Woodward 723PLUS User manual

Product Manual 26425

(Revision NEW)

Original Instructions

723PLUS Digital Control

Nile River Vessel Generator Control

Dredging International

8301-1146

Application Manual

General

Precautions

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.

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

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.

Translated

Publications

If the cover of this publication states "Translation of the Original Instructions"

please note:

The original source of this publication may have been updated since this

translation was made. Be sure to check manual 26311 , Revision Status &

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 Out-of-date translations are marked with .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.

Revisions—Changes 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

Manual 26425 723PLUS Nile River Generator Control

Woodward i

Contents

WARNINGS AND NOTICES...........................................................................II

ELECTROSTATIC DISCHARGE AWARENESS ................................................III

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

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

System Compliance............................................................................................. 1

General Safety Precautions................................................................................. 1

Identification Plate ............................................................................................... 1

CHAPTER 2. SYSTEM DESCRIPTION ........................................................... 2

Introduction.......................................................................................................... 2

Speed Sensing .................................................................................................... 2

Speed Reference................................................................................................. 2

Droop / KW Control.............................................................................................. 3

Fuel Limiters ........................................................................................................ 3

Alarms.................................................................................................................. 3

CHAPTER 3. TUNABLES............................................................................. 4

Introduction.......................................................................................................... 4

Configure Mode Tunables ................................................................................... 4

Service Mode Tunables....................................................................................... 5

CHAPTER 4. HAND-HELD PROGRAMMER.................................................... 8

Hand-held Programmer and Menus.................................................................... 8

Adjusting Setpoints.............................................................................................. 9

Hand-Held Programmer Keys ............................................................................. 9

CHAPTER 5. CONTROL WIRING DIAGRAM................................................. 11

CHAPTER 6. FUNCTIONAL BLOCK DIAGRAM............................................. 18

CHAPTER 7. PRODUCT SUPPORT AND SERVICE OPTIONS......................... 21

Product Support Options ................................................................................... 21

Product Service Options.................................................................................... 21

Returning Equipment for Repair........................................................................ 22

Replacement Parts............................................................................................ 22

Engineering Services......................................................................................... 23

Contacting Woodward’s Support Organization.................................................. 23

Technical Assistance......................................................................................... 24

723PLUS HARDWARE MANUAL .............................................................. 25

Illustrations and Tables

Figure 4-1. Hand-held Programmer................................................................... 10

723PLUS Nile River Generator Control Manual 26425

ii Woodward

Warnings and Notices

Important 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.

Overspeed /

Overtemperature /

Overpressure

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.

Personal Protective

Equipment

The products described in this publication may present risks that

could lead to personal injury, loss of life, or property damage. Always

wear the appropriate personal protective equipment (PPE) for the job

at hand. Equipment that should be considered includes but is not

limited to:

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

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.

Automotive

Applications

On- and off-highway Mobile Applications: Unless Woodward's control

functions as the supervisory control, customer should install a

system totally independent of the prime mover control system that

monitors for supervisory control of engine (and takes appropriate

action if supervisory control is lost) to protect against loss of engine

control with possible personal injury, loss of life, or property damage.

Manual 26425 723PLUS Nile River Generator Control

Woodward iii

Battery Charging

Device

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 Awareness

Electrostatic

Precautions

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.

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.

Follow these precautions when working with or near the control.

1. 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.

2. 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.

723PLUS Nile River Generator Control Manual 26425

iv Woodward

Manual 26425 723PLUS Nile River Generator Control

Woodward 1

Chapter 1.

General Information

Introduction

This manual is the functional description of Woodward 723PLUS Control

System 8301-1146. This 723PLUS control is made to Dredging International

specification as a generator control for the Nile River vessel.

723plus Digital Control 9906-619

GAP Diagram 5418-2825

Block Diagram 9971-1260

Plant Wiring 9971-1259

Use of this equipment by untrained or unqualified personnel could

result in damage to the control or the installation's equipment and

possible loss of life or personal injury. Make sure personnel using or

working on this equipment are correctly trained.

This manual covers only equipment which is manufactured by Woodward and does

not include operating instructions for the prime mover, or the driven devices or

processes. For information about other Woodward units used on the prime mover

please refer to the specific Woodward documentation supplied with each unit.

For specific operating information such as start-up, shutdown, and the prime

mover's response to signals from the Woodward control, refer to the prime

mover manufacturer's manual.

System Compliance

This system complies with the relevant industry specifications and regulations.

General Safety Precautions

Obey the following safety precautions when you install the unit:

Obey all cautions or warnings given in the procedures.

Never bypass or override machine safety devices.

Always use sufficient personnel and/or lifting equipment to move the cabinet.

Identification Plate

The identification plate is installed on the front of the plate in the upper right

corner. It contains the following information:

Part Number

Serial Number

Manufacturing Date

Weight

Customer Name

Customer

Power Supply Information

Always provide the model number and serial number in any correspondence

with Woodward.

723PLUS Nile River Generator Control Manual 26425

2 Woodward

Chapter 2.

System Description

Introduction

The 723PLUS control for this application receives an analog speed setting

signal from an external system. The 723PLUS biases this speed reference for

synchronizing purposes, kW droop, and to make the kW base load control

possible.

Depending on the actual speed, the control will set maximum load setpoints that

will act as a torque limit curve.

Control functions include:

Speed sensing

Speed reference

Droop / KW Control

Speed Control

Fuel Limiters

Alarms

Speed Sensing

The speed sensing of the engine is done by one or two speed sensors. The

speed sensors can be proximity probes or magnetic pick-ups.

The influence of the engine firing frequencies is attenuated by a low pass filter.

Speed fault indication

The speed channels are continuously checked for speed sensor failures. A

failure is latched when the speed signal drops below 10 rpm or raises above

2000 rpm. The speed sensor fault detection is overridden during shutdown and

stays overridden for *10 seconds after Run is selected.

Because the 723PLUS does not act as speed control unit, a double failure of

the speed probes does not result in a major alarm. Each sensor can individual

be setup, in case of failure, as minor alarm or major alarm.

Speed Reference

On starts the control will run the engine on min speed and will ramp the speed

after a adjustable delay to rated. The speed reference can be adjusted by the

Raise and Lower contacts or the Remote Speed Reference. To select remote

speed reference both the raise and lower contact have to be made. On failure of

the remote reference signal the speed can be controlled by the raise and lower

contacts.

The speed reference can be adjusted between the Min. Speed Limit and Max.

Speed Limit (adjustable in Configure). The range of the remote speed reference

is determined by 4mA Rem. Ref. and 20mA Rem Ref. An analog input below

2 mA or above 22 mA will create an alarm.

Manual 26425 723PLUS Nile River Generator Control

Woodward 3

Droop / KW Control

Load sharing with other prime movers is done in droop. The main engine control

has this droop function already internally. For that reason, the droop amount in

the 723PLUS is set default to 0%. In case the kW droop must be activated, the

droop % must be set to the correct amount. In kW droop, the control uses the

load sensor input to calculate the droop. The load can be controlled with the

raise and lower or the remote speed setpoint.

If the load reference enable switch is closed, the control can act in kW control.

The range of the remote load reference is determined by the 4mA KW Ref and

the 20 mA KW Ref. An analog input below 2 mA or above 22 mA will create an

alarm on both the remote reference and the load sensor. An alarm of one or

both the inputs will disable the KW Control.

Shutdown

The shutdown function, when activated by the external Run/Stop contact, sends

a minimum Speed reference signal out. Also in the configure menu one can

select if the speed reference should go to minimum speed reference on the

event of a Major alarm.

Fuel Limiters

A four-point Speed / KW limiter is present to prevent overloading of the engine

dependable on speed. This will overrule the kW setpoint in case this demand

will be too much at the actual speed. An additional four-point curve is present to

allow a certain extra kW amount per speed setpoint. This can be used in case

the torque limit is too critical at certain speed setpoints! Always contact the

engine OEM for the correct settings.

Alarms

In this application the following I/O signals can cause an alarm:

Speed Probe # 1 input

Speed Probe # 2 input

Remote Speed Reference input

Load sensor input

Remote Load Reference input

These inputs have three types of alarms: no alarm, minor alarm, and major

alarm. In the configure mode the type of alarm can be chosen:

1 means no alarm

2 means minor alarm

3 means major alarm

The following failure will always give a major alarm:

Overspeed

The Overspeed Trip level can be adjusted in the configure mode.

A minor alarm will activate the minor alarm relay output. A major alarm will

create a shutdown and will activate the major alarm relay output. To reset an

alarm use the external reset.

The shutdown on major alarm can be adjusted to no shutdown on major alarm

(when mechanical backup and reverse acting is used)and the relay’s can be

adjusted to have NO or NC contacts.

The remote speed input and manifold pressure input can be adjusted as not

used. In that case the alarms are overridden and the manifold limiter is set at

maximum output.

723PLUS Nile River Generator Control Manual 26425

4 Woodward

Chapter 3.

Tunables

Introduction

This chapter describes the parameters that can be tuned or monitored. Where

applicable, the nominal setting for each tunable is listed (the nominal values are

provided only as a guideline). The actual settings are obtained from the engine

manufacturer or determined during commissioning and should be noted in the

Actual column for future reference.

Refer to Chapter 4 (Hand-Held Programmer) for instructions about accessing

the tunables.

Configure Mode Tunables

** CONFIGURATION **

This menu is used to set the desired setpoints for the minimum and maximum

speed reference setpoints. Also Overspeed trip setpoint can be set.

Description Range Nominal

ctual

Min Speed RPM (0,2500) *800

Max Speed RPM (0,2500) *1900

Overspeed RPM (0,2500) *2000

** SET ALARMS **

This menu is used to configure the alarms for each specific parameter.

1= No Alarm

2= Minor Alarm

3= Major Alarm

It is selectable to go to minimum speed reference setpoint in case of major

alarm!

Description Nominal Range

ctual

Shtdwn on Maj Alarm? (TRUE,FALSE) *TRUE

MPU #1 Failed Alarm? (1,3) *2

MPU #2 Failed Alarm? (1,3) *2

Rem Spd Used? (TRUE,FALSE) *TRUE

Rem Spd Alm? (2,3) *2

Rem Load Used? (TRUE,FALSE) *TRUE

Rem Load Alm? (2,3) *2

KW Sensor Used (TRUE,FALSE) *TRUE

KW Sensor Alm? (2,3) *2

Major Alarm Relay NC ? (TRUE,FALSE) *TRUE

Minor Alarm Relay NC? (TRUE,FALSE) *TRUE

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