Software Manual

APPLICATION NAME : ZA40 for Propulsion Systems

CUSTOMER NAME
: WNSD
SOFTWARE NUMBER : 9926-927

MANUAL B36109.B

WARNING

WARNING

CAUTION

CAUTION

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 (overtemperature, or overpressure, where applicable) shutdown
device(s), that operates totally independently of the prime mover control device(s) to
protect against runaway or damage to the engine, turbine, or other type of prime
mover with possible personal injury or loss of life should the mechanical-hydraulic
governor(s) or electric control(s), the actuator(s), fuel control(s), the driving
mechanism(s), the linkage(s), or the controlled device(s) fail

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.

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.

When not installed in a control, modules should be kept in a protective antistatic

bag.

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, 2002
All Rights Reserved

Manual B36109.B

Table of Contents

TABLE OF CONTENTS

1.

GENERAL INFORMATION .................................................................................................. 1-1

1.1
1.2
1.3
1.4
1.5
1.6

INTRODUCTION ........................................................................................................................ 1-1

ASSOCIATED PUBLICATIONS ..................................................................................................... 1-1
SYSTEM COMPLIANCE.............................................................................................................. 1-2
GENERAL SAFETY PRECAUTIONS ............................................................................................. 1-2
NOTES, W ARNINGS AND CAUTIONS .......................................................................................... 1-2
SOFTWARE IDENTIFICATION LABEL ........................................................................................... 1-2

2.

ESD PROTECTION AND HANDLING ................................................................................. 2-1

3.

SYSTEM DESCRIPTION...................................................................................................... 3-1

3.1
3.2
3.3
3.4

GENERAL ................................................................................................................................ 3-1

HARDWARE CONFIGURATION .................................................................................................... 3-1
SOFTWARE CONFIGURATION .................................................................................................... 3-2
APPLICATION IO ...................................................................................................................... 3-2
3.4.1 Discrete inputs.......................................................................................................... 3-2
3.4.2 Relay outputs ........................................................................................................... 3-4
3.4.3 Analog inputs............................................................................................................ 3-4
3.4.4 Analog outputs ......................................................................................................... 3-5
3.4.5 Terminal 21/22 - Actuator output.............................................................................. 3-6
3.4.6 Terminal 9/10 - Loadsharing lines............................................................................ 3-6
BASIC CONTROL ...................................................................................................................... 3-6
3.5.1 Speed sensing.......................................................................................................... 3-6
3.5.2 Speed reference....................................................................................................... 3-7
3.5.3 Speed control ........................................................................................................... 3-7
MASTER/SLAVE LOAD SHARING ................................................................................................ 3-8
3.6.1 Soft loading .............................................................................................................. 3-9
3.6.2 Unloading ................................................................................................................. 3-9
FUEL LIMITS ............................................................................................................................ 3-9
3.7.1 Start, clutch and maximum fuel limits....................................................................... 3-9
3.7.2 Manifold pressure limiter .......................................................................................... 3-9
3.7.3 Torque limiter ........................................................................................................... 3-9
3.7.4 External limiter.......................................................................................................... 3-9

3.5

3.6
3.7

4.

SOFTWARE DOWNLOAD INSTRUCTIONS....................................................................... 4-1

4.1
4.2
4.3

INTRODUCTION ........................................................................................................................ 4-1

723PLUS W ITH NO APPLICATION SOFTWARE ............................................................................ 4-1
723PLUS W ITH APPLICATION SOFTWARE .................................................................................. 4-8

5.

TUNEABLES ........................................................................................................................ 5-1

5.1
5.2

GENERAL ................................................................................................................................ 5-1

CONFIGURE MODE .................................................................................................................. 5-1
5.2.1 * CONFIGURATION* ............................................................................................... 5-1
5.2.2 *SET ALARMS*........................................................................................................ 5-1
SERVICE MODE ....................................................................................................................... 5-1
5.3.1 *MONITOR ANALOG*.............................................................................................. 5-2
5.3.2 *UNCOUPLED DYN* ............................................................................................... 5-2
5.3.3 *PROPULSION DYN* .............................................................................................. 5-2
5.3.4 *GENERATOR DYN* ............................................................................................... 5-3
5.3.5 *LOAD SHARING* ................................................................................................... 5-3
5.3.6 *SPEED SETTING*.................................................................................................. 5-3
5.3.7 *FUEL LIMITERS*.................................................................................................... 5-3
5.3.8 *TORQUE LIMITER* ................................................................................................ 5-4
5.3.9 *CHARGE AIR LIMIT* .............................................................................................. 5-4
5.3.10 *MONITOR DI/DO*................................................................................................... 5-4
5.3.11 *TORSIONAL FILTER* ............................................................................................ 5-5

5.3

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Table of Contents

Manual B36109.B

5.3.12 *CONTROL MODE* ................................................................................................. 5-5

5.3.13 *PORT SETTING* .................................................................................................... 5-5
6.

HAND-HELD PROGRAMMER ............................................................................................. 6-1

6.1
6.2
6.3
6.4
6.5
6.6

HAND-HELD PROGRAMMER AND MENUS ................................................................................... 6-1

CONFIGURE MENUS ................................................................................................................. 6-1
SERVICE MENUS ..................................................................................................................... 6-1
DEBUG MENUS ........................................................................................................................ 6-1
ADJUSTING SETPOINTS ............................................................................................................ 6-2
HAND-HELD PROGRAMMER KEYS............................................................................................. 6-2

7.

CONTROL WIRING DIAGRAM ............................................................................................ 7-1

7.1

INTRODUCTION ........................................................................................................................ 7-1

8.

FUNCTIONAL BLOCK DIAGRAM ....................................................................................... 8-1

8.1

INTRODUCTION ........................................................................................................................ 8-1

TABLE OF FIGURES
Figure 3.1 System configuration..................................................................................................... 3-1
Figure 3.2 Engine response on stop order ..................................................................................... 3-3
Figure 6.1 Hand-held Programmer................................................................................................. 6-3

ii

Woodward

Manual B36109.B

1.

GENERAL INFORMATION

1.1

Introduction

General Information

This document is the functional description of the 9926-927 digital control software. This
software is designed for the 723plus Digital Control in accordance with WNSD
specification E 4-107.278.234 H.
The control is the standard approved control for marine propulsion ZA40 Diesel Engines.
The control can be used for single-engine propuslion plants, with or without shaft
generator and for twin-engine plants, in which two engines are coupled to one propeller
shaft.

The Applications Program contains software that can be used to verify the signal range
and provide for offset and gain adjustments (tuneables). In situations where the control
system's calibration is affected by the replacement of an I/O module or field device, the
affected module and/or field device can be checked and calibrated using the hand-held
programmer.
The manual describes the procedures necessary to install the software in the control and
take the control from a mechanically installed condition to the fully-operational condition.
The installation instructions for the control unit are given in Woodward Manual B02846
supplied with the 723plus Digital Control.

WARNING
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 only covers equipment 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.

1.2

Associated Publications
The following publications are required for the installation and commissioning of this
723plus control system:
Publication

Type

Number

723plus Digital Control & LinkNet I/O Modules

Manual

B02846 *

CONTROL WIRING DIAGRAM

Wiring diagram

9951-936 **

FUNCTIONAL BLOCK DIAGRAM

Schematic

9951-937 **

GAP Diagram

Software block diagram 9926-927 ***

* This manual is supplied with the 723plus Digital Control.

** These publications are included in this manual.
*** These diagrams are only available on special request.

Woodward

1-1

General Information
1.3

Manual B36109.B

System Compliance
This system complies with the relevant industry specifications and regulations.

1.4

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.

1.5

1.6

Notes, Warnings and Cautions

The following examples show how notes, warnings and cautions are used in this manual:
Notes are used in the text to provide useful information or hints. This is a note.

WARNING
Warnings are used when a procedure or action is dangerous and injury or death
might occur. This is a warning.

CAUTION
Cautions are used when a procedure or action can cause damage to equipment. This is a
caution.
Software Identification Label
When software is installed a software indentification label is installed on the front of the
unit. It contains the following information:
- Control ID
- Software P/N
- Revision
- Date.
Always give the model number and serial number of both the hardware and software in
any correspondence with Woodward.

1-2

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Manual B36109.B

2.

ESD Protection and Handling

ESD PROTECTION AND HANDLING

!

CAUTION
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.

Woodward

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 from the control cabinet unless absolutely
necessary. If you must remove the printed circuit board from the control cabinet,
follow these precautions:
-

Do not touch any part of the printed circuit board except the edges.

Do not touch the electrical conductors, the connectors, or the components

with conductive devices or with your hands.

When replacing a printed circuit board, keep the new board in the plastic
antistatic protective bag it comes in until you are ready to install it.
Immediately after removing the old board from the control cabinet, place it in
the antistatic protective bag.

2-1

ESD Protection and Handling

2-2

Manual B36109.B

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Manual B36109.B

3.

SYSTEM DESCRIPTION

3.1

General

System Description

The 723plus Digital Control in marine applications is designed to control two engines
connected to the same gear driving the propeller shaft with a fixed pitch or a CP propeller
and shaft generator(s) (see Figure 3.1).
The control selects its mode of operation according to the signals Slave order,
Propeller disengaged and Generator disengaged. Usually the two engines are
connected and the load is shared in Master/Slave mode. The master controls both
engines, the slave moves its fuel rack to the position the master requests.
The 723plus control has a built-in torque and charge air pressure limiter. Both are
programmable by 5 points. The slave uses its own limiter curves. It is therefore possible
to have different limiters on both engines or to limit the slave engine using an external
signal. If the master is limited the slave is also limited because the slave moves the fuel
rack to the same position as the master.
If only the generator is coupled the limiters are disabled and the 723plus runs with speed
droop. (If speed droop is not desired, the parameter speed droop has to be set to zero.)
The signal clutch generator can be connected to the circuit breaker feedback.
The master measures the engine speed using two pickups. The measured speed is
compared to the speed setting. The difference is amplified in a PID controller and the
actuator is controlled accordingly. The two pickups can be installed in different locations
to filter torsional vibrations.
The 723plus has two sets of PID parameters which are selected by the two clutch status.
The parameters gain, stability and compensation can be selected to be a function of the
engine speed. The gain can be increased if the speed error is at a given level.
It is not possible to close all four couplings at the same time.

Figure 3.1 System configuration

3.2

Hardware configuration
For more information about the hardware configuration please refer to hardware manual
(refer to 1.2 Associated Publications).

Woodward

3-1

System Description

3.3

Manual B36109.B

Software configuration
The internal software of the 723plus (FlashPROM) is standard; all adaptations on the
723plus are done by adjusting tuneables using the hand-held programmer. Some of
these parameters are described in this manual (see chapter 5. TUNEABLES).

3.4

Application IO
The 723plus control has the possibility to interact with the control environment by means
of discrete inputs, relay outputs and meter readout outputs.

3.4.1

Discrete inputs.
In total, 8 contact inputs are programmed and assigned to specific functions. These
contact inputs should be operated from the control panel and other devices to operate the
control system according the actual operating condition.
The following discrete inputs are available:
- Run/Stop order
- Master/Slave order
- Lower Speed/Base Load
- Raise Speed/Base Load
- Engage/disengage Propeller
- Engage/disengage Generator
- Unload order
- Override loadramp / reset pulse.
Discrete common
The discrete common is the common for the input switches and is normally connected to
the supply common.
Terminal 29 - Run/Stop
At a stop command (closed contact) the actuator output is set to minimum and the speed
reference is set to idle; the speed pickup alarm is disabled. The stop command is
non-latching. If the saftey systems issue a stop command (at overspeed) with the
propeller clutched-in, the actuator output is set to minimum and the speed reference
follows actual speed untill the actual speed reaches minimum speed.
At that moment the speed reference is set to idle and the speed pickup alarm is disabled.
At run command (open contact), the fuel limiter is set to the start-fuel limit and the pickup
failure detection is activated after a certain time. This time-delay can be adjusted in the
service menu.

3-2

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Manual B36109.B

System Description

Figure 3.2 Engine response on stop order

Terminal 30 - Master/Slave
If the contact is closed the 723plus operates in slave mode. In slave mode the 723plus
moves its actuator according to the value on the master input, which is connected to the
load indicator of the master. The controls own limiter is used.
The integrator of the PID controller is internally adapted to the actuator output signal
(tracking) to allow a bumpless transfer to master upon deactivation of the slave
command. At closing of the contact, the load (i.e. the actuator position) is ramped at the
set rate to the load on the master input.
Terminal 31 - Lower Speed
At closing of the contact the speed reference is lowered at an adjustable rate. At closing
of the contact together with the Raise speed contact the speed reference ramps with the
respective rate to the analog speed setting value.
Terminal 32 - Raise Speed
At closing of the contact the speed reference is raised at an adjustable rate. At closing of
the contact together with the lower speed contact, the speed reference ramps at the set
rate to the analog speed setting value.
Terminals 33 and 34 - Engage/disengage Propeller/Generator
If both contacts 29 and 30 are closed, the engine is not connected to any load, the
actuator is limited to clutch fuel and the PID parameter set 1 is selected.
At opening of the first contact (29 or 30) the fuel remains limited to clutch fuel for an
adjustable time-delay or until the control operates in slave mode. Then the clutch fuel
limiter is disabled and the PID parameter set 2 is selected.
The clutch fuel limiter and time-delay prevent smoke during clutching-in.
If contact 29 is closed (propeller disengaged) and contact 30 is open (generator
engaged), the charge air and torque limiter are disabled and the control runs in speed
droop (set speed droop to zero if it is not required).
Terminal 35 - Unload
At activation a reset pulse is issued if the contact is held closed for longer than two
seconds. The load is ramped down at an adjustable rate until the load indicator is at the
adjustable unload level. Once activated the unload cycle is finished without further notice
of the status of the unload order.

Woodward

3-3

System Description

Manual B36109.B

At activation of override loadramp the ramp is shortened, even if the unload sequence is
already in progress.
Terminal 36 - Override loadramp
If the contact is open the control ramps the load according to the ramp rate of the slave
selection and the unload order (up and down).
If the contact is closed the ramp rates are multiplied with the override factor.
3.4.2

Relay outputs
Three relay outputs are available and programmed for the following functions:
- Alarm
- Near fuel limiter
- Limiter active.
Terminal 5/6 - Alarm
This contact opens if an alarm occurs. If a second alarm occurs while the first is still
active, the output is set to no alarm for 1 second and then again to alarm (to retrigger the
alarm system).
Terminal 3/4 - Near fuel limiter
This contact closes if the control signal is nearer to the lowest of charge air, torque and
external limiter than the limiter distance value.
Terminal 7/8 - Limiter active / Overload
The contact closes if the control signal is limited by either charge air, torque or external
limiter.

3.4.3

Analog inputs
Analog inputs are present for master signal input, charge air pressure, external limiter
input and remote speed reference. Parameters to set-up the correct adjustment should
be adjusted in the service menu.
Terminal 41/42/43 - Master input (analog input #1)
Signal

Parameter

Electrical Range :4-20 mA

Physical Range : 0-100% of actuator position
At loss of signal the 723plus internally generates an unload command
Action at lost signal (alarm, shut down/backup speed control)
Scale of input signal; must correspond to Load indicator of master

Terminal 44/45/46 - Charge air pressure (analog input #2)

Signal

Parameter

3-4

Electrical Range : 4-20 mA

Physical Range : 0-4 bar; scaled by parameters
At loss of signal the value is set to maximum (= disabled)
Action at lost signal (alarm, shut down / backup speed control)

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Manual B36109.B

System Description

Terminal 42/48/49 - External limit (analog input #3)

Signal

Parameter

Electrical Range : 4-20 mA

Physical Range parameterised in % of actuator position
At loss of signal the last valid value is frozen or the value is set to maximum
(depending on the paramerisation)
Value at lost signal (maximum, freeze last value)
Action at lost signal (alarm, shut down / backup speed control)

Terminal 50/51/52 - Speed setting (analog input #4)

Signal

Parameter

Electrical Range : 4-20 mA

Physical Range : parameterised in % of rated speed
At loss of signal the last valid value is frozen
Action at lost signal (alarm, shut down / backup speed control)

Terminal 11/12 - Speed pickup 1

Signal
Parameter

Electrical Range : x pulses per revolution

Physical Range : y RPM
Number of teeth on flywheel (=number of pulses per revolution)
Rated speed
Action at loss of one pickup (alarm)
Action at loss of both pickup (shutdown, alarm/backup, speed control)

Terminal 13/14 - Speed pickup 2

Signal
Parameter

3.4.4

Electrical Range : x pulses per revolution

Physical Range : y RPM
Number of teeth on flywheel (=number of pulses per revolution)
Rated speed
Action at loss of one pickup (alarm)
Action at loss of both pickup (shutdown, alarm/backup, speed control

Analog outputs
Three analog outputs are available. One output is programmed as a tachometer output,
the second is programmed as a limiter output indicator, and the third is programmed to
indicate the actuator output. The actuator output can be used for 4-20 mA actuators.
Terminal 15/16 - Limiter output (analog output #1)
Signal

Woodward

Electrical Range : 4-20 mA

Physical Range : 0-100% of load indicator This value is the lower of the
limiters (charge air and torque limiter)
Its purpose is the information for the possible increase of the pitch of the
propeller control

3-5

System Description

Manual B36109.B

Terminal 17/18 - Load indicator (analog output #2)

Signal

Electrical Range : 4-20 mA

Physical Range : 0-100% of load indicator
The value is the actuator output on a different scale for indication of propeller
control as master output signal (to Master input) for actuators using 4-20 mA.
Scale of load indicator must match Master input.

Terminal 19/20 - Actual speed output (analog output #3)

Signal

3.4.5

Terminal 21/22 - Actuator output

Signal
Parameter

3.4.6

Electrical Range : 4-20 mA

Physical Range : 0-105% of nominal speed
The value is according to the actual speed setting used for the control

Electrical Range : 20-160 mA

Physical Range : 0-100% control output signal
Actuator sense (direct / reverse acting)

Terminal 9/10 - Loadsharing lines

Not used in marine application.

3.5

Basic Control
This chapter describes the operation and features include in the 723plus control.
- Speed sensing
- Speed reference
- Speed control.

3.5.1

Speed sensing
The engine speed sensing is done by two proximity sensors. The sensors can both be
installed on the flywheel of the engine, or one installed on the engine and one at the
gearbox to make use of the torsional-filter feature. The torsional-filter feature can be
activated with a programmable parameter.
The number of flywheel teeth is a configurable parameter and can be set for all engine
types. The minimum number of teeth to be configured is 50. This is to prevent the speed
signal falling bellow 250 Hz. The frequency that can be sensed is limited to between
250 Hz (minimum) and 2000 Hz (maximum).
Speed fault indication
The speed channels defined in the software are continuously checking for a speed
sensor fault. The speed sensor fault is triggered when the speed signal goes below
10 RPM or raises above 600 RPM. Speed sensor fault detection is overridden when the
stop command is given and during an adjustable time after the run command has been
given. In general it means that no speed fault indication is present when the engine stops
or starts.

3-6

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Manual B36109.B

System Description

Overspeed speed

WARNING
Overspeed is not sensed in the 723plus control. Overspeed must be detected by the
engine saftey system which has to give a stop command to the 723plus control.
As long as the stop command is active and the propellor is clutched-in, the actuator
output is set to minimum and the speed reference follows actual speed. In this way a
restart is possible when the saftey system removes the stop command. If the speed falls
below minimum speed and the stop command is removed, the engine is started on start
speed and with start limiter.
Speed filter
The speed filter parameter, which can be found in the dynamic settings menu, controls
the filter time constant of the input channel. The speed filter parameter reflects the cut-off
frequency of the two-pole low-pass speed filter. Decreasing the speed filter frequency
makes the speed channel less sensitive.

3.5.2

Speed reference
The speed reference can be controlled by the raise/lower contacts or the remote speed
reference signal. The speed reference is always set to start speed after the run/stop
contact is toggled. At activation of the remote speed reference the speed reference
ramps to the corresponding setpoint of the analog speed setting. At deactivation of the
remote speed reference the speed reference remains at the point where the remote
speed setting has been deactivated. The different ramp rates (lower, raise and remote)
are independently selectable. For the 9926-927 system, a speed reference bias input is
present to bias the internal speed reference for synchrophaser purposes.

3.5.3

Speed control
The speed control is responsible for setting the engine fuel rack position to maintain the
requested engine speed. The speed control part consists off the following sub functions.
- PID controller
- LSS Bus
- Run/Stop command
- Actuator.
PID controller
The controller is a Proportional-Integral-Derivative type of controller. It compares the
actual speed with the speed reference and determines the response characteristics of the
actuator signal. Three adjustable dynamic settings are available. The UNCOUPLED
dynamics are used when the engine is not connected to the shaft and optional shaft
generator. The PROPULSION dynamics are used when the propellor shaft is engaged.
The GENERATOR dynamics are used when only the generator is used.
For the uncoupled dynamics the following parameters can be set:
- Idle gain
- Rated gain
- Integrator rate
- Derivative ratio.
The two different gains are available to optimise the idle speed running and rated speed
stability of the engine. During ramping of the speed from idle to rated, the proportional
gain setting of the PID is continuously calculated from the actual speed.
At the moment the propeller shaft is engaged the PID changes the dynamic setting to the
propulsion dynamics. The propulsion dynamics make use of a speed/gain curve. The
proportional gain is then mapped against the actual RPM.

Woodward

3-7

System Description
-

Manual B36109.B

Rpm at P1
Gain at P1
Rpm at P2
Gain at P2
Rpm at P3
Gain at P3
Rpm at P4
Gain at P4
RPM at PS
Gain at PS
Integrator Rate
Derivative ratio
Window Width
Slow gain.

At the moment when only the (shaft) generator is in service and electrical load is applied
to the engine, the engine dynamics change to generator dynamics. The speed is constant
and fast load changes can occur. To deal with fast or instant load steps or rejection the
option of a fast gain and window can be used. When the difference between actual speed
and the speed reference exceeds the window width parameter the PID uses the fast gain
setting:
- Gain
- Integrator Rate
- Derivative Ratio
- Window Width
- Fast Gain.
Droop
Droop can be adjusted in all dynamic settings. For the Generator mode, but also for
uncoupled or coupled running of the engine. (Default the generator droop is adjusted at
5% and both coupled and uncoupled droop are %).
LSS Bus
The Low Signal Select bus selects between the PID or fuel limiters for control of the
actuator. The signal calling for the lowest fuel is the one used for control.
Shutdown on Major alarm
The shutdown function, when activated in the configure menu, sends a minimum fuel
signal to the actuator if a major alarm is present. When no engine stop is required at a
major alarm, for example loss of both speed signals, the control asks for maximum fuel
allowing the backup governor to take control of the engine. Disabling the stop function on
major alarm is only possible with a reverse-acting actuator and backup governor.
Actuator output
The actuator output is a forward-acting or reverse-acting 0-200 mA signal. The set-up of
the actuator output channel is done in the configure menu. The actuator signal is suitable
for 20-160 mA actuators.
3.6

Master/Slave load sharing

The Master/Slave load-sharing option is used when two engines are connected to one
gearbox driving the one load. The first engine clutched to the gearbox is master. The
second engine operates as slave. Operation as a slave engine means that the actuator
signal is controlled from an external 4-20 mA signal instead of its own PID controller. The
transfer is activated when an engine is selected as a slave and the clutch feedback
contact is present. During slave operation of a control, the PID output is tracked to the
master signal. This makes it possible to reverse the master/slave function bumpless. The
master becomes slave and the slave becomes master. This option is required in case the
master engine has to be clutched out.

3-8

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Manual B36109.B
3.6.1

System Description

Soft loading
To prevent instant load steps to an incoming slave engine, a soft loading function is
present. The soft loading ramp opens the actuator from the last control position to the
required position of the master. The soft load rate determines how fast or slow this
transfer is performed. The rate can be adjusted from the service menu.

3.6.2

Unloading
To disengage an engine from the gearbox, the engine should be unloaded to protect the
other engine which should pickup all the load immediately. The available unload function
should be triggered with an external contact. The unload function is only activated when
the engine is operating as a slave engine. The unload rate and the minimum load level
are adjustable in the service menu. A relay indication can be configured to indicate that
the slave engines are running at minimum actuator position. This output can be used to
trigger the clutch open command.

3.7

Fuel Limits
The control has the possibility to make use of several different limits. The fuel limits are
low signal selected with the speed control signal. The following fuel limits can be set:
- Maximum fuel limiter.
- Start fuel limiter.
- Clutch limiter.
- Torque limiter.
- Manifold pressure limiter.
- External limiter.

3.7.1

Start, clutch and maximum fuel limits

The start fuel limit is active after the run command has been given. The start fuel limit
stays active a certain time after the speed control takes control of the engine. Normally a
5 second stabilising time for the engine is sufficient to clear the start fuel limit. The clutch
fuel limit is active after the engine is started and the start fuel limit is disabled. The clutch
fuel limit is only active when the engine is disengaged from the propeller and the shaft
generator. The clutch fuel limit prevents the engine from overfueling when a propeller
shaft is engaged. Upon feedback of engaging the propeller shaft or the shaft generator
the maximum fuel limit is active and limits the maximum fuel.

3.7.2

Manifold pressure limiter

The manifold pressure limiter is a four slope curve which can be adjusted from the
service menu and limits the fuel depending on the actual manifold pressure. The manifold
pressure signal is fed into the control by means of an analog input. The manifold pressure
limiter is disabled when only the shaft generator is engaged or the manifold pressure
input signal has failed.

3.7.3

Torque limiter
The torque limiter is a four slope curve which can be adjusted from the service menu and
limits the fuel depending on the actual speed of the engine. The speed signal is fed into
the control by means of the normal speed inputs. The torque limiter is disabled when only
the shaft generator is engaged.

3.7.4

External limiter
The external limiter is a limiter which is proportional to the external limiter input. The
external limiter makes it possible to limit an engine with an external signal. The scaling of

Woodward

3-9

System Description

Manual B36109.B

the analog input and the limiter can be done form the service menu. The external limiter
is disabled when the external limiter input signal has failed.
In system 9926-927 the external limiter function is disabled and used for speed bias
input. See the description of analog input #3 (3.4.3 Analog inputs).

3-10

Woodward

Manual B36109.B

4.

SOFTWARE DOWNLOAD INSTRUCTIONS

4.1

Introduction

Software Download Instructions

This chapter describes two procedures for downloading application software to the
723plus Digital Control.
The software required to download the application software into the 723plus is not a
standard part of the application and is only supplied upon request. Only persons trained
in the use of the download software are permitted to use it.
The procedure 723plus With No Application Software (see section 4.2) should be
followed when the control has no application software or when during the download
process the communication with the PC or control was lost.
The second procedure 723plus With Application Software (see section 4.3) should be
followed when application software needs to be upgraded to a higher software revision
level or other application software.
For both procedures the following hardware is required:
- 723plus control with P/N 9906-619
- PC with MS Windows 95 or NT operating system
- RS-422 Download cable assembly with P/N 5416-870.
For both procedures the following software is required:
- Servlink.exe
- WatchWindow.exe
- SLSN.exe.
4.2

723plus With No Application Software

Do this procedure when the 723plus Digital Control has no application software loaded.
1.

Woodward

Double-click on the 723plus folder to show the following icons:

4-1

Software Download Instructions

4-2

Manual B36109.B

2.

Double-click on the Servlink.exe icon to run the program. The following screen
appears.

3.

Select File > New to create a new network definition file. The following screen
shows the communication settings Port, Mode and Baud Rate.

Woodward

Manual B36109.B

Software Download Instructions

4.

Press the OK button to display the following screen:

5.

If the ServLink program displays the following error:

Re-boot the 723plus Digital Control and, during the boot-up sequence, press the
Retry button until the following screen appears:

Woodward

4-3

Software Download Instructions

4-4

Manual B36109.B

6.

Double-click on the WatchWind icon:

7.

The following screen appears:

8.

Right-mouse-click on the Net1{<unidentified>} tab of the Explorer screen.

Woodward

Manual B36109.B

9.

Software Download Instructions

Select Load Application and the to display this dialog box:

10. Press the OK button and select the script file, in this example 9926-656.scp.

11. Press the Open button to display the following dialog box:

12. Press the Yes button to continue the download. The download status screen is
shown:

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4-5

Software Download Instructions

Manual B36109.B

13. The application software is now downloaded into the 723plus Digital Control.
Press the OK button and close the WatchWindow/program:

14. Select File > Exit to close the Servlink program.

15. The ServLink program shows the following screen:

Press the No button.

16. To write the control ID to the 723plus Digital Control, double-click on the
SLSN.exe icon:

4-6

Woodward

Manual B36109.B

Software Download Instructions

17. The following screen appears:

18. Press the OK button and the Set Serial Number screen appears. If the
SLSN.exe program displays the following screen:

a. Remove the download cable from the J1 port and plug in the handheld
programmer in the same port.
b. Press the arrow-down button once.
c. Press the arrow-right button until the * PORT SETTING * service header
appears.
d. Press the arrow-down button once, to enter the * PORT SETTING * service
header.
e. Press the minus button on the handheld to change Set Download Mode 2*
into Set Download Mode 1*.
The 723plus control is now set in the UPCI ServLink mode, and is ready for
another scan of the control. Press the Retry button for reconnection with the
control.

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4-7

Software Download Instructions

Manual B36109.B

19. Type the requested part number in the New Serial Number box and press the Set
button.

20. Verify that the Current Serial Number <unidentified> has changed in the
requested part number (in this example: 9926-656):

21. Press the Close button to exit the SLSN. exe program.
The application software has successfully been downloaded into the 723plus control.
4.3

723plus With Application Software

If the existing application software has to be replaced with software with a higher revision
letter do this procedure:

For more information about the handheld programmer see chapter 6. HAND-HELD
PROGRAMMER.
1.
2.
3.

4-8

Plug the ST2000 handheld programmer into the J1 port of the 723plus Digital
Control.
Press the arrow-down button once.
Press the arrow-right button until the * PORT SETTING * service header appears.

Woodward

Manual B36109.B
4.
5.

Software Download Instructions

Press the arrow-down button once to enter the * PORT SETTING * service
header.
Press the minus button on the handheld to change Set Download Mode 2* into
Set Download Mode 1*.

The 723plus control is now set in the UPCI ServLink mode and ready for downloading
new application software. To down load new software follow the procedure described in
section 4.2, 723plus With No Application Software.

Woodward

4-9

Software Download Instructions

Manual B36109.B

4-10

Woodward

Manual B36109.B

5.

TUNEABLES

5.1

General

Tuneables

This chapter describes the parameters that can be tuned or monitored. Section 5.2
describes the values that can be adjusted in Configure Mode. Section 5.3 describes the
values that can be configured in Service Mode.
Where applicable, the nominal setting for each tuneable 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.
5.2

Configure Mode

To access the Configure menus, the engine must be shutdown.

5.2.1

* CONFIGURATION*

Refer to chapter 6. HAND-HELD PROGRAMMER. On the Hand-held Programmer, press

the . key. The display will show 'To Enable CONFIGURE Press *ENTER*'. Press the
ENTER key and the display will show 'To Shutdown I/O, Press *ENTER*'. Press the
ENTER key to enter the Configure menus.

Description

Range

Nominal

4,200
4,200
(FALSE/TRUE)
(FALSE/TRUE)
(FALSE/TRUE)

60
60
TRUE
FALSE
FALSE

Description

Range

Nominal

Rmt Speed Input Alarm ?

Charge Air Input Alarm ?
Master Input Alarm ?
Ext.Limit Input Alarm ?

(1,2,3)
(1,2,3)
(1,2,3)
(1,2,3)

1
1
1
1

Gear #1 Teeth
Gear #2 Teeth
Reverse Acting Actuator ?
Stop Engine on Major Alm ?
Torsional Filter Used ?

5.2.2

5.3

Actual

*SET ALARMS*
Actual

Service Mode
Refer to chapter 6. HAND-HELD PROGRAMMER. On the Hand-held Programmer, press
the key. To move between menus, and to move through set-points within menus,
follow the instructions given for the Configure menus.
The service mode consist of several used to adjust and/or monitor various parameters.
The following service menus are available in service mode:

Woodward

5-1

Tuneables
5.3.1

Manual B36109.B

*MONITOR ANALOG*
Description

Range

Nominal

Actual

Range

Nominal

Actual

(0.01,10)
(0.01,10)
(0.01,10)
(0.01,10)
(0.0,10.0)
(0.1,20)

0.2
0.4
0.4
0.8
0
15

Range

Nominal

(0.01,10)
(0,1000)
(0.01,10)
(0,1000)
(0.01,10)
(0,1000)
(0.01,10)
(0,1000)
(0.01,100.0)
(0.0,1000.0)
(0.01,100.0)
(0.01,10)
(1.0, 100)
(0.01, 100)
(0, 10)
(0.1,20)

0.4
300
0.4
400
0.4
460
0.4
520
1.0
525
0.4
0.8
10
0.2
0
15

Engine Speed
Speed Reference
Limiter LSS (%)
Actuator Output (%)
Master Signal (%)
Rmt Spd Input (mA)
Ext Limit Input (mA)
Charge Air Input (mA)
Charge Air Press (bar)
Charge Air Limit (%)
External Limit (%)
Torque Limit (%)

5.3.2

*UNCOUPLED DYN*
Description
Idle Gain
Rated Gain
Integrator Rate
Derivative Ratio
Uncoupled Droop %
Speed Filter

5.3.3

*PROPULSION DYN*
Description
Gain at P1
Rpm at P1
Gain at P2
Rpm at P2
Gain at P3
Rpm at P3
Gain at P4
Rpm at P4
Gain at P5
Rpm at P5
Integrator Rate
Derivative Ratio
Window Width
Slow Gain
Coupled Droop %
Speed Filter

5-2

Actual

Woodward

Manual B36109.B
5.3.4

*GENERATOR DYN*
Description

Range

Nominal

(0.01,10)
(0.01,10)
(0.01,10)
(0.0,100)
(0.01,10)
(0.0,10)
(0.1,20)

0.4
0.4
0.8
10
0.9
0.0
15

Range

Nominal

(1.0,100)
(1.0,100)
(1.0,100)
(0.0,100)
(0.0,10)
(0.0,10)
(0.0,100)
(-100.0,100.0)
(0.1,10.0)
(-100.0,100.0)
90.0,200.0)

5.0
5.0
3.0
20
2.0
5.0
20
0.0
1.0
0.0
100.0

Range

Nominal

(0,1000)
(0,1000)
(0,1000)
(0,1000)
(1,1000)
(1,1000)
(-100,100)
(-100,100)
(-500,5000)
(-500,5000)
(0,60)

545
300
350
514
20
20
50
100
0
1000
5.0

Description

Range

Nominal

Start Fuel Limit

Clutch Fuel Limit

(0,100)
(0,100)

35
50

Gain
Integrator Rate
Derivative Ratio
Window Width
Fast Gain
Generator Droop%
Speed Filter

5.3.5

Load Rate(%/sec)
Unload Rate(%/sec)
Override factor
Min. Unload Level(%)
Slave Enable Dly(sec)
Clutch Delay (sec)
Slave Lim.at Clutching
Slave Offset
Slave Gain
% Act at 4 mA Output
% Act at 20 mA Output

Actual

*SPEED SETTING*
Description
Max. Speed Limit
Min. Speed Limit
Start Speed
Rated Speed
Raise Rate RPM/sec
Lower Rate RPM/sec
4 mA Rmt Spd(%rated)
20 mA Rmt Spd(%rated)
Tach at 4 mA Output
Tach at 20 mA Output
Speed Fault Override Time

5.3.7

Actual

*LOAD SHARING*
Description

5.3.6

Tuneables

Actual

*FUEL LIMITERS*

Woodward

Actual

5-3

Tuneables

Description

Range

Nominal

(0,100)
(-100,100)
(0,200)
(-100,100)
(0,200)
(0,100)
(0,100)

100
0
100
0
100
10.0
100

Range

Nominal

(0,1000)
(0,100)
(0,1000)
(0,100)
(0,1000)
(0,100)
(0,1000)
(0,100)
(0,1000)
(0,100)

0.0
50
300
50
400
70
460
80
520
100

Description

Range

Nominal

Press(bar) at 4 mA Input
Press(bar) at 20 mA Input
Charge Air at P1(bar)
Charge Air at P1(%)
Charge Air at P2(bar)
Charge Air at P2(%)
Charge Air at P3(bar)
Charge Air at P3(%)
Charge Air at P4(bar)
Charge Air at P4(%)
Charge Air at P5(bar)
Charge Air at P5(%)

(-10,10)
(0.0,20)
(0.0,10)
(0,100)
(0.0,10)
(0,100)
(0.0,10)
(0,100)
(0.0,10)
(0,100)
(0.0,10)
(0,100)

0.0
4.0
0.0
50
1.0
70
2.0
80
3.0
90
4.0
100

Range

Nominal

Max.Fuel Limit
Lim LSS% at 4 mA Output
Lim LSS% at 20 mA Output
Ext.Lim LSS% at 4 mA Input
Ext.Lim LSS% at 20 mA Input
Near Limit Ind(LSS%)
External Fuel Limit

5.3.8

Torque Lim at P1(RPM)

Torque Lim at P1(%)
Torque Lim at P2 (RPM)
Torque Lim at P2 (%)
Torque Lim at P3 (RPM)
Torque Lim at P3 (%)
Torque Lim at P4 (RPM)
Torque Lim at P4 (%)
Torque Lim at P5 (RPM)
Torque Lim at P5 (%)

5.3.10

Actual

*TORQUE LIMITER*
Description

5.3.9

Manual B36109.B

Actual

*CHARGE AIR LIMIT*

Actual

*MONITOR DI/DO*
Description

Actual

Stop contact
Slave contact
Lower contact
Raise contact
5-4

Woodward

Manual B36109.B

Description

Tuneables

Range

Nominal

Actual

Range

Nominal

Actual

(0,1)

0.5

Propulsion contact
Generator contact
Unload contact
Override contact
Alarm Relay
Overload Relay
Near Limit Relay

5.3.11

*TORSIONAL FILTER*
Description
Torsional Filter

5.3.12

*CONTROL MODE*
Description
Speed in Control
Slave in Control
Limiter in Control

5.3.13

Range

Nominal

TRUE/FALSE
TRUE/FALSE
TRUE/FALSE

FALSE
FALSE
FALSE

Range

Nominal

(1,2)

Actual

*PORT SETTING*
Description
Set download mode

Woodward

Actual

5-5

Tuneables

Manual B36109.B

5-6

Woodward

Manual B36109.B

6.

HAND-HELD PROGRAMMER

6.1

Hand-held Programmer and Menus

Hand-held Programmer

The Hand-held Programmer is a hand-held computer terminal that gets its power from the
723plus Digital Control. The terminal connects to the RS-422 communication serial port
on the control.
The programmer does a power-up self-test whenever it is plugged into the control. When
the self-test is complete, the screen will display two lines of information. This is
information relating to the application. Pressing the 'ID' key will change the display to
show the Woodward logo with the country name ("Woodward (NL)") and application
name of the system. Press "ID" again for the software part number.
The programmer screen is a four-line, backlighted LCD display. The display permits you
to look at two separate functions or menu items at the same time. Use the Up/Down
Arrow key to toggle between the two displayed items (an @ indicates the item in the
active menu). The BKSP and SPACE keys will scroll through the display to show the
remainder of a prompt if it is longer than the display screen's 18 characters.
The 723plus Digital Control has three sets of menus: the Service menus, the Configure
menus and the Debug menus. The Service menus allow easy access and tuning while
the engine is running. The Configure menus may only be entered if the I/O is shutdown,
and hence the engine stopped. The Debug menu allows access to the GAP software.
6.2

Configure Menus
To access the Configure menus, the engine must be shutdown. Press the . key. The
display will show, 'To Enable CONFIGURE Press *ENTER*'. Press the ENTER key and
the display will show, 'To Shutdown I/O, Press *ENTER*'. Press the ENTER key and this
will allow you to get into the Configure menus.

If the engine is running during this process, it will be shutdown due to the shutting down of
the I/O of the control.
To move between the menus use the and keys. To move through the setpoints
within a menu use the and keys,. Once within a menu, press the ESC key to return
to the menu header.
To leave the Configure menus press the ESC key. The message 'ReBooting Control'
appears. The setpoints are automatically saved when leaving Configure.

6.3

Service Menus
To access the Service menus press the key. To move between menus, and to move
through setpoints within menus, follow the instructions as for the Configure menus. Also
to return to the menu header, or to leave Service, follow the Configure instructions.

6.4

Debug Menus
To access the Debug first press (solid square) after which the key should be
pressed. To move between category menus use the and keys, once in the right
category move through the GAP blocks by using the and keys.
Within a GAP block every output and tuneable (*) input can been seen by using the
and keys.

Woodward

6-1

Hand-held Programmer

Manual B36109.B

A Tuneable (*) can be changed by using the Turtle Up or the Rabbit Up keys to
increase the value, and the Turtle Down or Rabbit Down keys to decrease the value
(see also adjusting setpoints).
To return to the menu header press the key, or to leave Service, follow the Configure
instructions.
6.5

Adjusting Setpoints
To adjust a set point, use the Turtle Up or the Rabbit Up keys to increase the value,
and the Turtle Down or Rabbit Down keys to decrease the value. The Rabbit Up and
Rabbit Down keys will make the rate of change faster than the Turtle Up and Turtle
Down keys. This is useful during initial set-up where a value may need to be changed
significantly. Where necessary, to select TRUE, use either the Turtle Up or the Rabbit
Up keys, and to select FALSE, use the Turtle Down or Rabbit Down keys.
To obtain an exact value, press the = key. Key in the required figure and press ENTER.

6.6

This may only be done if the figure is within 10% of the existing value.
To save setpoints at any time, use the SAVE key. This transfers all new setpoint values
into EEPROM memory. The EEPROM retains all setpoints when power is removed from
the control.

CAUTION
To prevent possible damage to the engine resulting from improper control settings,
make sure you save the setpoints before removing power from the control. Failure
to save the setpoints before removing power from the control causes them to revert
to the previously saved settings.
Hand-Held Programmer Keys
The programmer keys have the following functions (see Figure 6.1):
(left arrow)
(right arrow)
(up/down arrow)
(up arrow)
(down arrow)

(turtle up)
(turtle down)

Increases the displayed set point value slowly.

Decreases the displayed set point value slowly.

(rabbit up)

Increases the displayed set point value quickly (about 10 times

faster than the turtle keys).

(rabbit down)

Decreases the displayed set point value quickly (about 10 times

faster than the turtle keys).

(minus)
+ (plus)
(solid square)

6-2

Moves backward through Configure or Service, one menu at a

time.
Moves forward through Configure or Service, one menu at a time.
Toggles between the two displayed items (the first letter of the
active menu item will blink).
Moves backward through each menu, one step at a time.
Advances through each menu, one step at a time. Selects Service
from Main Screen.

Increases setpoint values by one step at a time.

Decreases setpoint values by one step at a time.
Debug mode.

Woodward

Manual B36109.B

ID
ESC
SAVE
BKSP
SPACE
ENTER
= (equals)
. (decimal)

Hand-held Programmer

Displays the In-Pulse Woodward logo, application name and

software revision.
To return to menu header or to main screen.
Saves entered values (set points).
Deletes last figure when entering exact values.
Not used.
Used when entering exact values and accessing Configure.
To enter exact values (within 10%).
To select Configure.

Figure 6.1 Hand-held Programmer

Woodward

6-3

Hand-held Programmer

Manual B36109.B

6-4

Woodward

Manual B36109.B

7.

CONTROL WIRING DIAGRAM

7.1

Introduction

Control Wiring Diagram

This chapter contains control wiring diagram 9951-936. Sheet one of the drawing
contains notes and additional information. The following sheets identify the system cables
and show their interconnections, and give the pin-out detail of each cable connector.

Woodward

7-1

Control Wiring Diagram

7-2

Manual B36109.B

Woodward

3A

:EZIS

639-1599

:EDOC EGAC
:ON GWD

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Manual B36109.B

8.

FUNCTIONAL BLOCK DIAGRAM

8.1

Introduction

Functional Block Diagram

This chapter contains functional block diagram 9951-937.

Woodward

8-1

Functional Block Diagram

8-2

Manual B36109.B

Woodward

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