Woodward Flo-Tech 8400-511 User manual

Hardware Manual

Digital Min/Max Flo-Tech™ Control

8400-511

for Cummins Jade/Bravo Engines

Manual 04168

DEFINITIONS

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.

•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 o

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.

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 batter

-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 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.

Manual 04168 Digital Min/Max Flo-Tech Control

Woodward i

Contents

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

CHAPTER 1. GENERAL INFORMATION........................................................... 1

Introduction.............................................................................................................1

Application ..............................................................................................................1

CHAPTER 2. INSTALLATION.......................................................................... 8

Scope......................................................................................................................8

Unpacking...............................................................................................................8

Power Requirements ..............................................................................................8

Mounting the Control ..............................................................................................8

Mounting the Flo-Tech Actuator/Throttle Body.......................................................9

Magnetic Pickups ...................................................................................................9

Connectors .............................................................................................................9

Wiring Instructions ..................................................................................................9

CHAPTER 3. DESCRIPTION OF OPERATION ................................................. 11

Introduction...........................................................................................................11

Digital Min/Max Flo-Tech Control .........................................................................11

Control Adjustment (PC Service Tool) .................................................................11

The Flo-Tech Actuator..........................................................................................11

Return Spring .......................................................................................................12

Control Operation .................................................................................................12

Control Features...................................................................................................12

CHAPTER 4. SERVICE OPTIONS ................................................................. 15

General.................................................................................................................15

Packing a Control .................................................................................................15

APPENDIX.DMMF SPECIFICATIONS........................................................... 16

Illustrations and Tables

Figure 1-1. Typical System Layout.........................................................................2

Figure 1-2. Digital Min/Max Flo-Tech Control Box .................................................3

Figure 1-3. Typical Flo-Tech Outline Drawing........................................................4

Figure 1-4. Network Connection Example..............................................................5

Figure 1-5a. Plant Wiring Diagram .........................................................................6

Figure 1-5b. Plant Wiring Diagram .........................................................................7

Digital Min/Max Flo-Tech Control Manual 04168

ii Woodward

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.

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.

Manual 04168 Digital Min/Max Flo-Tech Control

Woodward 1

Chapter 1.

General Information

Introduction

The Digital Min/Max Flo-Tech™ control system is equipped with an

overspeed shutdown feature that operates to protect against

runaway or damage to the engine. Failure to properly install and

operate the control system could result in possible personal injury or

loss of life.

This hardware manual describes the capabilities of the Woodward Digital

Min/Max Flo-Tech™ control, model 8400-511, for Cummins Jade/Bravo engines.

Application

The Woodward Digital Min/Max Flo-Tech control (DMMF) permits efficient idle,

fast-idle, and maximum engine-speed control of spark-ignited gas engines. Most

installations are on city buses or other vehicles fueled by natural gas.

The DMMF provides features which add to the convenience and protection of

vehicle operations. Note that all features may not be available with every

application. Key features are:

•Accelerator Interlock—De-activates the foot pedal and forces the engine

to idle when the bus door is open.

•Remote PTO (power take-off)—Sets a second idle speed to handle

parasitic loads such as air conditioning, air compressor, and alternator while

the vehicle is parked. This could also be used for operation of a power take

off used with handicapped access lifts or “kneeling buses”. The throttle is

disabled during this selection.

•Transmission Signal—Provides a voltage or current signal to transmit a

conditioned throttle position to the transmission.

•Protection Features—Fault detection is built into the control to prevent

damage or overspeed from possible faults in the actuator or foot pedal

control. An override contact input is provided to make it possible to “limp” off

the road with a speed-sensor or wiring problem.

•System Malfunction—A discrete output indicates when a failure has

occurred. The control flashes a two-digit code through a user-provided

shutdown lamp to indicate which problem(s) have occurred.

•SAE J1587-1708 Serial Network—The DMMF provides an SAE

J1587-1708 serial data link to allow communication with other networked

control modules, if needed. The network also provides the only means to

change and monitor set points within the control.

•Fault Logging—The control maintains a fault count that may be retrieved

(and cleared) through the use of the PC service tool software or a generic

SAE 1587-1708 hand held service tool.

•Cruise Control—Offers the driver the ability to maintain a desired road

speed, accelerate, decelerate, or resume a speed previously set.

•PTO—For applications like mixers, dump, and waste disposal vehicles, PTO

control lets you control engine speed through the cruise control switches.

Digital Min/Max Flo-Tech Control Manual 04168

2 Woodward

Figure 1-1. Typical System Layout

Manual 04168 Digital Min/Max Flo-Tech Control

Woodward 3

Figure 1-2. Digital Min/Max Flo-Tech Control Box

Digital Min/Max Flo-Tech Control Manual 04168

4 Woodward

Figure 1-3. Typical Flo-Tech Outline Drawing

Manual 04168 Digital Min/Max Flo-Tech Control

Woodward 5

Figure 1-4. Network Connection Example

Digital Min/Max Flo-Tech Control Manual 04168

6 Woodward

Figure 1-5a. Plant Wiring Diagram

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