Woodward 400 Operation Manual
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Woodward 400 Operation Manual

Woodward 400 Operation Manual

Closed loop test unit
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Product Manual 55037
(Revision C)
Original Instructions
400 Closed Loop Test Unit
(Suitcase Tester)
Procedures to Test 9900-323, A9900-413,
and 9900-413
Operation Manual

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  • Page 1 Product Manual 55037 (Revision C) Original Instructions 400 Closed Loop Test Unit (Suitcase Tester) Procedures to Test 9900-323, A9900-413, and 9900-413 Operation Manual...
  • Page 2 Revisions—Text changes are indicated by a black line alongside the text. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly undertaken.

  • Page 3: Table Of Contents

    Contacting Woodward’s Support Organization ............ 28   Technical Assistance .................... 29 Illustrations and Tables   Figure 1-1. Plant Wiring Diagram for the 400 Closed Loop Test Unit ....iii   Figure 1-2. 400 Closed Loop Test Unit ..............iv Woodward...

  • Page 4: Electrostatic Discharge Awareness

    PCB from the control cabinet, place it in the antistatic protective bag. 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 5: Figure 1-1. Plant Wiring Diagram For The 400 Closed Loop Test Unit

    Manual 55037 400 Closed Loop Test Unit Figure 1-1. Plant Wiring Diagram for the 400 Closed Loop Test Unit Woodward...

  • Page 6: Figure 1-2. 400 Closed Loop Test Unit

    400 Closed Loop Test Unit Manual 55037 Figure 1-2. 400 Closed Loop Test Unit Woodward...

  • Page 7: Chapter 1. Test Unit Description

    The interface cable must be completely installed on both the control and on the test unit prior to plugging in the 120 Vac power-supply cable. The Test Unit Power switch and the 400 Control Power switch should be in the Off position when attaching the 120 Vac power cord.
  • Page 8 200 Vdc. Actuator Current Amps This position reads the current to the actuator from the 400 control when the Actuator portion of the test unit is set for closed loop. When the Actuator portion of the test unit is set for open loop, the System Meter reads the current set by the Actuator Current dial on the test unit.
  • Page 9 Manual 55037 400 Closed Loop Test Unit Actuator The Actuator section provides readings of the actuator position as directed by the control unit under test. Simulated actuator current and LVDT signals are adjusted by the dials. Actuator Position The Actuator Position dial provides a 0 to 40 degree reading of actuator position as set by the actuator current being produced by the test unit or by the control under test.
  • Page 10 As test unit engine speed increases, more actuator position will be generated by the 400 control. After enough simulated fuel flow is generated, the control and test unit will sustain speed and continue to accelerate to rated speed.
  • Page 11 Manual 55037 400 Closed Loop Test Unit Turbine Inlet Temp A four-position switch provides automatic temperature simulations of –40, 1000, or 2000 °F (–40, 538, or 1093 °C). from the test unit to the control. The temperature being simulated by the test unit may be verified on the System Meter.
  • Page 12 In the Droop position this switch sets droop in the control. In the Isoch position this switch sets isochronous operation (0 droop) in the control. Loadshare Activates or deactivates the Loadshare circuit in the 400 control under test. Sync Provides a ±1.5 Vdc signal to the SPM input of the control. This simulates the input from a synchronizer.

  • Page 13: Chapter 2. Testing The Test Unit

    Connect a dc voltmeter across J7-U (+) to J7-n (–). It should read 0.00 ± 0.05 Vdc. Set the 400 Control Power switch to On. J7-U (+) to J7-n (–) should read 28.0 ± 4.0 Vdc. Turn the Test Unit Power switch to Off, and the reading should go to zero.
  • Page 14 400 Closed Loop Test Unit Manual 55037 Attach the (+) lead from External Inputs/Voltage to J7-v. Turn the Isoch/Droop switch to the Isoch position. The Isoch switch should provide a +28.0 ± 4.0 Vdc signal. Set the switch to Droop. The voltage at J7-v will go to 0.00 ±...
  • Page 15 Manual 55037 400 Closed Loop Test Unit 21. Turn the Test Phase Select to ØC. Attach the ac RMS voltmeter from J7-BB to J7-j. Read a constant 120 Vac (approximate) PT signal. 22. Attach the ac RMS voltmeter to J7-CC and p. Turn the CT switch On. The RMS voltage should be adjustable with the CT Amplitude potentiometer from 0 to approximately 6 Vac.
  • Page 16 400 Closed Loop Test Unit Manual 55037 30. Turn the Actuator Current dial clockwise until the Actuator Position meter reads 0 °. 31. Set the Temperature Loop switch to Closed. Set the System Meter Select to Turbine Temp. When the Actuator Position meter reads about 0 °, the temperature on the System Meter should read about 800 °.

  • Page 17: Chapter 3. Testing A 400 Fuel Control

    Remove the cables connecting the 400 control to the turbine, control panel, and actuator. Locate the 400 control in a work area where it will be readily accessible and the test technician can easily make adjustments to the boards in the control.

  • Page 18: Testing The Control

    Frequency. 11. Set the Reset To 60 Hz switch to the On (up) position. This completes the initial preparation of the test unit to test a 400 control. Testing the Control With the cover removed from the control, but none of the cables connected between the control and the test unit: Measure the resistance from each contact in J1, J2, and J3 to the chassis.
  • Page 19 Attach a 120 Vac power source to the test unit, and connect the interface cable between the test unit and the 400 control (J7 to J1, J2, and J3). See the plant wiring diagrams in this manual (Figure 1-1) and in manuals 82453 or 82315.

  • Page 20: Test And Calibration Of The Control

    If A5-R1 is adjusted to bring the reference voltage into tolerance, it will make careful calibration of the entire control necessary. Do not adjust the setting on a functioning 400 control. Record the voltage at A5-TP7. The reading should be -7.5 ± 0.5 Vdc.

  • Page 21: Speed Reference Test Module A3 9900-323 (K17)

    Load potentiometer on the test unit for 60 mA actuator current on the System Meter. Speed Reference Test Module A3 9900-323 (K17) Speed reference tests are provided for 400 controls 9900-323 and A9900-413. Select the test that fits your control. The test for A9900-413 begins on page 26. Speed Reference 9900-323 Turn the test unit Load switch to Off.
  • Page 22 Turbine Frequency meter. Release the Speed Raise switch. Turn the 400 Control Power switch to Off. 10. Turn the 400 Control Power switch to On. LED A3-DS4 (Reset) should light and, after restarting, the control frequency should return to 9213 ± 10 Hz on the Turbine Frequency meter.
  • Page 23 Manual 55037 400 Closed Loop Test Unit Turn the 3 Phase CT switch to On. Select Test Phase Select ØA and set System Meter Select to CT Volts RMS. Adjust the CT Amplitude to 1.6 ± 0.1 Vrms. Select ØB and ØC and check for 1.6 ± 0.1 Vrms at each position.

  • Page 24: Temperature Channel Module A7 9900-323

    Set the Setup/Signal Generator switch to Setup/Signal Generator. Set the System Meter Select to Turbine Temp. Adjust the Level potentiometer for a frequency of 8500 Hz. Switch the 400 Control Power switch Off and back On. LED A6-DS1 (Run) should light.
  • Page 25 Set the Setup/Signal Generator switch to Setup/Signal Generator, and adjust the Level potentiometer for a Turbine Frequency just above 8700 Hz. Turn the 400 Control Power switch Off and back On. Use the Level pot to slowly decrease the Turbine Frequency until LED A6-DS1 just goes out.

  • Page 26: Final Procedure

    5.31 ± 0.2 Vdc. Final Procedure Turn Off the 400 Control Power switch and the Test Unit Power switch. Remove the jumper from A5-TP1 and A5-TP2 on the 400 control. Remove the test cable and test unit from the 400 control.
  • Page 27 Turn the 400 Control Power switch to Off. 10. Turn the 400 Control Power switch to On. LED A3-DS4 (Reset) should light and, after restarting, the control frequency should return to 9560 ± 10 Hz on the Turbine Frequency Meter.
  • Page 28 400 Closed Loop Test Unit Manual 55037 Set the Droop/Isoch switch to Isoch. Set the Loadshare switch to the up position. LED A1-DS3 (Parallel-On) should light. Turn Loadshare to Off (down). Turn the 3 Phase CT switch to On. Select ØA and set the System Meter Select to CT Volts RMS.
  • Page 29 Set the Setup/Signal Generator switch to Setup/Signal Generator. Set the System Meter Select to Turbine Temp. Adjust the Level potentiometer for a Turbine Frequency of 9600 Hz. Switch the 400 Control Power Off and back On. LED A6-DS1 (Run) should light.
  • Page 30 Set the Setup/Signal Generator switch to Setup/Signal Generator and adjust the Level potentiometer for a Turbine Frequency just above 8700 Hz. Turn the 400 Control Power switch Off and back On. Slowly decrease the Turbine Frequency until LED A6-DS1 just goes out. The Turbine Frequency should be 5753 ±...
  • Page 31 The voltage at A6-TP4 should be 4.77 ± 0.2 Vdc. Final Procedure Turn off the 400 Control Power switch and the Test Unit Power switch. Remove the jumper from A5-TP1 and A5-TP2 on the 400 control. Remove the test cable and test unit from 400 control.

  • Page 32: Chapter 4. Product Support And Service Options

    A current list of Woodward Business Partners is available at www.woodward.com/directory. Product Service Options Depending on the type of product, the following options for servicing Woodward products may be available through your local Full-Service Distributor or the OEM or Packager of the equipment system.

  • Page 33: 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 34: 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 35: Technical Assistance

    400 Closed Loop Test Unit 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 36 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.

This manual is also suitable for:

9900-323A9900-4139900-413

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