Controlador de Bomba de Inyección Delphi DP210

Product Manual 26135
(Revision F)
Original Instructions
LCS ITB
LC-50
Installation, Programming, & Troubleshooting
OEM/Dealer Manual
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.
DEFINITIONS  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, 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.
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.
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 publications page on the Woodward website:
www.woodward.com/publications
The current revision and distribution restriction of all publications are shown in manual 26311.
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 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.
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.
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.
Revisions—Text changes are indicated by a black line alongside the text.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Copyright © Woodward 2001
All Rights Reserved
Manual 26135 LCS ITB / LC-50
Contents
CHAPTER 1. GENERAL INFORMATION ........................................................... 1

Purpose and Scope ................................................................................................1
Intended Applications .............................................................................................1
Introduction .............................................................................................................1
Service Tool Software ............................................................................................4
CHAPTER 2. SYSTEM DESCRIPTION / APPLICATION OVERVIEW ..................... 5
System Operation ...................................................................................................5
Overview of Control Application Process ...............................................................5
Hardware Configuration Application Process .........................................................6
CHAPTER 3. INSTALLATION........................................................................ 19
Mechanical Installation .........................................................................................19
Electrical Installation .............................................................................................21
CHAPTER 4. SOFTWARE PROGRAMMING .................................................... 25
Software Installation .............................................................................................26
Dynamics Menu ....................................................................................................39
Controller Tuning ..................................................................................................41
Initial File Construction .........................................................................................41
LC-50 Applications (Mixer Applications) ...............................................................47
Speed Governor Applications ...............................................................................48
Application Development Testing .........................................................................52
CHAPTER 5. TROUBLESHOOTING ............................................................... 53
Engine/Generator Troubleshooting ......................................................................53
Programming Troubleshooting .............................................................................56
CHAPTER 6. PRODUCT SUPPORT AND SERVICE OPTIONS ........................... 57
Product Support Options ......................................................................................57
Product Service Options .......................................................................................57
Returning Equipment for Repair ...........................................................................58
Replacement Parts ...............................................................................................58
Engineering Services............................................................................................59
Contacting Woodward’s Support Organization ....................................................59
Technical Assistance ............................................................................................60
APPENDIX A. ACRONYMS/ABBREVIATIONS ................................................ 62
APPENDIX B. CONFIGURATION FILE ........................................................... 63
Generator Version Format (LC-50G)....................................................................63
Industrial Version Format (LC-50I) .......................................................................68
APPENDIX C. DYNAMICS FILE FORMAT ...................................................... 73
LCS CONTROL SPECIFICATIONS ................................................................ 75
Woodward i
LCS ITB / LC-50 Manual 26135
Illustrations and Tables
Figure 1-1. Block Diagram of LCS Integrated Speed Control ................................2

Figure 2-1. Typical Governor Application Process .................................................6
Figure 2-2. Application Matrix .................................................................................7
Figure 2-3. MAP/Boost Fuel Limiting ....................................................................16
Figure 3-1. Typical LCS Application Wiring ..........................................................21
Figure 3-2. Voltage Threshold Curve ...................................................................22
Figure 4-1. Typical Programming Datalink Harness Wiring .................................25
Figure 4-2. Zirconia Oxygen Sensor Response ...................................................48
Figure 4-3. Pre-Catalyst Emissions ......................................................................48
Figure 4-4. Post-Catalyst Emissions ....................................................................48
Figure 4-5. Recommended Control Setting Changes ..........................................50
ii Woodward
Chapter 1.
General Information
Purpose and Scope

The purpose of this manual is to provide OEMs with the necessary background
information for applying the LCS ITB and LC-50 control to gas/gasoline
reciprocating engines. Topics covered include mechanical installation, electrical
wiring, software programming, and troubleshooting. While this manual is primarily
targeted at OEM customers, OEMs themselves may find it useful to copy some
of the information from this manual into their application user manuals.
Intended Applications
The LCS ITB and LC-50 controls are designed primarily for various industrial
applications, including but not limited to generator sets, welders, portable
refrigeration units, irrigation pumps, chipper shredders, and mobile industrial gas
or gasoline reciprocating engines. Key environmental characteristics of these
applications include industrial operating temperatures (–40 to +85 °C/–40 to +185
°F), European CE EMC requirements (10 V/m), minimal electrical transients (2 J
load dump), and lower operating voltages (12 V) (must be fed from a Class 2
power source).
Introduction
The LCS ITB and LC-50 provide a building block approach to total engine
management. The modular designs consist of a die-cast aluminum throttle body,
a mixer, and a fully programmable integrated digital speed control and bi-
directional actuator. The LCS ITB incorporates the Woodward LCS speed control
with a throttle plate. The LC-50 adds a venturi style annular ring mixer to the LCS
ITB. The units provide a number of speed setting, speed biasing, control, fuel
limiting, diagnostic, and datalink functions. The controller is available in two
versions, one for generator applications (G version) and one for industrial
applications (I version).
A simplified block diagram of the control’s functionality is shown in Figure 1-1. In

most applications, the OEM will enable at least one function from each category
of functions to create a valid control configuration. The functionality and
characteristics of the control can be tailored using a laptop computer loaded with
the Woodward Service Tool software.
The functions available are briefly described below. Chapter 2 contains a detailed
description of each function and feature.
Woodward 1
Speed setting functions include:
 Single speed select—Sets the speed set point to a single initial speed when
power is first applied
 50/60 Hz select—Selects between two speed set points when power is first
applied to the governor (G version only)
 Idle/rated select—Selects, ramps, and delays between two speed set points
while the engine is running
 Three-speed select—Selects and ramps between three speed set points
while the engine is running (I version only)
 Raise/lower adjust—Ramps between two speed limits based on signal
inputs while the engine is running (G version only)
Speed biasing functions include:

 Isochronous—Does not bias the current speed set point in any way
 Droop—Biases the current speed set point by a negative percentage based
on actuator position (G version only)
 Aux biasing—Biases the current speed set point by a percentage based on
an analog input voltage
 Isoch/droop select—Selects between isochronous and droop operation
when power is first applied (G version only)
 Aux bias/droop select—Selects between aux biasing and droop operation
when power is first applied (G version only)
Speed Biasing Functions Dynamics Functions
Isochronous Automatic Gain Trim
Droop Dual Dynamics
Aux Bias
Isoch/Droop Select
Aux Bias/Droop Select control

Speed Setting Functions
coefficients
<modified>
Single Speed desired
Control Functions Fuel Limit Functions
speed
50/60 Hz Select desired + speed desired
Speed Control Start Fuel Limiter
speed + error position
Idle/Rated Select
Position Control Boost Fuel Limiter
Three-Speed Select -
engine
Raise/Lower Adjust speed
<limited>
Speed Sensing Functions desired
position
actual +
Engine MPU Speed Sensing
Actuator position
Speed
Ignition Speed Sensing Position -
Pulses
engine position
speed error
Logic/Support Functions Configuration Error Actuator Functions
Overspeed Error Governor State Actuator Control
Failsafe Error Relay Control Actuator Gate
EE Fault Storage
Actuator
Torque
Figure 1-1. Block Diagram of LCS Integrated Speed Control
2 Woodward
Speed sensing functions include:
 MPU speed sensing—Converts flywheel or gear speed pulses into engine
speed in rpm
 Ignition speed sensing—Converts ignition coil fly back pulses into engine
speed in rpm
Control functions include:

 Speed control—Commands a desired actuator position based on the set
point versus engine speed error
 Position control—Commands a desired actuator position based on an
analog input voltage
Dynamics functions include:

 Dual dynamics select—Selects between two sets of speed control
coefficients while the engine is running
 Automatic gain trim—Monitors engine performance and trims speed control
gain settings based on programmable criteria
Fuel limiter functions include:

 Start fuel limiter—Limits the desired actuator position during engine cranking
and initial acceleration
 Boost fuel limiter—Limits the desired actuator position based on an analog
voltage from a MAP sensor (G version only)
Actuator control functions include:

 Actuator control—Commands an actuator torque based on the desired
versus actual actuator position
 Actuator gate—Overrides the actuator control during power up or error
conditions
Logic and support functions include:

 Overspeed error—Detects when the actual engine speed exceeds a
threshold
 Failsafe error—Detects a loss of the speed signal input
 Configuration error—Detects when a configuration has not been
downloaded into the control
 Relay control—Controls the relay output driver during error conditions
 Fault storage—Stores a fault code in EEPROM whenever an error condition
has occurred
 Governor state—Tracks the state of the engine (off, crank, start, run, or
error) based on error detection functions and actual engine speed
Woodward 3
Service Tool Software

Because the LCS ITB and LC-50 are digital control systems with no externally
accessible adjustments, a suite of companion software tools is available to help
the OEM with every phase of application development, manufacturing, and field
service. The LCS ITB and LC-50 Service Tool Software is a Microsoft Windows
based GUI (graphic user interface). The Service Tool Software is compatible with
Windows 95/98/NT/00 and gives the OEM the ability to:
 Tune the control with the engine running during application development
 Create configuration files for downloading into multiple controls
 Download configuration files during the manufacturing process
 Extract and view fault codes for field diagnosis
 Update control dynamics during field service
One distribution of the software service tool is available from Woodward

(software part number 9927-1000). This part number defaults to the dealer
distribution—tools need for field support only. The OEM distribution—tools for
development, manufacturing, and field support—is available by obtaining a
license (part number 8928-5002). Detailed descriptions of software installation
are available in Chapter 4.
4 Woodward
Chapter 2.
System Description /
Application Overview
System Operation
The LCS ITB and LC-50 controls are ready for operation immediately (within 0.25
second) when the power supply is connected. Power may be connected to the
control at the same time the engine starter motor is engaged. Upon starting, the
engine will immediately go to the speed value determined by the features that
have been enabled by the Configuration Table. The actuator will drive the throttle
to maintain adequate steady state and transient speed control performance.
Upon an engine shutdown command, the engine shutdown solenoid or solenoid

valve in the gas fuel supply should be de-activated and the power supply
disconnected from the speed control. The signal to this solenoid should be sent
directly from the engine control panel and should be independent of the LCS ITB
or LC-50 control.
Overview of Control Application Process

Figure 2-1 shows the typical application process used with the LCS ITB and
LC-50 control. There are essentially three phases of application—development,
production, and field support.
During the development phase, the OEM’s engineers create a specification that
calls out the features, functions, and desired performance of the final application.
Then various online data gathering exercises are performed to collect critical
dynamics, load, and position data from the governor. This data, along with pre-
determined parameter enable, is put into an application configuration file, and the
file is downloaded into a sample set of prototype assemblies. Various application
tests are carried out to check the robustness of the empirical data prior to
releasing it for production. The empirical data obtained to this point is specific to
a given engine/driven load combination. Once, known, all other parameters can
be set up in an office environment using the GUI tools.
Woodward 5
Empirical
Data Measurements
Application Application
Specification Actuator Tuning Development Testing
(for specific linkage
Initial
Governor or positioner? arrangement) Configuration File
Engine break-in effects
Number of speeds?
Engine-to-engine variance
Isoch/droop/load sharing? Engine Tuning Feature/function selection
Altitude effects
Speed sensing method? (for all speeds) Empirical and known data
Fuel quality effects
Alternate dynamics?
Mechanical wear effects
Fuel limiters? Load/Position Points
(for droop and
fuel limiter functions)
OEM Document Product Assembly

Control (In-house programming)
Governor Installation
Archiving
Configuration download
Distribution
Post-assembly testing
Revision Level
Final (Updated) Product Shipment
Field Service
Configuration File
- OR -
Troubleshooting
Feature/function selection Tuning changes
Empirical and known data
Woodward Product Assembly
Document Control (preprogrammed control)
Archiving Governor Installation
Distribution Post-assembly testing
Revision Level Product Shipment
Figure 2-1. Typical Governor Application Process
The OEM can choose either to download configuration files at the OEM’s facility,
or to purchase pre-programmed governors from Woodward. If the choice is to
download the configuration files at the OEM’s facility, the OEM is responsible for
all aspects of controlling the data. If the choice is to purchase a pre-programmed
control, Woodward has responsibility for controlling the data in its document
control system, and the OEM will be responsible for communicating software
modifications to Woodward.
After the application is assembled, it is tested, shipped, and installed at its final
destination. If any additional field service is required, a dealer network uses the
dealer distribution of the tool set to check fault codes or update dynamics
settings.
Hardware Configuration Application Process

The first step is to choose the appropriate hardware for the application. An ITB, a
mixer, and a version of the actuator must be selected. The ITBs and mixers
come in five different sizes.
6 Woodward
For both the LCS ITB and LC-50, the user must choose the appropriately sized
ITB for the application. The chart below illustrates how to choose the proper size.
The intersection of the operating rpm and the engine displacement will fall in a
specific ITB band. For example, a 4.0 L engine that will run at 2000 rpm, would
need a 43 mm ITB, as that point falls between the two lines for the 43 mm
(square marker lines.)
If the application will have multiple speed set points, some judgment needs to be
used to appropriately size the throttle. In general, the highest speed where the
engine will spend any significant percentage of its time, or the highest speed
where efficiency (or power) is important, should be used for sizing.
Application Matrix for LC 50 IT B

For NA and Turbo Engines at Rated Conditions
Assum es: 4-Stroke C ycle, 90% VE, 50°C Inlet Mixture Tem p, Stoichiom etric F/A Mixture, Natural Gas Fuel
4000
- A rea between lines for a given throttle s iz e defines
3800 operating range for that throttle
- V ertic al dis tanc e between lines defines optim um RPM
3600 range for a fix ed E ngine Displacem ent
- Horiz ontal dis tanc e between lines defines optim um E ngine
3400 Displacem ent range at a fix ed RPM
3200
3000
Ø25m m ITB
2800 Ø30m m ITB
Ø36m m ITB
2600
Engine RPM
Ø43m m ITB
2400 Ø50 m m ITB
2200
2000
1800
1600
1400
1200
1000
800
600
0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5
Engine Displacem ent (L)
Figure 2-2. Application Matrix
If the application is an LC-50 product, there are appropriately sized mixers for
each throttle size. A complete gaseous fuel delivery system requires:
 a fixed main adjustment screw (MAS) or closed-loop trim valve
 a zero-pressure regulator (ZPR)
 a fuel shut-off valve
Woodward 7
The mixer supplied with the LC-50 is a venturi style mixer. By locally increasing
the air speed in a pipe, the static pressure at the location of the restriction will be
lower than the pressure before this restriction. When a number of orifices are
made in the circumference of the venturi, the medium to be mixed (natural gas)
will be drawn into the venturi throat. If the pressure of the gas is kept equal to the
pressure before the venturi, the gas will be mixed with the air in a constant ratio.
The pressure is kept equal to the air pressure directly before the mixer, by means
of a zero pressure regulator and a compensation line. The venturi mixer is
maintenance free.
A main adjustment screw or closed-loop trim valve is provided to adjust the

required air/fuel ratio by means of an adjustable restriction in the fuel line
between the zero pressure regulator and the venturi mixer.
The compensation line ensures that the gas pressure is kept equal to the air
pressure before the venturi mixer. When no compensation line is used, the outlet
pressure of the ZPR will not be balanced as the air filter becomes dirty. As the air
filter gets dirty, there is an increased pressure drop after the air filter, and the
air/fuel ratio will become richer.
Controller Selection
Once the ITB and mixer have been selected, an actuator/controller version must
be chosen. The LCS control has an electrical connector with a 12 pin Deutsch
DT configuration (reference DT04-12PA) integrally molded into its housing.
Seven pins are assigned to specific functions and cannot be changed. The OEM
can define the remaining five pins through the Configuration File. There is a
limited amount of flexibility to provide analog input, discrete input, or output
functionality. The features available are described in detail on the following
pages.
The tables below show the possible assignments for each auxiliary-based
function in the control. An X indicates that a particular auxiliary is always used
when the function is enabled. A P or an A for a specific function denotes a
primary or alternate auxiliary input assignment for the function. This P and A
arrangement is intended to maximize flexibility in the feature set.
8 Woodward
Generator Version
Function Aux 1 Aux 2 Aux 3 Aux 4
Pins 8 & 5 Pin 10 Pin 4 Pin 6
Isochronous Load Sharing X
Remote Speed Setting X
MAP Fuel Limiting X
50/60 Hz Select A P
Lower Speed X
Raise Speed X
Isoch Speed Ctrl/Droop Select A P
Aux Bias / Droop Select X A P
Dual Dynamics Select A P
Idle/Rated Select X
Industrial Version
Function Aux 1 Aux 2 Aux 3 Aux 4
Pins 8 & 5 Pin 10 Pin 4 Pin 6
Isochronous Load Sharing X
Remote Speed Setting X
Dual Dynamics Select A P
Idle/Rated Select X
Three Speed Select X X X
Controller Features Description

As you review the following features, keep in mind that most applications will only
require a few of the functions to be activated. The choices are available to
provide maximum flexibility in a single package. The user will at a minimum pick
one feature from each of the following areas: speed setting, speed biasing,
speed sensing, and control functions. From the dynamics functions area the user
can set as many or as few as is necessary for stable operation. The user can
choose all or none of the fuel limiter functions, actuator control functions, and
logic functions depending on the application.
SPEED SETTING
Single Speed Select—This is the default setting for the controller. If no other
features are enabled, the engine will run at one set speed.
50/60 Hz Select ( G version only)—This feature allows the user to switch the
speed set point between a primary and secondary engine rated speed. A discrete
input is used to toggle between the two set speeds. The user can define whether
this input comes into AUX1 or AUX4. When the engine is started with the input at
the low state (ground), the controller controls to the primary speed setting and
uses dynamics for the primary speed. When the engine is started with the pin in
the high state (12V), the controller will run at the secondary speed setting with
the corresponding second speed dynamics. Any state changes on the AUX pin
will be ignored once the engine is running. The state is determined only when
power is first applied to the governor.
Related configuration file parameters: 50/60 Hz select, 50/60 Hz Aux, speed 1,

speed 2, and primary dynamics for both speeds
Woodward 9
Idle/Rated Select (G version only)—This feature allows the user to toggle the
speed set point between an idle and a rated speed. The toggle is accomplished
through an input into AUX2. When the AUX pin is in its low state, the engine runs
at idle speed with the primary set of dynamics. When the AUX pin is in the high
state, the engine runs at the higher rated speed with the corresponding
dynamics. The user can toggle between the two speed settings at any time
during operation. Transition rates between the two speeds can be controlled at a
user defined ramp rate if desired. If the user defined ramp rate is 0, the new set
speed is instantly engaged. When the AUX pin transitions from high to low (rated
to idle), a programmable time delay is executed before the desired speed is
ramped from rated to idle. For example in welder applications it may be desirable
to have a time delay before decelerating from rated to idle (to allow some time to
change the welding rod).
Related configuration file parameters: idle/rated select, rated to idle delay, speed
1, speed 2, primary dynamics for both speeds, speed decrease rate, speed
increase rate
Three-Speed Select (I version only)—Some refrigeration applications may find it

useful to have three engine speeds available: a highest speed for quick cool
down when warm goods are put into a container, a lowest speed to maintain the
load’s temperature once it has been cooled, and an intermediate speed for
increased cooling if the container door is opened to move goods in or out.
Typically, the discrete inputs for each of these speeds will come from an
automatic thermostat, and only one will be high at a time. Mobile access platform
(scissor lift) applications may also require three engine speeds, which
correspond to three basic operating modes: static lift, transient lift, and mobile
vehicle travel.
AUX2, AUX3, and AUX4 are used to select between three speeds. If none of the
inputs are tied to +12 V, the current speed and control dynamics are used by the
Speed Control function. If AUX2 is tied to +12 V, the desired speed is speed 1
with the corresponding gain dynamics. If AUX3 is high, the desired speed is
speed 2 with the corresponding gain dynamics. If AUX4 is tied to +12V, the
desired speed is speed 3 with the third set of gain dynamics. Transition rates
between the three speeds can be controlled at a user defined ramp rate if
desired. Any ramp rate set at 0 causes the desired speed to be set to the speed
reference instantly. AUX2, AUX3, and AUX4 must be associated with the lowest,
middle, and highest engine speeds, respectively. If more than one AUX input is
tied to +12 V, the lower of the two speeds is selected.
Related configuration file parameters: 3 speed select, speed 1, speed 2, speed 3,

primary dynamics for all speeds, speed decrease rate, speed increase rate
Raise/Lower Adjust (G version only)—This feature allows the user to change

the speed set point with external discrete inputs.
Related configuration file parameters: raise / lower speed, speed decrease rate,
speed increase rate, speed adj lower limit, speed adj upper limit
10 Woodward
Lower—This AUX2 discrete input acts directly on the internal speed set point
within the LCS ITB and LC-50, and will progressively decrease the speed set
point down to a programmable lower limit at a programmable rate for as long as
the input is in a high state. When this input goes low, the speed reference will
remain fixed at the last setting reached the instant the input went low.
Raise—This AUX3 discrete input acts directly upon the internal speed set point
within the LCS ITB and LC-50, and will progressively increase the speed
reference up to a programmable upper limit at a programmable rate for as long
as the input is in a high state. When this input goes low, the speed reference will
remain fixed at the last setting reached the instant the input went low.
SPEED BIASING
Isochronous—This is the default speed biasing function if none of the other
speed biasing functions are selected. This maintains the engine at one speed
setting throughout operation regardless of load.
Droop—This feature allows for a change in speed set point with a change in
load. This feature is primarily used when the generator is connected to a utility
bus or paralleled with another genset on an isolated bus. In this situation, the
utility will determine the frequency of the alternator. Should the governor speed
reference be less than the utility frequency, power in the utility bus will flow to the
alternator and motor the unit. If the governor speed is even fractionally higher
than the frequency of the utility, the governor will go to full load in an attempt to
increase the bus speed. Since the definition of a utility is a frequency that is too
strong to influence, the engine will remain at full fuel.
Isochronous governor control is impractical when paralleling with a utility

because a speed setting above utility frequency, by however small an amount,
would call for full fuel since the actual speed could not reach the reference
speed. Similarly, if the setting were even slightly below actual speed, the fuel
would go to fuel off position.
Droop provides one solution to this problem. Droop causes the governor speed
reference to decrease as load increases. An actuator position feedback device is
employed within the LCS ITB and LC-50 to monitor actuator position. Setting
Droop to 0% means the control will provide isochronous operation. The desired
engine speed reduces with the following formula:
speed reference * droop percentage * (actual position – no load actuator position)
(full load actuator position – no load actuator position)
The speed offset calculation requires valid information in the droop percentage,
no load actuator position, and full load actuator position parameters.
Related configuration file parameters: constant droop, droop percentage, no load

act pos, full load act pos
Woodward 11
Aux Biasing (Isochronous Load Sharing)—This feature allows the user to alter
the speed set point with an external signal. This input comes into AUX1, and is
programmable as either a 0–5 V input or 3V input. This function modifies the
desired engine speed with the following formula:
speed reference * bias percentage * offset AUX1 input voltage
The bias percentage is a programmable value up to approximately 7%. When

AUX1 is configured as a 0–5 V input, 5 V corresponds to the full bias percentage
in a positive direction; 0 V corresponds to the full bias percentage in a negative
direction; and 2.5 V corresponds to no bias. This analog input should be provided
by a voltage transmitter via twisted, shielded wire pairs.
When AUX1 is configured as a ±3 V input, +3 V corresponds to the full bias

percentage in a positive direction; –3 V corresponds to the full bias percentage in
a negative direction. This analog input will be available to interface with
Woodward’s standard Load Sharing Module. This auxiliary input acts directly on
the LCS ITB and LC-50 speed reference and biases it by a programmable
amount up to approximately ±7% in direct proportion to the ±3.0 Vdc signal. This
input will be active only when the LCS ITB and LC-50 is selected for isochronous
operation and should be provided via twisted, shielded wire pairs.
Isochronous Speed Control/Droop Select—This discrete input toggles

between the Isochronous and Droop features. The function looks at the state of
AUX4 or AUX2 (user-defined) at power up, as well as the state of the input as
defined by the user. The state of this AUX input is evaluated when power is first
applied. Any state changes after the engine is running are ignored.
The user can program the aux input state that enables droop. This is done by
programming droop polarity to aux high (12 V) or aux low (ground). For example,
if droop polarity is programmed to aux high, then droop will be active when the
aux pin is in the high state.
Related configuration file parameters: aux bias, bias percentage, aux 1 type, aux
1 level
Aux Bias/Droop Select—This discrete input toggles between auxiliary biasing

(also known as isochronous load sharing) and droop. The function looks at the
state of AUX4 or AUX2 (user-defined) at power up, as well as the state of the
input as defined by the user.
The user can program the aux input state that enables droop. This is done by
programming droop polarity to aux high (12 V) or aux low (ground). For example,
if droop polarity is programmed to aux high, then droop will be active when the
aux pin is in the high state.
Related configuration file parameters: aux bias / droop select, droop percentage,
aux biasing percentage, no load act pos, full load act pos, droop polarity, droop
aux, aux 1 type, aux 1 level
12 Woodward
SPEED SENSING
Magnetic Pickup (MPU)—The MPU input has been designed for variable
reluctance speed sensors and not Hall-effect devices. The frequency range of
the MPU input is: 100 Hz to 12 000 Hz (designed to accept at least 14 000 Hz to
provide a margin of safety). The required minimum peak-to-peak voltage is 2 V
@ 100 Hz and 25 V @ 12 kHz.
This function expects engine speed pulses present on pins 11 (MPU+) and 3
(MPU–). The number of flywheel or gear teeth that pass the magnetic pickup for
one crankshaft revolution must be programmed into events per engine rev in the
configuration file.
Related configuration file parameters: mpu, flywheel teeth
Ignition—The LCS ITB and LC-50 control will accommodate a 2–333 Hz signal
from an ignition input for 1, 2, 3, 4, 5, 6, and 8 cylinder engines with speed set
points between 1200 and 3600 rpm. The LCS ITB and LC-50 controls can
accommodate 2- and 4-cycle engines. For standard coil ignition, the source may
be the negative terminal of the coil primary. For distributorless or DIS (Direct
Ignition System) systems, the source for the ignition pulses may be two ignition
leads from the spark controller connected to MPU+ (pin 11) and MPU– (pin 3).
Take care not to reverse MPU+/– on a DIS system, or no speed will be sensed.
This function requires engine speed pulses present on pin 12 (IGN) of the
control. The type of engine (2-stroke or 4-stroke) and the number of cylinders (1
to 8) must also be programmed in this parameter byte.
Related configuration file parameters: ignition, cylinders count, strokes
CONTROL FUNCTIONS
Speed Control—This function is the governor function. It calculates the
difference between the desired speed and the actual measured engine speed,
and adjusts the desired actuator position as a result. Speed setting functions and
alternate dynamics functions are responsible for selecting the active speed set
point and set of dynamics for this function. The user must choose either this
function or the position control function. They cannot both be enabled.
Position Control—Commands a desired actuator position based on an analog

input voltage. This function requires AUX1 is configured as a 0–5 V analog input.
This function also requires that the Actuator Control and Actuator Gate functions
are turned on. This function does not require the Governor State function to be
enabled. The Position Control function essentially overrides the Governor State
function and translates a 0–5 V input into a desired position for the Actuator
Control function.
Woodward 13
The accuracy of the internal LCS position sensor is nominally ±10%

of full travel, and under some conditions can be ±20% of full travel. If
you are not using the full stroke of the actuator, this will magnify the
existing error of the LCS position sensor. Position-based features
need to be used cautiously and calibrated carefully. In summary, if
you need better than ±10 degrees of accuracy for position-based
features, mechanical alternatives should be considered.
Related configuration file parameters: position control, aux 1 type, aux 1 level
DYNAMICS FUNCTIONS
A variety of dynamics or gains are available for tuning the engine and throttle
response. The user can use as few or as many as desired. The response of the
throttle blade, or position control, is controlled by PID (proportional, integral, and
derivative) control terms. The speed control of the engine is controlled by reset,
gain, and compensation terms. Multiple sets of speed control dynamics
parameters are available for each engine speed. For the generator version, four
distinct sets of dynamics are available. The industrial version of the software has
6 sets of dynamics available.
Three-Point Gain Curve—The engine speed control gain is set up as a three-

point gain curve versus position to adjust for linearity of the throttle body and
engine response. For example, at low throttle positions a small change in throttle
angle can cause a large kW change, while at high throttle positions it can take a
large change in throttle angle to produce a relatively small change in kW out. The
three-point gain curve corrects for this characteristic. The position breakpoints
are common for all speeds and dynamics. Typical values are
Gain 1 25
Gain 2 40
Gain 3 100
Gain Position 1 25
Gain Position 2 30
Gain Position 3 40
Related configuration file parameters: gain 1, gain 2 and gain 3 for primary and
alternate dynamics as required, gpos 1, gpos 2, gpos 3
Dual Dynamics—This feature allows for toggling between two sets of user-
defined dynamics or gains. The two sets of gains are referred to as the primary
and alternate dynamics. This feature is mainly used for dual fuel engine
applications where engine response can change from operation on one gaseous
fuel to another. This feature may also be used for generator sets to allow
different dynamics for standalone and parallel operation. When this input is low,
the primary set of dynamics is used. When this input goes high, the dynamic set
points will immediately change to alternate dynamics and remain there until the
input is returned to the low state. When this feature is active, the LCS ITB and
LC-50 react to state changes at the user defined AUX3 or AUX4 while the engine
is running. Primary and alternate dynamics exist for each speed setting.
Related configuration file parameters: alternate reset and gains for each speed
being used
14 Woodward
Automatic Gain Trim—To correct for engine power variation and its effect on
governor performance, the LCS includes an automatic gain adjustment function
that trims the gain of the controller based on steady-state and transient engine
speed performance measurements. Based on performance criteria programmed
into the LCS and the stability or load transient performance of the engine, the
function will increase or decrease the currently active gain setting. This function
can be used to combat the effects of engine break-in, engine-to-engine variance,
altitude, temperature, and fuel quality. This function is not intended to mask
serious engine faults, like broken spark plugs, large vacuum leaks, or other such
failures. The automatic gain adjustment function can be disabled.
This function continuously monitors the speed of the engine relative to the
currently active speed reference. If this function observes a steady-state speed
band that exceeds a programmable set point, then the currently active gain
parameter is decremented by a programmable amount until a programmable
minimum gain setting is reached. If this function observes a transient offspeed
that exceeds a programmable set point, then the currently active gain parameter
is incremented by a programmable amount until a programmable maximum gain
setting is reached.
Related configuration file parameters: gain decrement, gain increment, minimum

gain, maximum gain, steady state, transient
The auto gain feature requires significant testing to configure properly. For details
on how to complete this testing, please contact Woodward.
Enabling the auto gain feature without performing the proper testing
can cause engine instability.
FUEL LIMITER FUNCTIONS
The accuracy of the internal LCS position sensor is nominally ±10%

of full travel, and under some conditions can be ±20% of full travel.
Position-based features need to be used cautiously and calibrated
carefully.
Start Fuel Limiter—A Start Fuel Limiter feature is included within the LCS
control. It sets the throttle valve partially open during cranking and while the
engine is accelerating to its desired speed set point in order to minimize
overshoot of the speed set point. The action of this start fuel limiter is as follows:
When power is applied to the LCS system, its actuator remains in the minimum
fuel position until the starter is engaged and actual engine speed exceeds a user
defined start speed threshold. As soon as the engine speed exceeds this
threshold, the actuator will position at the start fuel limit. The engine continues to
accelerate. When the actual engine speed exceeds the user defined run speed
threshold, the start fuel limit is removed, the governor is free to use the entire
position range, and the failsafe and overspeed limiters are activated. The run
speed threshold is typically 75% to 90% of the minimum desired operating
speed.
Woodward 15
The Start Fuel Limiting function is automatically reset whenever power is
removed from the LCS control. The Start Fuel Limit feature can be disabled in
the Configuration Table so that the feature is not used.
Related configuration file parameters: start fuel limiter, start spd thresh, start fuel
limit
Boost Fuel Limiter (MAP fuel limiting)—This analog input should come from a
manifold air pressure (MAP) or turbo boost pressure transducer so that the fuel
delivered to the engine can be limited as a function of pressure. A two-slope Fuel
Limit vs. Transducer Voltage (air pressure) curve—having three definable
points—can be programmed into the Configuration Table to provide the desired
fuel limit functionality. Note that the transducer should be powered from the LCS
control to avoid a ratiometric calibration issue that would affect the accuracy of
this function. Pressure transducers can be obtained from Woodward.
This feature can be useful when using a non-wastegated turbo to avoid

overloading the engine. As the MAP reaches an overboost condition, the LCS will
close the throttle down as indicated in the figure. A MAP sensor can be more
economical than a waste-gated turbo; however, a wastegated turbo may spool
up faster.
Related configuration file parameters: boost fuel limiter, boost pressure 1-3,
boost fuel limit 1-3
MAP / Boost Fuel Limiting
Max boost and steady-state
60 throttle position at max
50
transient overload (110%
load).
Fuel Limit
40
30
20
10
0 Throttle closes
0 1 2 3 4 5 completely at any higher
MAP Volts boost or overload.
Throttle is allowed to open completely

up to max boost at 100% load.
Figure 2-3. MAP/Boost Fuel Limiting
ACTUATOR CONTROL FUNCTIONS

Actuator Control—This function calculates the difference between the desired
position and the actual measured actuator position, and adjusts the actuator
torque as a result. Proportional, derivative, and integral parameters are
referenced by this function. This is the position control loop.
16 Woodward
Actuator Gate—When the governor state is ‘powerup,’ this function overrides
the output of the Actuator Control function and prevents the actuator from
developing any torque. When the governor state is ‘start’ or ‘run,’ this function
passes the torque command of the Actuator Control function directly to the
actuator. When the governor state is ‘error’ this function overrides the output of
the Actuator Control function and drives the actuator to minimum fuel, which is
dependent on the direction setting in the configuration. These gates control the
start fuel limit and fault conditions.
LOGIC AND SUPPORT FUNCTIONS

Overspeed Error—The LCS control has an overspeed function that can be set
by the OEM to shut down the engine at a speed that is typically 110% of rated
speed. When the control senses this speed, it will drive the throttle to minimum
position, turn on the relay contact output (if enabled), and the software will store
a fault bit in EEPROM (if fault storage is enabled). Cycling power to the LCS will
restore normal operation, but the fault bit will remain in non-volatile memory until
reset.
The LCS control should never be used as the primary overspeed

protection device.
Related configuration file parameters: overspeed, EE fault storage, relay control,

overspeed thresh
Failsafe Error—To protect the engine against overspeed upon loss of the speed
input signal, the control will drive the actuator to minimum throttle anytime the
control senses a missing speed input for a programmable amount of time not to
exceed 0.5 second. The relay contact output will also be turned on (if enabled)
and the software will store a fault bit in EEPROM (if fault storage is enabled).
Cycling power to the LCS will restore normal operation, but the fault bit will
remain in non-volatile memory until reset.
Related configuration file parameters: Failsafe, Failsafe timeout period, EE fault

storage, relay control
Configuration Error—The Configuration Error function is permanently enabled

to check for the presence or absence of a configuration file in the control during
power-up. If a configuration error is detected, software sets the configuration
error flag, activating the relay output and rendering the control inoperable until
the power is cycled.
Relay Control—This switchable, discrete output is a closure to ground capable

of sinking 250 mA with an output voltage rise of less than 1.5 V, and is available
to power external relays for devices such as fuel shutoff solenoids. It has an
internal protection diode, so it is not necessary to provide one externally. This
output is normally floating with a very weak resistor to an internal +5V, but when
an error condition occurs (overspeed, configuration, failsafe), this output sinks up
to 250 mA to ground.
Woodward 17
There are two conditions that will prevent this output from operating. The first is if
battery positive is accidentally connected to it, and the second is if it is shorted to
ground. If this output is intended to drive a fault light, these conditions will not be
obvious.
Fault Storage—Enabling this bit turns on the EE Fault Storage function when
the governor state is ‘error’. When the governor state transitions to ‘error,’ the
source of the error (configuration, overspeed, or failsafe) is stored as a set bit in
the control fault register of the LCS’s EEPROM.
Governor State—This function sets an internal state variable to one of four

values (powerup, start, run, or error) based on the current engine speed and
error function data. When power is first applied to the governor, its state is
‘powerup.’ As the engine is cranking and its speed exceeds the start speed
threshold, the state of the governor changes to ‘start’. When the engine speed
exceeds the run speed threshold, the state of the governor changes to ‘run’. If
any of the speed error functions (overspeed, failsafe) are enabled, and they
detect a speed error, then the state of the governor transitions to ‘error’ and
remains there until power to the control is cycled. This function is required for all
speed governor applications; it is not required for positioner applications.
Password Protection—This feature allows an OEM to password protect the

configuration files. This prevents unauthorized dealers or competitors from
reading configuration, dynamics, or fault information from the OEM’s controls. In
general the OEM should only use one security key for all LCS applications;
otherwise multiple copies of service tools and security key files will be required. If
you choose to put a value in this parameter, then you will also have to generate
companion encrypted security key file using the software tools and distribute this
key file with the dealer service tools.
If an OEM decides to put a value into the OEM SECURITY KEY field, and
downloads that configuration file into a control, the OEM must supply an
encrypted security key file called ACCESS.KEY when giving the OEM dealer
network a copy of the dealer service tools. If a dealer tries to work with an LCS
control and does not have a ACCESS.KEY file, the tool will not permit access to
the control’s data.
Related configuration file parameters: OEM Security Key, Make Key function
18 Woodward
Chapter 3.
Installation
Mechanical Installation
Locate the LCS control a distance from sources of extreme radiant heat, such as
exhaust manifolds or turbochargers. The operating temperature range of the
control is –40 to +85 °C (–40 to +185 °F). In spark-ignited applications, make
sure the LCS is located away from the ignition coil, and that harness wires are
not routed next to the spark plug wires.
While it is not a requirement, it is good practice to orient the connector feature on

the control in a horizontal or downward orientation to minimize fluid accumulation
between the enclosure and the mating connector’s gasket.
The 25, 30, and 36 mm throttles mount with 5 mm fasteners in a 43 mm square

bolt pattern. The 43 and 50 mm throttles use 6 mm mounting screws in a 57 mm
square pattern.
The LCS actuator has a rotation of 0–60 degrees. To get full blade rotation on
the ITB, a mechanical linkage exists inside the ITB that converts 0 to 60 degrees
actuator rotation to 3 to 85 degrees blade position.
The LC-50 mixer can be mounted in any of three orientations of the ITB to allow
convenient fuel system connections. The LCS ITB and LC-50 are intended to be
used with gaseous fuels from low quality pipeline natural gas to HD-5 LPG. The
quality of this range of fuel varies from a lower heating value of 850 BTU/SCF
(34.0 MJ/m³) to 2325 BTU/SCF (93.0 MJ/m³), and the specific gravity varies from
0.55 to 1.56 relative to air. When using a Woodward supplied ZPR, fuel pressure
should be 0.25 psi (7” water column) (1.7 kPa [178 mm water column]) to 1 psi
(28” water column) (6.9 kPa [711 mm water column]). Pressure supply range is
4–14” water for the R500Z, and 4–28” water for the R600Z.
The LC-50 mixer has two inlet sizes for air filter attachment. The smaller throttles
(25, 30, and 36 mm) have a 2.0-inch (50.8 mm) inlet. The larger throttles (43 and
50 mm) have a 2.5 inch (63.5 mm) inlet.
We recommend installing all components of the gas system, such as air filter,
main adjustment screw, and throttle valve in a symmetric way to minimize
possibility of unequal mixture distribution.
Curved pipes should not be installed closer to the venturi than 3D (where D is the
diameter of the venturi at the air inlet side).
Woodward recommends that you install a compensation line between the ZPR
and the air inlet to maintain consistent air/fuel ratio throughout the life of the
system. If a compensation line is not installed, the air/fuel ratio will be affected by
the changing restriction of the air cleaner as it accumulates dirt.
Woodward 19
If the Maxitrol ZPR is obtained from Woodward, the following installation
instructions apply. If another brand of ZPR is used, consult that manufacturer for
installation guidelines. The ZPR should be mounted with the spring tower up. If it
is not, the weight of the diaphragm and spring can offset the pressure setting.
The ZPR should be mounted as close to the MAS as possible to prevent
pressure drop across excessively long pipe lengths. This pressure drop and
associated system lag can cause stability and response issues with the mixer
air/fuel ratio control.
On a turbo-charged engine, the mixer should be located before the turbo

compressor. This will yield very high mixture homogeneity as well as allowing the
use of a standard ZPR and the ability to use low-pressure gas. To increase
safety, some engine manufacturers have mounted flame arrestors between the
inlet manifold and the cylinder head, ensuring that a backfire does not lead to an
explosion in the inlet manifold, aftercooler, etc., which are filled with ignitable
mixture.
The initial settings for the MAS and ZPR are indicated in the table below. These
settings should provide the ability to consistently start and run at an
approximately stoichiometric air/fuel ratio. The procedure for adjusting these
settings for optimum air/fuel ratio will be described in the air/fuel ratio tuning
section (Chapter 4). The main adjustment screw (MAS) settings are measured
from the MAS valve body (not the jam nut) to the exterior end of the MAS screw.
The zero-pressure regulator settings are measured from the top of the spring
adjustment screw to the top of the spring tower.
For dual-fuel configurations, the standard NG fuel set up should have a tee
added between the ZPR and MAS. The side-leg of the tee should then have the
MAS and ZPR for the LP fuel. The initial settings for dual-fuel NG and LP are the
same as the single-fuel settings below. The final air/fuel ratio adjustments should
be done on NG first, then LP, using the procedure in Chapter 4 for each fuel.
MAS and ZPR Initial Settings

ITB Size Natural Gas Propane
50 mm Screw Setting Position (mm)
MAS 19 16
ZPR 16 14
43 mm
MAS 17 15
ZPR 16 14
36 mm
MAS 11 9.5
ZPR 14 14
30 mm
MAS 11 9
ZPR 14 14
25 mm
MAS 10 8
ZPR 14 14
20 Woodward
Electrical Installation
A pinout of the LCS control, as viewed by looking into the control’s connector
feature, is shown in Figure 3-1. Typical connections to external devices are also
shown.
The LCS has an operating voltage range of 8 to 16 Vdc with a nominal voltage of
13.5 V. The power supply is load dump and reverse polarity protected, and
consumes 64 W maximum power at a peak current of 4 A (16 V) assuming 4 Ω
stator resistance at 25 °C. The control system should be protected with a 6 A
fuse in the voltage supply lines. Typical max average current is 1.8 A, or max 29
W at 16 V. The application should be configured to turn on power to the governor
when the engine is first cranked. Power should be removed just before the
engine is shut off so that the actuator loses torque and the return spring can
move the throttle to a minimum fueling position.
Variable Reluctance
Speed Sensor
(speed sensing option)
connector
key Governor Power
Controlled by
Flyback Voltage Application
IGN +12V
from Ignition Coil 12 1 +12V Power
(speed sensing option) (must be fed
MPU+ GND from a Class 2
11 2
power source)
AUX2 MPU-
+12V Power 10 3
Error
Relay RELAY AUX3
9 4 +12V Power
AUX1+ AUX1- (GND) Features Controlled

8 5
by Application
+5V OUT AUX4
7 6 +12V Power
+12V Power
MAP
connector
Sensor
key
note: AUX1+ and AUX1- can also be used as a +/-3V load sharing input
note: AUX1+ can also be used as a digital input like AUX2, AUX3, and AUX4
Pinout as Viewed Looking Into LCS Control
Figure 3-1. Typical LCS Application Wiring
Woodward 21
Several speed sensing options are supported. The LCS can sense speed from
ignition coils, DIS modules, or variable reluctance magnetic pickups (MPU).
When using the LCS with an ignition coil, attach the IGN input to the switched
side of the coil’s primary; typically this is the negative (–) terminal of the coil. Do
not rely on the condenser connections to determine which side of the primary coil
is the switched side—use a tachometer or frequency meter to check for engine
speed.
When interfacing the LCS to a DIS module, connect the LCS control’s MPU+ (pin
11) and MPU– (pin 3) input pins to the DIS module’s signal and ground input
pins. Be careful not to accidentally swap the connections; otherwise the engine
will not start.
When using a variable reluctance magnetic pickup, make sure the gap between
the pickup and the flywheel or gear teeth is sufficiently small so that the sensor
output voltage meets or exceeds the voltage threshold curve shown in Figure 3-2
for the full range of engine speeds. The resistance of the MPU must be less than
900 Ω.
25 Vpp
20 Vpp
15 Vpp
10 Vpp
5 Vpp
2kHz 4 kHz 6 kHz 8 kHz 10 kHz 12 kHz
MPU Input Voltage (peak-to-peak) Requirement vs. Input Frequency
Figure 3-2. Voltage Threshold Curve
The relay output driver is activated any time the governor detects an error
condition (overspeed, failsafe, or configuration error). The driver sinks up to 250
mA of current through an external device powered from +12 V. This driver is
internally protected against inductive flyback.
22 Woodward
The +5 Vdc Power Output is intended to power the pressure transducer used
with the manifold air pressure-biased fuel limiter function. The maximum output
current is 10 mA. If the external wire associated with this function is shorted to
ground, the actuator will lose its power and the ITB return spring will close the
throttle. If the short persists, the control’s internal regulator may go into thermal
shutdown but should not be permanently damaged. If the short is cleared, the 5
V supply will return after the regulator chip cools down. Use special care when
routing wire to this pin. Use well-insulated wire, and be sure to grommet any
holes in sheet metal through which it may be routed.
The LCS has three dedicated digital inputs (AUX2, AUX3, and AUX4) used to
activate various features of the control. Shorting an input pin to +12 V activates it.
Removing +12 V from an input pin or shorting the pin to ground deactivates the
input. At least 4 volts must be present on an input pin in order to change its state
from inactive to active. All discrete inputs will be the same voltage as the system
power supply and will be active only while the input is in a high state. Greater
than 4 Vdc is considered high, and less than 1 Vdc is considered low.
All connector pins are short-circuit protected to ground and power except pins 2,
3, and 5, which are not protected against shorts to battery positive. Installation of
a fuse on the power ground wire to pin 2 would provide protection to these pins
but does not mean one is not needed in the power connection. Pin one (B+) still
needs protection against a short to ground.
A combination analog/digital input (AUX1) is available on the LCS. When AUX1

is configured as a digital input, it must be grounded (not opened) to deactivate,
but otherwise the AUX1+ pin is treated the same way as AUX2, AUX3, and
AUX4. When the pin is used as a discrete input, it will have minimum impedance
of 10 kΩ, and when configured as an analog input, it would have minimum
impedance of 100 kΩ. When AUX1 is configured as a ±3 V analog input, the LCS
may be interfaced to other Woodward load sharing equipment through the
AUX1+ and AUX1– inputs. When AUX1 is configured as a 5 V analog input, +5V
OUT, AUX1+, and AUX1– may be used to sense manifold absolute pressure or
bias engine speed with a potentiometer.
The following Deutsch connector components are recommended for harness

designs:
Recommended Optional
Mating Connector DT06-12SA-P012 DT06-12SA
Secondary Lock W12S-P012 N/A
Sockets 0462-201-16141 0462-201-16141
Woodward part number 8928-396 is a kit that provides all the necessary Deutsch
components.
Woodward 23
Use 16 to 18 AWG (1 to 1.5 mm²) stranded copper wire with insulation that
meets temperature requirements in the harness design. In the event a wire is not
used for each of the 12 pins on the control, a Deutsch 114017 plug should be
used in place of each missing wire to environmentally seal the connector from
the elements. A wiring harness stress relief within 16 inches (406 mm) of the
control’s connector is recommended. The maximum recommended harness
length is 20 feet (6 m). Dress the harness with wire loom to contain it in a single
bundle. Use grommets when passing the harness through metal panels. Ground
the MPU signal wire shielding at the control, but do not ground the MPU signal
wire shielding at the MPU.
When using the ignition signal as the speed input, connect a two inch (51 mm)
insulated 18 AWG (1 mm²) wire between pins 3 and 11 (MPU+ and MPU-) of the
12 pin Deutsch connector.
Also use twisted pair, shielded wires for the AUX1 input when configured for
Isoch Load Sharing, 0–5 Vdc Remote Speed Setting, or MAP Fuel Limiting.
Ground this shielding on the engine near the control.
24 Woodward
Chapter 4.
Software Programming
This chapter covers the process of tuning, configuring, and servicing the control
via the LCS Service Tool Software Suite. It is assumed that the control has
already been installed on the engine.
The following hardware is required to work with the LCS control, regardless of
whether an application is being developed by engineering, a configuration file is
being downloaded in production, or the application is being serviced in the field:
 PC-compatible laptop or desktop computer* with at least one available serial
communications port, and Windows 95/98/00/NT as the operating system.
 Programming/datalink harness (part number 02-0004-174) as shown in
Figure 4-1.
*—There is a potential for serial port damage when communicating

with the LCS control. This is caused by a difference in ac voltage
between neutral and earth ground. If the PC RS-232 port ground is
referenced to ac neutral, and the LCS control is referenced to battery
ground (ac earth ground), a large amount of current can be
experienced. To avoid this situation, we strongly recommend placing
an isolation transformer between the ac outlet and the PC.
Variable Reluctance
Speed Sensor
(speed sensing option)
connector
key Governor Power
Controlled by
Toggle Switch
Flyback Voltage
IGN +12V
from Ignition Coil 12 1 +12V Power
(speed sensing option) (must be fed
MPU+ GND from a Class 2
11 2
power source)
TX AUX2 MPU-
10 3
RELAY AUX3
9 4
AUX1+ AUX1- (GND)

8 5
+5V OUT AUX4

7 6
PC Serial 1 2 3 4 5 connector
Port -- Male 6 7 8 9
key
DB9 Connector DTR
GND
CTS
RTS
DSR
Pinouts Viewed Looking into Control Connector and Computer Connector
Figure 4-1. Typical Programming Datalink Harness Wiring
Woodward 25
In addition to the hardware, the following are the distributions of tool software
needed to communicate with the control:
 Woodward part number 9927-1000, LCS Service Tools, Dealer Distribution
 Woodward part number 9927-1000, LCS Service Tools, OEM Distribution
(license Woodward part number 8928-5002)
The dealer distribution is required to update control dynamics and read out fault
codes. The OEM distribution is required to configure, tune, and secure the
control; it also includes the utilities from the dealer distribution.
Software Installation
The software tool is available for download form Woodward’s website:
www.woodward.com/ic/software/software.cfm
Select the LCS Control from the pull-down menu. Then select GO. A new screen
will appear with information about the product as well as installation instructions.
To download the software, press the DOWNLOAD button.
Before you can download, you will be prompted to log on to the Woodward site. If
you have never downloaded Woodward software, you will have to complete a
new registration.. Press this icon and fill out the information requested. If you
have already registered, enter your e-mail address and press Login. The
registration information is required so that we can alert you of updates to the
software tools.
26 Woodward
Once you have downloaded the software, double-click on the file (setupLCv1-0-
A.exe) and follow the on-screen prompts. The defaults install is a dealer
distribution in the default directory of LC-ctrl. To activate the OEM version, a
license authorization must be obtained. This can be obtained from the same
website.
You will need a serial number (obtained from your account manager) and a site
code (obtained by pressing Change License) on the LC Control Software.
This is the first screen that appears when the GUI is initialized. To use the GUI
Service tools, the user must have either an LCS with a supported firmware
revision or the user must have access to a valid configuration file. This feature
can also be used to identify the firmware revision of a particular configuration file.
The GUI supports several firmware revisions. The dialog box in the center of the
screen will indicate “LCS B/C”, “LCS D”, “LC-50G”, or “LC-50I” configuration
format will be used. This manual covers the LC-50G and LC-50I versions. If your
system comes up as B/C or D configuration format, contact Woodward for the
appropriate manuals.
 IDENTIFY CONTROL—Identifies which version of firmware an LCS has.
This requires that an LCS be connected to your laptop with a programming
harness.
 IMPORT CONFIG FILE—Opens an existing config file. Select the desired
file using the browser (config files use a *.lcs extension). Template files are
available to get started.
Once a valid file or valid LCS has been identified, the screen below is displayed.
The box in the center of the screen identifies which version of LCS is being used.
OEM Version of Main Screen
Woodward 27
Dealer Version of Main Screen
CONFIGURATION Menu—Gives the user access to the configuration file

handling options: edit config file, write to an LCS, read from an LCS, etc.
REAL-TIME TUNER Menu—Gives a user access to critical speed, dynamics,
and position information for tuning. Both GAIN and Engine RPM can be
monitored automatically by asserting the respective button. All data items must
be read or written to by the GET and SET buttons, respectively.
SECURITY KEY Menu—Creates a security password and associated key to
prevent other OEMs from viewing your *.lcs file.
FAULT CODES Menu—Fault codes can be viewed and reset from this menu.
DYNAMICS Menu—Provides access to a subset of the config file for dealers or
field service.
28 Woodward
Working with Configuration Files

This is the menu that is displayed when the CONFIGURATION Menu button is
pressed. Six options are available. After the configuration file or LCS has been
validated, its data is loaded into GUI’s memory.
Read Configuration From LCS: Loads the config file from a LCS to the GUI.
This requires that an LCS be connected to the computer through a programming
harness. When you select this option, you will be asked to turn power on to the
controller. Power is controlled by a toggle switch in the programming harness
(see beginning of chapter for harness description).
Read Configuration From a File: Opens a Windows browser and allows the
user to open an existing *.lcs file.
Write Configuration To LCS: Writes the active config file stored in the GUI to
the LCS EEPROM. This requires an LCS be connected to the computer through
a programming harness. When you select this option, you will be asked to turn
power on to the controller. Power is controlled by a toggle switch in the
programming harness (see beginning of chapter for harness description).
Write Configuration To File: Saves the active config file stored in the GUI to the
location of your choosing.
Write Configuration File To LCS: Writes configuration file from hard drive or
disk to the LCS.
Edit Configuration: Presents the LCS configuration file in a graphical format.
Exit: Returns to the main menu.
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EDIT Configuration—Screen 1
On all screens numerical values can be entered by directly typing them in the
field, or by pressing the up and down arrows to increase or decrease the value.
Features Configuration Menu—Generator Version
Features Configuration Menu—Industrial Version
30 Woodward
This first screen allows the user to select the options to be enabled. See the
Controller Features Description section of Chapter 2 for detailed explanations of
each of the features.
The Free Form Text box allows the user to have a unique description for each
configuration file. This text is stored in non-volatile EEPROM for future
identification.
The OEM Security Key box is where the password is entered, if desired.
A feature is enabled or disabled by selecting ON or OFF from the pull down

menu next to that feature.
For features that can be programmed to come in on a choice of multiple pins, a

status of each AUX input is displayed on the lower left of the screen. If the user
tries to put two features on the same AUX input, the status area will indicate that
with red text and the words CONFLICT Exists.
If a feature is not turned on, the associated parameters cannot be edited. For
example, if Droop is not turned on, the dialog box underneath asking for a droop
percentage, cannot be edited.
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When you press NEXT from the FEATURES CONFIGURATION Menu, the
DYNAMICS Menu appears.
This is where the engine governing speed control gains are configured. If the
LCS is being used as a positioner, no information is needed on this screen.
Dynamics Menu—Generator & Industrial Versions
If the LCS is being used as a governor, then the control dynamics, speed
sensing, and speed settings will be entered on this screen.
Primary and alternate refer to the dual dynamics function. If the dual dynamics
option was selected on the first screen, then values should be entered for both
primary and alternate gains.
Speed 1 box on the left is the primary speed setting. If 50/60 Hz, idle/rated, or
three-speed was selected, the pull-down menu at the top of the screen becomes
accessible. This allows you to enter the speed settings and dynamics for the
various functions.
Common gain, compensation, GPOS1, GPOS2, GPOS3 are common for all
speed settings and both primary and alternate dynamics.
The graph on the bottom right will show a plot of the primary dynamics for the
speed setting reflected in the speed select box.
The speed sensing mode is also defined here. If MPU is selected, an option
drops down for number of flywheel teeth. If ignition is selected, drop down menus
appear requesting inputs for number of cylinders and type of engine.
32 Woodward
The third screen in the configuration file editor is the positioner screen. The
proportional, integral, and derivative terms control the response of the throttle
blade. Typical values for throttle body applications are: proportional = 25 to 40,
integral = 15 to 25, derivative = 0 to 30.
No load and full-load actuator positions are used by the droop function. If droop
is not being used, no information is needed here.
Position Menu—Generator Version
Position Menu—Industrial Version
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The Fuel Parameters Menu is the fourth screen. This screen is where the fuel
limiting parameters are entered. If start fuel limiting and boost fuel limiting are not
being used, this screen can be skipped.
If start fuel limiting is being used, enter the actuator position limit on this screen.
The RPM threshold is entered on the next screen.
If boost fuel limiting is being used, enter the parameters here. These points act
as a three-point curve, with linear interpolation between points.
Fuel Parameters Menu—Generator Version
Fuel Parameters Menu—Industrial Version
34 Woodward
The fifth screen presents the Speed Parameters Menu. The start speed
threshold, run speed threshold, and overspeed threshold are entered here.
If the raise/lower function has been enabled, enter the ramp rates in speed
decrease rate and speed increase rate. The upper and lower limits for the
raise/lower function are also entered here. The ramp rates are also used by the
idle/rated function and the three-speed function. The speed will transition
between the various set speeds at these rates.
Speed Parameters Menu—Generator Version
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This is the final screen in the EDIT Configuration Menu. This screen is where the
auto gain parameters are entered. The GAIN DECREMENT and GAIN
INCREMENT indicate how much the gain should be altered when the system is
determined to be unstable. Minimum Gain and Maximum Gain are the limits for
any changes in the gain. Steady State (rpm) and Transient (rpm) are the
windows to determine instability. If the system is operating in a steady state
mode, then if the RPM varies by more than this amount the gain will be
decremented by the amount indicated in Gain Decrement. Likewise, during a
transient event, if the RPM varies outside the transient RPM window, the control
will increment gain.
36 Woodward
Real-Time Tuner
The OEM utility REAL-TIME TUNER is designed to give application engineers
the ability to tune an LCS control’s actuator position control loop and engine
speed control loop.
The program initializes the control for real-time communications while the main
control loops are executing. Because the real-time tuning software uses AUX2,
AUX3, AUX4, and the relay output to communicate, no auxiliary product features
can be enabled. Use of this feature requires an LCS be connected to the
computer through a programming harness. When you select this option, you will
be asked to turn power on to the controller. Power is controlled by a toggle switch
in the programming harness (see beginning of chapter for harness description).
Examples of how this tool is used are contained in the sections of this manual
dealing with actuator tuning and engine tuning.
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Working with Security Keys

If an OEM decides to make use of the password protection feature, this is where
the password is entered and the associated key is created. This screen is
accessed from the Main menu by pressing Security Key Menu. Enter the
password you would like to use in the text input box. Then press the Make Key
button. A file called “access.key” is created that must then be present in the
working directory any time you attempt to communicate with the LCS.
Viewing and Resetting Fault Codes

VIEW Fault Codes
To view the contents of a control’s fault register, press the VIEW FAULT CODES
button located in the FAULT CODES Menu.
The program will display which of the error bits are set within the register
(configuration error, overspeed error, or failsafe error). A configuration error is the
result of not downloading a configuration file into a new control. Overspeed, and
failsafe errors all relate to issues with the MPU or connection to an ignition
system. The underspeed fault does not apply to the LC50 ITB versions of the
LCS.
38 Woodward
RESET Fault Codes
To clear the contents of the control fault register, press the RESET FAULT
CODES button. The program will reset the state of all error bits.
Messages
In working with the LCS, the power must be cycled from time to time. The user
will be prompted to turn power on or off. If the power is not cycled in 10 seconds,
a message will appear which allows a retry or the cancellation of the current
activity.
Dynamics Menu
This is the menu displayed after pressing Dynamics menu. It allows access to a
subset of the entire configuration file. Dealers or field service personnel can
access all of the dynamics associated with the controller including: primary and
alternate reset, gain 1, gain 2, gain 3, and compensation for all speeds.
Read Dynamics From LCS—Loads the dynamics file from a LCS to the GUI.
This requires that an LCS be connected to the computer through a programming
harness. When you select this option, you will be asked to turn power on to the
controller. Power is controlled by a toggle switch in the programming harness.
Read Dynamics From File—Opens a Windows browser and allows the user to
open an existing *.dyn file
Write Dynamics To LCS—Writes the active dynamics file stored in the GUI to
the LCS controller. This requires that an LCS be connected to the computer
through a programming harness. When you select this option, you will be asked
to turn power on to the controller. Power is controlled by a toggle switch in the
programming harness.
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Write Dynamics To File—Saves the active dynamics file stored in the GUI to
the location of your choosing.
Write Dynamics File To LCS—Writes a dynamics file from the hard drive or disk
to the LCS.
Edit Dynamics—Presents the LCS dynamics file in a graphical format for
editing.
Restore Dynamics—Restores the original OEM settings. If a user writes
dynamics changes to the LCS and decides that they are not effective, pressing
restore will copy the original settings from backup memory area on the controller.
Exit
40 Woodward
When Edit Dynamics is pressed, the following screen is displayed.
Controller Tuning
Before continuing, the OEM should already have in mind which speed setting,
speed biasing, speed sensing, alternate dynamics, fuel limiting, and support logic
features should be enabled. For more information on the features available, see
the Features Description section of Chapter 2.
Initial File Construction

An initial configuration file must be created for every application. This file can
either be created from scratch or an existing file can be modified. The steps
below outline how to create the initial file.
1. Start the GUI program by selecting it from the Windows Start Programs
menu.
2. Select IMPORT CONFIG FILE.
3. An existing config file can be used if the application is similar to one already
developed. If this is the case, choose Config files from the file type drop
down and then select the appropriate file from the Windows browser. If this is
a new application, a template file can be opened. Select Template files from
the drop down menu and then select the template that matches your version
of LCS controller.
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4. Select the file by double-clicking on it, or single-clicking and then pressing
OPEN.
5. Once the file is opened, you are returned to the MAIN Menu.
6. To edit the configuration file, press the CONFIGURATION Menu button.
7. Then press the EDIT Configuration button.
8. You are taken to the first screen of the Configuration Menu. In this screen
select the features you have determined you would like enabled.
9. If inputs are selected on the AUX pins, the bottom left of the screen indicates
which inputs are associated with the AUX inputs. If a conflict exists, the text
will turn red. Make sure that all inputs are coming in on a unique Aux input
before continuing.
AUX Input Assignment Conflict Designation
10. For initial tuning, the AUTO-GAIN feature should be turned off.
42 Woodward
11. When all the features are selected press NEXT.
Initial Speed Governor Feature Settings
Initial Positioner Settings
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12. The next screen asks for dynamics information. If this is a new application,
reset, compensation, and gain can all be set to the values shown initially. A
common gain setting of 20 will give steady speed control for initial start-up
and air/fuel ratio tuning. The controller may not respond will to large
transients however. If this is for a positioner application, the values on this
screen will be ignored.
Initial Dynamics Settings for Speed Governor Applications
13. The appropriate speed setting should be entered on this screen.

14. The speed sensing mode is also entered here.
15. After entering these values, press NEXT.
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16. The POSITION Menu is displayed. Appropriate initial values for the PID
terms are: proportional = 35, integral = 10, derivative = 0.
Typical Speed Governor and Positioner Values
17. If droop is being used, full-load and no-load actuator positions will need to be
determined and entered here. (This can be after initial tuning.) Typical values
are approximately 15 at no load and 50 at full load.
18. Press NEXT.
19. The FUEL PARAMETERS Menus is displayed. Enter any desired values
here. The start fuel limit will help to avoid over-speed on start-up. Typical
values are 20 to 30. Boost fuel limit function is discussed in Chapter 2.
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20. Press NEXT.
21. The SPEED PARAMETERS Menus is displayed. Enter start speed threshold,
run speed threshold, and overspeed threshold here. Also enter any desired
raise/lower values here.
22. Press NEXT.

23. The AUTO-GAIN parameters Menu is displayed. This feature should be
turned off for initial tuning. So, these values should be zero.
46 Woodward
24. Press EXIT.
25. You are returned to the Main Menu. Press Write Configuration To File to
save your initial configuration file to a file. Press Write Configuration To LCS
to write the file to the controller and begin tuning.
LC-50 Applications (Mixer Applications)

After the initial program is configured, the air/fuel ratio should be optimized
before extensive engine speed governor tuning is done. Start with low gain
values and step slowly through load changes until the air/fuel ratio is tuned.
Initial settings are described in the hardware installation section of the

INSTALLATION chapter. These settings should get the gensets up and running
for final adjustment with an oxygen sensor or exhaust analyzer.
Know in advance how to safely shut off the engine during normal
and emergency stop conditions. Shutting off power to the governor
does not always guarantee a controlled shutdown; it depends on the
final application. Safety needs to be the overriding thought during
this procedure.
Air/Fuel Ratio Tuning

1. Insert an oxygen sensor or exhaust gas analyzer into the exhaust stream as
directed by the manufacturer of the sensor or analyzer.
2. Ensure a configuration file has been downloaded into the LCS controller (See
initial configuration file section.)
3. With LCS power off, press Start Real Time Tuner Menu and turn power on.
4. Start the engine.
5. If the engine overspeeds and shuts down, perform the following
o Exit Real Time Tuner Menu
o Remove power from the control.
o Go to the EDIT Configuration Menu, then go to screen 4, and adjust
the start fuel limit to a lower value.
o Repeat steps 3 through 5.
6. Start the engine and allow it to warm up for about 15 minutes.
7. Apply 75% to 90% load to the engine. With initial, low gain values in the
speed control loop, the load may need to be applied gradually to avoid under
and overspeed conditions.
8. Adjust the MAS to achieve the desired air/fuel ratio. Figures below show
characteristic response of oxygen sensors and exhaust gas. Clockwise
rotation of the MAS will cause the air/fuel ratio to become more lean.
Counter-clockwise rotation will cause the air / fuel ratio to become more rich.
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Figure 4-2. Zirconia Oxygen Sensor Response
Figure 4-3. Pre-Catalyst Emissions Figure 4-4. Post-Catalyst Emissions
9. The ZPR should then be adjusted at no-load. Clockwise rotation of the screw
will cause the mixture to become richer, counter-clockwise rotation will cause
the mixture to become leaner. When the cover is removed from the ZPR,
extra air leakage is introduced into the system. So, a final setting cannot be
determined until the ZPR spring tower is covered.
10. One or two more iterations at full load for the MAS and no load for the ZPR
should provide the correct air/fuel ratio over the entire operating range.
Speed Governor Applications
Know in advance how to safely shut off the engine during normal
and emergency stop conditions. Shutting off power to the governor
does not always guarantee a controlled shutdown; it depends on the
final application. Safety needs to be the overriding thought during
this procedure.
Speed governor applications require that the speed control loop be tuned for load
transients and steady-state stability. Use this procedure to derive the values of
the speed control coefficients (reset, gain, and compensation) for a fixed engine
speed. The speed control coefficients are described below:
48 Woodward
GAIN determines how fast the control responds to an error in speed when the
speed reference is changed or a load disturbance occurs. A value too high will
result in sustained, fast oscillations in speed. A value too small will result in poor
control performance and possibly slower oscillations.
RESET prevents slow hunting at steady state and controls damping when speed
error returns to zero after a speed disturbance. A value too high will result in
large, low frequency oscillations in engine speed. The actuator will tend to “bang”
from stop-to-stop. A value slightly too high is indicated by an over-damped
condition, or the speed error returning too slowly to zero. A value slightly too low
is indicated by an under-damped condition, or the speed value overshooting the
reference and returning, possibly with several damped oscillations. A value too
low will result in slow, low amplitude hunting of speed about the speed reference.
COMPENSATION term compensate for actuator lag. It adjusts the rate of change
in actuator output when a load disturbance occurs. A value too low will result in
slow and under-damped control. A value too high will result in excessive high
frequency actuator movement.
Because the dynamics of an engine depends on its speed of operation, some of

this tuning process must be repeated more than once. This procedure assumes
the following:
 The LCS ITB or LC-50 is already installed on the application.
 A programming harness is connected between the LCS, computer, power
source, and speed pickup.
 The OEM distribution of the service tools is already installed on the
computer.
 The air/fuel ratio tuning has been done. Therefore, a valid configuration file
is in the LCS.
 The generator is connected to a load bank with strip-chart recording
capability.
1. With LCS power off, press Real Time Tuner Menu and turn power on.
2. Start the engine.
3. If the actuator is rapidly oscillating (> 5 Hz) around a position and the engine
is making barking/chattering noises, lower the proportional term by 5%
decrements until the oscillation stops. (Use the P-Term slider and SET
button.)
4. If the actuator is limit cycling (~2 Hz) and the engine speed is oscillating
along with it, lower the common gain term by 5% decrements until the limit
cycling stabilizes. (Use the Common gain box and SET button.)
5. If the actuator is slowly hunting (< 0.5 Hz) and the engine speed is slowly
hunting with it, increase the reset term by 5% increments until the hunt is
minimized. Increasing the reset term too much will cause the actuator to start
limit cycling. When the switchover from hunting to limit cycling occurs, reduce
the reset term to eliminate the limit cycling.
6. If no good compromise can be found between hunting and limit cycling while
adjusting the reset term, lower the gain term by 5% and repeat the
adjustments on the reset term. Repeat lowering the gain if the reset
adjustments fail to yield a stable engine.
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7. Assuming the engine speed is fairly stable at this point, disturb the load on
the engine (or the speed setting) slightly, and observe how the engine speed
recovers. If the recovery has some ringing (oscillations with decreasing
amplitude) to it, reduce the gain term and increase the reset term. Repeat the
tap test until the recovery looks and sounds critically damped.
8. Attach a chart recorder to the engine to monitor its speed versus time.
9. Load and unload the engine in varying amounts. Observe the engine speed
response on the chart recorder. Based on the shape of the response to
changing load, change the reset and gain settings in one of three
combinations as shown in Figure 4-5.
Observed Transient Load Responses During Load Acceptance
Underdamped Overdamped Critically Damped
Decrease gain Decrease reset

No changes
Increase reset Increase gain
Figure 4-5. Recommended Control Setting Changes
10. The goal is to obtain the tightest possible critically damped response to load
transients, at least initially. The gain term affects how quickly the governor
reacts to a speed difference between the set point and the actual speed. The
reset term affects the damping (or anticipation) of the governor. In general,
the highest gain and lowest reset that still has good steady-state load stability
will give the best transient response to large load changes.
11. When the governor and engine have been tuned optimally. Press EXIT. The
following screen will appear. Press Yes and the changes will be saved to the
current configuration parameters. The changes are not resident in the LCS at
this time. As soon as you cycle power to the unit, the changes are erased
from the controller’s memory. To permanently change them, go to the
Configuration Menu and Write Config File To LCS. It is also a good idea at
this time to Write Config File To File, so that you have a record of the
changes.
50 Woodward
12. If the final application uses more than one engine speed or more than one
fuel, tuning values should be obtained with these settings.
13. Press the Real Time Tuner Menu selection. Set a different engine speed by
entering the value next to DESIRED SPEED, and press SET. Repeat the
tuning process as outlined in steps 9 through 11. Or run the engine with the
different fuel.
14. When optimal tuning is achieved, manually write down the reset and gain
values. Common gain and compensation are common to all speed settings
and dynamics so they should be optimized for all settings. DO NOT ACCEPT
THE TRANSFER CHANGES TO CONFIGURATION option when you exit
the real time tuner. This option will overwrite the values you established for
the primary fuel and speed setting 1. You will need to manually enter these
values in the appropriate places on SCREEN 2 of the EDIT Configuration
Menu.
15. If the final application uses droop, run the engine at no-load and full-load
conditions. Note the shaft position at both load conditions using the GET
APOS (actuator actual position) button.
16. Shut down the engine safely.
17. Remove power from the control.
18. Exit the REAL-TIME TUNER menu.
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Application Development Testing

The actuator tuning and engine tuning exercises outlined earlier in this manual
yield control loop settings that are optimized for a specific instance of a fuel
system, engine, and load. Due to fuel system tolerances, changing fuel quality,
engine-to-engine output power variations, load changes, environmental changes,
and long-term mechanical wear, it is NOT recommended that an initial
configuration file be put into production without some sort of application
development testing.
The LCS has been engineered to provide highly repeatable performance from
unit to unit; therefore, a configuration file must be robust enough to account for all
of the possible variations in an engine’s power output. A recommended, but not
comprehensive, list of tests might include:
 Cold start, warm start, and hot start tests
 Sea-level and high-altitude tests
 Fuel quality variation tests
 Engine break-in tests
 Long-term (endurance) tests
 Multiple engine application tests
The intention of such testing is to identify scenarios where the governor goes
unstable due to changes in the application. An actuator might rapidly oscillate
after some long-term wear testing due to the friction changes. In certain
environmental, fuel quality, or engine break-in tests the engine may actually
develop more or less power than during the tuning exercises, in which case the
governor may become unstable. In all cases of high-frequency instability, the
appropriate control coefficient must be reduced. This action must also be
balanced against basic performance requirement imposed on the application.
52 Woodward
Chapter 5.
Troubleshooting
This chapter presents several broad categories of application failures typically
experienced in the field, possible causes, and some tests used to verify the
causes. Because the exact failure experienced in the field is the product of the
mechanical/electrical failure combined with the configuration file resident in the
control, it is left as the OEM’s responsibility to create a more detailed
troubleshooting chart for the end user. Ideally, this end-user troubleshooting
chart will contain information about mechanical, electrical, engine, and load
failures in addition to the possible governor failures. For more detailed
information about governor system failure modes and effects, contact Woodward
for a copy of the system DFMEA.
The troubleshooting scenarios listed below assume the end user has a digital
multimeter at his disposal for testing voltages and checking continuity, and
assume that the application has been engineered and tested thoroughly.
Engine/Generator Troubleshooting
Problem Possible Cause Suggested Test/Correction
Engine does not start Stuck throttle/frozen shaft Move throttle by hand.
Assess smoothness, friction,
and return spring force.
Power not applied to control Disconnect starter motor

solenoid. Disconnect
harness from governor.
Activate application. Test for
+12 V between +12V pin and
ground pin.
+5V output shorted to ground Disconnect starter motor

solenoid. Activate
application. Test for +5 V
between +5V OUT pin and
AUX1– pin.
MPU gap too large Remove and reinstall MPU

per OEM’s instructions.
Rotate engine manually to
check for interference.
MPU signal connection open Disconnect harness from

governor. Activate
application. Test for at least
1.5 Vrms between MPU+ pin
and MPU– pin during
cranking.
Ignition signal connection open Disconnect harness from

governor. Activate
application. Test for
bouncing voltage between
IGN pin and ground pin
during cranking.
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Engine does not start No configuration file or Disconnect harness from
(cont.) incorrect configuration file in governor. Attach
controller programming harness to
computer. Read
configuration file from
controller and evaluate
parameters for correction.
Engine starts, but shuts MPU gap too large Remove and reinstall MPU
down on error per OEM’s instructions.
Rotate engine manually to
check for interference.
MPU signal intermittent Disconnect harness from

governor. Continuously
check resistance between
MPU+ pin and MPU– pin
while inspecting harness and
connectors during cranking.
Disconnect harness from

Ignition signal intermittent governor. Continuously
check continuity between
IGN pin and ignition coil
primary while inspecting
harness and connectors
during cranking.
Engine starts, runs, but Dual dynamics AUX shorted or Disconnect starter motor
is unstable open solenoid. Activate
application.
Check for correct voltage
level between dual dynamics
AUX pin and ground pin for
known application mode.
Dynamics values not tuned Follow engine governor

tuning procedure.
Air/fuel ratio not correct If using LC-50 mixer, MAS, &

ZPR, follow air/fuel ratio
tuning guidelines in Chapter
4. Otherwise, follow fuel
system manufacturer’s
guidelines.
Incorrect mode of AUX inputs shorted or open Disconnect starter motor
operation (speed, solenoid. Disconnect
speed bias function, harness from governor.
dynamics) Activate application. Check
for correct voltage level
between AUX pin(s) under
question and ground pin for
known application modes.
54 Woodward
Unable to develop full Non-indexed linkage slipped on Manually verify full travel of
power shaft throttle plate.
Shorted MAP sensor input Disconnect starter motor

solenoid. Activate
application. Verify AUX1+
voltage matches expected
voltage for known
atmospheric conditions.
Fault code set Disconnect harness from

governor. Attach
programming harness. view
status of fault codes. Take
appropriate action for active
faults.
Overspeed Error Gains not set properly for If overspeed occurs on
transients transient, raise common gain
to reduce overshoot.
Start Fuel Limit not set properly Lower rpm run threshold or
lower start fuel position.
Speed sensing error Follow instructions for MPU

or ignition signal intermittent
under Failsafe Error.
Failsafe Error MPU signal intermittent Disconnect harness from
governor. Continuously
check resistance between
MPU+ pin and MPU– pin
while inspecting harness and
connectors during cranking.
Disconnect harness from

Ignition signal intermittent governor. Continuously
check continuity between
IGN pin and ignition coil
primary while inspecting
harness and connectors
during cranking.
Increase failsafe timeout

Engine running at extremely period.
low speed
Configuration Error No configuration file written to Disconnect harness from
controller. governor. Attach
programming harness to
governor. Write appropriate
configuration file to controller
using the software tools.
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Programming Troubleshooting
Error message: Configuration file has OEM Make an access key with the
Missing ACCESS.KEY security key written to it software tools.
file
Error message: Configuration file not same Obtain proper configuration
The configuration data version as actuator file.
is the wrong format. Try
converting the data to
the current LCS
Firmware Rev
Error message: No power to actuator Check connections and
Timed Out! retry.
Error message: No power to actuator Check connections and
Unable to establish link. retry.
Exit real time tuner?
56 Woodward
Chapter 6.
Product Support and Service Options
Product Support Options

If you are experiencing problems with the installation, or unsatisfactory
performance of a Woodward product, the following options are available:
1. Consult the troubleshooting guide in the manual.
2. Contact the OE Manufacturer or Packager of your system.
3. Contact the Woodward Business Partner serving your area.
4. Contact Woodward technical assistance via email
([email protected]) with detailed information on the
product, application, and symptoms. Your email will be forwarded to an
appropriate expert on the product and application to respond by telephone
or return email.
5. If the issue cannot be resolved, you can select a further course of action to
pursue based on the available services listed in this chapter.
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.
Woodward Business Partner Support: Woodward works with and supports a

global network of independent business partners whose mission is to serve the
users of Woodward controls, as described here:
 A Full-Service Distributor has the primary responsibility for sales, service,
system integration solutions, technical desk support, and aftermarket
marketing of standard Woodward products within a specific geographic area
and market segment.
 An Authorized Independent Service Facility (AISF) provides authorized
service that includes repairs, repair parts, and warranty service on
Woodward's behalf. Service (not new unit sales) is an AISF's primary
mission.
 A Recognized Engine Retrofitter (RER) is an independent company that
does retrofits and upgrades on reciprocating gas engines and dual-fuel
conversions, and can provide the full line of Woodward systems and
components for the retrofits and overhauls, emission compliance upgrades,
long term service contracts, emergency repairs, etc.
A current list of Woodward Business Partners is available at

www.woodward.com/directory.
Product Service Options

Depending on the type of product, the following options for servicing Woodward
products may be available through your local Full-Service Distributor or the OEM
or Packager of the equipment system.
 Replacement/Exchange (24-hour service)
 Flat Rate Repair
 Flat Rate Remanufacture
Woodward 57
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.
Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned for repair,
please contact your Full-Service Distributor in advance to obtain Return
Authorization and shipping instructions.
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.
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.
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.
58 Woodward
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.
Product Training is available as standard classes at many Distributor locations.

Customized classes are also available, which can be tailored to your needs and
held at one of our Distributor locations or at your site. This training, conducted by
experienced personnel, will assure that you will be able to maintain system
reliability and availability.
Field Service engineering on-site support is available, depending on the product

and location, from one of our Full-Service Distributors. The field engineers are
experienced both on Woodward products as well as on much of the non-
Woodward equipment with which our products interface.
For information on these services, please contact one of the Full-Service

Distributors listed at www.woodward.com/directory.
Contacting Woodward’s Support Organization

For the name of your nearest Woodward Full-Service Distributor or service
facility, please consult our worldwide directory published at
www.woodward.com/directory.
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.
Products Used In Products Used In Products Used In

Electrical Power Systems Engine Systems Industrial Turbomachinery
Systems
Facility---------------- Phone Number Facility---------------- Phone Number Facility---------------- Phone Number
Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800
China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727
Germany: Germany------- +49 (711) 78954-510 India --------------- +91 (129) 4097100
Kempen ---- +49 (0) 21 52 14 51 India --------------- +91 (129) 4097100 Japan -------------- +81 (43) 213-2191
Stuttgart-- +49 (711) 78954-510 Japan -------------- +81 (43) 213-2191 Korea -------------- +82 (51) 636-7080
India --------------- +91 (129) 4097100 Korea -------------- +82 (51) 636-7080 The Netherlands - +31 (23) 5661111
Japan -------------- +81 (43) 213-2191 The Netherlands - +31 (23) 5661111 Poland--------------- +48 12 295 13 00
Korea -------------- +82 (51) 636-7080 United States ---- +1 (970) 482-5811 United States ---- +1 (970) 482-5811
Poland--------------- +48 12 295 13 00
United States ---- +1 (970) 482-5811
For the most current product support and contact information, please visit our
website directory at www.woodward.com/directory.
Woodward 59
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
Prime Mover Information

Manufacturer
Engine Model 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
Woodward Part Number & Rev. Letter
Control Description or Governor Type
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.
60 Woodward
Woodward 61
Appendix A.
Acronyms/Abbreviations
A/F air/fuel ratio

Isoch isochronous
CLI command line interface
DIS distributorless ignition system
EEPROM electrically-erasable programmable read-only memory
EMC electro-magnetic compatibility
GUI graphic user interface
ITB integrated throttle body
LC-50 Woodward system that incorporates LCS with an ITB and mixer
LCS Woodward electronic engine governor that contains both a rotary
actuator and a controller circuit board
MAP manifold air pressure
MAS main adjustment screw
MPU magnetic pick up
OEM original equipment manufacturer
stoichiometric chemically balanced air/fuel ratio
ZPR zero pressure regulator
62 Woodward
Appendix B.
Configuration File
The GUI Tool presents the configuration files in a graphical format for editing and
saving. This tool also creates a text file version of the configuration file that can
be viewed and edited with any text editor. If there is ever any need to review the
files in this form, this appendix presents the format. Consult the features
description section for a more thorough review of the following parameters. This
Appendix is intended only to be a decoder for the text version of the configuration
file.
A configuration file contains 60 parameter entries spread across three major

groupings—documentation/security, feature enable bits, and feature parameters.
All parameter entries use the following format:
;
; parameter number:
; parameter name:
; comment:
; lower bound:
; upper bound:
;
actual value
Each line starting with a semicolon is considered a comment, and is ignored

during a download. Parameter number relates a parameter’s location in the file to
a known memory address inside the control. Never change the order of
parameters within a file—incorrect data may be downloaded into the control as a
result. Parameter name is a mnemonic name given to a parameter so it is easier
to identify. Parameter names typically reflect the name stored inside the control
itself. A comment field is included with all parameters; this field of information
helps explain the meaning of a parameter’s value. Lower bound and upper bound
are limits placed on a parameter’s value. If the actual value of a parameter falls
outside the lower or upper limits, then the file will not be downloadable into the
control. Lines that do not start with a semicolon, and contain either a numeric or
single-quoted (‘xxx’) string, are considered actual parameter values.
Generator Version Format (LC-50G)

Documentation and security parameters include:
 Parameter #0: oem_free_form_text: The OEM may use this parameter to
record a configuration part number and revision level up to 20 characters in
length. If the parameter is not used, the parameter value must still contain a
set of single quotes (‘’).
 Parameter #1: oem_security_key: The OEM may use this parameter to
key his controls to his distribution of dealer service tools.. If the OEM
decides to not key his configuration files, then this parameter must still
contain a set of single quotes (‘’).
Woodward 63
Feature enable parameters include:
 Parameter #2: hardware_configuration_register: This parameter is used
to select the direction of actuator rotation, configure AUX1 for analog or
digital operation, and assign functions to alternate AUX input pins if
necessary. The value of hardware_configuration_register is the sum of the
bit values for each enabled option, as listed below:
o Bit 7 (value=128): rsvd, Reserved; setting this bit either way has no
effect on the controller’s operation.
o Bit 6 (value=64): A1anlg: when enabled, makes Aux 1 an analog
o Bit 5 (value=32): A1-5v: If AUX1 is an analog input and this bit is
enabled, AUX1 is a 0–5 V input instead of a ±3 V input
o Bit 4 (value=16): 5060A1: If the 50/60 Hz select function is enabled,
and this bit is enabled, then the selection function is based on the
state of AUX1 instead of AUX4 when power is first applied to the
governor.
o Bit 3 (value=8): isdpA2: If either the isoch/droop function or the aux
bias/droop function is enabled, and this bit is enabled, then droop will
be selected based on the polarity programmed into bit 1, and on the
state of AUX2 instead of AUX4 when power is first applied to the
governor.
o Bit 2 (value=4): ddA3: If the dual dynamics function is enabled, and
this bit is enabled, then the function is based on the state of AUX3
instead of AUX4.
o Bit 1 (value=2): dpolLOW: If either the isosch/droop function or the
aux bias/droop function is enabled, and this bit is enabled, then
droop will be selected whenever the appropriate AUX input is left
open or grounded. If this bit is not enabled, then droop will be
selected whenever the AUX input is shorted to +12 V.
o Bit 0 (value=1): rsvd: Reserved; setting this bit either way has no
 Parameter #3: feature_enable1: This parameter is one of three used to
turn on different functions within the control. Refer to Figure 1-1, the system
block diagram, to see the relationship between bits, function names, and
where they are within the control loop. The value of feature_enable1 is the
sum of the bit values for each enabled option, as listed below:
o Bit 7 (value=128): cmode: Enabling this bit turns on the Governor
State function. This function is required for all speed governor
applications; it is not required for positioner applications.
o Bit 6 (value=64): ovspd: Enabling this bit turns on the Overspeed
Error protection function when the governor state is ‘run’.
o Bit 5 (value=32): fsafe: Enabling this bit turns on the Failsafe Error
protection function when the governor state is ‘run’.
o Bit 4 (value=16): rsvd, Reserved; setting this bit either way has no
o Bit 3 (value=8): relay: Enabling this bit turns on the Relay Control
function when the governor state is ‘error’.
o Bit 2 (value=4): fltst: Enabling this bit turns on the EE Fault Storage
o Bit 1 (value=2): actgt: Enabling this bit turns on the Actuator Gate
function.
64 Woodward
o Bit 0 (value=1): servo: Enabling this bit turns on the Position Control
function. The Position Control function essentially overrides the
Governor State function and translates a 0–5 V input into a desired
position for the Actuator Control function.
The Configuration Error function does not have a bit in any

feature_enable byte; it is permanently enabled to check for the
presence or absence of a configuration file in the control during
power up.
Parameter #4: feature_enable2: This parameter is one of three used to turn on

different functions within the control. Refer to Figure 1-1, the system block
diagram, to see the relationship between bits, function names, and where they
are within the control loop. The value of feature_enable2 is the sum of the bit
values for each enabled option, as listed below:
o Bit 7 (value=128): hzsel: Enabling this bit turns on the 50/60 Hz
Select function when power is first applied to the governor.
o Bit 6 (value=64): idlrt: Enabling this bit turns on the Idle/Rated Select
function.
o Bit 4 (value=16): rslwr: Enabling this bit turns on the Raise/Lower
Adjust function .
o Bit 2 (value=4): droop: Enabling this bit turns on the Droop function.
o Bit 1 (value=2): auxbs: Enabling this bit turns on the Aux Bias
function.
o Bit 0 (value=1): isodp: Enabling this bit turns on the Isoch/Droop
Select function when power is first applied to the governor.
The Single Speed function does not have a bit in any feature_enable
byte; it is the default speed setting function if none of the other
speed setting functions are selected.
The Isochronous function does not have a bit in any feature_enable
byte; it is the default speed biasing function if none of the other
speed biasing functions are selected.
Parameter #5: feature_enable3: This parameter is one of three used to turn on

different functions within the control. Refer to Figure 1-1, the system block
diagram, to see the relationship between bits, function names, and where they
are within the control loop. The value of feature_enable3 is the sum of the bit
values for each enabled option, as listed below:
Woodward 65
o Bit 7 (value=128): bsdrp: Enabling this bit turns on the Aux
Bias/Droop Select function when power is first applied to the
governor.
o Bit 6 (value=64): duald: Enabling this bit turns on the Dual Dynamics
function.
o Bit 5 (value=32): spgov: Enabling this bit turns on the Speed Control
function.
o Bit 4 (value=16): adapt: This enables the auto-gain algorithm.
o Bit 3 (value=8): sfuel: Enabling this bit turns on the Start Fuel
Limiter.
o Bit 1 (value=2): bfuel: Enabling this bit turns on the Boost Fuel
Limiter function.
o Bit 0 (value=1): actrl: Enabling this bit turns on the Actuator Control
function.
Parameter #6: speed_sensing_mode: This parameter is used to turn on

different speed sensing functions within the control. Refer to Figure 1-1, the
system block diagram, to see the relationship between bits, function names, and
where they are within the control loop. The value of speed_sensing_mode is the
o Bit 7 (value=128): ignition: Enabling this bit turns on the Ignition
Speed Sensing function.
o Bit 6 (value=64): 2-stroke: Enabling this bit tells the Ignition Speed
Sensing function that the ignition pulses present on pin 12 (IGN) are
from a 2-stroke engine. Disabling this bit tells the ignition speed
sensing function that the pulses are coming from a 4-stroke engine.
o Bit 5 (value=32): mpu: Enabling this bit turns on the MPU Speed
Sensing function.
o Bits 2–0 (values 0-6): #cylinders: This set of bits specifies the
number of cylinders for the Ignition Speed Sensing function.
Feature parameters include:

Parameter #7: failsafe_timeout_period: Specifies a timeout period for the
Failsafe Error function between 0 and 512 milliseconds. Typical timeout value is
128 milliseconds.
Parameter #8: droop_percentage: Specifies the percentage reduction in engine
speed for the Droop function when the actuator position equals
full_load_actuator_position. Typical value is 10%.
Parameter #9: biasing_percentage: Specifies the percentage
reduction/increase in engine speed for the Aux Bias function when the input
voltage on AUX1 is –3 V, +3 V, 0 V, or 5 V. Typical value is 7%.
Parameter #10: start_fuel_limit: Specifies the maximum permitted shaft
position when the Start Fuel Limiter function is enabled and the governor state is
‘start1.’ Typical value is same as full_load_actuator_position.
Parameter #11, #12, and #13: boost_pressure_volt1, boost_pressure_volt2, and
boost_pressure_volt3: Specifies the x-points on the Boost Fuel Limiter curve.
Parameter #14, #15, and #16: boost_fuel_limit1, boost_fuel_limit2,
boost_fuel_limit3: Specifies the y-points on the Boost Fuel Limiter curve.
66 Woodward
Parameter #17: start_speed_threshold: Specifies the speed at which the
Governor State changes from ‘powerup’ to ‘start1.’ Typical value is 64 rpm to
detect engine cranking.
Parameter #18: run_speed_threshold: Specifies the speed at which the
Governor State changes from ‘start2’ to ‘run.’ Typical value is 90% of the lowest
speed_reference.
Parameter #19: overspeed_threshold: Specifies the speed threshold for
changing the Governor State from ‘run’ to ‘error’ via the Overspeed Error
function. Typical value is 10% to 20% above the highest speed_reference.
Parameter #20: reset1,: Primary set of dynamics for speed_reference1. Reset
helps stabilize the engine/governor loop. Typical initial value is: reset=25%.
Parameter #21, #22, #23, gain11, gain12, gain13: Primary set of dynamics for
speed_reference1. Gain affects engine load transient response and frequency of
engine hunting. These are the y-points for the three point gain curve. The x-
points are parameters #38, 39, 40.
Parameter #24: alternate_reset1,: Secondary set of dynamics for
speed_reference1. Reset helps stabilize the engine/governor loop. Typical initial
value is: reset=25%.
Parameter #25, #26, #27, alternate_gain11, alternate_gain12,
alternate_gain13: Primary set of dynamics for speed_reference1.
Parameter #28: reset2, : Primary set of dynamics for speed_reference2.
Parameter #29, #30, #31, gain21, gain22, gain23: Primary set of dynamics for
speed_reference2. These are the y-points for the three point gain curve. The x-
points are parameters #38, 39, 40.
Parameter #32: alternate_reset2: Secondary set of dynamics for
speed_reference2.
Parameter #33, #34, and #35: alternate_gain21, alternate_gain22, and
alternate_gain23: Alternate set of dynamics for speed_reference2.
Parameter #36: compensation: Dynamic term common to all speed settings and
dynamics.
Parameter #37: common_gain: Common to all speed settings and dynamics.
Parameter #38, #39, #40: gain_position1, gain_position2, gain_position3: Y-
points for the three point gain curve. Common for all speed settings and all
dynamics.
Parameter #41: gain_decrement: Used by auto-gain algorithm to decrement the
gain by a predefined amount.
Parameter #42: gain_increment: Used by auto-gain algorithm to increase the
gain by a predefined amount.
Parameter #43: min_gain: Used by auto-gain algorithm as lower limit.
Parameter #44: max_gain: Used by auto-gain algorithm to upper limit.
Parameter #45: rated_to_idle_delay: Specifies the amount of time to delay
before ramping from rated speed (speed_reference2) to idle speed
(speed_reference1) for the Idle/Rated Select function.
Parameter #46: speed_adjust_lower_limit: Specifies the lowest desired speed
possible with the Raise/Lower Adjust function.
Parameter #47: speed_adjust_upper_limit: Specifies the highest desired speed
possible with the Raise/Lower Adjust function.
Parameter #48, #49, and #50: proportional, derivative, and integral: Control
coefficients for the Actuator Control function.
Woodward 67
Parameter #51: events_per_engine_rev: Specifies the number of flywheel or
gear teeth that pass the face of a MPU for one revolution of the engine’s
crankshaft.
Parameter #52, #53: speed_reference1, speed_reference2: Specifies the
desired engine speeds depending on the enabled speed select function.
Speed_reference1 is the default speed setting.
Parameter #54: steady_state: Used by auto-gain algorithm
Parameter #55: transient: Used by auto-gain algorithm.
Parameter #56, #57: speed_decrease_rate, speed_increase_rate: Specifies the
ramping rates for the Raise/Lower Adjust function.
Parameter #58, #59: no_load_actuator_position, full_load_actuator_position:
Specifies the 0% engine load and 100% engine load actuator positions for the
Droop function.
Industrial Version Format (LC-50I)

An industrial configuration file contains 58 parameter entries.
Documentation and security parameters include:

 Parameter #0: oem_free_form_text: The OEM may use this parameter to
record a configuration part number and revision level up to 20 characters in
length. If the parameter is not used, the parameter value must still contain a
set of single quotes (‘’).
 Parameter #1: oem_security_key: The OEM may use this parameter to
key his controls to his distribution of dealer service tools.. If the OEM
decides to not key his configuration files, then this parameter must still
contain a set of single quotes (‘’).
Feature enable parameters include:

 Parameter #2: hardware_configuration_register: This parameter is used
to select the direction of actuator rotation, configure AUX1 for analog or
digital operation, and assign functions to alternate AUX input pins if
necessary. The value of hardware_configuration_register is the sum of the
bit values for each enabled option, as listed below:
o Bit 6 (value=64): A1anlg: If enabled, AUX1 is an analog input
instead of a digital input.
o Bit 5 (value=32): A1-5v: If AUX1 is an analog input and this bit is
enabled, AUX1 is a 0–5 V input instead of a ±3 V input
o Bit 2 (value=4): ddA3: If the dual dynamics function is enabled, and
this bit is enabled, then the function is based on the state of AUX3
instead of AUX4.
68 Woodward
o Bit 7 (value=128): cmode: Enabling this bit turns on the Governor
State function. This function is required for all speed governor
applications; it is not required for positioner applications.
o Bit 6 (value=64): ovspd: Enabling this bit turns on the Overspeed
Error protection function when the governor state is ‘run’.
o Bit 5 (value=32): fsafe: Enabling this bit turns on the Failsafe Error
protection function when the governor state is ‘run’.
o Bit 3 (value=8): relay: Enabling this bit turns on the Relay Control
o Bit 2 (value=4): fltst: Enabling this bit turns on the EE Fault Storage
o Bit 1 (value=2): actgt: Enabling this bit turns on the Actuator Gate
function.
o Bit 0 (value=1): servo: Enabling this bit turns on the Position Control
function. The Position Control function essentially overrides the
Governor State function and translates a 0–5 V input into a desired
position for the Actuator Control function.
The Configuration Error function does not have a bit in any

feature_enable byte; it is permanently enabled to check for the
presence or absence of a configuration file in the control during
power up.

o Bit 6 (value=64): idlrt: Enabling this bit turns on the Idle/Rated Select
function.
o Bit 5 (value=32): 3-spd: Enabling this bit turns on the Three-Speed
Select function.
o Bit 3 (value=8): rsvd: Reserved; this feature is not supported at this
time. The bit should not be enabled.
Woodward 69
o Bit 1 (value=2): auxbs: Enabling this bit turns on the Aux Bias
function.
The Single Speed function does not have a bit in any feature_enable
byte; it is the default speed setting function if none of the other
speed setting functions are selected.
The Isochronous function does not have a bit in any feature_enable
byte; it is the default speed biasing function if none of the other
speed biasing functions are selected.

o Bit 6 (value=64): duald: Enabling this bit turns on the Dual Dynamics
function.
o Bit 5 (value=32): spgov: Enabling this bit turns on the Speed Control
function.
o Bit 4 (value=16): adapt: This enable the auto-gain algorithm.
o Bit 3 (value=8): sfuel: Enabling this bit turns on the Start Fuel
Limiter.
o Bit 0 (value=1): actrl: Enabling this bit turns on the Actuator Control
function.
 Parameter #6: speed_sensing_mode: This parameter is used to turn on
different speed sensing functions within the control. Refer to Figure 1-1, the
system block diagram, to see the relationship between bits, function names,
and where they are within the control loop. The value of
speed_sensing_mode is the sum of the bit values for each enabled option,
as listed below:
o Bit 7 (value=128): ignition: Enabling this bit turns on the Ignition
Speed Sensing function.
o Bit 6 (value=64): 2-stroke: Enabling this bit tells the Ignition Speed
Sensing function that the ignition pulses present on pin 12 (IGN) are
from a 2-stroke engine. Disabling this bit tells the ignition speed
sensing function that the pulses are coming from a 4-stroke engine.
o Bit 5 (value=32): mpu: Enabling this bit turns on the MPU Speed
Sensing function.
o Bits 2-0 (values 0-6): #cylinders: This set of bits specifies the
number of cylinders for the Ignition Speed Sensing function.
70 Woodward
Feature parameters include:
 Parameter #7: failsafe_timeout_period: Specifies a timeout period for the
Failsafe Error function between 0 and 512 milliseconds. Typical timeout
value is 128 milliseconds.
 Parameter #8: biasing_percentage: Specifies the percentage
reduction/increase in engine speed for the Aux Bias function when the input
voltage on AUX1 is –3 V, +3 V, 0 V, or 5 V. Typical value is 7%.
 Parameter #9: start_fuel_limit: Specifies the maximum permitted shaft
position when the Start Fuel Limiter function is enabled and the governor
state is ‘start1.’ Typical value is same as full_load_actuator_position.
 Parameter #10: start_speed_threshold: Specifies the speed at which the
Governor State changes from ‘powerup’ to ‘start1.’ Typical value is 64 rpm
to detect engine cranking.
 Parameter #11: run_speed_threshold: Specifies the speed at which the
Governor State changes from ‘start2’ to ‘run.’ Typical value is 90% of the
lowest speed_reference.
 Parameter #12: overspeed_threshold: Specifies the speed threshold for
changing the Governor State from ‘run’ to ‘error’ via the Overspeed Error
function. Typical value is 10% to 20% above the highest speed_reference.
 Parameter #13: reset1: Primary set of dynamics for speed_reference1.
Reset helps stabilize the engine/governor loop. Typical initial value is:
reset=25%.
 Parameter #14, #15, #16, gain11, gain12, gain13: Primary set of dynamics
for speed_reference1. Gain affects engine load transient response and
frequency of engine hunting. These are the y-points for the three point gain
curve. The x-points are parameters #38, 39, 40.
 Parameter #17: alternate_reset1: Secondary set of dynamics for
speed_reference1. Reset helps stabilize the engine/governor loop. Typical
initial value is: reset=25%.
 Parameter #18, #19, #20, alternate_gain11, alternate_gain12,
alternate_gain13: Primary set of dynamics for speed_reference1. Gain
affects engine load transient response and frequency of engine hunting.
These are the y-points for the three point gain curve. The x-points are
parameters #38, 39, 40.
 Parameter #21 : reset2: Primary set of dynamics for speed_reference2.
reset=25%.
 Parameter #22, #23, #24, gain21, gain22, gain23: Primary set of dynamics
for speed_reference2. Gain affects engine load transient response and
frequency of engine hunting. These are the y-points for the three point gain
curve. The x-points are parameters #38, 39, 40.
 Parameter #26, #27, and #28: alternate_gain21, alternate_gain22, and
alternate_gain23: Alternate set of dynamics for speed_reference2. Gain
 Parameter #29: reset3: Primary set of dynamics for speed_reference3.
reset=25%.
Woodward 71
 Parameter #30, #31, and #32: gain31, gain32, and gain33: Primaru set of
dynamics for speed_reference3. Gain affects engine load transient
response and frequency of engine hunting.
 Parameter #34, #35, and #36: alternate_gain31, alternate_gain32, and
alternate_gain33: Alternate set of dynamics for speed_reference3. Gain
 Parameter #37: compensation: Compensation nulls out the lag effect of
the actuator control loop. Typical initial value is: 50%.
 Parameter #38: common_gain:
 Parameter #39, #40, #41: gain_position1, gain_position2,
gain_position3: Y-points for the three point gain curve. Common for all
speed settings and all dynamics.
 Parameter #42: gain_decrement: Used by auto-gain algorithm to
decrement the gain by a predefined amount.
 Parameter #43: gain_increment: Used by auto-gain algorithm to increase
the gain by a predefined amount.
 Parameter #44: min_gain: Used by auto-gain algorithm as lower limit.
 Parameter #45: max_gain: Used by auto-gain algorithm to upper limit.
 Parameter #46: rated_to_idle_delay: Specifies the amount of time to delay
before ramping from rated speed (speed_reference2) to idle speed
(speed_reference1) for the Idle/Rated Select function.
 Parameter #47, #48, and #49: proportional, derivative, and integral:
Control coefficients for the Actuator Control function.
 Parameter #50: events_per_engine_rev: Specifies the number of flywheel
or gear teeth that pass the face of a MPU for one revolution of the engine’s
crankshaft.
 Parameter #51: speed_reference1: Specifies the desired engine speeds
depending on the enabled speed select function. Speed_reference1 is the
default speed setting.
 Paramter #52: speed_reference2, speed_zone_1_to_2: Secondary speed
reference. Uses dynamics gain2x and alternate gain2x and reset 2
 Parameter #53: speed_reference3, speed_zone_1_to_3
 Parameter #54: steady_state: Used by auto-gain algorithm
 Parameter #55: transient: Used by auto-gain algorithm.
 Parameter #56, #57: speed_decrease_rate, speed_increase_rate:
Specifies the ramping rates for the Raise/Lower Adjust function.
72 Woodward
Appendix C.
Dynamics File Format
A dynamics file contains five parameter entries for the five available speed
control gains. All parameter entries use the following format:
;
; parameter number:
; parameter name:
; comment:
; lower bound:
; upper bound:
;
actual value
Each line starting with a semicolon is considered a comment, and is ignored

during a download. Parameter number relates a parameter’s location in the file to
a known memory address inside the control. Never change the order of
parameters within a file—incorrect data may be downloaded into the control as a
result. Parameter name is a mnemonic name given to a parameter so it is easier
to identify. Parameter names typically reflect the name stored inside the control
itself. A comment field is included with all parameters; this field of information
helps explain the meaning of a parameter’s value. Lower bound and upper bound
are limits placed on a parameter’s value. If the actual value of a parameter falls
outside the lower or upper limits, then the file will not be downloadable into the
control. Lines that do not start with a semicolon and contain a number are
considered actual parameter values.
Woodward 73
74 Woodward
LCS Control Specifications
Specifications
Power Supply 12 V systems (8–16 Vdc) reverse polarity protection; must be
fed from a Class 2 power source
Power Consumption 64 W maximum
Torque 0.34 Nm (0.25 lb-ft)
Mass/Weight 425 g (15 oz)
Control Characteristics
Speed Input and Range Magnetic pickup, ignition coil input, or DIS input
MPU input 100 to 12 000 Hz
IGN input 1, 2, 3, 4, 5, 6, & 8 cylinder engines with rated speeds of 1200–
4000 rpm
Engine Type 2-cycle or 4-cycle gasoline, diesel, or gaseous fuel
Target speed Programmable
Actuator Torque High-efficiency torque motor delivers 0.34 Nm (0.25 lb-ft)
(standard model) over 60° travel range to operate fuel or air
control
Steady State Fuel Type: Gasoline Diesel Gaseous
Speed MPU Input: ±0.35% ±0.25% ±0.35%
Regulation Ignition Input: ±0.50% n/a ±0.50%
Functions/Auxiliary Inputs
Function Options Isochronous speed (50 or 60 Hz), multiple speeds, two or three
speed, droop, dual dynamics, adjustable max fuel stop,
manifold air pressure-biased fuel limiter
Programmable Through 12-pin Deutsch connector
Aux1 Options Auxiliary load sharing, remote speed setting, MAP fuel limiting,
50/60 Hz select, isochronous load sharing/droop select
Aux2 Options Lower speed, isochronous speed control/droop select,
isochronous load sharing/droop select, idle/rated select, three
speed select
Aux3 Options Raise speed, dual dynamics select, three speed select
Aux4 Options 50/60 Hz select, isochronous speed control/droop select,
isochronous load sharing/droop select, dual dynamics select,
three speed select
Aux5 Options Is permanently configured as an output to drive a relay
Environment
Ambient
Operating Temperature –40 to +85 °C (–40 to +185 °F)
Storage Temperature –40 to +125 °C (–40 to +257 °F)
EMI/RFI EN50081-1 (emissions)
EN50082-2 (immunity)
Humidity US MIL-STD 810E, Method 507.3, Procedure III
Salt Spray US MIL-STD 810E, Method 509.3, Procedure I
Shock US MIL-STD 810E, Method 516.4, Procedure I
Random Vibration US MIL-STD 202F, Procedure 214A, Test Condition ID
Drop SAE J1211, Paragraph 4.8.3 (modified)
Thermal Shock SAE J1455, Paragraph 4.1.3.2
Dust SAE J1455, Paragraph 4.7
Pressure Wash A modified SAE J1455, Paragraph 4.5
Fluid Resistance A modified SAE J1455, Paragraph 4.4
Inlet Pressure Sealed shaft bearings: 2 bar (29 psi) gage
Standard shaft bearings:0.068 bar (1 psi) gage
Compliance
UL/cUL Listed (UL requires a Class 2 power source)
CE Compliant
Other 89/392/EEC Machinery Directive
Reliability and Quality Goals
The LCS control system has a reliability target of 17 500 hours MTBF. It also has a quality goal of
less than 25 PPM when measuring out-of-the-box defects. This quality goal is a target based on
continuous improvement.
We appreciate your comments about the content of our publications.
Send comments to: [email protected]
Please reference publication 26135F.
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.
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Product Manual 26135

Installation, Programming, & Troubleshooting

To prevent damage to a control system that uses an alternator or battery-charging

To prevent damage to electronic components caused by improper handling, read

Revisions—Text changes are indicated by a black line alongside the text.

CHAPTER 1. GENERAL INFORMATION ........................................................... 1

Illustrations and Tables

Figure 1-1. Block Diagram of LCS Integrated Speed Control ................................2

Purpose and Scope

A simplified block diagram of the control’s functionality is shown in Figure 1-1. In

Speed biasing functions include:

Speed Biasing Functions Dynamics Functions

Isochronous Automatic Gain Trim

Droop Dual Dynamics

Aux Bias/Droop Select control

Overspeed Error Governor State Actuator Control

Failsafe Error Relay Control Actuator Gate

Figure 1-1. Block Diagram of LCS Integrated Speed Control

Control functions include:

Dynamics functions include:

Fuel limiter functions include:

Actuator control functions include:

Logic and support functions include:

Service Tool Software

One distribution of the software service tool is available from Woodward

Upon an engine shutdown command, the engine shutdown solenoid or solenoid

Overview of Control Application Process

OEM Document Product Assembly

Figure 2-1. Typical Governor Application Process

Hardware Configuration Application Process

Application Matrix for LC 50 IT B

Engine Displacem ent (L)

Figure 2-2. Application Matrix

A main adjustment screw or closed-loop trim valve is provided to adjust the

Controller Features Description

Related configuration file parameters: 50/60 Hz select, 50/60 Hz Aux, speed 1,

Three-Speed Select (I version only)—Some refrigeration applications may find it

Related configuration file parameters: 3 speed select, speed 1, speed 2, speed 3,

Raise/Lower Adjust (G version only)—This feature allows the user to change

Isochronous governor control is impractical when paralleling with a utility

Related configuration file parameters: constant droop, droop percentage, no load

The bias percentage is a programmable value up to approximately 7%. When

When AUX1 is configured as a ±3 V input, +3 V corresponds to the full bias

Isochronous Speed Control/Droop Select—This discrete input toggles

Aux Bias/Droop Select—This discrete input toggles between auxiliary biasing

Related configuration file parameters: mpu, flywheel teeth

Related configuration file parameters: ignition, cylinders count, strokes

Position Control—Commands a desired actuator position based on an analog

The accuracy of the internal LCS position sensor is nominally ±10%

Three-Point Gain Curve—The engine speed control gain is set up as a three-

Related configuration file parameters: gain decrement, gain increment, minimum

FUEL LIMITER FUNCTIONS

The accuracy of the internal LCS position sensor is nominally ±10%

This feature can be useful when using a non-wastegated turbo to avoid

Throttle is allowed to open completely

Figure 2-3. MAP/Boost Fuel Limiting

ACTUATOR CONTROL FUNCTIONS

LOGIC AND SUPPORT FUNCTIONS

The LCS control should never be used as the primary overspeed