Product Manual 36044

(Revision C)
Original Instructions

Air/Fuel Ratio Control

Installation and Operation Manual

 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.
General
Precautions Failure to follow instructions can cause personal injury and/or property damage.

This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, on the publications
Revisions page of the Woodward website:
www.woodward.com/publications

The latest version of most publications is available on the publications page. If

your publication is not there, please contact your customer service representative
to get the latest copy.

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
Proper Use 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.

If the cover of this publication states "Translation of the Original Instructions"

please note:
The original source of this publication may have been updated since this
Translated translation was made. Be sure to check manual 26311 , Revision Status &
Publications Distribution Restrictions of Woodward Technical Publications, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.

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.
Copyright © Woodward 1964
All Rights Reserved
 Manual 36044 Air/Fuel Ratio Control

Warnings and Notices

Important Definitions
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
 DANGER—Indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
 WARNING—Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
 CAUTION—Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
 NOTICE—Indicates a hazard that could result in property damage only
(including damage to the control).
 IMPORTANT—Designates an operating tip or maintenance suggestion.

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,
Overspeed / loss of life, or property damage.
Overtemperature / The overspeed shutdown device must be totally independent of the
Overpressure prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.

The products described in this publication may present risks that

could lead to personal injury, loss of life, or property damage. Always
wear the appropriate personal protective equipment (PPE) for the job
Personal Protective at hand. Equipment that should be considered includes but is not
limited to:
Equipment
 Eye Protection
 Hearing Protection
 Hard Hat
 Gloves
 Safety Boots
 Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.

Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
Start-up property damage.

On- and off-highway Mobile Applications: Unless Woodward's control

functions as the supervisory control, customer should install a
system totally independent of the prime mover control system that
Automotive monitors for supervisory control of engine (and takes appropriate
action if supervisory control is lost) to protect against loss of engine
Applications
control with possible personal injury, loss of life, or property damage.

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 Air/Fuel Ratio Control Manual 36044

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.
Battery Charging
Device

Electrostatic Discharge Awareness

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
Electrostatic contact while handling the control).
Precautions  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.
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.

Follow these precautions when working with or near the control.

1. 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.
2. 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 36044 Air/Fuel Ratio Control

Air/Fuel Ratio Control

Description
The air/fuel ratio control system provides a signal which is a function of generator
load. The signal is then used to adjust a device (not furnished by Woodward) to
control the engine air/fuel ratio and improve engine performance and efficiency.

The air/fuel ratio control system consists of a resistor box, an AFR control, and a
commercial transducer. The transducer is supplied by others to fit their particular
application.

The generator voltage, either 120 or 208–240 volts 3 phase, is connected directly
to the resistor box and AFR control or is through current and potential
transformers. Usually, the current and potential transformers supplied by the
switchboard manufacturer to power the switchboard instruments can also power
the load sensing portion of this system. These are terminals 1 through 12 of the
AFR control. The voltage proportional to load current is obtained from the resistor
box having 0.3 ohm resistors connected in series with the current transformer in
each phase. Each resistor is set so that at rated full load, unity power factor, the
voltage across the resistor is less than 1.5 volts.

The AFR control measures kilowatts through circuitry which detects the in-phase
component of the load current for each phase of the generator. The signals
obtained from each phase are added, and their sum is fed into a constant current
amplifier. The amplifier output is the output of the AFR control, and provides a
1–5 mA signal to the transducer (internal resistance, 2500 ohms).

AFR Control Installation

Refer to Figure 2 for mounting information. Ambient temperature must be
between –40 and +160 °F (–40 and +71 °C). Provide adequate ventilation for
cooling and space for installation and servicing.

This control can be tested and calibrated before it is installed (see Bench
Calibration).

Electrical Connections
Figure 3 provides typical wiring instructions; however, a plant wiring diagram for
your specific control part number must be used for actual installation.

There are no high currents in the circuits to the AFR control. Regular switchboard
wire can be used for connections from the current transformer secondaries to the
resistor box and to the AFR control gear. Use 18 or 20 AWG (0.5 or 0.8 mm²)
stranded wire with oil resistant insulation to all connections on the AFR control.
Avoid solid wire because vibration or other disturbances may cause failure.

HIGH VOLTAGE—Never disconnect current transformers from the

resistor box or AFR control when the CTs are energized. The current
transformers can develop dangerously high voltages when open
circuited while energized.

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Air/Fuel Ratio Control Manual 36044

Figure 1. AFR Block Schematic Diagram

The generator voltage supply to the AFR control must be 120 or 208 to 240 volts,
three phase. A potential transformer selected to provide a voltage within either
range can be used. The burden on the potential transformers is about 50 VA
three phase. Wye-Wye, delta-delta, or open delta potential transformer
connections are satisfactory.

 For 120 volt operation, make connections at the following terminals: ΦA to

1, ΦB to 3, and ΦC to 5.

 For 208 to 240 volt operation make the following connections: ΦA to 2, ΦB

to 4, and ΦC to 6.

Make the connections as shown in your plant wiring diagram between the
resistor box and AFR control. The wires between the resistor box and the AFR
control must connect directly to the resistor box terminals as shown. These
resistors have values of a fraction of an ohm and are adjusted at the factory.
Connection at any other point in the current transformer secondary circuit will, by
adding an unknown wire resistance, nullify this calibration and result in an
improper load signal in the AFR control.

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Manual 36044 Air/Fuel Ratio Control

Figure 2. AFR Outline Drawing

The current transformers must be sized so the voltage across terminal pairs 7
and 8, 9 and 10, 11 and 12, is 0 Vac at no load and up to 1.5 Vac at rated full
load with unity power factor. When this is correct, connect the current
transformers to the resistor box as shown in the plant wiring diagram.

Make the connections for the transducer to terminals 18 (+) and 21. Jumper
terminals 15 to 16.

Installation Check
With the AFR Control input wires (1 through 12) connected, measure the load
voltage across terminals 14 (+) and 16. It must read 10 Vdc at rated full load. The
reading will be proportionately less at smaller loads (5 V at half load and 2.5 V at
one-quarter load). This is adjusted with the load gain potentiometer in the AFR
control.

If the reading is only one-third of what it should be when the generator is loaded,
one of the connections from the resistor box to the AFR is reversed. Leave the
meter connected to AFR terminals 14 and 16. Using 18 AWG (0.8 mm²) or
heavier wire, no longer than 4 inches (10 cm), short circuit terminals A and D (9
and 10) at the resistor box. If the meter reading drops further, the connections
from these terminals to the input plug are correct. Repeat the procedure for the
other two phases.

HIGH VOLTAGE—Never disconnect current transformers from the

resistor box or AFR control when the CTs are energized. The current
transformers can develop dangerously high voltages when open
circuited while energized.

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Air/Fuel Ratio Control Manual 36044

Figure 3. Typical Wiring Diagram AFR

(Do not use for construction.)

If shorting any of these pairs of terminals increases the meter reading, it indicates
reversed connections from here to the AFR control.

If just one phase current signal is reversed, the meter will read approximately 3.3
volts at AFR terminals 16 (negative) to 14 (positive) with full load on the
generator. If two are reversed, 14 will be negative and 16 will be approximately
3.3 volts positive. If all three are reversed, 14 will be negative and 16 will be
approximately 10 volts positive. In other words, the correct full load reading of the
10 volts from 16 (negative) to 14 (positive) will be decreased by 6.6 volts for each
reversed load signal. Shorting out the incorrect current signal resistor reduces
this decrease to 3.3 volts.

lf there is a reduction in voltage for each pair of resistor terminals that is shorted,
but the meter reading is appreciably lower than it should be, it is possible that two
or all three of the phase wiring are exchanged. Shut the unit down and correct
the wiring.

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Manual 36044 Air/Fuel Ratio Control

Bench Calibration
The AFR control can be calibrated to match a specified curve before it is
installed. See the Typical Wiring Diagram (Figure 3) for test connections.

Power is supplied to terminals 1, 3, and 5, or 2, 4, and 6 depending on the

generator supply voltage, or a 48 Vdc power source connected to AFR terminals
13 (+) and 17 (–). Connect to the transducer terminals the transducer itself or a
2500 ohm resistor. If the transducer is used, the adjustments can be made
reading transducer output direct. If a resistor is used, adjustments are made by
reading the current flowing in the output circuit to the resistor. The signal input to
the AFR control is at terminals 14 (positive) and 15 (negative) with the jumper
between 15 and 16 removed. The input signal must be a battery voltage
adjustable from 0 to 10 volts to simulate the load from zero to rated full load.

Adjustments
There are six adjustments on the AFR control to permit adjustment of the
computer output to match the desired computer output vs. load curve. These
adjustments are set to customer’s specifications using factory test equipment.
Changing these settings in the field without the test equipment is not
recommended and should not be attempted unless absolutely necessary. A
typical curve is shown below.

 The “A” adjustment holds the output constant on the desired level at low
loads until point “B” has been reached.

 The “B” or “Slope-Start” adjustment permits a change in the point at which

the system takes over. It must be readjusted every time a change Is made
to the “C” adjustment.

 The “C” or “Low-Slope” adjustment establishes the slope or the rate at the
lower end of KW range.

 The “D” or “Knee” adjustment changes the point at which the slope changes.

 The “E” or “High Slope” adjustment is the fifth adjustment.

The load gain sets the output of the load section to 10 volts dc at full load unity
power factor.

Figure 4. Adjustment Diagrams

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Please reference publication 36044C.

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