Woodward MCB Manual

Application and Hardware Manual
Indian Railway Locomotive Electronic

Control
System 8701-1349
Indian Railway
Manual B37818
WARNINGDANGER OF DEATH OR PERSONAL INJURY

WARNINGFOLLOW INSTRUCTIONS
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.
WARNINGOUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify
that you have the latest revision, be sure to check the Woodward website:
www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The
latest version of most publications is available at:
www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get
the latest copy.
WARNINGOVERSPEED PROTECTION
The engine, turbine, or other type of prime mover should be equipped with an overspeed
shutdown device to protect against runaway or damage to the prime mover with possible
personal injury, loss of life, or property damage.
The overspeed shutdown device must be totally independent of the prime mover control
system. An overtemperature or overpressure shutdown device may also be needed for
safety, as appropriate.
WARNINGPROPER USE
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or property
damage, including damage to the equipment. Any such unauthorized modifications: (i)
constitute "misuse" and/or "negligence" within the meaning of the product warranty
thereby excluding warranty coverage for any resulting damage, and (ii) invalidate product
certifications or listings.
CAUTIONPOSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY

CAUTIONBATTERY CHARGING
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.
CAUTIONELECTROSTATIC DISCHARGE
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.
IMPORTANT DEFINITIONS
A WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in
damage to equipment or property.
A NOTE provides other helpful information that does not fall under the warning or caution
categories.
RevisionsText changes are indicated by a black line alongside the text.
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.
Woodward 2006
All Rights Reserved
Manual B37818
IRLEC
Contents
REGULATORY COMPLIANCE ...................................................................... III
CHAPTER 1. GENERAL INFORMATION .......................................................... 1
Introduction ............................................................................................................ 1
Application ............................................................................................................. 1
CHAPTER 2. INSTALLATION ........................................................................ 3

Introduction ............................................................................................................ 3
Unpacking .............................................................................................................. 3
Power Requirements ............................................................................................. 3
Location Considerations ........................................................................................ 3
Introduction Installation Checkout Procedure ........................................................ 3
CHAPTER 3. SYSTEM WIRING DRAWINGS .................................................... 5

Introduction ............................................................................................................ 5
CHAPTER 4. SYSTEM HARDWARE DESCRIPTION ........................................ 11

Introduction .......................................................................................................... 11
733 Digital Control ............................................................................................... 12
Input/Output Arrangement ........................................................................... 13
Temperature Specifications ......................................................................... 13
733 Wiring Pin Out ....................................................................................... 13
PC Interface ......................................................................................................... 16
Using Watch Window................................................................................... 16
Power Supply Module .......................................................................................... 20
Testing Power Supply Module: .................................................................... 20
Pressure Transducer ........................................................................................... 21
1. Boost Air Pressure Transducer: ............................................................... 21
2. Lube Oil Pressure Transducer: ................................................................ 21
3. Fuel Pressure Transducer: ...................................................................... 21
Load Control Potentiometer ................................................................................. 22
Procedure for testing LCP Module (No Load) .............................................. 23
Procedure for testing LCP Module (Load) ................................................... 23
Actuator Feedback Sensor (RVDT) ..................................................................... 25
Testing Procedure ........................................................................................ 25
Wiring Detail................................................................................................. 25
Electrical Data .............................................................................................. 25
Mechanical Data .......................................................................................... 25
Environmental Data...................................................................................... 25
LCD Display ......................................................................................................... 27
Engine Main Parameters ............................................................................. 28
Engine More Parameters ............................................................................. 28
Shutdown and OST Status........................................................................... 29
ENGINE OVERSPEED STATUS ................................................................. 30
This parameter indicates the electrical or mechanical OST Switch position.30
Alarms History .............................................................................................. 30
Trending ....................................................................................................... 31
Data Logging........................................................................................................ 32
Reset Counters ............................................................................................ 35
LEDs Indication on the Front Door ...................................................................... 35
Ready To Start ............................................................................................. 35
Shutdown ..................................................................................................... 35
OS Test ........................................................................................................ 35
Magnetic Speed Pickup ....................................................................................... 36
How to Mount Magnetic Pickup on the Cam Gear Cover ............................ 38
Magnetic Pickup Installation......................................................................... 39
UG-Actuator ......................................................................................................... 40
Terminal Shaft and Drive Shafts .................................................................. 40
Hydraulic Pump ............................................................................................ 40
Control Linkage ............................................................................................ 42
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Manual B37818
IRLEC
Linkage Installation ....................................................................................... 43

Testing the functionality of MCBG Actuator on TEST Stand ........................ 44
CHAPTER 5. SYSTEM DESCRIPTION .......................................................... 47

Introduction ........................................................................................................... 47
Start-up Adjustments .................................................................................... 47
Procedure For Rack Calibration Procedure .................................................. 47
Overspeed Testing ............................................................................................... 49
Procedure for Testing Mechanical OST ....................................................... 49
Procedure for Testing Electronic OST .......................................................... 49
Adjustment of Various Engine Parameters .......................................................... 51
Notch wise engine speed .............................................................................. 51
Maximum permissible fuel rack at each notch ............................................. 52
Maximum Permissible Fuel Rack in Relation to Boost air Pressure ............ 53
PID Response............................................................................................... 54
Load Control Timing From Max to Min. Field Position .................................. 55
Rack Calibration ........................................................................................... 56
Fuel Transmitter Calibration ......................................................................... 57
CHAPTER 6. TUNABLE ............................................................................. 59

Service Value List ................................................................................................. 59
Configure Value List ............................................................................................. 63
Service Tunable Description................................................................................. 64
Configure Tunable Description ............................................................................. 72
CHAPTER 7. TROUBLESHOOTING .............................................................. 73

CHAPTER 8. SERVICE OPTIONS ................................................................ 77
Returning Equipment for Repair ........................................................................... 78
Replacement Parts ............................................................................................... 79
How to Contact Woodward ................................................................................... 79
Engineering Services ............................................................................................ 80
Technical Assistance ............................................................................................ 81
CONTROL SPECIFICATIONS ...................................................................... 83
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Regulatory Compliance
Woodward Governor declares that this controlling device complies with the
requirements of IEC571-1 as per the detail given by RDSO.
NOTICE: This controlling device is intended to be put into service only upon
incorporation into DLW locomotives.
Woodward
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Manual B37818
Electrostatic Discharge Awareness

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.
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 (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
Do not touch any part of the PCB except the edges.
Do not touch the electrical conductors, the connectors, or the
components with conductive devices or with your hands.
When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
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Manual B37818
IRLEC
Chapter 1.
General Information
Introduction
This chapter describes the basic function of Woodward Indian Railway
Locomotive Electronic Control (IRLEC) models 8701-1349.
Power Requirements
The control requires a voltage source of 18 to 75 Vdc.
Application
This IRLEC controls the speed of locomotives in variable speed applications.
The control includes inputs for a magnetic pickup (MPU) for monitoring speed,
an input of boost air pressure, an input of lube oil pressure for LOP tripping, an
input of fuel pressure for fuel pressure measurement and an input for fuel rack
opening.
The serial channels provide for various control interfaces. Port is switchable to
be a Watch Window PC interface or a hand-held programmer port for
monitoring and programming the IRLEC.
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Manual B37818
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IRLEC
Manual B37818
IRLEC
Chapter 2.
Installation
Introduction
This chapter contains general installation instructions for the IRLEC system..
Power requirements, environmental precautions, and location considerations
are included to help you determine the best location for the control. Additional
information includes unpacking instructions, electrical connections, and
installation checkout procedures.
Unpacking
Before handling the control, read Chapter 2, Electrostatic Discharge Awareness.
Be careful when unpacking the electronic control. Check the control for signs of
damage such as bent panels, scratches, and loose or broken parts. If any
damage is found, immediately notify the shipper.
Power Requirements
The control requires a voltage source of 18 to 75 Vdc.
Location Considerations
Consider these requirements when selecting the mounting location:
adequate ventilation for cooling.
Space for servicing and repair.
Protection from direct exposure to water or to a condensation-prone
environment.
Protection from high-voltage or high-current devices, or devices which
produce electromagnetic interference.
Selection of a location that will provide an operating temperature range of
40 to +70 C (40 to +158 F).
The control must NOT be mounted on the engine.
Introduction Installation Checkout Procedure

With the installation complete as described in this chapter, do the following
checkout procedure before beginning set point entry or initial start-up
adjustments.
Visual inspection
a. Check the linkage between the actuator and fuel-metering device for
looseness or binding.
b. Check for correct wiring in accordance with the control wiring diagram,
Figure 1-2.
c. Check for broken terminals and loose terminal screws.
d. Check the speed sensor(s) for visible damage. If the sensor is a
Woodward
Manual B37818
magnetic pickup, checks the clearance between the gear and the sensor, and
adjusts if necessary. Clearance should be between 0.25 and 1.25 mm (0.010
and 0.050 inch) at the closest point. Make sure the gear run out does not
exceed the pickup gap.
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IRLEC
Manual B37818
IRLEC
Chapter 3.
System Wiring Drawings
Introduction
This chapter gives the information about system wiring.
Woodward
Manual B37818
IRLEC
Figure 3-1 IRLEC Functional Overview

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Manual B37818
IRLEC
Figure 3-2 Cabinet General Arrangement

Woodward
INPUT
(72 VDC)
1 COMMON
2 24 VDC
3 N/C
POWER SUPPLY
MODULE
USB PORT
FOR COMM.
WITH PC
RS 485
GND. (4)
72V (50)
LCP (29A)
Figure 3-3 Control Wiring Diagram

MECH. OST
READY TO START
(GREEN)
SHUTDOWN
(RED)
RESET
ELECT. OST
FUEL LIMITER BYPASS
OFF
OST ENABLE
TB 1C
TB 1B
TB 1A
OS TEST
(RED)
RELAY
MODULE
LOAD CONTROL
POTENTIMETER
72 VDC SUPPLY
SOL A/ESRA (15A/15)
SOL B/ESR2 (12A/12)
SOL C/ESR3 (7C/7)
SOL D/ESR4 (3A/3)
OUTPUT
(5 VDC)
OUTPUT
(24 VDC)
RXB + TXB
Woodward
TXA + RXA
COMMON
DISPLAY
N/C
RS-485 Communication
(-)
(+)
Actuator Output 2
Digital/PWM Output Return
DO Circuit Power Input
Digital/PWM Output 4
Boolean Input Return
Boolean Input 4
Boolean Input 3
Boolean Input 2
Boolean Input 1
Digital/PWM Return
Digital/PWM Input 4
Digital/PWM Input 3
Digital/PWM Input 2
Digital/PWM Input 1
Power (-)
Power (+)
RS-485 COMMON
RS-485 (-)
RS-485 (+)
(-)
(+)
SHLD.
(-)
(+)
(-)
(+)
SHLD
(-)
(+)
(-)
(+)
(-)
(+)
(-)
(+)
RS-232 COMMON
RS-232 TX
RS-232 TX
Analog Input 3
Analog Input 2
Analog Input 1
MPU/Proximity 2
MPU/Proximity 1
Actuator Output 1
Analog Input 4
RS-232 Communication
733 DIGITAL
CONTROL
N/C
I
S
O
L
A
T
O
R
N/C
Manual B37818
IRLEC
Manual B37818
IRLEC
Figure 3-4 UG-Actuator Wiring Diagram

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Manual B37818
IRLEC
Figure 3-5 Interfacing Cables Detail

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Manual B37818
IRLEC
Chapter 4.
System Hardware Description
Introduction
This chapter gives information about the type of components used in the system
(8701-1349).
The IRLEC system includes:
A 733 Digital Control
ServLink Watch Window or a handheld terminal
for adjusting control parameters
UG actuator to position the fuel metering
Power supply module
Magnetic pickup for speed sensing
72 Vdc Relay Module for desired notch position
Three pressure transducers for sensing LOP, FOP, BAP
Feedback Sensor for sensing engine fuel rack.
Load Control Potentiometer Module
LCD (Liquid Crystal Display) for data monitoring
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Manual B37818
IRLEC
733 Digital Control
The 733 control uses a GAP programmable processing core that provides all
the necessary functions in a single CPU. The below listed specifications give
some insight to the processor capability relative to other Woodward controls.
Processor type Motorola MPC565
Clock frequency 56 MHz
Math support Floating point CPU
Real time clock built into CPU
RTC accuracy 1 Minute / month
Flash memory 1 Mbytes
RAM 512 Kbytes
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IRLEC
Input/Output Arrangement
The standard I/O (input/output) for this product is:
Type of Input
# of Inputs
Options/Details
DC Power Input
Power Input
1832 Vdc, protected from reverse

polarity
Analog Inputs
Function Configurable Inputs
MPU / Proximity Speed Sensor
4
2
Current (420 mA)

10 25000 Hz (general purpose use)
106000 Hz (when used as fuel

injection
Speed input)
Analog Outputs
Actuator output
Function Configurable outputs
Current (either 420 mA or 20160

mA)
Current (420 mA)
Discrete Inputs
Configurable Switch, PWM, or Prox inputs
Configurable Switch or Contact inputs
4
4
Switch to return pins to activate

Switch to return pins to activate
Discrete Outputs
Configurable Relay Driver or PWM Outputs
Low side drivers
Communication Ports
Serial Ports
CAN Ports
2
3
(1)RS-232, (1)RS-485
(1)Isolated, (2)On-Engine use
Temperature Specifications
The 733 control may be used in applications with an ambient temperature from
40 to +100 C (40 to +212F).
733 Wiring Pin Out
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Manual B37818
IRLEC
Speed Inputs
MPU/Proximity 1 (+)
MPU/Proximity 1 ()
MPU/Proximity 1 shield
G3
F3
F2
MPU/Proximity 2 (+)
MPU/Proximity 2 ()
MPU/Proximity 2 shield
G1
F1
F2
Digital / PWM Input 1

Digital / PWM Return
E3
E2
D2

E1
D3
Boolean Input 1
Boolean Input 3
Boolean Input Return
C3
C1
B2
Boolean Input 2
Boolean Input 4
E1
D3
B3
A3
Analog Output 2 (+)

Analog Output 2 ()
A1
A2
H3
G2
Actuator Output 2 (+)

Actuator Output 2 ()
H1
H2
K3
J3
J2
Digital / PWM Output 3

Digital / PWM Output Return
K1
J1
K2
P2
N3
N1
M1
N2
Analog Input 3 (+)

Analog Input 3 ()
Analog Input 4 (+)
Analog Input 4 ()
Analog Input 3&4 Shield
L1
M2
M3
L3
L2
Digital Inputs
Analog Outputs
Analog Output 1 (+)
Analog Output 1 ()
Actuator Outputs
Actuator Output 1 (+)
Actuator Output 1 ()
Power Outputs
Proximity Power (+)
Proximity Power ()
D1
D2
Digital Outputs
DO Circuit Power Input
Analog Inputs
Analog Input 1 (+)

Analog Input 1 ()
Analog Input 2 (+)
Analog Input 2 ()
Analog Input 1&2 Shield
Power Input
Power (+)
Power ()
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Y3
Y1
Manual B37818
IRLEC
CAN Communications
CAN 1 High
CAN 1 Low
CAN 1 Common
CAN 1 shield
CAN 2 High
CAN 2 Low
CAN 2&3 shield
S1
S3
T2
S2
P3
R3
R2
RS-485 Communications
RS-485 (+)
RS-485 ()
RS-485 Common
RS-232/485 shield
Termination jumper (+)
Termination jumper ()
X3
X1
Y2
W2
W3
W1
RS-232 Communications
RS-232 TX
RS-232 RX
RS-232Common
RS-232/485 shield
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15
T3
T1
X2
W2
CAN 3 High
CAN 3 Low
CAN 2&3 shield
P1
R1
R2
Manual B37818
IRLEC
PC Interface
The Woodward Watch Window can be used to interface with the ServLink
Server, as a means for displaying the Service & Configure tunable/monitors,
with the ability for tuning the parameters. Watch Window also offers the ability to
upload the tunable parameters from the control, into a file, and also to download
the parameters stored in the file, into a control (of the same type/application).
Using Watch Window

Here are brief instructions for using Watch Window in conjunction with Servlink
to view the variables for your IRLEC on PC (Personal Computer). These
instructions are meant to be introductory only. Full on-line help is available in
each application. It is assumed that you already have ServLink and Watch
Window installed. The default location can be found by clicking the START icon
on the main menu bar and then clicking the PROGRAMS menu item. Look for
an icon called WOODWARD WATCH WINDOW.
1. Make sure that all other programs that may access your computer
communication ports are shut down.
2. Get the right cable to talk from your PC to the control (5416-870).
3. Start the Servlink server and open a new file. Select the proper com port
for your PC, verify that POINT-TO-POINT communication mode is
selected, verify that the baud rate is 115200.
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IRLEC
4. Select OK. If everything is working right, you should see an animated

picture of a string of 1 and 0 flying from the control to the PC on your
screen. You now have a network definition file whose default name is
NET1.
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Manual B37818
5. Start the watch window application. When watch window executes, you
will have a screen displaying three windows entitled Watch Window,
Explorer, and Inspector.
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IRLEC
Manual B37818
IRLEC
6. The explorer window will have two groups displayed, SERVICE and
CONFIGURE. Double clicking on either of these will expand them to
show groups of values. Explorer is used only to locate a tunable or
monitor value. In order to change a value or monitor a value, you
must drag and drop a value from the explorer window into the
Inspector window. Once a value is displayed in the Inspector, you can
see several blocks of information. The most important blocks for a
tunable value are the FIELD and VALUE blocks. The FIELD block is
used to identify a particular value, and the VALUE block display the
current value of a variable. There are two types of values available in
Watch Window. One is a monitor value, which is marked in the
INSPECTOR window with a pair of glasses. This mean it may only be
looked at. The other value is read/write value, which is marked with a
pencil. The read/write type may be modified using the up and down
arrows in the value block.
The Inspector is used to monitor and edit variables available through the
Servlink Server. The Inspector is composed of a set of tabbed sheets. Each
sheet contains a grid (the grid shown in the following example is reduced - other
fields headers are available to define which control a variable relates to, and if
relevant, which category and block name. Each sheets tab is labeled with a
user-definable name. The user has the ability to add and remove sheets using
menu items and/or tool bar buttons in the Main Window.
An icon to the left of the variable defines whether it is a monitor value, configure
tunable or service tunable (or debug tunable if relevant)
: Service Tunable
: Monitor Value
: Configure Tunable
One or more variables can be selected using the mouse (left click) or keyboard
(arrow keys).If the user wishes to select multiple variables, they can do so by
performing one of these sequences:
Select a variable, hold down the shift key, and arrow up or down until
all of the variables.
Click on a variable, hold down the shift key, and click on the last variable
in the series that the user wishes to select.
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Manual B37818
IRLEC
Power Supply Module

The Power Supply Module has a DC-to-DC converter and a battery charger
circuit. The Specification of Power Supply Module is given below.
Input Voltage Range: 18-75 Vdc
Output Voltage: 24 Vdc
Output Current: 6.26 Amps
Figure 4-4 Power Supply Module
Testing Power Supply Module:

There is one terminal at the input (for 72 Vdc) and four terminals at the output.
Out of four terminals, three terminals are for 24 Vdc and one terminal is for 5
Vdc.
Connect 72 Vdc supply to the input terminal of the power supply module and
measure the voltage across output terminal. If the output voltage is 23.5 to 24.5
Vdc at 24 Vdc terminal, and 5.0 Vdc at the 5 Vdc terminal, the supply module is
healthy otherwise it is faulty.
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IRLEC
Pressure Transducer
Three pressure transducers are used.
1. Boost Air Pressure Transducer:

2
Working Range:
0 to 5 Kg/cm
Signal Output:
420mA
Supply Voltage:
830Vdc
Accuracy
0.25% FS
Operating Temperatures -40C to 125C
Configuration:
2 wire
2. Lube Oil Pressure Transducer:

2
Working Range:
0 to 10 Kg/cm
Signal Output:
420mA
Supply Voltage:
830Vdc
Accuracy
0.25% FS
Configuration:
2 wire
3. Fuel Pressure Transducer:
Working Range:
0 to 10 Kg/cm
Signal Output:
420mA
Supply Voltage:
830Vdc
Accuracy
0.25% FS
Configuration:
2 wire
Figure 4-6 Pressure Transducer
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Manual B37818
IRLEC
Load Control Potentiometer

In most governor applications, the primary function of the governor is to
automatically maintain a specific engine speed under varying load conditions, by
regulating the fuel supply to the engine. In the case of traction diesel engine
governor, it has to basic functions to perform.
To maintain a desired engine speed at each notch, set by the drivers
throttle handle.
To maintain constant power output of the engine at each notch
speed.
Thus for each throttle setting (notch position), a constant engine speed and a
predetermined fixed rate of fuel supply required. To satisfy both these
conditions, the load on the engine must be adjusted by increasing or decreasing
excitation of the traction generator as the locomotive operating conditions (track
gradient, load of auxiliaries, etc.) vary. The governor thus performs the function
of load control to maintain constant horsepower output of the engine at each
speed setting. The voltage output of LCP (P/N: 1784-1063) varies from 24 Vdc
to 68. The voltage at max field excitation is 24 Vdc. The voltage at min. field
excitation is 68 Vdc. The voltage can be measured with the help of multimeter
by connecting across terminals 29A (+) and 4(-). This voltage can be adjusted
through a trim pot mounted on the PCB.
Figure 4-8 Load Control Potentiometer
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Manual B37818
IRLEC
Procedure for testing LCP Module (No Load)

1. Connect 72 Vdc source across terminal 71(+) and 4(-). The output
voltage between wires 29A and 4 should be 24 Vdc. To vary this voltage
5%, adjust the trimpot on the base of PCB.
2. Switch ON the 4 20 mA source and apply 4 mA. The output voltage
will be 24 Vdc.
3. Increase the 4 20 mA signal in steps of 4 mA and notice a
corresponding change in the output voltage from 24 Vdc to 68 Vdc.
Procedure for testing LCP Module (Load)

1. Connect a 1K ohms/10 W power resistor between terminals IP (+) and
IN (-). The output DC voltage should not vary more than 2 Vdc.
2. Similar testing as no load testing can be conducted now.
S.No.
Current in mA
1.
2.
3.
4.
5.
6.
0
4
8
12
16
20
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23
Output Voltage (No

Load)
24.0
24.0
35.2
47.0
59.1
67.5
Output Voltage (Load)

24.9
24.9
36.0
47.7
59.3
70.8
Manual B37818
IRLEC
72 VDC Relay
We use 72 VDC relay module (P/N: 1731-2082) having 5 relays (one spare) to
sense notch position. The A notch signal coming from loco is connected to
terminal 1(+), B notch signal to terminal 2(+), C notch signal to terminal 3(+)
and D notch signal is connected to terminal 4(+). The Common terminal of all
four relays is shorted together and connected to loco negative (4).
The potential free contact of each relay is connected to 733 control. The 24 Vdc
+ve is connected to module terminals 16, 26, 36 and 46. The module terminal
15 is connected to 733 terminal #36, module terminal 25 is connected to 733
terminal #35, module terminal 35 is connected to 733 terminal #34 and module
terminal 45 is connected to 733 terminal #33. For more detail see Figure1-3
(control wiring diagram).
Figure 4-9 Relay Module
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IRLEC
Actuator Feedback Sensor (RVDT)

The contact less sensor utilizes the orientation of a magnetic field for the
determination
of the measurement angle. Therefore, a magnet is attached to the sensor shaft,
the magnetic field orientation is captured with an integrated circuit. An analogue
output signal represents the calculated angle
The housing is made of a special high-grade temperature-resistant plastic
material. Fixings are in the form of elongated slots, which allow simplicity in
mounting together with ease of mechanical adjustment. The transducer is not
sensitive to either dirt or dampness. Electrical connections are made via a
shielded cable with 3 lead wires, which is sealed into the housing.
Testing Procedure
a. Supply 5.0 +/- 0.2 Vdc to Pins D (+) and F (-) of 9 Pin Connector.
b. Measure sensor output at Pins E (+) and F (-) to 4.25 - 4.45 Vdc at
minimum actuator terminal shaft position (Actuator terminal shaft can
be moved with the help of Serrated Wrench).
c. Verify feedback sensor output is 0.44 - 0.84 Vdc at maximum actuator
terminal shaft position (Actuator terminal shaft can be moved with the
help of Serrated Wrench). The terminal shaft can be bringing back to
zero by giving some RPM from Test Stand Drive.
Verify that feedback sensor output voltage decreases uniformly as the actuator
terminal shaft is moved from minimum to maximum position.
Wiring Detail
Ground:
Voltage supply:
Output signal:
green
brown
white
Electrical Data
Operating voltage [VDC]:
5 0,5
Measuring range []:
30...180 (10-steps)
Output signal [V]:
5,5...94,5% (ratiometric of supply voltage 5V 0,5V)
Conductor length, bare, tinned [mm]:
approx. 500
Conductor diameter [mm]: approx. 0,127
Mechanical Data
Mounting:
Mechanical travel []:
with 2 fillister-head screws M4 and washer

360,continuous
Environmental Data
Vibration:
5...2000 Hz / Amax=0,75 mm / amax=20 g
Temperature range [C]:
-40...+125 (supply voltage 5V)
6
Mechanical life [movements]: > 50 x 10
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Figure 4-10 Feedback Sensor
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LCD Display
A coloured LCD touch screen, display of reputed make is available on the front
panel of the controller unit and has a minimum of 6 of graphical display. The
size of each character displayed on the screen is minimum 5mm. The
brightness of the display is such that it is clearly visible under both day and night
conditions from a distance of 2 meters. The main page of the display is as per
RDSO given format. Alarm status is displayed at the bottom of the screen.
Subsequent pages have different information about MCBG parameters and
alarm logs etc.
POWER REQUIREMENTS:
Power connection via removable three position terminal block.
Supply Voltage: +24 VDC 20%
Typical Power1: 8 W
Maximum Power2: 14 W
The LCD display has five programmed pages as per railway requirement and
pressing buttons F1, F2, F3, F4 and F5 can access these pages individually.
When the governor is initially powered up, it will default to the Engine Main
Parameters page. Here is what the display look like. The Main Engine
Parameters Page can also be accessed while in any other page by pressing F1
button. Some buttons like NEXT, PREV, EXIT, ALARM, and TREND are also
provided on the Display touch screen.
You can scroll display pages by pressing NEXT and PREV. Pressing ALARM
and TREND can directly access alarm History and Trending pages. You can
come out from any page directly to main page i.e. Engine Main Parameters by
pressing EXIT.
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The LCD display provides the following Information.
Engine Main Parameters

The general format of the engine parameters displayed by Display is given
below
The Engine Parameters Page provides the following information:

LOP: The lube oil pressure of the engine.
FOP: The fuel pressure of the engine.
BAP: The boost air pressure of the engine.
NOTCH: The notch position of the engine.
ENGINE SPPED: The actual speed of the engine.
FUEL RACK: The fuel rack opening of the engine.
LCP: The excitation position of the engine.
Engine More Parameters

Pressing F2 button on the Display can access this page.
The Engine More Parameters Page provides the following information:
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ENGINE MODE: This mode gives the following information.

NONE: This message will appear when the engine is ready to start.
SPPED IN CONTROL: This message will appear when the engine is running at
Rated speed.
START FUEL LIMITER: This message indicates the maximum actuator
opening during cranking.
BOOST AIR PRESSURE LIMIT: This message will appear when there is
maximum allowable rack opening at any particular booster pressure (for more
detail see fuel limiter curve).
RACK LIMIT ACTIVE: This message will appear when there is maximum
allowable rack opening at any particular Notch.
ELECT. OVERSPEED ACTIVE: This message will appear when Electrical OST
is selected through key switch provided on the door.
MECH. OVERSPEED ACTIVE: This message will appear when Mechanical
OST is selected through key switch provided on the door.
ENGINE STOP: This message will appear when the engine is stopped normally
(D Notch Shutdown)
ENGINE SPPED REF: This parameter indicates the speed reference at individual notch.
ENGINE PEAK SPEED: This parameter gives the peak speed recorded by governor. The peak
speed can be reset any time by pressing the Reset button on the door. This parameter helps in
knowing engine overspeed tripping during OST.
ACTUATOR OUTPUT: This parameter indicates Actuator opening in %.
LCP POSITION %: This parameter indicates LCP Position in %.
Shutdown and OST Status

The Shutdown and OST Status Page provides the following information:
ENGINE SHUTDOWN STATUS

This parameter indicates following engine shutdowns.
ENGINE OVERSPEED: The Engine will shutdown when the engine speed
exceeds the engine electrical OST limit and this message will appear on the
display
LOW LUBE OIL SHUTDOWN: The Engine will shutdown when the lube oil
pressure is below the desired level and this message will appear on the display.
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SPEED SENSOR FAIL: The Engine will shutdown when the speed sensor fails
and this message will appear on the display.
NORMAL SHUTDOWN (D NOTCH): The Engine will shutdown when there is
normal shutdown (D Notch) and this message will appear on the display.
NO SHUTDOWN: This message will appear only when Engine is running well.
ENGINE OVERSPEED STATUS
This parameter indicates the electrical or mechanical OST Switch position.
ELECTRICAL OST ACTIVE: This message will appear below the Engine
Overspeed Status if OST Selector switch position is on Electrical OST.
MECHANICAL OST ACTIVE: This message will appear below the Engine
Overspeed Status if OST Selector switch position is on Mechanical OST.
Alarms History
The Alarms History Page provides the following information:
Alarm History page provide alram history with date and time stamping. It indicates both generation
and acknowledgement time of alarms. Alarms can be cleared by pressing Clear button.
The list of alarms normally generated by Governor will be:
1. LUBE OIL SIGNAL FAULT: This signal fault will appear on the display when
there is any wire break in Lube Oil Pressure Sensor
2. FUEL PRESSURE SIGNAL FAULT: This signal fault will appear on the display when
there is any wire break in Fuel Pressure Sensor.
3. AIR MANIFOLD SIGNAL FAULT: This signal fault will appear on the display when
there is any wire break in Boost Air Pressure Sensor.
4. ACT. FEEDBACK SENSOR FAULT: This signal fault will appear on the display when
there is any wire break in Feedback Sensor (RVDT).
5. SPPED SENSOR FAULT: This signal fault will come on the display when there is any wire
break or Magnetic Pick-up Failure.
6. ENGINE OVERSPEED TRIP: This alarm will appear when the engine shutdown due to
Electrical Overspeed.
7. LOW LUBE OIL SHUTDOWN: This alarm will appear when the engine shutdown due to
Low Lube Oil or Lube oil Signal Fault.
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Trending
The Trending provides the real time curve of Engine Speed.
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Data Logging
The electronic governor has data logging facility. It uses CFM Card (1GB) to
record alarm history and time spent on each notch for last 24 hours with date
and time spent.
When you connect a USB cable in between Display and PC, below window will
appear on PC.
Double click on LOGS folder and the below window will appear on your PC.
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Double click on EVENTS folder if you want to check alarm history. The below
window will appear.
Double click on the excel file and the alarm history with date and time stamp will
appear on your PC in the form given below.
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Double click on NTCH_DLY folder if you want to check time spent on individual
notch. The below window will appear.
Double click on the excel file and the cumulative time spent on each notch in
seconds for last 24 hours with date and time stamp will appear on your PC in the
form given below.
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Reset Counters
st
th
Counters calculating time on 1 to 8 Notch can be reset any time through PC.
Set up communication between Governor and PC as per procedure mentioned
on page 16. Now go to Service mode and drag menu NOTCH DELAY
COUNTER RESET. Now select tunable RESET NOTCH 1 COUNTER to
RESET NOTCH 8 COUNTER to reset desired counter.
LEDs Indication on the Front Door

Ready To Start
This indication will appear on the control panel when the control system and the
power supply module are okay.
Shutdown
This indication will appear on the control panel when the control system is in
shutdown mode.
OS Test
This indication will appear on the control panel when the control system is in
Overspeed test mode.
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Magnetic Speed Pickup

The magnetic speed pickup (MPU) is used to detect the speed of the prime
mover. It is necessary when the prime mover drives something other than an
alternator, and is often used where an alternator is driven directly by the prime
mover and when a control signal is necessary before the alternator comes up to
its proper output voltage. A speed sensor circuit, either a section on the
governor amplifier chassis or a separate unit, is needed to convert the MPUs
output signal to one usable by the governor amplifier.
The magnetic pickup produces a voltage output when any magnetic material
moves through the magnetic field at the end of the pickup. Since most engines
and turbines have flywheels or other large gears made of magnetic material
(usually iron or steel), magnetic pickups can usually be installed without adding
attachments to gear or shaft. Nonmagnetic material such as aluminium, brass
and some stainless steels, will not excite the magnetic pickup.
The MPU makes use of a stray magnetic field and no provision for return
magnetic circuits or paths is necessary. Any device which produces a dynamic
discontinuity of magnetic material in the field of the pickup will produce an
electrical voltage. Although gears are the normal devices measured by an MPU,
other devices such as a vibrating surfaces, moving bar, crank, wheel spokes, or
a steel head screw mounted on some moving surface will work equally well if
surface speed and other factors are taken in account. The MPU may be excited
by a keyway or slot in a wheel, there is likely to be an unwanted background
signal due to varying density or eccentricity of the material. It is better to excite
the MPU from a protrusion on the surface. This places the pickup at a relatively
great distance from the materials between excitation periods and is likely to pick
up stray signals.
The output of a magnetic pickup is affected by three factors.
Voltage increases with increases of the surface speed of the monitored
magnetic material.
Voltage decreases as the air gap between the magnetic pickup and the
surface of the gear tooth is increased.
Voltage waveform is determined by the size and shape of the gear tooth
in relation to the size and shape of the pole piece.
With any given speed and clearance conditions, a maximum power output will
result when the field is filled with a relatively infinite mass of magnetic material at
one instant and a complete absence of such material the next. A reasonable
approach to these conditions exists when the cross-section of the exciting
masses is equal to or greater than that of the pole piece, and the space between
is equal to or greater than three rimes the diameter of the pole piece.
As the magnetic pickup-gear relationship begins to deviate from the
specifications listed above, the MPU output waveform may deteriorate to an
unacceptable shape. Because the speed sensor detects zero-crossings, the
waveform should cross zero only twice for each tooth (once going positive and
once going negative)
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Figure 4-16 Magnetic Pickup Dimensions

In above figure the optimum dimensions of A, B, C and F are given as they
relate to D, the diameter of the pole piece of the magnetic pickup. The optimum
relationship foe maximum output is as follows:
A equal to or greater than D
B equal to or greater than C
C equal to or greater than three times D
F equal to or greater than D
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Mount the magnetic pickup radially to the outside diameter of the desired gear
either through a housing or on a rigid bracket. Make sure the gear is of magnetic
material. The gap between the pickup and the outside diameter of the gear
should be set normally between 0.25 and 1.02 mm (0.010 and 0.040 ) at the
closest point [make sure the gear has less than 0.51 mm (0.020 ) diametric
runout]. Since the signal strength is inversely proportional to gap distance, a
weak signal may be generated with more than 1.02 mm (0.040 ) gap. A shield of
non-magnetic material may be installed between the gear and the pickup if
necessary for physical shielding. Since the material spaces the pickup face
farther from the gear, and since an electromagnetic force may be generated by
enough to operate the speed signal circuit.
Most electronic controls require a minimum output of 1.5 Vac (rms) from the
magnetic speed pickup at the lowest controlling speed. Above figure shows the
maximum air gap allowed for each surface speed and diametral pitch or gear
module to produce this maximum required voltage.
MPU Hertz = No. Teeth x Gear RPM x Gear Ratio

60
Example: MPU Hertz = 120 Teeth x 1800 RPM x 1
60
MPU Hertz = 3600 Hertz
How to Mount Magnetic Pickup on the Cam Gear Cover

With the prime mover shutdown, turn the pickup in until it just touches the
0
outside diameter of the gear. One 360 -turn counter clockwise will move the
pickup out 0.0555 inch (1.41 mm). Screw out the amount required for the
0
desired gap. If possible, run the gear slowly through 360 rotation to check the
clearance of the pickup. When the gap is set, tighten the jam nut securely
against the housing or bracket so the pickup cannot turn in or out. Repeat the
procedure for the second MPU
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Magnetic Pickup Installation

Woodward MCBG system comprises of one magnetic pick up unit, which is
installed on the cam gear cover. Two holes will need to be drilled on the cam
gear cover. The location where the holes need to be drilled on the cam gear
cover is shown on the drawing.
Figure 4-17 CAM Gear
Figure 4-18 Magnetic Pickup Mounted on CAM Gear Cover

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UG-Actuator
The UG-Actuator provides the muscle power required to control the engine fuel
rack. It has a self-contained oil sump so a separate oil supply is not required.
The UG-Actuator takes a given electrical input signal and converts it to a
proportional hydraulic output-shaft position to control engine fuel flow. The
standard UG-Actuator produces approximately 20J (15ft-lbs) of work over42
degrees of rotary output. The oil pump is the proven high-output gerator,
designed to provide long life with minimal maintenance. The actuators electric
to hydraulic transducer uses a Woodward built torque motor which converts the
20-160mA control signal to a given output position.
Terminal Shaft and Drive Shafts

Terminal Shaft - .500-36 Serrated
Drive Shaft 1.125-48 Serrated
Work 15ft-lb
Hydraulic Pump
The UG-Actuator is equipped with a Gerator pump. High speed and low speed
pumps are available, depending on the drive speed from the engine. The pump
uses oil from the self-contained UG-Actuator sump to provide 1172kPa (170 psi)
internal operating pressure. The direction of rotation is selected by pump
housing alignment. The pump operates in one direction only. The drive uses a
maximum of 375 W (0.5hp). If the actuator oil pump is rotated in the wrong
direction, oil pressure will not be generated in the actuator.
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Figure 4-19 UG Actuator
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Control Linkage
The terminal shaft rotates 42 degrees. Use 2/3 of the total rotation between no
load and full load. 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.
WARNING
To prevent possible serious injury or loss of life, or damage to the engine, be sure to
allow sufficient overtravel at each end of the terminal shaft so the actuator can
shutdown the engine, and also give maximum fuel when required. Misadjusted
linkage could prevent the actuator from shutting down the engine.
Many control problems are related to the linkage between the actuator and the
engine. Use only first-quality rod ends for the linkage, rod ends that will last
under the nearly constant motion associated with precise control. The linkage
must be stiff, not subject to engine-caused vibration. 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.
Installed linkage 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. Use a linear
linkage. Linear linkage moves the fuel-setting shaft in direct proportion to the
movement of the actuator output.
Design the linkage so the power output of the engine is proportional to the
position of the actuator output shaft.
Figure 4-20 Terminal Shaft Travel

a. Overtravel to insure prime mover stops are reached.
b. No load to full travel normally 2/3 of full governor travel is
recommended.
c. Travel required to accelerate the prime mover.
d. Travel required to decelerate or shut down prime mover.
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Linkage Installation
Install the serrated lever (0.500-36 serrations) to the output shaft of the actuator
(the serrations of both are matching).
Install the link by fixing one end of the rod end with the hole in the serrated lever
and tighten by M 12 allen bolt and nut with the spacer fitted on the bolt. Take the
other end of the rod right through the hole of the oil drip pan as shown in the
diagram and fix the other end of the rod end with the DLW spring lever clevis
DLW P/L No. 10131670. Please note that machining of DLW spring lever clevis
to 0.630-0.650 mm width is required to insert the other end of the rod end.
Tighten the link by M 12 allen bolt and nut arrangement. Put the spacer with the
bolt.
Calibrate the linkage with zero fuel rack position with zero in actuator.
Figure 4-21 Linkage
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Testing the functionality of MCBG Actuator on TEST Stand

The Woodward Actuator has following accessories, which needs to be checked.
a.
b.
c.
d.
e.
UG Actuator
Feedback Sensor
LOP Sensor.
FOP Sensor.
BAP Sensor.
The following items are required to test the Actuator.

a.
b.
c.
d.
e.
f.
g.
h.
i.
Woodward test Stand (8909-053).

Current Source from 0 200mA.
Voltage Regulated Power Supply range from 0 24 VDC.
24-ohm resistance.
9 Core Harness Connected one end with mating connector.
14 Core Harness Connected one end with mating connector.
Multimeter.
L-N Key Set.
Serrated Wrench (30943)
Follow the procedure given below to test UG Actuator on Test stand.
1. Put the Actuator on the Woodward test stand (8909-053). The fitment of
actuator on test stand will be same as PGEV fitment. You will get the
reference from the picture given for actuator fitment.
2. Fill the actuator with specified oil up to the indicator.
3. Check the wiring of actuator and its accessories as per drawing.
Feedback Sensor (9-pin connector; Ref. WD per Specification Report)
a.
Starting with Sensor shaft mark down in Coupling slot and Coupling set
screw at about 11 oclock position, adjust sensor mounting to align Sensor
shaft to actuator terminal shaft so Coupling can be freely rotated without
binding. Sensor shaft should stay centered in Coupling slot when rotated.
The end of Sensor shaft must not touch the end of the actuator terminal
shaft. [ ]
b. Supply 5.0 +/- 0.2 Vdc to Pins D (+) and F (-). Record ____________ Vdc.
c. Adjust feedback sensor output measured at Pins E (+) and F (-) to 4.25
4.45 Vdc at minimum actuator terminal shaft position.
Record
______________ Vdc.
d. Verify feedback sensor output is 0.44 - 0.84 Vdc at maximum actuator
terminal shaft position. Record _______ Vdc. Record max. term. shaft
angle _____ deg.
e. Verify that feedback sensor output voltage decreases uniformly as the
actuator terminal shaft is moved from minimum to maximum position. [ ]
f. Verify that hysteresis is acceptable by recording output voltage at 20 deg.
terminal shaft rotation by first approaching from minimum and then
approaching from maximum terminal shaft position.
The voltage
difference Vdc 1 ___ - Vdc 2 ___ should be less than 0.15 Vdc. ___. Readjust sensor mounting if necessary.
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g. Verify that setscrew on terminal shaft adapter and the two feedback sensor
clamp screws are tightened. [ ]
h. Record feedback sensor serial number. _________________________
4.
Pressure Transmitters (14-pin connector; Ref. WD per Specification Report)

a. For Boost Air Pressure transmitter, connect + 24 Vdc from power
supply through a milliamp meter then to Pin F and connect power
supply negative through a 240 ohm resistor then to Pin G; connect
pressure source to BOP port (top/right).
1) Verify
3.80-4.20
mA
Record__________mA
at
zero
gage
pressure.
2
2) Verify 11.65-12.05 mA at 35.6 psig (2.5 Kg/cm , 2.45 bar).

Record_______mA
3) Record transmitter serial number. _________________________
b. For Lube Oil Pressure transmitter, connect + 24 Vdc from power supply
through a milliamp meter then to Pin H and connect power supply
negative through a 240 ohm resistor then to Pin I; connect pressure
source to LOP port (middle).
1) Verify
3.80-4.20
mA
at
zero
gage
pressure.
Record__________mA
2
Record______mA
c.
For Fuel Oil Pressure transmitter, connect + 24 Vdc from power supply
through a milliamp meter then to Pin J and connect power supply
negative through a 240 ohm resistor then to Pin K; connect pressure
source to FOP port (bottom/left).
1) Verify
3.80-4.20
mA
Record__________mA
at
zero
gage
pressure.
2

Record_______mA
5.
Verify magnetic pick up wiring is per wiring diagram on Spec. Report. [ ]
6.
Actuator Output (connect through 9-pin connector A (+) and B (-))

a. Verify calibration in accordance with TSP-10245. [ ]
b. Confirm shaft rotation at 20 mA ____(1-2 deg.) and at 160 mA ____(3740 deg.).
7.
General
a. Actuator is free of leaks. [ ]
b. Verify there is no electrical conductivity (electrical short) between any
of the wired connector pins and the actuator housing (megger test). [ ]
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Chapter 5.
System Description
Introduction
This chapter contains information on control calibration. It includes initial
prestart-up and start-up settings and adjustments.
Start-up Adjustments
1. Complete the installation and connect all the interfacing cables between
the Control and the Actuator.
2. Close the 72 Vdc Switch on the panel. Check the green Ready to Start
indication appears on the front of panel.
3. Do the rack calibration.
Procedure For Rack Calibration Procedure

Connect the Hand Held terminal or PC to the 9 pin communication port mounted
on the door. Start as per process explained on page 16 (PC Interface). Bring
fuel rack manually to min. position. Now see the FEEDBACK SENSOR VOLTS
in the DISPLAY menu as shown in figure given below. Now go to
CALIBRATION OF ANALOG I/O menu and enter the above seen voltage in
RVDT VOLTS AT MIN RACK tunable. Now bring back fuel rack manually to
max. position. Now again see the FEEDBACK SENSOR VOLTS in the
DISPLAY menu. Now again go to CALIBRATION OF ANALOG I/O menu and
enter the above seen voltage in RVDT VOLTS AT MAX RACK tunable. Now
right click on Net1 (Dflt Control ID) and select SAVE VALUES to save all
changes you made and then press ESC button to come out of the program.
Crank the engine. Minimum voltage required from the speed sensor to operate
the control is 1.0 Vrms. Well get this voltage when the engine runs above 85
rpm during cranking. Before cranking ensure that the speed setting lever is at
Idle Notch. The engine will start running at Idle Speed.
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Overspeed Testing
Procedure for Testing Mechanical OST
th
Put the Engine on 8 Notch. Switch on the Mechanical OST Enable key switch
mounted on the control box door. Red LED mounted on the door will glow and
Locomotive RPM will gradually move to the OST set point and hold there. In
case mechanical OST not operating upto this rpm, shed staff should readjust
engine mechanical OST and repeat the same procedure.
In case mechanical OST fail to trip Loco, MCBG will issue shutdown command
to locomotive at ten RPM above the mechanical OST setpoint. It is the second
Electronic tripping from the MCBG which will work only when mechanical OST
fail. Press F3 button on the display and Mechanical OST Active status will be
displayed on the display as per picture given below.
Procedure for Testing Electronic OST

th
Put the Locomotive on 8 Notch. Switch on the OST key switch mounted on the
control box door in the Electrical OST position. Red LED mounted on the door
will glow and Engine RPM will gradually move to Electrical OST set point. Once
the RPM reaches to set point, governor will issue a shutdown command and a
message (Engine Overspeed Shutdown) will appear in the display in
Shutdown and OST Page. At the same time governor will generate an alarm
in the Alarm History Page with date and time stamping.
Press F3 button on the display and Electrical OST Active status will be displayed
on the display as per picture given below.
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Adjustment of Various Engine Parameters

Notch wise engine speed
Do the communication with MCBG as per process explained on page 16 (PC
Interface). Select the SPEED REF SETTING in Service menu and drag it on
the right hand side (Inspector 1) as per picture given below. Now set the desires
speed by clicking on up and down arrow. Any speed can be set. Now right click
on Net1 (Dflt Control ID) and click on save values to save the changed
parameters.
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Maximum permissible fuel rack at each notch

Interface). Select the MAX RACK LIMIT in Service menu and drag it on the
right hand side (Inspector 1) as per picture given below. Now set the desires
rack limit by clicking on up and down arrow. Now right click on Net1 (Dflt Control
ID) and click on save values to save the changed parameters.
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Maximum Permissible Fuel Rack in Relation to Boost air

Pressure
Interface). Select the LIMITER SETTING in Service menu and drag it on the
right hand side (Inspector 1) as per picture given below. Now set the desires fuel
limit by clicking on up and down arrow. Now right click on Net1 (Dflt Control ID)
and click on save values to save the changed parameters.
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PID Response
Interface). Select the SPEED PID ADJUSTMENT in Service menu and drag it
on the right hand side (Inspector 1) as per picture given below. Now set the
speed dynamics to remove hunting by clicking on up and down arrow. Now right
click on Net1 (Dflt Control ID) and click on save values to save the changed
parameters.
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Load Control Timing From Max to Min. Field Position

Interface). Select the LOAD REGULATION in service menu and drag it on the
right hand side (Inspector 1) as per picture given below. Now set the load
regulation timing by clicking on up and down arrow. Now right click on Net1 (Dflt
Control ID) and click on save values to save the changed parameters.
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Rack Calibration
Interface). Select the CALIBRATION OF ANALOG I/O in Service menu and
drag it on the right hand side (Inspector 1) as per picture given below. Now
calibrate the engine rack as per rack calibration procedure explained on page
42. Now right click on Net1 (Dflt Control ID) and click on save values to save the
changed parameters.
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Fuel Transmitter Calibration

Interface). Select the CALIBRATION OF ANALOG I/O in Service menu and
drag it on the right hand side (Inspector 1) as per picture given below. Now
calibrate the desired pressure sensor by changing its gain and offset. Now right
click on Net1 (Dflt Control ID) and click on save values to save the changed
parameters.
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Chapter 6.
Tunable
Service Value List
Service Prompt
Default
Range
Range
*SPEED REF SET*

IDLE/NOTCH 1 (rpm)
NOTCH 2 (rpm)
NOTCH 3 (rpm)
NOTCH 4 (rpm)
NOTCH 5 (rpm)
NOTCH 6 (rpm)
NOTCH 7 (rpm)
NOTCH 8 (rpm)
400
450
550
650
750
850
950
1050
200 TO 1000
200 TO 1000
200 TO 1000
200 TO 1000
200 TO 1000
200 TO 1000
200 TO 1200
500 TO 1300
*ALARM MONITOR*
SHUTDOWN
SPEED SENSOR FAULT
LOW LUBE OIL PRESSURE
LOW FUEL PRESSURE
OVERSPEED
ACT POS SIGNAL FAILURE
LUBE OIL SIGNAL FAIL
FUEL PRESS SIGNAL FAIL
AIR BOX SIGNAL FAIL
MONITOR
MONITOR
MONITOR
MONITOR
MONITOR
MONITOR
MONITOR
MONITOR
MONITOR
*CONTROL MODE*
SPEED IN CONTROL
AIR BOX LIMITER IN CNTRL
ENGINE SHUTDOWN
MONITOR
MONITOR
MONITOR
*CALIBRATION KEY*
ENTER CAL PASSWARD
49
0 TO 999
0.00
1.00
0.00
1.00
0.00
1.00
0.79
33.0
4.18
0.0
33.0
-50.0 TO 50.0
0.00 TO 3.00
-30.0 TO 30.0
0.00 TO 3.00
-50.0 TO 50.0
0.00 TO 3.00
0.01 TO 5.00
0.0 TO 35.0
0.01 TO 5.00
0.0 TO 35.0
*CALIBRATION ANALOG I/O*

AIR PRES SIGNAL OFFSET
AIR PRES SIGNAL SPAN
LUBE OIL PRES SIGNL OFFSET
LUBE OIL PRES SIGNAL SPAN
FUEL PRES SIGNAL OFFSET
FUEL PRES SIGNAL SPAN
RVDT VOLTS AT MAX RACK
MAX. RACK OPENNING (mm)
RVDT VOLTS AT MIN RACK
MIN RACK OPPENNING (mm)
Woodward
59
Final
Value
Manual B37818
IRLEC
*DISPLAY*
ACTUAL SPEED
SPEED REFERENCE
NOTCH POSITION
ACTUATOR OUTPUT
ACTUATOR FEEDBACK
BOOST AIR PRESS (bar)
LUBE OIL PRESS (bar)
LOAD BIAS %
FUEL PRESS (bar)
FEEDBK SENSR VOLTS
MONITOR
MONITOR
MONITOR
MONITOR
MONITOR
MONITOR
MONITOR
MONITOR
MONITOR
MONITOR
*L/O PRESS MONITOR*

NOTCH1 TRIP DELAY
NOTCH2 TRIP DELAY
NOTCH3 TRIP DELAY
NOTCH4 TRIP DELAY
NOTCH5 TRIP DELAY
NOTCH6 TRIP DELAY
NOTCH7 TRIP DELAY
NOTCH8 TRIP DELAY
IDLE NTCH LUBE OIL REF.
TH
8 NTCH LUBE OIL REF.
42.0
0.5
0.5
0.5
0.5
0.5
0.5
0.5
1.1
4.2
10.0 to 120.0
10.0 to 120.0
10.0 to 120.0
10.0 to 120.0
10.0 to 120.0
10.0 to 120.0
10.0 to 120.0
10.0 to 120.0
0.0 to 5.0
0.0 to 16.0
12.0
15.0
18.0
21.0
24.0
27.0
30.0
33.0
0.0 TO 35.0
0.0 TO 35.0
0.0 TO 35.0
0.0 TO 35.0
0.0 TO 35.0
0.0 TO 35.0
0.0 TO 35.0
0.0 TO 35.0
FALSE
1215.0
MONITOR
TRUE TO FALSE
1100.0 TO 1300.0
1205.0
FALSE
FALSE
FALSE
1100.0 TO 1300.0
TRUE TO FALSE
TRUE TO FALSE
TRUE TO FALSE
3.50
3.50
4.50
0.01 TO 20.0
0.01 TO 20.0
0.01 TO 20.0
*MAX RACK LMT*

NOTCH 1 RACK (mm)
NOTCH 2 RACK (mm)
NOTCH 3 RACK (mm)
NOTCH 4 RACK (mm)
NOTCH 5 RACK (mm)
NOTCH 6 RACK (mm)
NOTCH 7 RACK (mm)
NOTCH 8 RACK (mm)
*ENGINE OST*
OST ENABLE
OST RPM
OST FAIL TRIP RPM
*TRIP SETTING*
OVERSPEED TRIP (rpm)
LOP TRIP BYPASS
BAP TRIP BYPASS
RACK LIMIT BYPASS
*SPEED PID ADJUSTMNT*
GAIN1
IDLE GAIN
RATED GAIN
60
Woodward
Manual B37818
IRLEC
RESET1
IDLE RESET
RATED RESET
COMPE1
0.04
0.04
0.10
60.0
0.01 TO 20.0
0.01 TO 20.0
0.01 TO 20.0
0.001 TO 100.0
IDLE COMPE
RATED COMPE
WINDOW WIDTH
GAIN RATIO
80.0
80.0
5.0
1.0
0.001 TO 100.0
0.001 TO 100.0
0 TO 200
1.0 TO 20.0
BAP LMT GAIN

BAP LMT INT
0.50
0.02
0.01 TO 20.0
0.01 TO 20.0
33.0
54.75
0.0
1.0 TO 1000.0
1.0 TO 1000.0
0.0 TO 500.0
0.0
100.0
0.0
0.0 TO 100.0
0.0 TO 100.0
0.0 TO 15.0
7.0
8.0
7.0
5.0
5.0
2.0
MONITOR
MONITOR
0.01 TO 15.00
0.01 TO 20.00
0.01 TO 20.00
0.01 TO 10.00
2.0 TO 50.0
5.0 TO 100.0
65
0.0
43.29
0.05
56.61
0.25
69.30
0.6
76.59
1.10
86.58
1.70
100.0
0.025
53.33
0.1
61.66
0 TO 100
0.00 TO 30.00
0.00 TO 100.00
0.00 TO 30.00
0.00 TO 100.00
0.00 TO 30.00
0.00 TO 100.00
0.00 TO 30.00
0.00 TO 100.00
0.00 TO 30.00
0.00 TO 100.00
0.00 TO 30.00
0.00 TO 110.00
0.00 TO 30.00
0.00 TO 100.00
0.00 TO 30.00
0.00 TO 100.00
0.2
68.33
0.00 TO 30.00
0.00 TO 100.00
0.01
0.00 TO 20.00
*SPEED REF RATES*

RAISE RATE (rpm/sec)
LOWER RATE (rpm/sec)
IDLE DROOP (rpm)
*SPEED DROOP*
MIN LOAD ACTUATOR (%)
MAX LOAD ACTUATOR (%)
SPEED DROOP (%)
*LOAD REGULATION*
SLOW LOAD CUT RATE
FAST LOAD CUT RATE
SLOW LOAD UP RATE
FAST LOAD UP RATE
SLOW RATE DEADBAND
FAST RATE DEADBAND
LOAD BIAS (%)
LCP ACTIVE
*LIMITER SETTING*
START FUEL LIMITER
BOOST AIR PRS (bar) P1
BOOST AIR LMTR P1 ACT%
*ACTUATOR SETTING*
DITHER Amp (map_p)

Woodward
61
Manual B37818
IRLEC
*NTCH DLY COUNTER RST*

RESET NOTCH 1 COUNTER
RESET ALL COUNTERS
62
Woodward
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
TRUE TO FALSE
TRUE TO FALSE
TRUE TO FALSE
TRUE TO FALSE
TRUE TO FALSE
TRUE TO FALSE
TRUE TO FALSE
TRUE TO FALSE
TRUE TO FALSE
Manual B37818
IRLEC
Configure Value List

SPEED CONTROL
NO OF TEETH SPEED SENSOR 1
GEAR RATIO
SPEED SENSOR FAILED AT
NO OF TEET SPEED SENSOR 2
SPEED SET FOR PID
IDLE 1 FOR GAIN
IDLE FOR GAIN
RATED FOR GAIN
IDLE 1 FOR RESET
IDLE FOR RESET
RATED FOR RESET
IDLE 1 FOR COMPENSATION
IDLE FOR COMPENSATION
RATED FOR COMPENSATION
200
350
1050
200
350
1050
200
350
1050
200 TO 1000
200 TO 1000
500 TO 1500
200 TO 1000
200 TO 1000
500 TO 1500
200 TO 1000
200 TO 1000
500 TO 1500
FALSE
20
160
TRUE TO FALSE
ACTUATOR DRIVER
USE ACTUATOR DITHER?
ACTUATOR MIN mA
ACTUATOR MAX mA
MISCELLANEOUS
EMG SHUTDOWN LATCH?
USE AUTO START MODE?
USE SPEED DROOP?
Woodward
63
Manual B37818
IRLEC
Service Tunable Description

* Speed Ref Setting *
IDLE/NOTCH 1 (rpm)
Is the first notch rpm reference at which

the prime mover has to run.
NOTCH 2 (rpm)
Is the second notch rpm reference at

which the prime mover has to run.
NOTCH 3 (rpm)
Is the third notch rpm reference at which

NOTCH 4 (rpm)
Is the fourth notch rpm reference at which

NOTCH 5 (rpm)
Is the fifth notch rpm reference at which

NOTCH 6 (rpm)
Is the sixth notch rpm reference at which

NOTCH 7 (rpm)
Is the seventh notch rpm reference at

which the prime mover has to run.
NOTCH 8 (rpm)
Is the eighth notch rpm reference at which

*Alarm Monitor*
SHUTDOWN
If true, indicates control is in shutdown

mode.
SPEED SENSOR FAULT
If true, indicates speed is not sensed by

magnetic pickup.
LOW LUBE OIL PRES.
If true, indicates lube oil pressure is low at

desired speed level.
LOW FUEL PRESSURE
If true, indicates fuel pressure is low at

desired speed level.
OVERSPEED
If true, indicates control tripped due to

overspeed.
ACT POS SIG FAILURE
If true, indicates wire break or Feedback

Sensor (RVDT) fail.
LUBE OIL SIGNAL FAIL
If true, indicates wire break or Lube Oil

Pressure Transducer fail.
FUEL SIGNAL FAILURE
If true, indicates wire break or Fuel

AIR BOX SIGNAL FAILURE
If true, indicates wire break or Air

64
Woodward
Manual B37818
IRLEC
*Control Mode*
SPEED IN CONTROL
If true, indicates control is running in

speed control mode and no limiter is
active.
AIR BOX LIM IN CONT
If true, indicates Air Box Pressure Limiter

limiting fuel rack.
SHUTDOWN ENGINE
If true, indicates control is in shutdown

mode.
*Calibration I/O*
AIR PRES SIGNAL OFFSET
If it is necessary to calibrate the Air Box

Pressure Transducer, adjustment of this
parameter will alter the offset. To
calibrate the transducer, Set the
pressure to zero, and ensure that the
control is measuring Zero. If not, Adjust
the offset until it does. Then set the
pressure to its maximum range. Ensure
that the control measuring 20. If not,
adjust the gain until it does. Return the
mA input to zero, and check the control
is still measuring zero. If not repeat the
calibration process.
AIR BOX SIGNAL SPAN
If it is necessary to calibrate the Air Box

parameter will alter the span.
LUBE OIL SIGNAL OFFSET
If it is necessary to calibrate the Lube Oil

parameter will alter the offset. To
LUBE OIL SIGNAL SPAN
If it is necessary to calibrate the Lube Oil

FUEL PRES SIGNAL OFFSET
If it is necessary to calibrate the Fuel

Pressure Transducer, adjustment
of this parameter will alter the offset. To
Woodward
65
Manual B37818
IRLEC
FUEL PRES SIGNAL SPAN
If it is necessary to calibrate the Fuel

RVDT VOLTS AT MAX RACK
Is the voltage as seen in the

Handheld/PC when the fuel rack of the
engine is at max position.
Is the value as seen at the engine rack at

max position.
RVDT VOLTS AT MIN RACK
Is the voltage as seen in the

Handheld/PC when the fuel rack of the
engine is at min position.
MIN. RACK OPENNING (mm)

min position.
MAX RACK OPENNING (mm)

max position. This value should be
entered same as value of Rack Max.
*L/O Press Monitor*

NOTCH 1 TRIP DELAY
is the delay in sec. within which engine

will stop/trip if the desired L/O pressure
is not achieved at Notch1.
NOTCH 2 TRIP DELAY

NOTCH 3 TRIP DELAY

NOTCH 4 TRIP DELAY

NOTCH 5 TRIP DELAY

NOTCH 6 TRIP DELAY

NOTCH 7 TRIP DELAY

NOTCH 8 TRIP DELAY

66
Woodward
Manual B37818
IRLEC
IDLE NTCH LUBE OIL REF (bar)

th
8 NTCH LUBE OIL REF (bar)
is the desired L/O pressure at Idle Speed

is the desired L/O pressure at Eighth
Speed
*Max RCK LMT*

NOTCH 1 RACK (mm)
is the max allowable rack opening (in mm) at

Notch1.
NOTCH 2 RACK (mm)

Notch2.
NOTCH 3 RACK (mm)

Notch3.
NOTCH 4 RACK (mm)

Notch4.
NOTCH 5 RACK (mm)

Notch5.
NOTCH 6 RACK (mm)

Notch6.
NOTCH 7 RACK (mm)

Notch7.
NOTCH 8 RACK (mm)

Notch8.
*Engine OST*
OST ENABLE
Woodward
67
if selected true, will enable OST menu. Now if

th
the engine is at 8 Notch and OST switch
Manual B37818
IRLEC
mounted inside the control is on, then engine
rpm will move toward OST rpm set point.
OST RPM
OST FAIL TRIP RPM
th
is the rpm above 8 Notch rpm setting to test

engine mechanical OST.
is the rpm at which controller will issue a stop
command automatically if engine goes above
OST rpm and mech. OST does not operate.
*Trip Setting*
OVERSPEED TRIP (rpm)
LOP TRIP BYPASS
AIR PRESS BYPASS
RACK LIMIT BYPASS
Is the first electronic overspeed trip set point.

If selected true will bypass the L/O trips
If selected true will bypass the fuel limiter.
If selected true will bypass the Rack limiter.
*Speed PID Adjustment*

GAIN 1
Determine how fast the control responds to an

error in engine speed from the engine speedreference setting. The gain is set to provide
stable control of the engine at light or
unloaded conditions.
IDLE GAIN

error in engine speed from the engine speedreference setting. The gain is set to provide
stable control of the engine at light or
RATED GAIN
Determine how fast the control responds to

an error in engine speed from the engine
speed-reference setting. The gain is set to
provide stable control of the engine at light or
RESET 1
Compensate for the lag time of the engine. It

adjust the time required for the control to
return the speed to zero error after a
disturbance. Reset is adjusted to prevent slow
hunting and to minimize speed overshoot after
a load disturbance.
IDLE RESET

a load disturbance.
RATED RESET

a load disturbance.
Compensation compensate for the time the
actuator and engine takes to react to the
signal from the control. Increasing
compensation increases actuator activity and
transient performance.
COMPE 1
68
Woodward
Manual B37818
IRLEC
IDLE COMPE

RATED COMPE

WINDOW WIDTH
Is the magnitude (in rpm) of speed error at

which the control automatically switches to
fast response. The control uses the absolute
value of speed error to make this switch.
The absolute value is the difference between
the speed reference and the speed. A window
width too narrow will result in cycling that
always factors in the Gain Ratio.
GAIN RATIO
Is the ratio of the gain setting at steady state

to the gain setting during
transient conditions. The Gain ratio operates
in conjunction with the
window width and gains adjustments by
multiplying the gain set point by the gain ratio
when the speed error is greater than the
window width. This makes the control
dynamics fast enough to minimize engine
speed overshoot on start-up and to reduce the
magnitude of speed error when loads are
changing. This allows a lower gain at steady
state for better stability and reduced steadystate actuator linkage movement
error in engine rack limit logic. The gain is set
to provide stable control of the engine.
a load disturbance.
BAP LIMITER GAIN
BAP LIMITER RESET
*Speed Rates*
RAISE RATE (rpm/sec)
LOWER RATE (rpm/sec)
IDLE DROOP (rpm)
is the rate at which the speed reference is

increased when notch position is changed.
is the rate at which the speed reference is
decreased when notch position is changed.
is the % of rated speed by which the speed
reference is dropped at zero to idle speed.
*Speed Droop*
MIN LOAD ACTUATOR (%)
MAX LOAD ACTUATOR (%)
Woodward
69
sets the minimum output required to the

actuator.
sets the maximum output required to the
actuator.
Manual B37818
SPEED DROOP (%)
IRLEC
is the % of rated speed by which the speed
reference is dropped at zero to full load.
*Load Regulation*
SLOW LOAD CUT RATE
is the rate at which the LCP output moves from

min. to max.
FAST LOAD CUT RATE

min. to max.
SLOW LOAD UP RATE

max. to min.
FAST LOAD UP RATE

max. to min.
SLOW RATE DEADBAND
is the speed error within this window and dead

band slow load rates will be applicable.
FAST RATE DEADBAND
is the speed error within this window and dead

band after which the fast load rates will be
applicable.
is the LCP output.
LOAD BIAS %
LCP ACTIVE
if true, indicates LCP is giving command to

excitation system of alternator for load control.
*Limiter Setting*
START FUEL LIMITER
is the max. actuator output during engine

startup.
AIR BOX PRS (bar) P1
these are the tunables for the setup of fuel limiter

curve according to the air box pressure.
AIR BOX LIM P1 ACT%

curve according to the fuel rack opening.

curve according to the airbox pressure.
AIR BOX LIM P3 ACT%

curve according to the fuel rack opening.

curve according to the air box pressure.
AIR BOX LIM P6 ACT%
these are the tunables for the setup of fuel

limiter curve according to the fuel rack opening.

limiter curve according to the air box pressure
AIR BOX LIM P7 ACT%

limiter curve according to the fuel rack opening.
70
Woodward
Manual B37818
IRLEC
these are the tunables for the setup of

fuel limiter curve according to the air box
pressure.
AIR BOX LIM P8 ACT%

fuel limiter curve according to the fuel
rack opening.

pressure.
AIR BOX LIM P9 ACT%

rack opening.

pressure.
AIR BOX LIM P2 ACT%

rack opening.

fuel limiter curve according to the airbox
pressure.
*Limiter Setting*
DITHER Amp (map_p)
*Notch Delay Counter Reset*
RESET ALL COUNTERS
Woodward
71
This is the tunable to reset notch 1 time

calculating counter.
This is the tunable to reset 1 to 8 notch
counters simultaneously.
Manual B37818
IRLEC
Configure Tunable Description

Speed Control
NO OF TEETH SPD SNSR 1
GEAR RATIO
SPEED SENSOR FAILED AT

NO OF TEETH SPD SNSR 2
is the number of teeth (or holes) on the speed

sensing disc, for the speed sensor.
Enter the speed sensor gear ratio. This
value is the ratio of the speed sensor gear to
the engine shaft. This gear ratio is the
result of dividing the speed of the speed
sensor gear by the speed of the
engine shaft.
is the engine speed at which governor will
issue a shutdown command
is the number of teeth (or holes) on the speed
sensing disc, for the speed sensor.
Speed Set For PID

IDLE 1 FOR GAIN
IDLE FOR GAIN
RATED FOR GAIN
IDLE 1 FOR RESET
IDLE FOR RESET
RATED FOR RESET
IDLE 1 FOR COMPENSATN
IDLE FOR COMPENSATION
RATED FOR COMPENSATN
is the engine speed at which gain 1 will

come in control.
is the engine speed at which idle gain will
come in control.
is the engine speed at which rated gain will
come in control.
is the engine speed at which reset I will
come in control.
is the engine speed at which idle reset will
come in control.
is the engine speed at which rated reset will
come in control.
is the engine speed at which compensation 1
will come in control.
is the engine speed at which idle
compensation will come in control.
is the engine speed at which rated
compensation will come in control.
Actuator Driver
USE ACTUATOR DITHER?
ACTUATOR MIN. mA
ACTUATOR MAX Ma
MISCELLANEOUS
EMG SHUTDOWN LATCH?
USE AUTO START MODE?
USE SPEED DROOP
72
Woodward
is the parameter which enable dither

is the Actuator output at 0%.
is the actuator output at 100%.
Manual B37818
IRLEC
Chapter 7.
Troubleshooting
The following troubleshooting guide is an aid in isolating trouble to the
control, actuator.
NOTE
The control can be damaged with the wrong voltage. When replacing a
control, check the power supply, battery etc. for the correct voltage
SYMPTOM
Ready to start
indication is not
coming on door.
CAUSE
1. 72 Vdc supply switch
may be in off position
2. LED may be defective.
3. 733 control is not

power on.
4. Power supply module

may be defective.
5. Harness may be
defective.
Woodward
73
REMEDY
Switch on the switch.
Check the voltage across
LED (24 VDC) and its
Wiring.
Remove the connector
from 733 control and
measure the DC voltage
across terminals Y3 Y1.
If voltage is
available, 733
control is defective.
Replace the control.
Check the voltage
across power supply
module input (72VDC)
and output terminal
(24VDC). If no voltage
across output, the
module is defective.
a. Check the voltage
across terminal 50 and
4 of excitation panel
(72 VDC).
b. Check the voltage
across 17 pin
connector terminal G
and H (72VDC).
Manual B37818
IRLEC
SYMPTOM
Display is blank
CAUSE
Absence of power supply
to the control unit or
display, or display may be
defective.
No speed
sensing.
Magnetic pickup could be

defective
Speed Sensor
Failure
Magnetic pickup could be

defective
Lube Oil Signal

Failure
LOP Sensor could be

defective.
Check the LOP sensor

wiring. If wiring is ok
then sensor is faulty
Boost Air Signal BAP Sensor could be

Failure
defective.
Check the BAP sensor

wiring. If wiring is ok
then sensor is faulty.
Feedbak Sensor
Failure
Check the position

sensor wiring. If wiring
is ok then sensor is
faulty.
74
Woodward
Fuel rack position sensor

could be defective.
REMEDY
Check the voltage across
Display terminal
(24VDC). If voltage is
available then display is
faulty. If no voltage then
checks display wiring
and power supply
module healthiness by
measuring voltage.
a. Check the resistance
across magnetic
pickup terminals
(190 215 )
b. Check the speed
sensor wiring.
c. Check the clearance
between sensor tip
and gear teeth.
For this testing refer
the guidelines given in
manual on page no 38
(how to mount
magnetic pickup)
Repeat above process.
Manual B37818
SYMPTOM
Engine
shutdown due to
overspeed
Engine
shutdown due to
low lube oil
pressure.
Engine not
delivering rated
Horsepower.
Engine not
moving on the
track.
Woodward
75
IRLEC
CAUSE
Overspeed set point may
be low.
REMEDY
Connect pc with MCBG
using RS 232 cable and
follow the
communication process
given in manual and
check the overspeed set
point. Change the
setpoint and save values.
Non linear movement of

rack linkage
Engine is in Overspeed
test mode.
Check the linkage and

adjust it if required.
Switch off the OST
Enable switch.
Lube oil pressure not

building up.
a. Check the Lube oil

pressure system or its
pipelines to actuator.
Fuel Limiter active.

BAP Sensor faulty
Turbo charger problem
LCP Module problem
b. Check the Lube oil

sensor and its wiring.
Bypass fuel limiter
and reload the engine.
Check and change the
sensor.
Check the turbo charger.
Check the LCP Module
circuit. The minimum
voltage across terminal
29A and 4 should be
24 VDC.
Manual B37818
76
Woodward
IRLEC
Manual B37818
IRLEC
Chapter 8.
Service Options
Product Service Options
The following factory options are available for servicing Woodward equipment,
based on the standard Woodward Product and Service Warranty (5-01-1205) that
is in effect at the time the product is purchased from Woodward or the service is
performed:
0
Replacement/Exchange (24-hour service)
1
Flat Rate Repair
2
Flat Rate Remanufacture
If you are experiencing problems with installation or unsatisfactory performance
of an installed system, the following options are available:
0
Consult the troubleshooting guide in the manual.
1
Contact Woodward technical assistance (see How to Contact Woodward

later in this chapter) and discuss your problem. In most cases, your
problem can be resolved over the phone. If not, you can select which
course of action you wish to pursue based on the available services listed
in this section.
Replacement/Exchange
Replacement/Exchange is a premium program designed for the user who is in
need of immediate service. It allows you to request and receive a like-new
replacement unit in minimum time (usually within 24 hours of the request),
providing a suitable unit is available at the time of the request, thereby
minimizing costly downtime. This is also a flat rate structured program and
includes the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205).
This option allows you to call in the event of an unexpected outage, or in
advance of a scheduled outage, to request a replacement control unit. If the unit
is available at the time of the call, it can usually be shipped out within 24 hours.
You replace your field control unit with the like-new replacement and return the
field unit to the Woodward facility as explained below (see Returning Equipment
for Repair later in this chapter).
Charges for the Replacement/Exchange service are based on a flat rate plus
shipping expenses. You are invoiced the flat rate replacement/exchange charge
plus a core charge at the time the replacement unit is shipped. If the core (field
unit) is returned to Woodward within 60 days, Woodward will issue a credit for
the core charge. [The core charge is the average difference between the flat
rate replacement/exchange charge and the current list price of a new unit.]
Return Shipment Authorization Label. To ensure prompt receipt of the core,
and avoid additional charges, the package must be properly marked. A return
authorization label is included with every Replacement/Exchange unit that
leaves Woodward. The core should be repackaged and the return authorization
label affixed to the outside of the package. Without the authorization label,
receipt of the returned core could be delayed and cause additional charges to be
applied.
Woodward
77
Manual B37818
IRLEC
Flat Rate Repair

Flat Rate Repair is available for the majority of standard products in the field.
This program offers you repair service for your products with the advantage of
knowing in advance what the cost will be. All repair work carries the standard
Woodward service warranty (Woodward Product and Service Warranty
5-01-1205) on replaced parts and labor.
Flat Rate Remanufacture

Flat Rate Remanufacture is very similar to the Flat Rate Repair option with the
exception that the unit will be returned to you in like-new condition and carry
with it the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205). This option is applicable to mechanical products
only.
Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned to Woodward
for repair, please contact Woodward in advance to obtain a Return Authorization
Number. When shipping the item(s), attach a tag with the following information:
name and location where the control is installed;
name and phone number of contact person;
complete Woodward part number(s) and serial number(s);
description of the problem;
instructions describing the desired type of repair.
CAUTIONELECTROSTATIC DISCHARGE
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.
Packing a Control
Use the following materials when returning a complete control:
protective caps on any connectors;
antistatic protective bags on all electronic modules;
packing materials that will not damage the surface of the unit;
at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
a packing carton with double walls;
a strong tape around the outside of the carton for increased strength.
78
Woodward
Manual B37818
IRLEC
Return Authorization Number

When returning equipment to Woodward, please telephone and ask for the
Customer Service Department [1 (800) 523-2831 in North America or
+1 (970) 482-5811]. They will help expedite the processing of your order through
our distributors or local service facility. To expedite the repair process, contact
Woodward in advance to obtain a Return Authorization Number, and arrange for
issue of a purchase order for the item(s) to be repaired. No work can be started
until a purchase order is received.
NOTE
We highly recommend that you make arrangement in advance for return
shipments. Contact a Woodward customer service representative at
1 (800) 523-2831 in North America or +1 (970) 482-5811 for instructions and
for a Return Authorization Number.
Replacement Parts
When ordering replacement parts for controls, include the following information:
the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
the unit serial number, which is also on the nameplate.
How to Contact Woodward

In North America use the following address when shipping or corresponding:
Woodward Governor Company
PO Box 1519
1000 East Drake Rd
Fort Collins CO 80522-1519, USA
Telephone+1 (970) 482-5811 (24 hours a day)
Toll-free Phone (in North America)1 (800) 523-2831
Fax+1 (970) 498-3058
For assistance outside North America, call one of the following international
Woodward facilities to obtain the address and phone number of the facility
nearest your location where you will be able to get information and service.
FacilityPhone Number
Brazil+55 (19) 3708 4800
India+91 (129) 4097111
Japan+81 (476) 93-4661
The Netherlands +31 (23) 5661111
You can also contact the Woodward Customer Service Department or consult
our worldwide directory on Woodwards website (www.woodward.com) for the
name of your nearest Woodward distributor or service facility.
Woodward
79
Manual B37818
IRLEC
Engineering Services
Woodward Industrial Controls Engineering Services offers the following aftersales support for Woodward products. For these services, you can contact us by
telephone, by email, or through the Woodward website.
Technical Support
Product Training
Field Service
Contact information:
Telephone+1 (970) 482-5811
Toll-free Phone (in North America)1 (800) 523-2831
Emailicinfo@woodward.com
Websitewww.woodward.com
Technical Support is available through our many worldwide locations or our
authorized distributors, depending upon the product. This service can assist you
with technical questions or problem solving during normal business hours.
Emergency assistance is also available during non-business hours by phoning
our toll-free number and stating the urgency of your problem. For technical
support, please contact us via telephone, email us, or use our website and
reference Customer Services and then Technical Support.
Product Training is available at many of our worldwide locations (standard
classes). We also offer customized classes, which can be tailored to your needs
and can be held at one of our locations or at your site. This training, conducted
by experienced personnel, will assure that you will be able to maintain system
reliability and availability. For information concerning training, please contact us
via telephone, email us, or use our website and reference Customer Services
and then Product Training.
Field Service engineering on-site support is available, depending on the
product and location, from one of our many worldwide locations or from one of
our authorized 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. For field service engineering assistance, please
contact us via telephone, email us, or use our website and reference Customer
Services and then Technical Support.
80
Woodward
Manual B37818
IRLEC
Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:
General
Your Name
Site Location
Phone Number
Fax Number
Prime Mover Information

Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, gaseous, steam, etc)
Rating
Application
Control/Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:
Woodward Part Number and Revision Letter

Control Description or Governor Type
Serial Number
Serial Number
Serial Number
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.
Woodward
81
Manual B37818
82
Woodward
IRLEC
Control Specifications
Input Power
Voltage 1832 Vdc (24 Vdc nominal)
Power Consumption 12 W nominal, 20 W maximum
Speed Signal Inputs (2)
Speed Input Voltage Magnetic Pickup: 1.470.0 V peak-to-peak
Proximity Switch: 528 Vdc
Speed Input Frequency 10 Hz to 25 kHz
Proximity Input Duty Cycle 1090% to 10 kHz, 2080% to 20 kHz
Magnetic Pickup Diagnostics Open wire detection
Discrete Inputs (8)
Type 4 isolated inputs configurable for PWM, Boolean, or proximity
4 non-isolated inputs are dedicated Boolean inputs
Discrete Input Type Sinking with internal pull-up Impedance 10 k
Proximity Probe Frequency/Duty Cycle 10 Hz 7 kHz; 1090% to 3 kHz, 2080% to 7
kHz PWM Frequency/Duty Cycle 100 Hz 1 kHz; 1090% duty cycle
Analog Inputs (4)
Type 420 mA, transducers externally powered
Input Impedance 200
Resolution 12 bits
Accuracy 0.5% of 020 mA (05 V) typical (1 sigma)
1.3% of 020 mA (05 V) max (3 sigma)
Current Outputs, 420 mA (3)
Type 420 mA
Resolution 12 bits
Accuracy 0.5% of 020 mA (05 V) typical (1 sigma)
1.3% of 020 mA (05 V) max (3 sigma)
Diagnostics Current readback provided
Current Outputs, 420/20160 mA (1)
Type 420 mA or 20160 mA
Accuracy 0.8% of full scale (20 mA) typical (1 sigma)
2.1% of full scale max (3 sigma)
1.1% of full scale (160 mA) max (3 sigma)
3.3% of full scale max (3 sigma), Resolution 12 bits
Diagnostics Current readback provided
Boolean/PWM Outputs (4)
Type isolated outputs sinking to dedicated return
Each output can be configured as either Boolean or PWM
Max Output Current 500 mA (Boolean), 150 mA (PWM)
PWM Frequency Range 501000 Hz (configurable)
Proximity Probe Power Output (1)
Voltage Level 17 Vdc, isolated
Current Limit 60 mA
Environment
Max Operating Temperature 40 to +100 C (40 to +212 F)
Storage Temperature 40 to +120 C (40 to +248 F)
Humidity 95% at +60 C (+140 F)
Mechanical Vibration US MIL-STD 202F, Method 214A, TC(B)
Mechanical Shock US MIL-STD 810C, Method 516.2, Procedure I
CE Compliant EMC Directive, ATEX Directive (Zone 2, Group II)
EMC EN 61000-6-2:2001 Immunity for Industrial Environments
EN 61000-6-4:2001 Emissions for Industrial Environments
Enclosure Protection IP-66
We appreciate your comments about the content of our publications.

Send comments to: icinfo@woodward.com
Please include the manual number from the front cover of this publication.
PO Box 1519, Fort Collins CO 80522-1519, USA

1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811 Fax +1 (970) 498-3058
Email and Websitewww.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.
09/1/F

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Application and Hardware Manual

Indian Railway Locomotive Electronic

WARNINGDANGER OF DEATH OR PERSONAL INJURY

CAUTIONPOSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY

RevisionsText changes are indicated by a black line alongside the text.

CHAPTER 2. INSTALLATION ........................................................................ 3

CHAPTER 3. SYSTEM WIRING DRAWINGS .................................................... 5

CHAPTER 4. SYSTEM HARDWARE DESCRIPTION ........................................ 11

Linkage Installation ....................................................................................... 43

CHAPTER 5. SYSTEM DESCRIPTION .......................................................... 47

CHAPTER 6. TUNABLE ............................................................................. 59

CHAPTER 7. TROUBLESHOOTING .............................................................. 73

CONTROL SPECIFICATIONS ...................................................................... 83

Electrostatic Discharge Awareness

Before doing maintenance on the electronic control, discharge the static

Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam

Introduction Installation Checkout Procedure

Figure 3-1 IRLEC Functional Overview

Figure 3-2 Cabinet General Arrangement

Figure 3-3 Control Wiring Diagram

SOL A/ESRA (15A/15)

SOL B/ESR2 (12A/12)

SOL C/ESR3 (7C/7)

SOL D/ESR4 (3A/3)

Digital/PWM Output Return

DO Circuit Power Input

Boolean Input Return

Figure 3-4 UG-Actuator Wiring Diagram

Figure 3-5 Interfacing Cables Detail

733 Digital Control

1832 Vdc, protected from reverse

Current (420 mA)

106000 Hz (when used as fuel

Function Configurable outputs

Current (either 420 mA or 20160

Switch to return pins to activate

Low side drivers

733 Wiring Pin Out

Digital / PWM Input 1

Digital / PWM Input 3

Analog Output 2 (+)

Actuator Output 2 (+)

Digital / PWM Output 3

Analog Input 3 (+)

Analog Input 1 (+)

Using Watch Window

4. Select OK. If everything is working right, you should see an animated

Power Supply Module

Figure 4-4 Power Supply Module

Testing Power Supply Module:

1. Boost Air Pressure Transducer:

2. Lube Oil Pressure Transducer:

3. Fuel Pressure Transducer:

Figure 4-6 Pressure Transducer

Load Control Potentiometer

Figure 4-8 Load Control Potentiometer

Procedure for testing LCP Module (No Load)

Procedure for testing LCP Module (Load)

Output Voltage (No

Output Voltage (Load)

Figure 4-9 Relay Module

Actuator Feedback Sensor (RVDT)

with 2 fillister-head screws M4 and washer

Figure 4-10 Feedback Sensor

SPEED REF SET

CALIBRATION ANALOG I/O

L/O PRESS MONITOR

MAX RACK LMT

SPEED REF RATES

NTCH DLY COUNTER RST