Woodward UG40-DI Governor / Installation and commissioning manual
Language: english Author: Woodward Genre: Manual Format: PDF Quality: eBook Number of pages: 66 Description: This manual is applicable to the UG40-DI Governor and describes its mechanical and electrical installation, operation and set-up. It is arranged in ten chapters: - GENERAL INFORMATION - ESD PROTECTION AND HANDLING - DESCRIPTION - INSTALLATION - GOVERNOR MECHANICAL OPERATION AND ADJUSTMENTS - CALIBRATION OF THE DIGITAL INTERFACE - ADJUSTMENT OF THE DIGITAL INTERFACE - ALARMS, DIAGNOSTICS AND SERIAL COMMUNICATIONS - TROUBLESHOOTING AND REPAIRS. The UG40-DI is a mechanical-hydraulic governor with a digital interface for controlling diesel engines. The UG40-DI uses a 250 PSI oil supply and is mechanically linked to the fuel racks. The maximum travel of the output (terminal) shaft is 38°, and the recommended travel of the output shaft is 25° from no load to full load (refer to Section 4.5 for more details). Normally, the UG40-DI operates isochronously (constant speed) regardless of load on the engine, except during operation as described in Chapter 3. DESCRIPTION. Speed droop is incorporated in the UG40-DI to divide and balance load between units driving the same shaft or paralleled in an electrical system. A load limit control is also a standard feature on the UG40-DI. It limits the amount of fuel supplied by restricting the travel of the governor output shaft. An indicator dial shows the governor output shaft limit position. The load limit control may also be used for manually shutting down the engine.
Table of Contents
1. GENERAL INFORMATION ......................................................................................................1 1.1 INTRODUCTION............................................................................................................................1 1.2 DESCRIPTION ..............................................................................................................................1 1.3 SYSTEM COMPLIANCE .................................................................................................................1 1.4 GENERAL SAFETY PRECAUTIONS .................................................................................................1 1.5 NOTES, WARNINGS AND CAUTIONS ..............................................................................................1 1.6 IDENTIFICATION PLATE.................................................................................................................2 1.7 TECHNICAL DATA ........................................................................................................................2 1.8 SOFTWARE VERSIONS .................................................................................................................2 2. ESD PROTECTION AND HANDLING .....................................................................................6 3. DESCRIPTION..........................................................................................................................7 3.1 INTRODUCTION............................................................................................................................7 3.2 DI CONTROL PANEL AND GOVERNOR DIAL PLATE.........................................................................7 3.3 MECHANICAL GOVERNOR.............................................................................................................7 3.3.1 Introduction...................................................................................................................7 3.3.2 Component description ................................................................................................7 3.3.3 Operation of the UG40-DI Mechanical Part .............................................................. 12 3.4 DIGITAL INTERFACE .................................................................................................................. 14 3.4.1 Introduction................................................................................................................ 14 3.4.2 Component Description............................................................................................. 15 3.4.3 Operation................................................................................................................... 15 4. INSTALLATION..................................................................................................................... 16 4.1 INTRODUCTION......................................................................................................................... 16 4.2 INSTALLATION REQUIREMENTS.................................................................................................. 16 4.3 UNPACKING.............................................................................................................................. 16 4.4 STORAGE................................................................................................................................. 16 4.5 MOUNTING THE GOVERNOR ...................................................................................................... 16 4.6 LINKAGE ATTACHMENTS ........................................................................................................... 17 4.7 OIL SUPPLY ............................................................................................................................. 18 4.8 ELECTRICAL CONNECTIONS ...................................................................................................... 21 5. GOVERNOR MECHANICAL OPERATION AND ADJUSTMENTS ..................................... 22 5.1 INTRODUCTION......................................................................................................................... 22 5.2 CHECK THE MAXIMUM SPEED SETTING...................................................................................... 22 5.3 INITIAL OPERATION FOR A NEW GOVERNOR – MECHANICAL ....................................................... 22 5.3.1 Adjustments............................................................................................................... 22 5.3.2 Compensation Adjustments ...................................................................................... 22 5.4 READING SETTINGS FROM MECHANICAL GOVERNOR ON THE ENGINE.......................................... 24 5.4.1 Procedure.................................................................................................................. 24 6. CALIBRATION OF THE DIGITAL INTERFACE................................................................... 25 6.1 INTRODUCTION......................................................................................................................... 25 6.1.1 Calibration on test bench........................................................................................... 25 6.1.2 Calibration on engine ................................................................................................ 25 6.2 FUNCTIONS OF UG40-DI DURING CALIBRATION......................................................................... 25 6.2.1 Introduction................................................................................................................ 25 6.2.2 Explanation of the UG40-DI panel during calibration................................................ 25 6.3 CALIBRATION ON TEST BENCH .................................................................................................. 27 6.3.1 Procedure.................................................................................................................. 27 6.4 CALIBRATION ON ENGINE .......................................................................................................... 28 6.4.1 Procedure.................................................................................................................. 28 6.5 CALIBRATION FLOW CHART....................................................................................................... 28 UG40-DI Manual Manual B03575.C ii Woodward 7. ADJUSTMENT OF THE DIGITAL INTERFACE ................................................................... 31 7.1 INTRODUCTION ......................................................................................................................... 31 7.1.1 Adjustment................................................................................................................. 31 7.1.2 Fine tuning................................................................................................................. 31 7.2 FUNCTIONS OF UG40-DI DURING ADJUSTMENT......................................................................... 31 7.2.1 Introduction................................................................................................................ 31 7.2.2 Explanation of the UG40-DI panel during calibration and adjustment ...................... 31 7.2.3 Displaying values on the Dial Panel speed setting knob and speed indicator .......... 34 7.3 ADJUSTMENT............................................................................................................................ 34 7.3.1 Procedure .................................................................................................................. 35 7.4 FINE-TUNING............................................................................................................................ 35 7.4.1 Procedure .................................................................................................................. 35 7.5 ADJUSTMENT FLOW CHART....................................................................................................... 35 7.6 FINE-TUNING FLOW CHARTS ..................................................................................................... 41 7.6.1 Speed Setting fine-tuning .......................................................................................... 41 7.6.2 Fuel limit fine tuning................................................................................................... 42 7.6.3 Clutch fuel limit fine tuning......................................................................................... 43 8. ALARMS, DIAGNOSTICS AND SERIAL COMMUNICATIONS........................................... 44 8.1 INTRODUCTION ......................................................................................................................... 44 8.1.1 Alarm indication and operation.................................................................................. 44 8.1.2 Serial interface........................................................................................................... 44 8.2 UG40-DI ALARM INDICATION AND OPERATION........................................................................... 44 8.2.1 Introduction................................................................................................................ 44 8.2.2 Explanation of the UG40-DI panel for alarms and diagnostics ................................. 44 8.2.3 Alarm flash codes ...................................................................................................... 45 8.3 UG40-DI SERIAL INTERFACE .................................................................................................... 46 8.3.1 Serial link with PC - alarm page ................................................................................ 46 8.3.2 Serial link with PC - parameter page......................................................................... 46 8.3.3 Serial link with PC - uploading software .................................................................... 47 9. TROUBLESHOOTING AND REPAIRS................................................................................. 49 9.1 INTRODUCTION ......................................................................................................................... 49 9.2 TROUBLESHOOTING (MECHANICAL AND ELECTRICAL) ................................................................. 49 9.2.1 Preliminary inspection ............................................................................................... 49 9.2.2 Oil .............................................................................................................................. 50 9.2.3 Compensating adjustment and needle valve ............................................................ 50 9.3 TROUBLESHOOTING CHART....................................................................................................... 50 9.3.1 Definitions.................................................................................................................. 50 9.3.2 Trouble-shooting chart............................................................................................... 51 9.4 GOVERNOR FIELD REPAIRS....................................................................................................... 55 9.4.1 Removal of governor from engine ............................................................................. 55 9.5 RETURNING THE UG40-DI TO WOODWARD................................................................................ 56 Manual B03575.C UG40-DI Manual Woodward iii Table of Figures FIGURE 1.1 OUTLINE DRAWING OF UG40-DI GOVERNOR.......................................................................4 FIGURE 3.1 DI CONTROL PANEL AND GOVERNOR DIAL PLATE................................................................7 FIGURE 3.2 SCHEMATIC DIAGRAM OF THE UG40-DI ..............................................................................9 FIGURE 4.1 RECOMMENDED OUTPUT SHAFT TRAVEL ADJUSTMENT...................................................... 17 FIGURE 4.2 OIL CHART...................................................................................................................... 19 FIGURE 4.3 OIL DRAIN PLUG.............................................................................................................. 20 FIGURE 4.4 UG40-DI ELECTRICAL CONNECTIONS .............................................................................. 21 FIGURE 8.1 EXAMPLE ALARM AND DIAGNOSTICS PAGE ....................................................................... 46 FIGURE 8.2 EXAMPLE UG40-DI PARAMETERS PAGE .......................................................................... 47 FIGURE 8.3 TYPICAL TERMINAL PROGRAM UPLOAD MESSAGES........................................................... 48 FIGURE 8.4 CHECKSUM FAILED MESSAGE .......................................................................................... 48 UG40-DI Manual Manual B03575.C
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Woodward UG40-DI Governor / Installation and commissioning manual
Author: Woodward
Genre: Manual
Format: PDF
Quality: eBook
Number of pages: 66
Description: This manual is applicable to the UG40-DI Governor and describes its mechanical and
electrical installation, operation and set-up. It is arranged in ten chapters:
- GENERAL INFORMATION
- ESD PROTECTION AND HANDLING
- DESCRIPTION
- INSTALLATION
- GOVERNOR MECHANICAL OPERATION AND ADJUSTMENTS
- CALIBRATION OF THE DIGITAL INTERFACE
- ADJUSTMENT OF THE DIGITAL INTERFACE
- ALARMS, DIAGNOSTICS AND SERIAL COMMUNICATIONS
- TROUBLESHOOTING AND REPAIRS.
The UG40-DI is a mechanical-hydraulic governor with a digital interface for controlling diesel
engines. The UG40-DI uses a 250 PSI oil supply and is mechanically linked to the fuel racks.
The maximum travel of the output (terminal) shaft is 38°, and the recommended travel of the
output shaft is 25° from no load to full load (refer to Section 4.5 for more details).
Normally, the UG40-DI operates isochronously (constant speed) regardless of load on the
engine, except during operation as described in Chapter 3. DESCRIPTION.
Speed droop is incorporated in the UG40-DI to divide and balance load between units driving
the same shaft or paralleled in an electrical system.
A load limit control is also a standard feature on the UG40-DI. It limits the amount of fuel
supplied by restricting the travel of the governor output shaft. An indicator dial shows the
governor output shaft limit position.
The load limit control may also be used for manually shutting down the engine.
Table of Contents
1. GENERAL INFORMATION ......................................................................................................11.1 INTRODUCTION............................................................................................................................1
1.2 DESCRIPTION ..............................................................................................................................1
1.3 SYSTEM COMPLIANCE .................................................................................................................1
1.4 GENERAL SAFETY PRECAUTIONS .................................................................................................1
1.5 NOTES, WARNINGS AND CAUTIONS ..............................................................................................1
1.6 IDENTIFICATION PLATE.................................................................................................................2
1.7 TECHNICAL DATA ........................................................................................................................2
1.8 SOFTWARE VERSIONS .................................................................................................................2
2. ESD PROTECTION AND HANDLING .....................................................................................6
3. DESCRIPTION..........................................................................................................................7
3.1 INTRODUCTION............................................................................................................................7
3.2 DI CONTROL PANEL AND GOVERNOR DIAL PLATE.........................................................................7
3.3 MECHANICAL GOVERNOR.............................................................................................................7
3.3.1 Introduction...................................................................................................................7
3.3.2 Component description ................................................................................................7
3.3.3 Operation of the UG40-DI Mechanical Part .............................................................. 12
3.4 DIGITAL INTERFACE .................................................................................................................. 14
3.4.1 Introduction................................................................................................................ 14
3.4.2 Component Description............................................................................................. 15
3.4.3 Operation................................................................................................................... 15
4. INSTALLATION..................................................................................................................... 16
4.1 INTRODUCTION......................................................................................................................... 16
4.2 INSTALLATION REQUIREMENTS.................................................................................................. 16
4.3 UNPACKING.............................................................................................................................. 16
4.4 STORAGE................................................................................................................................. 16
4.5 MOUNTING THE GOVERNOR ...................................................................................................... 16
4.6 LINKAGE ATTACHMENTS ........................................................................................................... 17
4.7 OIL SUPPLY ............................................................................................................................. 18
4.8 ELECTRICAL CONNECTIONS ...................................................................................................... 21
5. GOVERNOR MECHANICAL OPERATION AND ADJUSTMENTS ..................................... 22
5.1 INTRODUCTION......................................................................................................................... 22
5.2 CHECK THE MAXIMUM SPEED SETTING...................................................................................... 22
5.3 INITIAL OPERATION FOR A NEW GOVERNOR – MECHANICAL ....................................................... 22
5.3.1 Adjustments............................................................................................................... 22
5.3.2 Compensation Adjustments ...................................................................................... 22
5.4 READING SETTINGS FROM MECHANICAL GOVERNOR ON THE ENGINE.......................................... 24
5.4.1 Procedure.................................................................................................................. 24
6. CALIBRATION OF THE DIGITAL INTERFACE................................................................... 25
6.1 INTRODUCTION......................................................................................................................... 25
6.1.1 Calibration on test bench........................................................................................... 25
6.1.2 Calibration on engine ................................................................................................ 25
6.2 FUNCTIONS OF UG40-DI DURING CALIBRATION......................................................................... 25
6.2.1 Introduction................................................................................................................ 25
6.2.2 Explanation of the UG40-DI panel during calibration................................................ 25
6.3 CALIBRATION ON TEST BENCH .................................................................................................. 27
6.3.1 Procedure.................................................................................................................. 27
6.4 CALIBRATION ON ENGINE .......................................................................................................... 28
6.4.1 Procedure.................................................................................................................. 28
6.5 CALIBRATION FLOW CHART....................................................................................................... 28
UG40-DI Manual Manual B03575.C
ii Woodward
7. ADJUSTMENT OF THE DIGITAL INTERFACE ................................................................... 31
7.1 INTRODUCTION ......................................................................................................................... 31
7.1.1 Adjustment................................................................................................................. 31
7.1.2 Fine tuning................................................................................................................. 31
7.2 FUNCTIONS OF UG40-DI DURING ADJUSTMENT......................................................................... 31
7.2.1 Introduction................................................................................................................ 31
7.2.2 Explanation of the UG40-DI panel during calibration and adjustment ...................... 31
7.2.3 Displaying values on the Dial Panel speed setting knob and speed indicator .......... 34
7.3 ADJUSTMENT............................................................................................................................ 34
7.3.1 Procedure .................................................................................................................. 35
7.4 FINE-TUNING............................................................................................................................ 35
7.4.1 Procedure .................................................................................................................. 35
7.5 ADJUSTMENT FLOW CHART....................................................................................................... 35
7.6 FINE-TUNING FLOW CHARTS ..................................................................................................... 41
7.6.1 Speed Setting fine-tuning .......................................................................................... 41
7.6.2 Fuel limit fine tuning................................................................................................... 42
7.6.3 Clutch fuel limit fine tuning......................................................................................... 43
8. ALARMS, DIAGNOSTICS AND SERIAL COMMUNICATIONS........................................... 44
8.1 INTRODUCTION ......................................................................................................................... 44
8.1.1 Alarm indication and operation.................................................................................. 44
8.1.2 Serial interface........................................................................................................... 44
8.2 UG40-DI ALARM INDICATION AND OPERATION........................................................................... 44
8.2.1 Introduction................................................................................................................ 44
8.2.2 Explanation of the UG40-DI panel for alarms and diagnostics ................................. 44
8.2.3 Alarm flash codes ...................................................................................................... 45
8.3 UG40-DI SERIAL INTERFACE .................................................................................................... 46
8.3.1 Serial link with PC - alarm page ................................................................................ 46
8.3.2 Serial link with PC - parameter page......................................................................... 46
8.3.3 Serial link with PC - uploading software .................................................................... 47
9. TROUBLESHOOTING AND REPAIRS................................................................................. 49
9.1 INTRODUCTION ......................................................................................................................... 49
9.2 TROUBLESHOOTING (MECHANICAL AND ELECTRICAL) ................................................................. 49
9.2.1 Preliminary inspection ............................................................................................... 49
9.2.2 Oil .............................................................................................................................. 50
9.2.3 Compensating adjustment and needle valve ............................................................ 50
9.3 TROUBLESHOOTING CHART....................................................................................................... 50
9.3.1 Definitions.................................................................................................................. 50
9.3.2 Trouble-shooting chart............................................................................................... 51
9.4 GOVERNOR FIELD REPAIRS....................................................................................................... 55
9.4.1 Removal of governor from engine ............................................................................. 55
9.5 RETURNING THE UG40-DI TO WOODWARD................................................................................ 56
Manual B03575.C UG40-DI Manual
Woodward iii
Table of Figures
FIGURE 1.1 OUTLINE DRAWING OF UG40-DI GOVERNOR.......................................................................4
FIGURE 3.1 DI CONTROL PANEL AND GOVERNOR DIAL PLATE................................................................7
FIGURE 3.2 SCHEMATIC DIAGRAM OF THE UG40-DI ..............................................................................9
FIGURE 4.1 RECOMMENDED OUTPUT SHAFT TRAVEL ADJUSTMENT...................................................... 17
FIGURE 4.2 OIL CHART...................................................................................................................... 19
FIGURE 4.3 OIL DRAIN PLUG.............................................................................................................. 20
FIGURE 4.4 UG40-DI ELECTRICAL CONNECTIONS .............................................................................. 21
FIGURE 8.1 EXAMPLE ALARM AND DIAGNOSTICS PAGE ....................................................................... 46
FIGURE 8.2 EXAMPLE UG40-DI PARAMETERS PAGE .......................................................................... 47
FIGURE 8.3 TYPICAL TERMINAL PROGRAM UPLOAD MESSAGES........................................................... 48
FIGURE 8.4 CHECKSUM FAILED MESSAGE .......................................................................................... 48
UG40-DI Manual Manual B03575.C
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