Woodward 8909-555 Product Manual
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Woodward 8909-555 Product Manual

Portable speed loop tester with load sensor
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Released
Product Manual 55011
(Revision J, 05/2019)
Original Instructions
Portable Speed Loop Tester
with Load Sensor
8909-555 for 2301/2301A/EGM
Installation and Operation Manual

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Summary of Contents for Woodward 8909-555

  • Page 1 Released Product Manual 55011 (Revision J, 05/2019) Original Instructions Portable Speed Loop Tester with Load Sensor 8909-555 for 2301/2301A/EGM Installation and Operation Manual...
  • Page 2 Revisions— A bold, black line alongside the text identifies changes in this publication since the last revision. 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.

  • Page 3: Table Of Contents

    Product Support Options ..................16 Product Service Options ..................16 Returning Equipment for Repair ................17 Replacement Parts ....................17 Engineering Services ................... 18 Contacting Woodward’s Support Organization ............ 18 Technical Assistance ................... 19 1. F 2301 M 8270-973 ....21...

  • Page 4: Warnings And Notices

    Start-up On- and off-highway Mobile Applications: Unless Woodward's control functions as the supervisory control, customer should install a system totally independent of the prime mover control system that...

  • Page 5: Electrostatic Discharge Awareness

    Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715 , Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules.

  • Page 6: Chapter 1. General Information

    General Information Introduction The Woodward 8909-555 portable speed loop tester (suitcase tester) provides a convenient engine-and- actuator simulator needed to test and adjust 2301, 2301A, and EGM Woodward governors. The tester provides both static and closed loop speed tests as well as test facilities for Load Sensor portions of the 2301 systems.
  • Page 7 The 2301, 2301A, and EGM controls can be reverse acting. Reverse-acting controls are used in systems which go to maximum fuel should the electrical control fail. Direct-acting systems go to minimum fuel should the electrical system fail. Woodward...
  • Page 8 The CT current is 5 A, but in some conditions this may vary slightly. To all tester voltages to be transmitted to the control without change, use 1 mm² (18 AWG) wire and keep the lead from the test to the control under 600 mm (2 ft) in length. Woodward...

  • Page 9: Figure 1-1. Suitcase Tester Control Panel

    The setting of 10 equals +5 volts. For a negative voltage, turn the dial counterclockwise from 5. The setting of 0 equals –5 volts. The BIAS VOLTAGE pot is connected only to the banana plug and does not affect tester operation. Figure 1-1. Suitcase Tester Control Panel Woodward...

  • Page 10: Figure 1-2. Suitcase Tester Block Diagram

    Released Manual 55011 Portable Speed Loop Tester Figure 1-2. Suitcase Tester Block Diagram Woodward...

  • Page 11: Chapter 2. Operating Procedures

    ACTUATOR VOLTAGE meter. In step 9, set the LOAD ADJ for 2 Vdc on the ACTUATOR VOLTAGE meter. Place the POWER switch in the ON position. If the control under test has an active failsafe circuit, hold down the START switch for about 5 seconds. Woodward...
  • Page 12 Continue this while increasing the LOAD ADJ to obtain the maximum load setting. 13. Adjust the control under test for the best stability and response of the system. The response is observed by watching the ACTUATOR VOLTAGE meter and by listening to the speaker (SPEAKER switch ON). Woodward...
  • Page 13 For convenience, the maximum wire length used in the harness should be about 60 cm/2 ft. A different color wire should be used throughout the harness, or at least the same colors should be used only at opposite ends of the tester terminal strip Woodward...

  • Page 14: Chapter 3. Tester Performance Check

    Newer testers do not have this switch. These units detect input voltage and adjust automatically. Test Box Setup Initial Adjustment Preset the tester as follows: LEVEL/NULL RANGE 10.0 LOAD ADJ BIAS VOLTS ACTUATOR LOAD ON/LOAD OFF ACCELERATION 100%/SEC SPEAKER EGM/2301 2301 REV/NORM NORM Woodward...
  • Page 15 L.S.T. switch positions, measure the PT voltages and record them on the data sheet as follows: L.S.T. Position Active PT Voltage none none A phase to B phase 110 V B phase to C phase 110 V C phase to A phase All voltages are ±10 percent Woodward...
  • Page 16 With the ACCELERATION switch at 50%/SEC, the elapsed time from 0 to 5000 Hz should be 2 ± 0.6 second. With the ACCELERATION switch at 30%/SEC, the elapsed time from 0 to 5000 Hz should be 3 ± 0.8 second. Woodward...

  • Page 17: Chapter 4. Troubleshooting

    PTs Are Low or Show 0 Voltage Possible mis-setting of the LINE VOLTAGE SELECT switch. CTs Are Low or Show 0 Voltage Possible mis-setting of the 2301/2301A switch. Counter Does Not Read Correctly No adjustments, send to the factory for repair. Woodward...

  • Page 18: Chapter 5. Product Support And Service Options

     An Authorized Independent Service Facility (AISF) provides authorized service that includes repairs, repair parts, and warranty service on Woodward's behalf. Service (not new unit sales) is an AISF's primary mission.  A Recognized Engine Retrofitter (RER) is an independent company that does retrofits and...

  • Page 19: Returning Equipment For Repair

    To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules.

  • Page 20: Engineering Services

    Field Service engineering on-site support is available, depending on the product and location, from one of our Full-Service Distributors. The field engineers are experienced both on Woodward products as well as on much of the non-Woodward equipment with which our products interface.

  • Page 21: Technical Assistance

    Portable Speed Loop Tester Technical Assistance If you need to contact technical assistance, you will need to provide the following information. Please write it down here before contacting the Engine OEM, the Packager, a Woodward Business Partner, or the Woodward factory: General...
  • Page 22 2301 Models 8271-308/-442/-467/-500/-652/-706 ......27 2301A Reverse-Acting Models 8272-290/-291/-293 ....... 30 2301A Direct-Acting Models 8272-268/-287/-288/-289....34 2301A High-Voltage Reverse-Acting Model 9905-031 ....38 2301A 24 Vdc Reverse-Acting Model 9905-133 ......43 2301A 24 Vdc Direct-Acting Model 9905-131 ......... 47 Woodward...

  • Page 23: Appendix 1. Functional Test For 2301 Model 8270-973

    Appendix 1. Functional Test for 2301 Model 8270-973 (Refer to Woodward manuals 82567 and 55012) Remove all connections to the control. Inspect the wiring, terminal blocks, and chassis for damage. Set the multimeter to the highest resistance scale and measure between each terminal and the chassis.
  • Page 24 Replace the jumper first and then the pickup lead and restart the tester. 19. Short across terminals 22 and 23. The actuator voltage should go to zero. 20. Set SPEED ADJ to the desired speed for the unit. Woodward...

  • Page 25: Appendix 2. Functional Test For 2301 Model 8271-444

    Appendix 2. Functional Test for 2301 Model 8271-444 (Refer to Woodward manuals 82407 and 55012) Remove all connections to the control. Check that the appropriate jumper is installed on the back of the printed circuit board. This test will assume the jumper is on position 3 for this procedure and steps 9 and 17 (reference manual 82407).
  • Page 26 22. Short across terminals 22 and 23. The actuator voltage should go to maximum. Remove the short, and restart the unit. 23. Set RATED SPEED ADJ to the desired speed for the unit. Woodward...

  • Page 27: Appendix 3. Functional Test For 2301 Models 8271-308/-442/-467/-500/-652/-706

    Appendix 3. Functional Test for 2301 Models 8271-308/-442/-467/-500/-652/-706 (Refer to Woodward manuals 82406, 82595, and 55012) Remove all connections to the control. Check that the appropriate jumper is installed on the back of the printed circuit board. This test will assume that the jumper is on position 3 for this procedure and steps 9 and 17 (reference manuals 82406 and 82595).
  • Page 28 Apply 1.5 Vdc to the MPU terminals. Speed should increase. Apply 1.5 Vdc to the SW1 terminals. Speed should decrease. 25. With LOAD GAIN full clockwise, and a jumper on terminals 26 and 27, apply 1.5 Vdc to the SW2 terminals. Speed should increase. Woodward...

  • Page 29: Appendix 4. Functional Test For 2301A Reverse-Acting Models 8270-290/-291/-293

    Power Up of Tester and 2301A Control The tester requires 115 Vac, 60 Hz supply. The tester provides the 24 Vdc power needed by the 2301A. 10. Connect power to both the tester and the control. Turn the power to the control OFF. Woodward...
  • Page 30 19. Check that the speed returns to the same setting within 2 Hz whether the LOAD ON/LOAD OFF switch is on or off. 20. Turn the tester LOAD ON/LOAD OFF switch off, as it will not be used beyond this step. Woodward...
  • Page 31 Minimum Fuel Circuit Checkout 27. Remove the jumper across terminals 16 and 17 (minimum fuel). The ACTUATOR VOLTAGE meter should go to maximum (at least 6.5 Vdc). Reconnect the jumper and restart the tester. Woodward...
  • Page 32 32. With LOAD GAIN full clockwise, and a jumper from terminal 14 to 16 (Isoch), apply 1.5 Vdc to terminals 10 (+) and 11 (–). Speed should increase. THIS COMPLETES THE TEST. Remove 24 Vdc power from the control. Turn off the tester. Woodward...

  • Page 33: Appendix 5. Functional Test For 2301A Direct -Acting Models 8272-268/-287/-288/-289

    Power Up of Tester and 2301A Control The tester requires 115 Vac, 60 Hz supply. The tester provides the 24 Vdc power needed by the 2301A. 10. Connect power to both the tester and the control. Turn the power to the control OFF. Woodward...
  • Page 34 19. Check that the speed returns to the same setting within 2 Hz whether the LOAD ON/LOAD OFF switch is on or off. 20. Turn the tester LOAD ON/LOAD OFF switch off, as it will not be used beyond this step. Woodward...
  • Page 35 Minimum Fuel Circuit Checkout 27. Remove the jumper across terminals 16 and 17 (minimum fuel). The ACTUATOR VOLTAGE meter should go to minimum (0 Vdc). Reconnect the jumper and restart the tester. Woodward...
  • Page 36 32. With LOAD GAIN full clockwise, and a jumper from terminal 14 to 16 (Isoch), apply 1.5 Vdc to terminals 10 (+) and 11 (–). Speed should increase. THIS COMPLETES THE TEST. Remove 24 Vdc power from the control. Turn off the tester. Woodward...

  • Page 37: Appendix 6. Functional Test For 2301A High -Voltage Reverse -Acting Model 9905-031

    The tester and the control both require 115 Vac, 60 Hz supply. The same supply may be used for both units. A switch should be installed in the supply to the control box. The tester includes a power on/off switch. Woodward...
  • Page 38 17. If the unit still does not start, it is a probable failure of the 2301A control. Setup of Tester 17. Set the tester LEVEL/NULL so actuator voltage reads 6.0 to 6.5 Vdc. 18. Adjust 2301A GAIN and RESET as needed. Woodward...
  • Page 39 26. Start Fuel Limit must always be completely clockwise for reverse-acting controls. Check that the pot on the 2301A control is fully clockwise. 27. Remove the jumper across terminals 0 and 18 (close to override failed speed signal). Reconnect the magnetic pickup lead and restart the tester. Woodward...
  • Page 40 33. With LOAD GAIN full clockwise, and a jumper from terminal 0 to 14 (Isoch), apply 1.5 Vdc to terminals 10 (+) and 11 (–). Speed should increase. THIS COMPLETES THE TEST. Remove 115 V power from the control. Turn off the tester. Woodward...

  • Page 41: Appendix 7. Functional Test For 2301A 24 Vdc Reverse -Acting Model 9905-133

    The tester requires 115 Vac, 60 Hz supply. The tester provides the 24 Vdc power needed by the 2301A [control terminals 1(–) and 2(+)]. Connect power to both the tester and the control. Turn the power to the control OFF. Woodward...
  • Page 42 17. Check that the speed returns to the same setting within 2 Hz whether the LOAD ON/LOAD OFF switch is on or off. 18. Turn the tester LOAD ON/LOAD OFF switch off, as it will not be used beyond this step. Woodward...
  • Page 43 Minimum Fuel Circuit Checkout 25. Remove the jumper across terminals 2 and 3 (minimum fuel). The ACTUATOR VOLTAGE meter should go to maximum (at least 6.5 Vdc). Reconnect the jumper and restart the tester. Woodward...
  • Page 44 Remove the voltage and speed should return to normal. Reverse the polarity of the voltage input, and the speed should decrease by about the same amount. THIS COMPLETES THE TEST. Remove 24 Vdc power from the control. Turn off the tester. Woodward...

  • Page 45: Appendix 8. Functional Test For 2301A 24 Vdc Direct -Acting Model 9905-131

    While holding the START switch down, set the RANGE for 10% over rated speed on the frequency readout. (Notice that the speed is set for Hz, not rpm.) Select engine ACCELERATION at 30%/SEC, 50%/SEC, or 100%/SEC. (If unknown, set at 100%/SEC.) REV/NORM to NORM EGM/2301 to 2301 2301/2301A to 2301A Now turn POWER to OFF Woodward...
  • Page 46 2301A GAIN and RESET as necessary for stable operation at all speeds, but no erratic actuator voltage changes should occur. Return the RATED SPEED pot to rated speed. (This verifies that the ten-turn RATED speed pot can control over the entire speed range, as selected with the internal 2301A DIP switch.) Woodward...
  • Page 47 Minimum Fuel Circuit Checkout 25. Remove the jumper across terminals 2 and 3 (minimum fuel). The ACTUATOR VOLTAGE meter should go to minimum (0 Vdc). Reconnect the jumper and restart the tester. Woodward...
  • Page 48 Remove the voltage and speed should return to normal. Reverse the polarity of the voltage input, and the speed should decrease by about the same amount. THIS COMPLETES THE TEST. Remove 24 Vdc power from the control. Turn off the tester. Woodward...

  • Page 49: Tester Specifications

    Released Manual 55011 Portable Speed Loop Tester Tester Specifications Woodward Part Numbers: 8909-555 Speed Loop Tester with Load Sensor for 2301/2301A/EGM Line Input 115/230 Vac 50/60 Hz (switch selectable on older units; automatic selection on newer units) Power Supply 24 Vdc, 350 mA maximum Actuator Input 0–200 mA maximum...

  • Page 50: Revision History

    Released Manual 55011 Portable Speed Loop Tester Revision History Changes in Revision J—  Replaced 110 V measurement with 0 V in Test Box Setup Procedure, step 14a Woodward...
  • Page 51 Released Manual 55011 Portable Speed Loop Tester THIS PAGE INTENTIONALLY LEFT BLANK Woodward...
  • Page 52 Email and Website—www.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website.

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