the Output of a Woodward MPU to Drive a

Remote Tachometer or Other Device
Attach to Control Posts
Should a remote device be driven by a magnetic pickup, it is important that the
connection be made on the governor posts which accept the input from the MPU.
Polarity must be maintained as indicated on these posts or it is possible to short
the system to ground and cause damage to the electronic circuits and render the
governor inoperable. Woodward electronic controls are not directly grounded, but
in many cases the negative (–) post or common is tied to ground through the
battery powered supply. Should an additional device also be grounded or
powered by the same grounded battery system, a short circuit is possible.

The MPU device provided by Woodward is not grounded, and polarity is not
established until connections are made to the governor. Almost all remote
devices will have a power source in addition to two leads for input. One of these
input connections will be circuit common (–) and this should be determined prior
to connection with the governor.

EPG and 2500 Governors

Since these units are indirectly tied to ground, care must be taken that polarity of
the remote device and of the governor is not reversed.

2301 Governor
The 2301 governor is isolated from ground, and care should be taken that any
device added to the system is also isolated from earth ground.

Shielding
Governor circuits have been carefully shielded, and circuits to remote devices
must also be shielded from interference, since this could prevent adequate
governor control. Inadequate shielding could cause unstable control.

Minimum Signal
Most Woodward controls require a minimum speed-signal strength of 1.5 Vac
from the magnetic pickup during cranking. The addition of remote devices to the
output of the magnetic pickup could prevent the reception of an adequate signal
to allow engine start-up.

Make sure all polarity has been established and the system is not
shorted to ground before trying to start the engine after adding an
auxiliary device to the MPU output. Attempting to start the system
with reversed polarity between the auxiliary device and the control
could destroy either or both devices. Should the control be damaged
due to the reversed polarity, dangerous overspeed is possible,
damaging equipment, causing personal injury or even death.

Woodward advises dedicating the entire output of a governor

magnetic pickup to the exclusive use of driving the control system.
This information is provided for those installations where the output
of the magnetic pickup is also used to drive other devices.

12 Woodward
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