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Automotive protective asset protection economics Pgpl governor manual iv woodward battery charging device to prevent damage to a control system that uses an alternator or batterycharging device, make sure.
When you read, you form. 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.
A NOTE provides other helpful information that does not fall under the warning or caution categories. Woodward Governor Company reserves the right to update any portion of this publication at any time. Information provided by Woodward Governor Company is believed to be correct and reliable.
However, no responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken. Illustrations and Tables Figure Terminal Shaft Travel Oil Chart Viscosity Comparisons System Wiring Overview Wiring Direct from Battery to Control Test Wiring Schematic Chapter 1.
Regulatory Compliance 1. Connect the ground terminal to earth ground. Wiring must be suitable for at least 90 C. Substitution of components may impair suitability for Class I, Division 2 applications. La substitution de composants peut rendre ce matriel inacceptable pour les emplacements de Classe I, applications Division 2. The actuator is designed for use with Woodward A series, series, Peak , and controls. The driver converts a given electrical signal into a mA output to the actuator which drives the output shaft position through the action of a torque motor and follower-type pilot valve.
A contactless sensor located on the power cylinder provides the position feedback necessary for loop closure. Power cylinders with 16, 23, 39, and 79 J 12, 17, 29, and 58 ft-lb outputs are available with linear output see manual , PG Power Cylinder Assemblies , and 16, 23, 39, and 79 N m 12, 17, 29, and 58 lb-ft rotating output.
The output shaft or rod end and rack position indicators are the same parts used in the PG governor and in the same relative position. The existing booster, remote heat exchanger, and remote servo options can be used. The actuator may be equipped with a special tooth gear and magnetic pickup, using the governor drive to sense prime mover speed.
This permits an added convenience when converting from a PG hydraulic-mechanical governor to an electronic control system. The frequency sensed by the MPU must match the frequency range of the electronic control. The drive uses a maximum of W 0. In some cases the actuator may require an oil cooler to operate at the high end of the drive speed range. Contact your Woodward representative for help on determining if an oil cooler is needed.
The actuator uses a PG spur gear pump. The pump is Drive speeds from to rpm are available with check valves for either clockwise or counterclockwise rotation. Speeds up to rpm maximum are available with plugs for single direction only. This manual provides outline drawings to show the most common actuator configurations refer to manual for other PG base assemblies.
The outline drawings include information on electrical wiring, installation dimensions, drive requirements, oil requirements, and output shaft dimensions. The drawings are provided for reference only. Do not use the drawings for construction.
Driver The driver requires Vdc supply voltage and a mA input from the governor control. The driver sends excitation voltage to the position sensor and receives feedback voltage. It sends a mA output to the actuator torque motor. The driver has a built-in mA current limit to prevent damage to the torque motor.
The driver also provides a mA position output signal that is suitable for driving a valve position indicator. References The following publications provide additional information about installation, operation, and storage of Woodward products. This information must be obtained from the appropriate manual for the electronic control. Chapter 2. Be particularly careful to avoid striking the drive shaft, terminal shaft, or the electrical connectors. Abuse can damage seals, internal parts, and factory adjustments.
Do not set the actuator on its drive shaft. This leaves a light film of oil on internal parts to prevent rust. No internal cleaning or flushing is necessary before installation and operation. The little oil left in the actuator is clean, multiviscosity engine oil which will not contaminate the oil selected to operate the actuator. Fill the actuator with oil selected to match the expected operating conditions. If the actuator is a direct replacement for a PG governor, you may use the same grade and weight of oil that was being used in the governor.
Use only new, clean oil in the actuator. Do not allow dirt or contamination to enter the actuator while filling with operating oil. Do not use oil drained from the PG governor. Refer to Oil Supply later in this chapter, and to manual , Oils for Hydraulic Controls, for more information. For long-term storage more than a year , storage in an environment with large temperature changes, humid or corrosive atmosphere, etc.
See the outline drawing for installation instructions and dimensions. Drive Connection Make sure the actuator drive shaft turns freely before installing the actuator. The drive gear or coupling must slip freely into the governor drive of the prime mover. Do not apply external force. The drive must be free of binding, side load, or excess end-play. Improper alignment or fit between the parts can result in excessive wear or actuator-drive seizure.
Mount the actuator squarely on the mounting pad. Torque the mounting bolts evenly. There can be no movement or rocking of the actuator on the prime mover mounting pad. Control Linkage The terminal shaft provides the following outputs: linear version The additional overtravel should be split and used at both ends to provide maximum fuel when required and to assure shutdown at minimum-fuel actuator position see Figure Misadjusted linkage could prevent the actuator from shutting down the prime mover.
Many control problems are related to linkage between the actuator and the prime mover. Use only first-quality rod ends for the linkage, rod ends that will last under the nearly constant motion associated with precise speed control.
The linkage must be stiff, not subject to vibration from the prime mover. The linkage must be as light as possible and still maintain the attributes of stiffness. Linkage which is too heavy can damage the actuator as well as make it difficult to achieve steady control. All dynamic adjustments are made in the electronic control. The actuator has a plug in place of the PG needle valve, and turning it will have no effect.
Installed linkages must operate smoothly, be free of binding, and free of lost motion due to worn parts. If there is a collapsible member in the linkage, be sure it does not yield each time the actuator moves the linkage rapidly. Design the linkage so the power output of the prime mover is proportional to the position of the actuator output shaft. Follow the prime mover manufacturers instructions on linkage selection, installation, and adjustment.
In the case of a direct exchange, make sure that the linkage is in good condition and the installation of the lever on the actuator is in the same position as it was on the governor. To prevent possible injury while the PGPL Actuator is moving the linkage through its normal operating range, make sure you provide adequate guarding around the linkage.
Oil Supply Use the information given in Figures and as a guide in the selection of a suitable oil also refer to manual , Oils for Hydraulic Controls. Oil grade selection is based on the operating temperature range of the actuator. Also use this information to aid in recognizing and correcting common problems associated with oil used in the actuator.
Many operation and maintenance problems associated with PGPL Actuators are directly related to the selection and condition of the oil in the actuator. Use care in the selection and make sure that the oil in the actuator is not contaminated. It must have a viscosity index that allows it to perform over the operating temperature range and it must have the proper blending of additives that cause it to remain stable and predictable over this range.
Poor actuator response or instability is an indication that the oil is too thick or too thin. Actuator oil must be compatible with seal material, that is, nitrile, polyacrylic, and fluorocarbon. Many automotive and gas engine oils, industrial lubricating oils, and other oils of mineral or synthetic origin meet these requirements. Fill the actuator with oil to the mark on the oil sight glass.
After the prime mover is started and the actuator is at operating temperature, add oil if necessary. Oil must be visible in the glass under all operating conditions. When oil starts to run out of the tapped hole, replace the pipe plug. Excessive component wear or seizure in the actuator indicates the possibility of: Insufficient lubrication caused by: an oil that flows slowly when it is cold, especially during start-up; no oil in the actuator.
Contaminated oil caused by: dirty oil containers; an actuator exposed to heating and cooling cycles, which created condensation of water in the oil. Oil not suitable for the operating conditions caused by: changes in ambient temperature; an improper oil level which creates foamy, aerated oil. Using oils outside this range could cause the actuator to be unable to prevent a runaway prime mover.
Operating an actuator continuously beyond the high limit temperature of the oil will result in oil oxidation. This is identified by varnish or sludge deposits on the actuator parts. To reduce oil oxidation, lower the actuator operating temperature with a heat exchanger or other means, or change to an oil more oxidationresistant at the operating temperature. Oil Maintenance Replace the actuator oil if it is contaminated, and change it if it is suspected of contributing to instability.
Drain the oil while it is still hot. Flush the actuator with a clean solvent having some lubricating quality fuel oil or kerosene before refilling with new oil. If drain time is insufficient for the solvent to completely drain or evaporate, flush the actuator with the same oil it is being refilled with to avoid dilution and possible contamination of the new oil. Oil that has been carefully selected to match the operating conditions and is compatible with actuator components should give long service between oil changes.
Check oil conditions regularly and change oil if any deterioration or contamination is suspected. Regularly scheduled oil changes will extend the life of the actuator and improve actuator operation.
Properly selected oil should permit annual oil changes, but more frequent changes are recommended. These wires must be terminated inside a junction box external to the actuator. Input and output wiring must be in accordance with Class I, Division 2 wiring methods and in accordance with the authority having jurisdiction.
Wiring Instructions External wiring connections and shielding requirements for a typical control installation are shown in the plant wiring diagram Figures and These wiring connections and shielding requirements are explained in the balance of this chapter. Electromagnetic interference EMI is the undesirable interaction of electronic circuits with each other and sometimes with themselves.
Woodward has established procedures to prevent most EMI which will affect prime mover control circuits. Following these procedures is a slight extra expense in planning and installing electronic governing system, but is inexpensive insurance over the life of the plant.
Follow all of the shielding instructions to assure maximum efficiency and dependability of the electronic governing system.
See Figure to see how to connect wiring from the battery to the control. Maximum wire lengths are: 1. Shielded Wiring All shielded cable must be twisted conductor pairs. Do not tin put solder on braided shield. All signal lines should be shielded to prevent picking up stray signals from adjacent equipment. Connect the shields to the control case as show in Figure Wire exposed beyond the shield should be as short as possible, not exceeding mm 6 inches.
The other end of the shields must be left open and insulated from any other conductor. Do not run shielded signal wires with high voltage or high current wires. Driver Mounting Install the driver box in a location with space for wiring access. Do not expose the driver to sources of radiant heat. Do NOT install the driver box directly on the prime mover. Choose a protected location so the control will not be damaged when moving the prime mover or when nearby equipment is moving.
Mount the driver close enough to the actuator and battery to meet the wire-length requirements listed above. The Woodward Company has manufactured millions of governor control systems in made their one millionth unit.
DROOP in reference to any governor control, is the amount of allowable sag from the desired set point, or speed. If you are winsome corroborating the ebook Mercedes Clk Service Manual in pdf coming, in that instrument you outgoing onto the evenhanded website. Woodward PGPL Their applications include engines driving pumps, compressors, alternators, variable speed dc generators, marine propulsion units, and paper machines.
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