Installation and Operation Manual

Digital Reference Unit

with high, low, and intermediate setpoints

Manual 82006 (Revision A)

 WARNING—DANGER OF DEATH OR PERSONAL INJURY
WARNING—FOLLOW 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.
WARNING—OUT-OF-DATE PUBLICATION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.
WARNING—OVERSPEED 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.
WARNING—PROPER 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.

CAUTION—POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY

CAUTION—BATTERY 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.
CAUTION—ELECTROSTATIC 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.

Revisions—Text 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 1989
All Rights Reserved
Manual 82006 Digital Reference Unit

Contents

ELECTROSTATIC DISCHARGE AWARENESS .................................................. II

CHAPTER 1. GENERAL INFORMATION ........................................................... 1
Introduction.............................................................................................................1
Digital Reference Units...........................................................................................1
Applications ............................................................................................................1
CHAPTER 2. INSTALLATION AND ADJUSTMENT ............................................. 3
Introduction.............................................................................................................3
Unpacking and Inspection ......................................................................................3
Location Considerations.........................................................................................3
Setting the Output Limits ........................................................................................3
Setting Ramp Rates ...............................................................................................5
Plant Wiring ............................................................................................................5
Relays.....................................................................................................................6
External Reference.................................................................................................6
CHAPTER 3. APPLICATIONS ......................................................................... 8
CHAPTER 4. SERVICE OPTIONS ................................................................. 10
Product Service Options.......................................................................................10
Returning Equipment for Repair...........................................................................11
Replacement Parts ...............................................................................................12
How to Contact Woodward...................................................................................12
Engineering Services ...........................................................................................13
Technical Assistance............................................................................................14

Illustrations and Tables

Figure 1-1. Digital Reference Unit Block Diagram .................................................2

Figure 3-1. Plant Wiring Diagram and Outline Drawing .........................................7
Figure 4-1. Wiring Applications ..............................................................................8
Figure 4-2. Wiring Diagrams ..................................................................................9

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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.

CAUTION—ELECTROSTATIC 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.

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Manual 82006 Digital Reference Unit

Chapter 1.
General Information

Introduction
This manual provides description, installation, and maintenance information for
the Woodward Digital Reference Unit with three set points.

Digital Reference Units

Digital Reference Units use a precise linear ramp to provide a 0 to 8 volt
reference signal to the attached control. The reference unit can be used with a
speed or load control or a Process and Import/Export control. The reference unit
has two separate ramps which are switch selectable to control the 0–8 volt
reference signal.

The high, low, and intermediate points on the ramp are selectable on the
reference unit. The same set points are used by both ramps. One of the ramps is
always engaged so any movement of the output is at the speed of the engaged
ramp.

Options
Digital Reference units are available for use with a low voltage power source (10
to 45 Vdc) or a high-voltage power source (90 to 150 Vdc or 88 to 132 Vac at 45
to 440 Hz.)

The three-relay option may be used to provide indication of when the output is at
low limit, set point, or high limit, or to cause automatic switching functions within
the same system.

Part Number Power Supply Relay Indication

8272-682 10–45 Vdc No
8272-683 10–45 Vdc Yes
8272-684 90–150 Vdc or No
88–132 Vac 45–440 Hz
8272-685 90–150 Vdc or Yes
88–132 Vac 45–440 Hz

Applications
Digital Reference Units are used in place of MOPs (Motor Operated
Potentiometers), but provide more precise and more dependable control
functions. The Digital Reference Unit set points are easier to adjust than those
on a MOP, and the adjustable ramp time is generally not available with a MOP.
Installation of the maintenance-free Digital Reference Unit is less restrictive than
is installation of a MOP.

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Digital Reference Unit Manual 82006

Figure 1-1. Digital Reference Unit Block Diagram

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Manual 82006 Digital Reference Unit

Chapter 2.
Installation and Adjustment

Introduction
This chapter includes information on unpacking, installation, setup, and checkout
of the Digital Reference Unit. Information on power requirements, location
considerations, and wiring information is also included.

Unpacking and Inspection

Before handling the unit, read page ii, Electrostatic Discharge Awareness.
Visually inspect the unit for damage such as bent or dented panels, and loose or
broken components. Immediately notify the shipper of any damage.

Compare the part number on the front panel with the chart on page 1 of this
manual to be sure the reference unit is compatible with the supply voltage to be
used.

CAUTION—BATTERY
To prevent damage to a direct-current powered control, make sure that the
alternator or other battery-charging device is turned off or disconnected
before disconnecting the battery from the control.

Location Considerations
The unit can be installed in any position that provides adequate ventilation and
space for servicing. Maximum power use is 3.0 W. The unit will generate a
minimal amount of heat during operation. The Digital Reference Unit will operate
between –40 and +185 °F (–40 to +85 °C). It is designed to withstand 4 Gs of
vibration between 5 and 500 Hz, and 60 Gs of shock.

The unit is not designed for mounting on the engine. Do not expose the box to
rain, or pressure wash.

The location should provide ready access to the terminals on the control which is
to be influenced by the unit.

See Figure 3-1 for installation dimensions.

Setting the Output Limits

The Low Limit potentiometer sets the minimum output from the Digital Reference
Unit. The Range potentiometer sets the maximum output at a position above the
Low Limit setting. Since the Low Limit setting changes the setting of the High
Limit (Range), it is necessary to always set the Low Limit first and to reset the
Range (High Limit) after any change in the Low Limit.

The following step-by-step procedure should be followed any time the limits are
set or reset.

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Digital Reference Unit Manual 82006
To determine and preset the Digital Reference Unit output values, set up the
speed, load, or process control as it would be used without the Digital Reference
Unit. Replace the reference unit connections to the control with wiring, switches,
or potentiometers, as indicated on the plant wiring diagram for the control. Adjust
the control for the speeds, loads, or process values which the reference unit will
set. For each operating condition (low limit, high limit, and intermediate set point)
measure and record the voltage on the terminals to which the output of the
reference unit will be connected. (See Chapter 4 for wiring suggestions between
the reference unit and various controls.)

It is sometimes difficult to use this method to determine the voltages of the

reference unit output on load-sharing lines. Since the load-sharing lines voltage
is one-half of the load gain voltage, it is easy to calculate the reference unit
output voltage proportional to the load-gain voltage. Zero load is zero volts. One-
half load is 1/2 by (1/2 x load gain). With the typical 6 volts load gain, this would
be 1.5 volts. Full load for the same system is then 1 x (1/2 x load gain) or 3 volts.

1. Attach a voltmeter capable of reading 0 to 8 Vdc to terminals 10(+) and

11(–).

NOTE
The reference unit can produce a negative voltage. If a negative voltage
output is desired, the voltmeter at terminals 10 and 11 should be able to read
both + and – outputs.

2. Connect the power supply and appropriate switches to terminals 1 through

5. Close the switch between terminals 2 and 5. (Set the FIRST ramp time
counterclockwise to minimize the time required to reach the limits or set
point.) When the output stops ramping down, adjust the Low Limit
potentiometer through the cover of the reference unit for the desired output
as indicated by the voltmeter. (Clockwise on the potentiometer will increase
the low-limit position.)

3. Open the switch between terminals 2 and 5, and close the switch between
terminals 2 and 3. Adjust the Range pot to provide the maximum desired
output from the reference unit. Clockwise will increase the High Limit
setting.

4. Open the switch between terminals 2 and 3, and close the switch between
terminals 2 and 5. The output should decrease to the desired low limit. If
readjustment is necessary, ramp back to High Limit and readjust the Range
potentiometer (clockwise is increase.)

5. Open all the switches. Close the switch between terminals 2 and 4. The
output will ramp to the set-point position. Adjust the set-point potentiometer
up or down as necessary.

NOTE
When selecting two inputs at the same time, Set Point has priority over the
Raise, and Lower has priority over the Set Point. If Raise is permanently
closed, the unit will automatically go to the High Limit when neither Lower
nor Set Point switches are closed.

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Manual 82006 Digital Reference Unit

Setting Ramp Rates

The reference unit is shipped with ramp rates 1 and 2 independently adjustable
from a minimum of 20 seconds to a maximum of 120 seconds. If the 20 second
to 120 second ramp rate is not applicable to the particular installation, the ramp
rates may be changed by setting a miniature rocker switch. The switch is located
inside the cover on the printed circuit board, just to the right of the "ramp time
second" adjustment potentiometer.

The four switches on the mini-switch are numbered. Switches 1 and 2 control the
ramp times for the second ramp. Switches 3 and 4 set the ramp time for the first
ramp. The unit defaults to the first ramp, if the second ramp is not selected.
Approximate ramp times available are shown in the following table:

Ramp Time with Ramp Time with

Switch Location Adjustment Full CCW Adjustment Full CW
1st (default) Ramp
3 open 4 open 5 seconds to 25 seconds
3 open 4 closed 20 seconds to 120 seconds
3 closed 4 open 100 seconds to 10 minutes
2nd Ramp Selected
1 open 2 open 5 seconds to 25 seconds
1 open 2 closed 20 seconds to 120 seconds
1 closed 2 open 100 seconds to 10 minutes

Ramp time is the time it takes the output to ramp from the low limit to the high
limit and is independent of the values of the limits. The ramps are linear.

The time to ramp from the Low Limit to the Set Point is dependent on where the
Set Point is adjusted. If the Set Point is halfway between the low and high limits,
the ramp time will be one-half of the overall ramp time.

Plant Wiring
After the ramp rates have been selected, and the low limit, high limit, and
intermediate output positions are set, the reference unit should be permanently
wired into the electronic control loop.

Wire according to the plant-wiring diagram (Figure 3-1) and according to the
applications chart in Chapter 4. Observe the shielded wiring requirements
between the reference unit and the control system. All shields should terminate
at the control system only, not the reference unit. Do not terminate any shield at
both the reference unit and the control, as this will reduce the effectiveness of the
shield.

NOTE
The electronics of the Digital Reference Unit always respond to the lowest
signal selected, should two or more of the selection switches be closed at
the same time. The ramp will stop should a selection be opened before the
limit or set point has been reached.

When Set Point is selected, the output will ramp up or down as necessary to
reach the predetermined set point.

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Digital Reference Unit Manual 82006

Relays
Some Digital Reference Units are equipped with three relays for use by the
system operator. The relay contacts are 5 A resistive at 30 Vdc, or 2 A resistive
at 115 Vac.

External Reference
The Digital Reference Unit will provide ramp-speed setting for EPG and 2500
controls by connecting the external reference from these controls to terminal 7 on
the reference unit, and then connecting the output from the reference unit to the
speed-setting connections on the speed control. Terminals 8 and 9 on the
reference unit must be jumpered to allow the external reference feature to
function.

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Manual 82006 Digital Reference Unit

Figure 3-1. Plant Wiring Diagram and Outline Drawing

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Digital Reference Unit Manual 82006

Chapter 3.
Applications

The wiring diagrams in Figure 4-1 show some of the methods used to connect
the reference unit to various electronic speed/load controls. Use of the unit is not
limited to the installations shown.

Figure 4-1. Wiring Applications

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Manual 82006 Digital Reference Unit

Figure 4-2. Wiring Diagrams

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Digital Reference Unit Manual 82006

Chapter 4.
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:
• Replacement/Exchange (24-hour service)
• Flat Rate Repair
• Flat Rate Remanufacture

If you are experiencing problems with installation or unsatisfactory performance

of an installed system, the following options are available:
• Consult the troubleshooting guide in the manual.
• 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.

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Manual 82006 Digital Reference Unit

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.

CAUTION—ELECTROSTATIC 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.

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Digital Reference Unit Manual 82006

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.

Facility Phone Number

Brazil +55 (19) 3708 4800
India +91 (129) 230 7111
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 Woodward’s website (www.woodward.com) for the
name of your nearest Woodward distributor or service facility.

12 Woodward
Manual 82006 Digital Reference Unit

Engineering Services
Woodward Industrial Controls Engineering Services offers the following after-
sales 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
Email—icinfo@woodward.com
Website—www.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.

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 Digital Reference Unit Manual 82006

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

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number

Woodward Part Number and Revision Letter

Control Description or Governor Type

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.

14 Woodward
 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 Website—www.woodward.com

Woodward has company-owned plants, subsidiaries, and branches,

as well as authorized distributors and other authorized service and sales facilities throughout the world.
Complete address / phone / fax / email information for all locations is available on our website.

06/6/F