Pg-Eg Integral EG Actuator For PG Governors: Product Manual 36637 (Revision J, 7/2016)
Pg-Eg Integral EG Actuator For PG Governors: Product Manual 36637 (Revision J, 7/2016)
Pg-Eg Integral EG Actuator For PG Governors: Product Manual 36637 (Revision J, 7/2016)
(Revision J, 7/2016)
Original Instructions
PG-EG
Integral EG Actuator for PG Governors
This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26455, Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, on
Revisions the publications page of the Woodward website:
www.woodward.com/publications
Revisions—Changes in this publication since the last revision are indicated by a black line
alongside the text.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Manual 36637
Copyright © Woodward, Inc. 1995–2016
All Rights Reserved
Manual 36637 PG-EG Integral EG Actuator for PG Governors
Contents
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Regulatory Compliance
Other European Compliance:
Compliance with the following European Directives or standards does not qualify
this product for application of the CE Marking:
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Chapter 1.
General Information
Introduction
This manual contains information about the Woodward Integral EG Actuator for
PG governors as an add-on unit:
to form the PG-EG actuator (no ballhead) or
to create a ballhead backup governor (PGA-EG or PGG-EG) from the PGA
or PGG governor.
In this manual, PG-EG refers to any of these three governor types.
This manual covers the EG, governor components affected by the EG, and
information pertaining to the PG-EG. For more general governor information,
refer to the PGA governor manual (36604) or the PGG governor manual (36627).
Description
The EG is an electro-hydraulically controlled actuator that accepts a (0 to 200)
mA signal, and outputs on a standard PG servo proportional to the mA signal.
Direct-Acting Reverse-Acting
Fuel Rack Position (0.050 to 0.950) inches TR (0.050 to 0.950) inches TR
Control Current (20 to 160) mA (160 to 20) mA
Vibration Resistance
The EG actuator is in itself resistant against vibration due to the torque motor
beam being mass-stabilized in all three axes. As a consequence, vibrations have
minimal influence on the position of the beam.
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Figure 1-5. PGA-EG/PGG-EG 200 With and Without Mode Select Block
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Chapter 2.
Installation
Introduction
This chapter describes receiving, storage, and installation requirements for the
actuator.
The surface of this product can become hot enough or cold enough
to be a hazard. Use protective gear for product handling in these
circumstances. Temperature ratings are included in the specification
section of this manual.
Initial Operation
Before initial operation of the engine equipped with this actuator, read
all of this installation chapter. Make sure that all installation steps have
been correctly accomplished and all linkages are secured and properly
attached. Carefully review the direction of rotation for the actuator oil
pump.
Receiving
Your PG governor is shipped from the factory bolted to a wooden platform in a
vertical position. After being tested at the factory, the governor is drained of oil.
This leaves a light film of oil covering the internal parts, preventing rust. No
internal cleaning is required.
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Most PG governors lift from an eye-bolt threaded into a 0.375-16 (inch) hole in
the center of the cover. PG-200, PG-300, and PG-500 governors must be lifted
with a sling. Some PG governors have split covers which need to be lifted with a
sling as well.
Storage
The governor may be stored for up to a year as received from the factory. Store
the governor in a vertical position. Fill completely with oil if extended storage is
necessary.
Mounting Requirements
A gasket must be used between the governor and the accessory mounting pad.
A 0.81 mm (0.032 inch) thick gasket is recommended for this purpose. The
gasket is used to absorb imperfections between the governor base and the
mounting pad, and to avoid oil leakage between the governor and the drive
portion of the engine.
Install the governor square on the accessory pad, using the correct length of
coupling between the governor and the drive. Make sure the driveshaft does not
bind, and that there is no excessive side load on the driveshaft assembly. Make
sure the coupling is tight, and do not use force when installing the drive shaft into
the coupling. The governor must be installed in a vertical position.
Linkage
Align the linkage from the governor to the fuel pumps or valves to eliminate
binding and excessive backlash. The relationship of governor/terminal shaft
angular position to the fuel control position must be adjusted in accordance with
the engine manufacturer's specifications. The linkage must not limit the
governor's ability to call for maximum fuel or to shut down the engine.
Linkage must not give during major transients and must not be so heavy that it
hinders accurate governor response. Linkage must be designed to resist wear.
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The fuel-control linkage must be adjusted so at least 15 % of the governor travel
(output) from minimum position has been used when the fuel control is at idle no-
load (A and D; see Figure 2-1). This minimum setting is required due to the
location of the compensation cut-off port (if so equipped).
Most governors are equipped with an oil spray to reduce or prevent vibration-
induced damage to the torque-motor assembly.
All governors have hydraulic connections for a booster. For information regarding
selecting the correct booster type, refer to Manual 36684.
When connecting a start booster to the governor, at least two lines are required:
Oil to booster inlet, which takes oil from the governor sump to the
booster inlet
Oil from booster outlet #1, which takes oil from the booster outlet #1 to
the accumulator system of the governor. By supplying oil under pressure
during starting from the booster into the accumulator, the governor
should distribute the oil internally without any delay.
In most cases there should be no need to connect other lines between the
booster and the actuator or governor.
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line (oil from booster outlet #3) to the first stage relay piston to assist opening up
the output servo of the governor.
All governors have hydraulic connections for a heat exchanger which allows oil to
be circulated to an external cooler to ensure that the governor oil temperature
remains between 71 °C and 93 °C (160 °F and 200 °F) under all operating
conditions. In case a heat exchanger is used on a governor also equipped with
an oil spray, extra attention is required. Since the spray tube is located at the
same height as the oil-to-cooler connection on the governor’s power case, these
two connections are hydraulically linked. This means that the oil spray will no
longer function when combined with a cooler, since the oil will follow the path
with the least resistance. In order to prevent this, we recommend adding an
orifice to the oil-to-cooler line exactly where it leaves the power case to ensure
enough flow of oil is going to the oil spray.
Standard electrical connections are made to the four-pin connector on the side of
the column (see figures). Optionally, the EG actuator may be wired to the
connector on the receiver bracket through an internal mounting bracket.
Instead of a connector, the governor may be equipped with a flying lead, leaving
the governor on the side of the column. This option is used mostly on governors
in a high-vibration environment.
Clearances
Leave adequate clearance to connect the linkage, to fill the governor with oil, and
to remove the cover (if necessary).
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Governor Oil
Governor oil must have lubricating and hydraulic properties. The oil must have a
viscosity index that allows it to perform over the operating temperature range of
the governor. The oil must have additives that allow it to remain stable and
predictable over the operating temperature range of the governor. The oil used in
the governor must be compatible with the nitrile, polyacrylic, and fluorocarbon
seals used in the governor.
Many oils and synthetic lubricating fluids used in the engines controlled by PG
governors meet these specifications. When possible use the same grade and
weight of oil used in the engine. Information in this manual is intended to be used
only in the selection of the governor lubricating oil, not for selecting engine lube
oil. USE ONLY NEW, CLEAN OIL. DO NOT USE USED ENGINE OIL IN THE
GOVERNOR.
Woodward governors and actuators are designed to give stable operation with
oils which provide 50 to 3000 SUS (Saybolt Universal Seconds) of viscosity
throughout the operating temperature range. Ideally the viscosity at the normal
operating temperature should be between 100 and 300 SUS. Poor governor
response or instability is often an indication that the oil being used is too thick or
too thin.
For more detailed information on the choice of governor oil, refer to manual
25071, Oils for Hydraulic Controls.
Oil Problems
A filter is located between the oil pump and the control pilot valve of the EG
actuator. Should this filter become clogged, it can seriously hinder the ability of
the actuator to control, even on the mechanical ballhead side. Take extra care
with the PG to be sure that oil is clean and that it does not deteriorate due to
heat.
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PG-governors operating with internal oil-pressures in excess of 1655 kPa
(240 psi) often require a heat exchanger to protect the oil from damage.
To avoid contamination of the governor, the replacement oil must be free of dirt,
water, or other foreign material. Use clean containers to store and transfer oil.
Refer persistent or recurring oil problems to an oil specialist.
After the oil is selected, fill the governor with new, clean oil, in the volumes listed
here: Type 12/29/58 (1.4 L / 1.5 qt), Type 200/300 (6.2 L / 6.5 qt), Type 500
(6.6 L / 7.0 qt).
While the engine is not running, fill the governor to the maximum level indication.
During normal operation, this level should not drop below the minimum level. Do
not add oil when operating the governor.
PG-EG 200, 300, and 500 cases must be filled in two stages. Fill with about
4 liters/quarts before starting, then add the amount needed to bring the oil up to
operating levels after start-up. On these governors, there is an oil level dipstick
inside the fill port cap. On newer types, a small sight gauge glass has been
added onto the terminal shaft housing. Always use the dipstick for accurate oil
level readings. All other PG-EGs have an oil filler cup in the cover and a special
long oil gauge glass on the power case.
To prevent contamination of the flapper nozzle system, an oil filter has been fitted
to the oil feed line going to the EG actuator. Check this filter every time the oil is
changed, and clean if necessary.
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Use white spirit or another oil-based cleaning fluid to wash backward, against the
normal flow direction onto a filter cloth or similar. Do not use sharp tools to probe
into the filter. Debris content should come out leading a flow of cleaning fluid thru
the filter. Use a soft brush to help the particles get loose from the mesh surface.
Inspect the content of the filter. Normal wear of the PG-EG actuator should
produce very few particles, so if you find a lot of debris you should investigate its
origin. Make sure the cans used to add oil are clean (no dust, no water, no other
oil remains).
If a filter is very dirty and cannot be cleaned it should be replaced by a new filter:
Woodward number 3005-533.
If, over time, filters continue to be very dirty, consider reducing the time between
cleaning. Clogged filter can seriously reduce the flow of oil to the EG-actuator,
thus making it very difficult to maintain its dynamic behavior.
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Chapter 3.
Principles of Operation
The balance of these hydraulic pressures and forces positions the pilot valve in
the bushing and causes the pilot valve to follow the position of the torque motor
beam. To center the pilot valve in the bushing in steady state, the gap between
the flapper (the torque motor beam) and the nozzle is adjustable by means of the
center adjustment.
The control land of the pilot valve, balanced between the regulated pressure
below and the pilot valve control pressure above, provides a hydraulic
amplification of the position of the torque-motor beam. This permits accurate
positioning of the plunger in the bushing without having the bushing rotate to
eliminate static friction as is necessary in the mechanical pilot valve system.
Torque-motor System
The torque-motor system consists of an electromagnetic coil and a beam. On top
of the beam, an armature is mounted which is placed into the electromagnetic
field of the coil. The beam itself is suspended by a torsion spring, allowing a
small degree of rotation of the beam around the center of the torsion spring but
no translations.
The torque-motor beam is balanced between the restoring spring, the level-
adjust spring, and the torque from the torque-motor. With the system in steady
state, the pilot valve of the flapper nozzle system is centered and the servo is
stationary.
By changing the current to the coil, the amount of torque on the armature
changes, and thus the torque on the torque-motor beam. This will change the
gap between the beam and the pilot valve, cause the pilot valve to follow the
movement of the beam, and allow oil to flow to or from the servo. The resultant
change in servo position causes the restoring lever to load or unload the
restoring spring, and thus restores the equilibrium of the torque-motor beam at
the new current level. The torque motor beam resumes its original position, and
the gap between the beam and the pilot valve will be restored to its original size
with the pilot valve centered.
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Chapter 4.
Operation and Adjustments
Introduction
Because the PGA-EG and PGG-EG are each a combination of an electric
actuator and a ballhead governor, routine start-up adjustments can be more
complex than on other governors.
Centering Adjustment
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1. Install the guiding plate and mount the screws by hand. Do not tighten the
screws but allow small adjustments.
2. First check visually if the plate is set perpendicular to the pin. Adjust this by
moving the plate in its slots until it is.
3. Now run the tailrod up and down. This will set the plate in the correct
position and ensure the slot and the tailrod are exactly parallel. Now tighten
the screws to a torque of (0.7 to 0.8) N·m / (6 to 7) lb-in.
The switch is mounted in one of two locations, depending on whether or not the
governor is equipped with a mode select valve.
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In electrical mode, the actuator pilot valve and the ballhead pilot
valve are placed in series. In order for the governor to operate in this
mode, it is necessary to raise the mechanical speed setting over the
electrical speed setting, since this offset will open the ballhead pilot
valve and keep it “out of the way.” This speed difference should
amount to 5 % to 10 % of the maximum speed.
Under EG mode, the ballhead will still control if the PG speed setting
is lower than the EG.
The mode select valve consists of a pilot valve located in a block which is
mounted onto the side of the governor power case. Internal governor hydraulics
are routed through the block. When the pilot valve is driven against a return
spring, the valve will switch. When the driving force is removed, the spring
returns the pilot valve and the valve switches back. Two pilot valves are
available: a direct-acting one and a reverse-acting one.
Five different methods are available to drive the mode select valve:
Manual—Turning a knob clockwise directs pressure oil against the end of the
valve plunger and forces the plunger against the return spring to switch into PG
mode. Turning the manual knob counterclockwise connects the operating end of
the mode select valve plunger to drain, allowing the return spring to move the
plunger and switch to EG mode.
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Direct Pneumatic—Air pressure drives a plunger which shuttles the direct-acting
mode select valve plunger against the return spring to switch into PG mode.
Removal or loss of air pressure will cause the return spring to move the plunger
back and switch to EG mode.
Maintenance
The mode select valve should require minimal or no maintenance. O-rings should
be replaced to eliminate possible oil leaks. The pneumatic, electric, or manual
actuator which sets the position of the pilot valve may be removed from the
housing for cleaning or repair.
Applications
The ballhead governor and the electric-input actuator operate continually, with
each having its own desired fuel-output position. PGA-EG hydraulics select the
lesser of the two fuel outputs for the actual fuel output.
Setting up for reverse-acting means that the electronics in the control are
programmed for reverse-acting; the actuator must be calibrated to accept this
reverse signal. Loss of electrical signal to the actuator causes the actuator to call
for increased fuel, moving the output to increase until the ballhead takes over
control (remember that for correct actuator use, the mechanical speed setting
must be raised by 5 % to 10 %). This means that the reverse-acting setup of
control and governor results in automatic switching from electrical control to
ballhead control should electronic failure occur, although at a higher speed.
When control and actuator are set up for direct-acting, loss of electronic signal to
the actuator means that the actuator goes to minimum fuel. Since the ballhead is
set to a speed 5 % to 10 % above the electronic maximum speed, it cannot take
over control.
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Chapter 5.
Product Support and Service Options
OEM or Packager Support: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.
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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 option allows you to call your Full-Service Distributor 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 Full-Service Distributor.
Flat Rate Repair: Flat Rate Repair is available for many of the standard
mechanical products and some of the electronic 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.
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. This option is applicable to mechanical products only.
When shipping the item(s), attach a tag with the following information:
return number;
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.
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.
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.
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Engineering Services
Woodward’s Full-Service Distributors offer various Engineering Services for our
products. For these services, you can contact the Distributor by telephone or by
email.
Technical Support
Product Training
Field Service
Technical Support is available from your equipment system supplier, your local
Full-Service Distributor, or from many of Woodward’s worldwide locations,
depending upon the product and application. This service can assist you with
technical questions or problem solving during the normal business hours of the
Woodward location you contact.
You can also contact the Woodward Customer Service Department at one of the
following Woodward facilities to obtain the address and phone number of the
nearest facility at which you can obtain information and service.
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Technical Assistance
If you need to contact technical assistance, you will need to provide the following information.
Please write it down here before contacting the Engine OEM, the Packager, a Woodward
Business Partner, or the Woodward factory:
General
Your Name
Site Location
Phone Number
Fax Number
Number of Cylinders
Type of Fuel (gas, gaseous, diesel,
dual-fuel, etc.)
Power Output Rating
Application (power generation, marine,
etc.)
Control/Governor Information
Control/Governor #1
Serial Number
Control/Governor #2
Serial Number
Control/Governor #3
Serial Number
Symptoms
Description
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.
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Revision History
Changes in Revision J—
Updated Figures 1-1 through 1-5
Changes in Revision H—
Added filter cleaning instructions
Changes in Revision G—
Updated Declaration of Incorporation
Changes in Revision F—
Added Regulatory Compliance information
Added installation information and warnings to Chapter 2
Added Declarations
Changes in Revision E—
Chapter 2—Added paragraph advising how to use an external cooler with
actuators that have oil spray
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Declarations
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