L-Series Position Controller Rohs Compliant: Product Manual 35154 (Revision - , 07/2019)

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Product Manual 35154

(Revision -, 07/2019)
Original Instructions
L-Series Position Controller

RoHS Compliant
Installation and Operation Manual

Released
Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions.
General
Precautions Failure to follow instructions can cause personal injury and/or property damage.
This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26455, Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, on
Revisions the publications page of the Woodward website:
www.woodward.com/publications
The latest version of most publications is available on the publications page. If

your publication is not there, please contact your customer service representative
to get the latest copy.
Any unauthorized modifications to or use of this equipment outside its specified

mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
Proper Use modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifications or listings.
If the cover of this publication states "Translation of the Original Instructions"

please note:
The original source of this publication may have been updated since this
Translated translation was made. Be sure to check manual 26455, Customer Publication
Publications Cross Reference and Revision Status & Distribution Restrictions, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.
Revisions— A bold, black line alongside the text identifies changes in this publication since the
last revision.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Manual 35154
Copyright © Woodward, Inc. 2019
All Rights Reserved
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Manual 35154 L-Series Position Controller RoHS Compliant
Contents
ACRONYMS/ABBREVIATIONS...................................................................... 3
WARNINGS AND NOTICES .......................................................................... 4
ELECTROSTATIC DISCHARGE AWARENESS ................................................. 5
REGULATORY COMPLIANCE ....................................................................... 6
CHAPTER 1. GENERAL INFORMATION ......................................................... 8
Purpose and Scope ................................................................................................8
How to Use This Manual ........................................................................................8
Intended Applications .............................................................................................8
L-Series Description ...............................................................................................8
Programmable Features .........................................................................................9
Service Tool Software ..........................................................................................10
CHAPTER 2. SYSTEM DESCRIPTION/APPLICATION OVERVIEW .................... 11
System Operation .................................................................................................11
Current Limiting based on Temperature ...............................................................16
Faults ....................................................................................................................16
CHAPTER 3. INSTALLATION ...................................................................... 19
General Installation, Operation Notes and Requirements ....................................20
Unpacking .............................................................................................................20
Mechanical Installation .........................................................................................20
Electrical Installation .............................................................................................26
Description of Electrical I/O ..................................................................................29
CHAPTER 4. SERVICE TOOL ..................................................................... 35
Introduction ...........................................................................................................35
Description ............................................................................................................35
Getting Started .....................................................................................................37
L-Series Configuration ..........................................................................................38
Configuration Parameters.....................................................................................39
Position Calibration and Verification .....................................................................50
Calibration Sequence Overview ...........................................................................51
Position Verification ..............................................................................................51
CHAPTER 5 L-SERIES CONTROL SPECIFICATIONS ..................................... 55
CHAPTER 6. TROUBLESHOOTING ............................................................. 59
Introduction ...........................................................................................................59
General System Troubleshooting Guide ..............................................................60
Engine/Generator Troubleshooting ......................................................................60
CHAPTER 7 PRODUCT SUPPORT AND SERVICE OPTIONS ........................... 63
Product Support Options ......................................................................................63
Product Service Options .......................................................................................63
Returning Equipment for Repair ...........................................................................64
Replacement Parts ...............................................................................................64
Engineering Services ............................................................................................65
Contacting Woodward’s Support Organization ....................................................65
Technical Assistance ............................................................................................66
APPENDIX A. L-SERIES CONFIGURATION SUMMARY .................................. 67
REVISION HISTORY .................................................................................. 68
DECLARATIONS ....................................................................................... 69
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Illustrations and Tables
Figure 2-1. L-Series Operation .............................................................................11

Figure 2-2. L-Series Position Control Functional Overview .................................12
Figure 2-3. PWM Linear Demand to Position .......................................................13
Figure 2-4. PWM Non-Linear Demand to Position ...............................................13
Figure 2-5. Analog 0–5 V Linear Demand to Position ..........................................14
Figure 2-6. Analog 0–5 V Non-Linear Demand to Position ..................................14
Figure 3-1. L-Series Outline Drawing ...................................................................22
Figure 3-2. L-Series Cover Types ........................................................................23
Figure 3-3a. L-Series Shaft Types .......................................................................24
Figure 3-3b. L-Series Shaft Types .......................................................................25
Figure 3-3c. L-Series Shaft Types ........................................................................26
Figure 3-4. Typical L-Series Position Control Application Wiring .........................28
Figure 3-5. Acceptable PWM Input Types ............................................................31
Figure 3-6. Relay Driver Output............................................................................32
Figure 3-7. Typical AUX1 and AUX2 Usage ........................................................33
Figure 3-8. Ground Junction Point........................................................................34
Figure 4-1. Example Service Tool Screen ............................................................35
Figure 4-2a. Typical Programming Datalink Harness Wiring ...............................36
Figure 4-2b. Programming Harness Wiring ..........................................................37
Figure 4-3. Configuration Selection Options ........................................................39
Figure 4-4. Configuration Editor—Analog Settings ..............................................40
Figure 4-5. Configuration Editor—PWM Settings .................................................41
Figure 4-6. Configuration Editor—Discrete Output Settings ................................42
Figure 4-7. Configuration Editor—Alarm/Shutdown Settings ...............................43
Figure 4-8. Service Tool—Overview Tab .............................................................45
Figure 4-9. Service Tool—Alarms Tab .................................................................47
Figure 4-10. Service Tool—Shutdowns Tab ........................................................47
Figure 4-11. Service Tool—Internal Shutdowns Tab ...........................................48
Figure 4-12. Service Tool—Identification Tab ......................................................48
Figure 4-13. Service Tool—PID Tuning Window..................................................49
Figure 4-14. Service Tool—PID Tuning Properties Window ................................50
Figure 4-15. Service Tool—Verify Position Calibration ........................................52
Figure 4-16. Service Tool—Manual Position Calibration .....................................52
Figure 4-17. Service Tool—Manual Position Calibration Settings .......................53
Figure 4-18. Service Tool—Auto Position Calibration ..........................................54
Figure 5-1. Bode Plot of L-Series Response ........................................................58
Table 3-1. Connector Pins ....................................................................................29

Table 5-1. Analog Command Input ......................................................................55
Table 5-2. PWM Command Input .........................................................................56
Table 5-3. Discrete Input ......................................................................................56
Table 5-4. Discrete Output ...................................................................................56
Table 5-5. TPS Output ..........................................................................................57
Table 5-6. RS-232 Serial Communication Service Port .......................................57
Table 5-7. Electronics Temperature Sensor .........................................................57
Table 6-1. Engine/Generator Troubleshooting Chart ...........................................60
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Acronyms/Abbreviations
AUX auxiliary
EEPROM electrically-erasable programmable read-only memory
EMC electro-magnetic compatibility
GUI graphic user interface
I/O inputs/outputs
Isoch isochronous
ITB integrated throttle body
L-Series Woodward electronic engine governor that contains both a rotary actuator and a
controller circuit board
MPU magnetic pick up
OEM original equipment manufacturer
PWM pulse-width modulated
rpm revolutions per minute
RS-232 a communications standard
TPS throttle position sensor
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Warnings and Notices

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

attempting to replace or service an L-Series on a “live” running
engine. All safety protective systems (overspeed, over temperature,
Lockout/Tagout overpressure, etc.) must be in proper operational condition prior to
the start or operation of a running engine. Personnel should be
(LOTO)
equipped with appropriate personal protective equipment to
minimize the potential for injury due to release of hot hydraulic
fluids, exposure to hot surfaces and/or moving parts, or any moving
parts that may be activated and are located in the area of control of
the L-Series.
The engine, turbine, or other type of prime mover should be

equipped with an independent fuel shut-off device to protect against
fuel leakage or damage to the prime mover with possible personal
Independent Fuel injury, loss of life, or property damage. The fuel shut off device must
be totally independent of the prime mover control system. An
Shutoff Required
overtemperature or overpressure shutdown device may also be
(Overspeed / needed for safety, as appropriate.
Overtemperature /
Overpressure)
The products described in this publication may present risks that

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

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
Start-up property damage.
On- and off-highway Mobile Applications: Unless Woodward's

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

battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.
Battery Charging
Device
Electrostatic Discharge Awareness

Electronic controls contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts:
 Discharge body static before handling the control (with power to
Electrostatic the control turned off, contact a grounded surface and maintain
Precautions contact while handling the control).
 Avoid all plastic, vinyl, and Styrofoam (except antistatic
versions) around printed circuit boards.
 Do not touch the components or conductors on a printed circuit
board with your hands or with conductive devices.
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
Follow these precautions when working with or near the control.

1. Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic
materials. Wear cotton or cotton-blend materials as much as possible because these do not store
static electric charges as much as synthetics.
2. Do not remove the printed circuit board (PCB) from the control cabinet unless absolutely necessary.
If you must remove the PCB from the control cabinet, follow these precautions:
 Do not touch any part of the PCB except the edges.
 Do not touch the electrical conductors, the connectors, or the components with conductive
devices or with your hands.
 When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in
until you are ready to install it. Immediately after removing the old PCB from the control cabinet,
place it in the antistatic protective bag.
External wiring connections for reverse-acting controls are identical
to those for direct-acting controls.
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Regulatory Compliance
European Compliance for CE Marking:

These listings are limited only to those units bearing the CE Marking:
EMC Directive: Declared to Directive 2014/30/EU of the European Parliament and of the Council
of 26 February 2014 on the harmonization of the laws of the Member States
relating to electromagnetic compatibility (EMC)
RoHS Directive: Declared to 2011/65/EC COUNCIL DIRECTIVE of the

European Parliament and of the Council of 8 June 2011
on the restriction of the use of certain hazardous
substances in electrical and electronic equipment.
Exemptions in Use: 6(a), 6(c), 7(a), 7(c)-I
These listings are limited only to those units bearing the ATEX markings as well as the CE Mark:
ATEX Directive: Declared to Directive 2014/34/EU of the European

Parliament and of the Council of 26 February 2014 on the
harmonization of the laws of the Member States relating
to equipment and protective systems intended for use in
potentially explosive atmospheres
Zone 2, Category 3, Group II G, Ex nA IIC T3 Gc X
–40 °C ≤ Tamb ≤+105 °C, IP56
Other European and International Compliance:

Compliance with the following European Directives or standards does not qualify this product for
application of the CE Marking:
Machinery Compliant as partly completed machinery with Directive
Directive: 2006/42/EC of the European Parliament and the Council
of 17 May 2006 on machinery.
Pressure Exempt per Article 1.2(j) of 2014/68/EU where pressure

Equipment is not a significant design factor
Directive:
North American Compliance:

These listings are limited only to those units bearing the CSA identification
CSA: CSA Certified for Class I, Division 2, Groups A, B, C, & D, T3C at 105 °C
Ambient for use in Canada and the United States.
Certificate 1380416
This product is certified as a component for use in other equipment. The final
combination is subject to acceptance by the authority having jurisdiction.
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Special Conditions for Safe Use:
Connect ground terminal to earth ground.
Wiring must be in accordance with North American Class I, Division

2 or European Zone 2, Category 3 wiring methods as applicable, and
in accordance with the authority having jurisdiction.
Field wiring must be suitable for at least 105 °C.
The installer of the L-Series must take responsibility for meeting

Clause 26.4.2 of EN60079-0 (Ed. 6 or 7) regarding impact testing. The
actuator by itself does not meet this requirement and therefore must
be sufficiently protected when installed. See Chapter 2, Mechanical
Installation, for more details.
The actuator should be protected from exposure to sunlight and rain.
EXPLOSION HAZARD—Do not connect or disconnect while circuit is

live unless area is known to be non-hazardous.
Substitution of components may impair suitability for Class I,

Division or Zone applications.
RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher

tant que l’installation est sous tension, sauf en cas
l’ambiance est décidément non dangereuse.
La substitution de composants peut rendre ce matériel

inacceptable pour les emplacements de Classe I,
applications Division ou Zone.
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Chapter 1.
General Information
Purpose and Scope

The purpose of this manual is to provide the necessary background information for applying the L-Series
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.
How to Use This Manual

The following summarizes how to install an L-Series actuator into a new or existing system:
 Unbox and inspect the hardware.
 Mount and wire the hardware following the procedures and recommendations in Chapter 3.
 Optionally configure the control using the Service Tool (Chapter 4).
 Optionally stroke the valve and verify dynamics and functionality.
 Troubleshooting guidelines are provided in Chapter 5.
 Specifications are provided in Appendix C.
Intended Applications
The L-Series control is designed 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
extended industrial operating temperatures (–40 to +105 °C/–40 to +221 °F), Industrial EMC
Requirements, electrical transients, and lower operating voltages (12/24 V).
L-Series Description
The L-Series provides a building block approach to total engine management. The modular bi-directional
actuator design easily attaches to fuel pumps, mixers, or throttle bodies. For information on Woodward
throttle body applications, refer to manual 35144 (ITB and LC-50).
Woodward also offers L-Series actuator versions for Speed Control and Process Control, like Air/Fuel
Ratio control, applications. Refer to manuals 35141(Speed Control) and 35153 (Process Control).
The L-Series position control accepts a position command and drives the 0–60 degree output shaft to the
commanded position based on an internal shaft position sensor. The high-efficiency torque motor delivers
0.34 Nm (0.25 lb-ft) nominally over 60° travel range to operate fuel or air control devices (see
specifications in Appendix C for torque performance over the full product temperature range).
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The L-Series position control accepts either a PWM command or a 0–5 V command for output
positioning. The command signals are issued by the appropriate supervisory engine management
system, and the L-Series must be set up properly in software to expect the correct signal for the
application.
For status purposes, a relay driver output is available on the L-Series control which changes state
whenever a fault or error condition is experienced by the
L-Series controller.
If the system so requires, the L-Series provides a direct position output signal in the form of a dc voltage.
The throttle position (TPS) output represents full counterclockwise (ccw) to clockwise (cw) rotation of the
actuator shaft, and thus gives the operator an external position indication after installation and while the
unit is operating.
More detail on the features of the L-Series can be found later in this manual.
When included with an ITB, the actuator depends solely on the return
spring inside the throttle body assembly to drive toward minimum
fuel when not powered, therefore other positive shutdown devices
like fuel shut-off solenoids are recommended to ensure shutdown
upon loss of signal to the control system. Also, separate overspeed
trip devices are always mandatory.
The gasket must be ordered separately.
Programmable Features
Control setup and tuning is accomplished through the use of a PC (personal computer), Woodward
Service Tool software, and a programming harness. The features identified below are described in
Chapters 2 and 4. Briefly, the programmable features include:
 4 General Setup Parameters
o Position Demand Select (PWM or Analog)
o Fail Direction (ccw or cw)
o Min Position Direction (ccw or cw)
o Actuator Curve Selection (Linear or Non-linear)
 PWM Setup Parameters
o PWM Drive Select (Push-Pull, High-Side Drive or Low-Side Drive)
o PWM Offset
 4 Valve Position Control Parameters
o Proportional Gain
o Integral Gain
o Derivative Gain
o Friction/Dither Setting
 10 Non-Linear Actuator Settings
o Position Request (5 curve input points)
o Actuator Position (5 curve output points)
 12 Discrete Output Settings
o Output’s Non-Fault Condition (ON or OFF)
o 11 Selections as Discrete Output Indications
 10 Fault Settings
o Latching or Non-Latching Fault Indications
o Position Error Magnitude
o Position Error Delay
o 7 Fault Selections as Alarms or Shutdowns
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Service Tool Software

The L-Series 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:
 Configure product settings based on application requirements
 Tune the control with the engine running during application development
 Create configuration files for downloading into multiple controls
 Download configuration files
 Extract and view fault codes for field diagnosis
 Update control dynamics during field service
 Calibrate the control for user stops
Detailed descriptions of software installation are available in Chapter 4.
The Service Tool is not included, but can be downloaded from the
Woodward Internet website (www.woodward.com/software/).
The actuator must be properly set up using the L-Series Service Tool
prior to starting the engine.
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Chapter 2.
System Description/Application Overview
System Operation
The L-Series actuator is 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 power-up, the actuator will immediately go to the commanded position. The actuator will then drive
to maintain the position commanded by the supervisory control.
Optionally, a Run Enable input can be used to activate or de-activate the L-Series output. It can also be
used to reset shutdown fault conditions.
Upon an engine shutdown command, the independent engine shutdown solenoid or solenoid valve in the
fuel supply should be de-activated and the power supply disconnected from the speed control. This
shutdown signal should be sent directly from the engine control panel and should be independent and
separate from the L-Series controller.
Position Demand
(Analog/PWM)
Customer Actual Position (0-5V)

Controller
Status
L-Series
Run Enable
Power Input
(10-32Vdc)
RS-232
Service Tool
Figure 2-1. L-Series Operation
Driver Input Power

The L-Series will handle a voltage range of 10 to 28 Vdc at full specified torque. The actuator is functional
in the range of 8 to 32 Vdc, but accuracy and/or torque can be diminished at the extreme ends of this
range.
The supply voltage failure levels are below 6.25 V and above 33 V. The unit can be configured to either
alarm or shut down upon detection of a supply voltage fault.
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LCS Position Control Functional Overview

TPS
TPS De-code
Act’l Position Ouput
Scaling &
(0.75-4.25 V for CW-CCW) Pos’n
Fault
Configuration Settings Linearizatoin Sensor
F Detection
Direction
CW / Tuning
Calibration Settings 5-pt curve CCW
LAT
Linear/ Motor
Anlg Dmd NonLinear Motor
Scaling &
Analog Demand Aux 2 Fault Position
PWM
Fault User Driver
(0.5-4.5 V) Detection Controller
Position Scaling
F Demand
Selection S
Pwm + PWM Dmd
(configured)
PWM Demand Scaling &
10-90% Duty Fault
Detection Fault
6-26 Vdc
300-1500 Hz F
Serial Aux 4 Scaling & Fault F

RS232
Aux 3 Service Port Fault
Communications Logic Detection OverTemp F
On-Board
Temp Sensor
Current
Limters
12/24V Input Power +12/24V

(8-32 Vdc)
Scaling &
Fault Fault
S (shutdown)
Detection Fault Logic
F (any fault) A (alarm)
+V
Discrete
Status F (any fault)
Out Logic
(discrete output driver)
24Vdc = ON (status ok) Discrete
Relay
Out
Run Enable
(optional)
Figure 2-2. L-Series Position Control Functional Overview
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Position Command Signal

The L-Series can accept either a PWM command signal input or an analog 0–5 Vdc command signal
input, depending on how the software application is configured.
The PWM will function with various types of input sources, including high-side, low-side open collector,
and push-pull—depending on the configuration. It will handle a PWM frequency range from 300 to 1500
Hz at amplitudes ranging from 5 V up to battery voltage. Normal operating range is from 10% to 90% duty
cycle, representing the hard stops in the actuator (Figure 2-1). The input can be optionally set to a non-
linear mode which provides a 5-point curve relationship between position signal and desired position
(Figure 2-2).
The input failure levels are below 3% and above 97% duty cycle. The unit can be configured to either
alarm or shut down on detection of a position command failure. The shutdown failsafe direction is also
user configurable as either clockwise or counterclockwise.
A user-configurable offset is available to adjust the input duty-cycle reading, as needed.
100 user-defined shutdown

Desired Actuator Position, %
90 failsafe direction
80
70
60
50
40
30
user-defined shutdown
20
failsafe direction
10
0
0 10 20 30 40 50 60 70 80 90 100
PWM Position Signal Duty Cycle, %
Figure 2-3. PWM Linear Demand to Position

80
70
60
50
40
30
20
user-defined points
10
0
0 10 20 30 40 50 60 70 80 90 100
PWM Position Signal Duty Cycle, %
Figure 2-4. PWM Non-Linear Demand to Position
The 0–5 V input uses a different pin in the connector, and it has a usable range of 0.5 to 4.5 V to
command the throttle from minimum to maximum position (Figure 2-3). The input can be optionally set to
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a non-linear mode which provides a 5-point curve relationship between position signal and desired
position (Figure 2-4).
The input failure levels are below 0.2 and above 4.8 V. The unit can be configured to either alarm or shut
down on detection of a position command failure. The shutdown failsafe direction is also user-
configurable as either clockwise or counterclockwise direction.

80
70
60
50
40
30
failsafe direction
10
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Position Signal Voltage
Figure 2-5. Analog 0–5 V Linear Demand to Position

80
70
60
50
40
30
20 user-defined points
10
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Position Signal Voltage
Figure 2-6. Analog 0–5 V Non-Linear Demand to Position
Discrete Output
A discrete output is provided to serve as a status indicator. 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 it is available to
power external relays for devices such as alarms or fuel shutoff solenoids. The circuit is protected
internally against overcurrent and inductive spikes, so external clamping is not necessary.
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This output can be configured to be either normally on/open (preferred failsafe setting) or normally
off/closed. In addition, the faults that drive the relay status can be configured individually. For details refer
to Chapter 4 (Service Tool).
There are two conditions that will prevent the discrete output from operating correctly. The first is if battery
positive is accidentally connected to it, and the second is if it is shorted to ground. The circuit will protect
itself in the event of a mis-wire, but it will hold the output open (floating) until the fault is removed.
Run Enable Discrete Input

An optional Run Enable discrete input can be configured for use. The Run Enable operation provides a
closed-to-run and an open to force the shaft controller into a low-current “limp” mode. The Run Enable
can also be used to clear a latching shutdown condition since a closure of the input will issue a reset
command.
Actual Position Feedback (TPS)

The L-Series provides a 0–5 V signal representing actual shaft rotational position, where 0.75 V and 4.25
V correspond to full counterclockwise to clockwise rotation, respectively. This signal is fed directly off the
position sensor to ensure no delays are introduced by the processor. However, this signal is also
uncorrected, so the difference between this signal and actual position can vary up to ±10% over the
operating temperature range.
Additional Inputs/Outputs
Auxiliary Inputs—There are four auxiliary inputs on the L-Series controller, all of which are capable of
both analog and discrete functions. They can all be functionally defined for purpose in the software
application. Although they are very flexible, two of them are shared with the serial communications, so will
be unavailable if the L-Series is connected to the Service Tool. More detail concerning the auxiliary inputs
is provided in Chapter 3 (Installation).
5V Output—A 5 Vdc output has been provided on the L-Series actuator to power external sensors, if
necessary. The 5 V output is limited to 10 mA, but this is sufficient for most light-duty ratiometric sensors.
Communications
RS-232 communications are available on the L-Series when used with an external transceiver connected
to pins 4 and 6. Serial communications allow for the use of a service and configuration tool with the L-
Series actuator. The simplest way to establish this interface is to use Woodward kit # 8923-1061.
Functions available through this port include tuning, monitoring, and configuration of the position
controller. Detailed driver status information is also available.
Any RS-232 wiring must meet the requirements in the EIA RS-232 Standard document. The RS-232
standard states that the length of the RS-232 cable between the driver and the PC must be less than 50 ft
(15 m) with a total capacitance less than 2500 pF. The RS-232 data rate is fixed at 19.2 kbps. The
communication port is non-isolated and susceptible to both EMI noise and ground loops related to PC
connections and typical industrial environments.
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The service port is not isolated and is not intended to function while
the prime mover is in normal operation. The service port is provided
for configuration and setup only.
Temperature Sensing
The L-Series has an on-board temperature sensor to monitor board temperatures and protect the unit
from overtemperature. This temperature is monitored and a fault is annunciated if the set point is
exceeded.
Current Limiting based on Temperature

The controller provides actuator current limiting based on the electronics temperature. Dependent on
board and actuator thermal models, the software reduces current as necessary to avoid conditions that
would damage the device due to extreme temperatures.
Current limiting based on temperature begins when the combined current and temperature environment
causes board temperatures greater than 117 °C. The limit curve is a linear derate from full current at 117
°C down to zero current at 125 °C. At 125 °C, an OverTemp fault is annunciated. Depending on the
current (actuator torque) and ambient operating temperatures, the unit may never reach a reduced level.
Faults
Faults are separated into two categories: Logged Faults and Current Faults. The Current Faults are
volatile and reset every time power is applied. The Current Faults annunciates faults that are presently
active/detected; they may latch or not latch depending on the fault. All latching Current Faults are reset by
a power cycle or Service Tool reset. All logged faults are latched and written to the EEPROM. They must
be cleared through the Service Tool.
A fault can have three effects on the control: change the discrete output state (Alarm), Shutdown–drive to
fail direction and change the discrete output state (Alarm), or Shutdown–go limp and change the discrete
output state (Alarm). A parameter is available to configure the fault to either an alarm or a shutdown. The
shutdown action performed (go limp or drive to fail direction) is fault-dependent. Some faults are
dedicated shutdowns and cannot be configured—they are identified as such below. A "go limp" command
overrides a "drive to fail position" if more than one fault is set.
Faults can be configured as either latching or non-latching. This is a general setting that applies to all
faults, unless otherwise noted. When configured as non-latching, a Reset is not needed. If latching mode
is configured, a Reset or power-cycle is required to clear the fault and resume positioning.
Watchdog Reset
Watchdog Reset is true if a watchdog timer timeout occurred which resulted in a reset of the
microprocessor. This is a hard-coded alarm. If detected, the control will attempt to continue normal
operation.
Brownout Reset
Brownout Reset is true if CPU Voltage drops below 4.2 V but not below 1 V. The brownout detect circuit
will reset the CPU. This is a hard-coded alarm. If detected, the control will attempt to continue normal
operation.
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EEPROM Fail
EEPROM Fail indicates failure or corruption of the internal non-volatile memory. If the CRC is not correct
for the EEPROM data, this fault will be set true. This is a hard-coded internal shutdown. If detected, the
control output will go limp. A power cycle is required to clear this fault.
Position Sense Fail

This indicates a failure of the internal Position Sensor. This is a hard-coded internal shutdown. If
detected, the control output will drive to the Fail Direction using current control. This fault latches and
requires a reset or power cycle to clear.
Failure levels: >4.75 V and < 0.25 V

Persistence: 650 ms
Voltage Sense Fail

Indicates an out-of-range signal on the input power. Could indicate input power out of range or a fault in
the supply voltage sense circuitry.
Failure levels: >33 V and <6.25 V

Persistence: 650 ms
Can be configured as an alarm or shutdown. If configured as a shutdown, the control will drive to Fail
Direction (using current control) if this fault is detected. If configured as an alarm, the control will internally
default to an assumed 32 V power supply voltage (decreased torque at lower actual voltages) and
attempt to continue normal operation if this fault is detected. The value displayed on the Service Tool will
show sensed value, not default.
Temp Sense Fail

Indicates a failure of the internal on-board Temperature Sensor.
Failure levels: >150 °C and <–45 °C

Persistence: 650 ms
Hysteresis: 5 °C (<145 °C or >–40 °C to clear)
Direction (using position control) if this fault is detected. If configured as an alarm, the control will
internally default to 25 °C and attempt to continue normal operation if this fault is detected. The value
displayed on the Service Tool will show sensed value, not default.
OverTemp
If the on-board temperature sensor reads above 125 °C, this error will be set. Above 125 °C, the
processor can fail in an unpredictable manner, so this fault is recommended as a shutdown. The Current
Limiting based on temperature will effectively make the output "limp" by reducing the drive current to zero.
Failure levels: >125 °C

Persistence: 650 ms
Hysteresis: 5 °C (<120 °C to clear)
Can be configured as an alarm or shutdown. If configured as a shutdown, the control will go limp if this
fault is detected. If configured as an alarm, the control will attempt to continue normal operation if this
fault is detected.
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Position Error
Position Error detection logic will indicate a difference between commanded position and actual position
exceeded for longer than the set delay. The error magnitude and duration are customer-configurable
parameters.
Failure levels: Set by customer variable, Error > |PosErrorMax|

Persistence: Set by customer variable, Position Error Delay.
Hysteresis: none
Override: Whenever the current is being limited to a factor of 1/2 normal maximum or less. This would be
because of high temperature (see section on Temp Sensing and Current Limiting) or a shutdown that
causes the output to go "limp".
Direction (using position control) if this fault is detected. If configured as an alarm, the control will attempt
to continue normal operation if this fault is detected.
Relay Output Shorted

The relay driver is thermally protected against wiring errors. If incorrectly wired, the output will turn off and
then set the Error Bit.
PWM Input Failed (Position Demand Failed)

PWM Input Failed is only active when the position demand is configured for 'PWM'.
Failure levels: >97% Duty and < 3% Duty

Persistence: 250 ms
Hysteresis: 1% (<96% or >4% to clear)
0.5 V Analog (Aux2) Input Failed (Position Demand Failed)

Analog (Aux2) Input Failed is only active when the position demand is configured for '0.5 V'.
Failure levels: >4.8 V and < 0.2 V

Persistence: 650 ms
Hysteresis: 0.05 V (<4.75 V or >0.025 V to clear)
Run Enable Shutdown

Run Enable discrete input is opened, only active when this input is configured for use.
This is a hard-coded shutdown. The control will go limp if this condition is detected.
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Chapter 3.
Installation
Introduction
This chapter provides instructions on how to mount and connect the L-Series controller into a system.
Hardware dimensions are provided for mounting the device to a specific application.




applications Division ou Zone.
External fire protection is not provided in the scope of this product. It

is the responsibility of the user to satisfy any applicable
requirements for their system.
The L-Series is used on engines that typically have a high noise

level. Always use appropriate hearing protection while working
around the L-Series.
The surface of this product can become hot enough or cold enough
to be a hazard. Use protective gear for product handling in these
circumstances. Temperature ratings are included in the specification
section of this manual.
Do not connect any cable grounds to “instrument ground”, “control

ground”, or any non-earth ground system. Make all required
electrical connections based on the wiring diagrams (Figure 3-4).
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General Installation, Operation Notes and Requirements
Use an independent device for positive shutdown, such as a fuel

shut off valve is highly recommended. Failure to comply with this
recommendation can cause personal injury and/or property damage.
Use of an external spring to return to minimum fuel is highly
recommended. Failure to comply with this recommendation can
cause personal injury and/or property damage.
Use of a predicted min fuel shutdown procedure is highly
recommended. Failure to comply with this recommendation can
cause personal injury and/or property damage.
Unpacking
Be careful when unpacking the actuator. Check the unit for signs of damage, such as bent or dented
panels, scratches, and loose or broken parts. Notify the shipper and Woodward if damage is found.
Mechanical Installation
Mounting Location
Locate the L-Series 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 +105 °C (–40 to +221 °F). In
spark-ignited applications, make sure the L-Series is located away from the ignition coil, and that harness
wires are not routed next to the spark plug wires.
Mounting Orientation
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.
Actuator Configuration
The L-Series actuator utilizes a 2” (51 mm) square mounting bolt pattern and is intended to fit within an
envelope of 2.618 x 2.618 x 2.540 (66.50 x 66.50 x 64.52 mm) with the short dimension along the shaft
axis. Two shaft seal configurations are available, an internal lip seal and an external lip seal with spring
backup (Figure 3-2). In addition, six independent output shaft configurations are available (Figure 3-3).
Consult Woodward Applications Engineering for the application appropriate seal and shaft configuration.
Mounting Hardware
Use #10 or M5 fasteners to attach the L-Series control to the mounting bracket. The bracket and
attaching hardware must be designed to hold the weight and to withstand the vibration associated with
prime mover mounting. Use the appropriate fasteners for securing the mounting bracket to the engine.
The installer of the L-Series must take responsibility for meeting

Clause 26.4.2 of EN60079-0 (Ed. 6 or 7) regarding impact testing. The
actuator by itself does not meet this requirement and therefore must
be sufficiently protected when installed. See Chapter 2, Mechanical
Installation, for more details.
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The actuator should be protected from exposure to sunlight and rain.
Leak-check all gaseous fuel connections. Leaking gaseous fuel can

cause explosion hazards, property damage, or loss of life.
The L-Series ITB valve should be used in a well-ventilated area. A

methane detector should be used if the valve will be used in an
enclosed installation.
The L-Series ITB represents a pinch hazard with the power

connected or disconnected. The internal return spring keeps the
valve loaded closed. To prevent bodily harm or injury, keep all
hands, fingers, etc. away from the valve element at all times.
The L-Series actuator output shaft is integral to the unit’s accuracy

and performance. Take special care to prevent damage to the output
shaft or ITB bore. Do not use a sharp or metallic object to open the
ITB.
Secondary retention of the bolts should be utilized. Consult the OEM

regarding retention methods.
The L-Series ITB is not intended to support the inlet or outlet piping.
A suitable bracket must be constructed to support the valve and
piping separately to prevent damage to the throttle body.
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Figure 3-1. L-Series Outline Drawing
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Figure 3-2. L-Series Cover Types
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Figure 3-3a. L-Series Shaft Types
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Figure 3-3b. L-Series Shaft Types
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Figure 3-3c. L-Series Shaft Types
Electrical Installation
A wiring pinout of the L-Series control, as viewed by looking into the control’s connector feature, is shown
in Figure 3-4. Typical connections to external devices are also shown.
The L-Series has an operating voltage range of 8 to 32 Vdc with nominal voltages of 12 or 24 Vdc. The
power supply is reverse polarity protected, and consumes 32 W maximum power at a peak current of 1 A
(32 V) assuming 4 Ω stator resistance at 25 °C. These assumptions are based on the fact that the
software limits the power to the rotary actuator to 25 W at any given time and input voltage (in the valid
range). The control system should be protected with a 6 A slow-blow fuse in the voltage supply lines.
Typical max average current is 2.1 A, or max 25 W at 12 V. The application should be configured to turn
on power to the actuator when the engine is first cranked.
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Electrical Connections




applications Division 2 ou Zone 2.
Prior to installation, refer to the wiring diagrams and the representative I/O interfaces schematic in this
chapter. Also, review the hardware I/O specifications in Appendix C.
The control will only meet ingress protection specifications while the
Deutsch connector is installed in the unit. As such, the unit should
not be exposed to operating environments unless the mating
connector is installed. In addition, if a wire is not used for each of the
12 pins on the control, a Deutsch 114017 plug must be used in place
of each missing wire. Failure to adhere to these guidelines may
result in product failure or decreased life.
Use 1 to 1.5 mm² (16 to 18 AWG) stranded copper wire with insulation
that meets temperature requirements in the harness design. A wiring
harness stress relief within 400 mm (16”) of the control’s connector
is recommended. Limit all I/O and signal lines to less than 30 m (98
ft). Also limit input power (B+/B–) connections to an earth grounded
battery or conditioned power interface to less than 10 m (33 ft) from
the L-Series product.
Wiring must be in accordance with North American Class I, Division

2 or European Zone 2, Category 3 wiring methods as applicable, and
in accordance with the authority having jurisdiction.
Field wiring must be suitable for at least 105 °C.
A conditioned power interface is an interface which offers equivalent

common mode and differential mode conditioning of that of a
grounded 24 V lead acid battery.
Dress the harness with wire loom to contain it in a single bundle. Use grommets when passing the
harness through metal panels.
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Connector
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.
Crimping methods for the Deutsch connector pins must be followed as

prescribed by the manufacturer. Woodward is not responsible for
damage or loss of performance resulting if any other method of crimping
is used. Use of the listed part numbers of Deutsch connector components
is strongly recommended.
6A FUSE
+
12/24 Vdc
connector POWER INPUT + 1 -
key
TPS OUTPUT 2 THROTTLE POSITION
12 1 V (0.75 VDC TO 4.25 Vdc )
PWM -/AUX -
3
(SIG. GND)
11 2
AUX3+/RS232 TX 4
10 3 SERIAL COMMUNICATIONS (USE
INPUT POWER GND 5 WOODWARD 8923-1061 TO
9 4 CONNECT TO COMPUTER)
AUX4+/RS232 RX 6
8 5
+5V OUT 7 12 V/24 V OPTIONAL RUN ENABLE DISCRETE
7 6 INPUT (CLOSED TO RUN)
AUX1+ 8
connector 5 Vdc - 32 Vdc, 500 mA max.
key RELAY DRIVER 9
RELAY COIL
CUSTOMER CONTROL
Connector Pinout as Viewed 0.5-4.5 +
AUX2+ 10
Looking Into PWM OR 0.5-4.5 V
L-Series Control PWM + POSITION COMMAND
PWM+ 11
-
POS. CMD COMMON
IGN 12
VIS-168
08/3/4
Figure 3-4. Typical L-Series Position Control Application Wiring
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Table 3-1. Connector Pins
Connector
Description Comment
Pin #
1 +12V/24 Vdc Input Power Supply power
2 TPS Signal Output Direct position feedback output indication
Ground for the PWM or AUX command signal
3 PWM – / AUX –
common
4 RS-232 transmit For use with the service tool
5 Input Power Ground Ground for the 12 V/24 V input power
6 RS-232 receive For use with the service tool
7 5 V Out Power for external sensors (10 mA max)
8 Aux Input 1 Optional Run Enable discrete input
9 Relay Driver Output Status signal and fault detection output
10 Aux Input 2 0–5 V command signal input
11 PWM + PWM command signal input
12 Ignition Input Not used—Leave open
Description of Electrical I/O

Representative circuitry for the L-Series inputs/outputs is provided in Figure 3-5 below.
Power Supply Input (+12 Vdc/24 Vdc at pin 1, ground at pin 5)—The L-Series is configured for 12 or 24
V nominal operation, although it will handle 8–32 V. The power supply terminals are reverse polarity
protected, and in the case that a reverse polarity condition exists, the L-Series actuator will not power-up
and will remain at the minimum stop if attached to a throttle body with an internal return spring.
Woodward recommends using a 6 A slow-blow fuse on the power supply line feeding pin 1 of the L-Series
actuator.
The input power must be fused. Failure to fuse the L-Series could,
under exceptional circumstances, lead to personal injury, damage to
the control valve, and/or explosion.
PWM Command Input (+PWM at pin 11, PWM ground at pin 3)—This actuator can be configured to
handle a PWM signal from a high-side or low-side open-collector or open-drain source, as well as from a
push-pull (customer pull-up) source. The necessary pull-up and pull-down voltages to accommodate the
open-collector sources are handled within the L-Series actuator. Nominally, the frequency of PWM is 1
kHz, but it will handle the full range of 300 to 1500 Hz. See Figure 3-5 below, which describes the
possible input types and configurations for the PWM input.
This actuator can also be commanded using an analog signal of 0–5

V. See the description below for the auxiliary input pins. AUX2 is
used as the analog command input. The PWM and AUX2 input pins
should not be tied together.
RS-232 Connections (pin 4 and pin 6)—These pins are for serial communication with the L-Series
actuator. An external RS-232 transceiver is necessary to make communications possible with the
Woodward L-Series Service Tool. A connectivity kit can be purchased from Woodward to accomplish this.
Further instructions for using this connectivity kit are provided in Chapter 4. See also the description
below on Auxiliary Inputs.
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TPS Output (pin 2, referenced to either pin 3 or pin 5)—This pin feeds the output of the Hall effect
position sensor to the terminal wiring. The output range of this pin should be approximately 0.75 Vdc
when the actuator is full counterclockwise (when viewed at the end of the shaft), and approximately 4.25
Vdc when the actuator is at full clockwise. This gives the end user an indication of throttle position.
The TPS output is meant for an approximate indication of shaft

position only. The unconditioned output accuracy must be
considered when using this signal externally. Refer to the
specification for TPS accuracy.
It is recommended that the TPS output be used to externally verify

that the position command and subsequent actual position matches
the command signal sent. In addition to a positioning error
validation, the TPS signal should be monitored to detect out-of-range
errors on the TPS output. Failure to comply with this
recommendation can result in undetected system faults, and in
extreme cases, can cause personal injury and/or property damage.
Do not try to inject signals into the TPS output, as it will negatively
impact the performance of the L-Series actuator. This output is
meant to be used with a high impedance device, such as a voltmeter.
Do not tie pin 2 directly to battery or ground. If the application does
not use this output, leave it open.
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For this type of PWM Source... ...the L-Series PWM Input looks like...
High-Side Open-Collector (open-drain) PWM Source L-Series Configured for “Pull-Down”
5 - 32 VDC
L-Series
Pin 11
To
PNP (or P-Channel FET) 4 kW 9.5 kW Processor
Internal Clamped to 5V, then
12 kW
Command compared with 2.5V reference.
L-Series Configured for “Pull-Up”

Low-Side Open-Collector (open-drain) PWM Source
Internal 5V
Pull-Up
L-Series 12 kW
NPN (or N-Channel FET) Pin 11
To
Internal 4 kW 9.5 kW Processor
Command
Compared with 2.5V
reference.
Push-Pull PWM Source (three kinds)
5 - 32 VDC L-Series Configured for “Push-Pull”
L-Series
Pin 11
To
Internal 5 - 32 VDC
Processor
Command OR 13.5 kW
Clamped to 5V, then

compared with 2.5V reference.
Internal
Command
5 - 32 VDC
OR
Internal
Command
Figure 3-5. Acceptable PWM Input Types
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Relay Driver Output (pin 9)—This pin provides the end user with a means for detecting a fault or
shutdown condition that is experienced by the L-Series actuator. It is a low-side driver capable of sinking
250 mA (not to exceed 500 mA) through an external load such as a lamp or relay. This circuit is internally
protected against over-current conditions and inductive flyback, such as from a relay coil. By default, this
circuit will be configured in a failsafe manner, meaning it will be active (conducting) when no fault exists,
but if power is lost or a fault is detected by the L-Series actuator, the circuit will open. See Figure 3-6
below for typical usage of this feature.
It is recommended the Relay Output be configured for the failsafe

‘Normally On’ mode, to ensure maximum fault protection and
annunciation. Failure to follow these guidelines could, under
exceptional circumstances, lead to personal injury and/or property
damage.
5-32 VDC,
500mA maximum
Lamp Relay
Indicator Coil
OR Relay Driver
Status back
L-Series
to Processor
Pin 9
Self-Protecting From
.01mF FET Processor
Figure 3-6. Relay Driver Output
5V Output (pin 7, referenced to pin 3)—The +5 Vdc Power Output is intended to power any external
transducer that depends on a steady 5 V source. The maximum output current is 10 mA.
Auxiliary Inputs (pins 4, 6, 8, and 10)—The L-Series has three dedicated digital inputs (AUX2, AUX3,
and AUX4) used to activate various features of the control. Shorting an auxiliary input pin to battery
voltage activates it. Removing battery voltage from an input pin or shorting the pin to ground deactivates
the input. If it is decided not to use battery voltage with the auxiliary digital inputs, it is recommended that
at least 3 V 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. For AUX2, AUX3, and AUX4, greater than 2.5 Vdc is considered high, and less than 0.8 Vdc is
considered low. For the AUX1 discrete input only, the input must exceed 3 V to activate the discrete state.
AUX3 and AUX4 are also used for digital communications such as RS-232 (service tool) or CAN (If the
CAN option was purchased). RS-232 and CAN will NOT run simultaneously.
When used as a position control, AUX1 on the L-Series actuator can be configured as a run enable
discrete input. This configuration must be specified in the configuration of the device using the Service
Tool. If AUX1 is selected to perform the run enable function, then 5 V (5–32 V) applied to pin 8 will allow
the control to run normally. When this input is opened, the actuator will be in stand-by mode. When in
stand-by, the actuator driver will be disabled, and the shaft will be limp.
AUX2 can be used as a 0–5 V command signal for position control. The software must recognize that the
unit is expecting an analog command as opposed to a PWM command. See Figure 3-7 below for typical
usage of AUX1 and AUX2 when the L-Series is configured as a position control.
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This actuator can also be commanded using a PWM signal. See the
description above in the PWM Command Input section. The PWM and
AUX2 input pins should not be tied together.
All connector pins are short-circuit protected to ground and power

except pins 3 and 5, which are not protected against shorts to battery
positive. Installation of a fuse on the power ground wire to pin5
would provide protection to these pins but does not mean one is not
needed in the power connection. Pin 1 (B+) still needs protection
against a short to ground.
5-32 VDC L-Series

Aux.1 Input
Run Enable Discrete
(Pin 8) Clamp to 5V
Discrete Input ** Run/Stop
Closed to Run 10k Signal to
Processor
1000pF 10k
L-Series
Aux.2 Input
(Pin 10) Clamp to 5V Analog
Command
0.5V to 4.5VDC 10k Signal to
Command Signal Processor
1000pF 499k
** if optional external Run Enable is chosen during L-Series configuration, Aux. 1 can be used to enable or
disable the actuator output shaft torque.
Figure 3-7. Typical AUX1 and AUX2 Usage
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Ground Junction—This grounding junction is provided for joining external ground wires. THERE IS NOT
AN INTERNAL CONNECTION TO CIRCUIT GROUND. Terminal pins 3 and 5 must be used for access to
the circuit ground. This junction point is completely electrically isolated from the L-Series actuator’s
electronics, and is solely for convenience during installation.
GROUND
Ground
Junction
JUNCTION
Figure 3-8. Ground Junction Point
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Chapter 4.
Service Tool
Introduction
This chapter covers the process of tuning, configuring, calibrating, and servicing the control via the L-
Series Service Tool. It is assumed that the control has already been installed on the engine.
Many applications are delivered pre-configured, calibrated, and

tuned. These units do not require the use of the Service Tool.
Description
The Service Tool software is used to configure, tune, and troubleshoot the L-Series controller. This
chapter describes installation and use of the Service Tool. It identifies the parameters available that can
be viewed. It also provides detailed information on configuring and setting up the L-Series to the
customer-specific field application.
The Service Tool software resides on a PC (personal computer) and communicates to the L-Series
through connector pins 4 and 6. An external
RS-232 transceiver is necessary to make communications possible with the Woodward L-Series service
tool. A connectivity kit (Woodward # 8923-1061) can be purchased from Woodward to accomplish this.
Figure 4-1. Example Service Tool Screen
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The following hardware is required to work with the L-Series control:
 PC-compatible laptop or desktop computer* with at least one available serial communications port,
and Windows 95/98/00/NT/Me/XP as the operating system.
 Programming/datalink harness as shown in Figure 4-2.
In addition to the hardware, the following are the distributions of tool software needed to communicate
with the control:
 Woodward part number 9927-1222, L-Series Service Tool
There is a potential for serial port damage when communicating with

the L-Series 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 L-Series 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.
Figure 4-2a. Typical Programming Datalink Harness Wiring
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Figure 4-2b. Programming Harness Wiring
Getting Started
Installation Procedure
The Service Tool software can be downloaded and installed from the Woodward internet site
(www.woodward.com).
An improperly configured control could cause an overspeed or other

damage to the engine. To prevent possible serious injury from an
over-speeding engine, read and follow this entire procedure before
starting the engine.
What to do next
After the software is installed, connect a serial communications cable between the RS-232 connections
on the L-Series control and an unused serial port on your computer. Run the Service Tool program and
select the appropriate comm port. Once connected to the control, the status bar will display ‘connected’
and the Service Tool screen will populate with monitor parameters.
An unsafe condition could occur with improper use of these software

tools. Only trained personnel should have access to these tools.
Service Tool Help

More help on using Service Tool is available and included with the installation of the Service Tool product.
Service Tool Help can be accessed from the Service Tool ‘Contents’ drop-down window selection under
the Help menu located on the Main Window.
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Software Version Identification

The Service Tool software version can found by selecting ‘About’ under the Help menu. The L-Series
software version can be found on the right-most tab sheet (Identification) of the Service Tool screen. The
Service Tool and Control must be connected to view this information. Refer to this version information in
any correspondence with Woodward.
Configuration Password
If a password has been saved in the configuration file, the file cannot be opened without first entering the
password. Once a configuration with a password has been loaded into the L-Series driver, the control
configuration cannot be opened without the password. All other service tool functions do not require a
password including: writing over a password protected file configuration, writing over a password
protected control configuration, using the Position Calibration Tool, and using the Edit Position PID.
L-Series Configuration
The L-Series can be configured either on-line or off-line. On-line configuration can only be performed
when the Service Tool is connected to and communicating with the L-Series control. Off-line configuration
can be done at any time, however, settings will not take effect until they are loaded into the control.
If using non-linear mode, control power must be cycled after loading

a new configuration.
The current L-Series control configuration settings can be viewed at any time when connected to the
control by opening the Configuration Editor (File/Open Control Configuration). See Figure 4-3.
A Configuration Summary worksheet is provided in Appendix Bf this manual to allow documentation of

application configuration settings.
OEM Configuration File Data

The OEM can save configuration file specific data with the service tool by selecting Properties under the
File menu pull down. This is a text field and can be used to store data such as:
 Customer
 Engine Type
 Application Type
 Notes
Configuring the Unit—On-Line

Unit configuration is summarized as follows:
 Open the Configuration Editor Dialog by selecting ‘File/Open Control Configuration’.
 Edit the configuration settings.
 Load the configuration to the L-Series control.
As changes are made to Configuration parameters, they are not used

by the driver until a ‘load’ command is issued. Selecting the ‘Close
Window’ box/button closes the Configuration Editor and does not
make any changes to the driver.
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Configuring the Unit—Off-Line

Unit configuration is summarized as follows:
 Open the Configuration Editor Dialog using the File/New or File/Open options.
 Edit the configuration settings.
 Save the configuration to a file. At a later date simply open the configuration and load it into the
control.
Figure 4-3. Configuration Selection Options
Configuration Parameters
There are three tab sheets that contain all the configuration settings: Overview, Discrete Output, and
Alarm/Shutdown.
Overview Tab Sheet

Changing the Demand Source will modify the parameter settings available as well as the displayed
indications within the Service Tool.
A description of each configuration parameter and its adjustment range is also available in the contents of
the Service Tool Help.
Position Demand Source

The Position Demand Source can be set to one of the following:
0.5 V Selects an analog (0–5 V) position demand input.
PWM Selects a PWM position demand input.
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Figure 4-4. Configuration Editor—Analog Settings
Proportional Gain
Sets the position controller PID’s proportional gain. Increased gain corresponds to increased PID output
(higher proportional = faster response). This setting can also be dynamically adjusted using the PID
Tuning screen. Allowed values: 0–100%.
Integral Gain
Sets the position controller PID’s integral gain. Increased gain corresponds to increased PID output
(higher integral = faster response). This setting can also be dynamically adjusted using the PID Tuning
screen. Allowed values: 0–100%.
Derivative Gain
Sets the position controller PID’s derivative gain. Increased gain corresponds to increased PID output
(higher derivative = faster response). This setting can also be dynamically adjusted using the PID Tuning
screen. Allowed values: 0–100%.
Friction/Dither Setting
Sets the position controller’s friction and dither values. This parameter should be set to zero (no effect)
while tuning the PID and then increased for optimum response. If unsure, a typical value would be 25.
Allowed values: 0–100.
Min Position and Fail Direction

Sets the position controller direction. Also sets the shutdown failsafe direction. Allowed values: cw and ccw.
Non-linear Actuator
Selects either a Linear position command, when unchecked, or a Nonlinear 5-point curve command.
Linear/Nonlinear refers to the relationship between the position requested and the position commanded to
the position PID. When this box is checked, additional parameters appear to set up the 5-point demand
curve (Figure 4-4).
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If the non-linear curve is changed, control power must be cycled.
Position Request (%)

There are five breakpoint values that correspond to the position requested by the analog or PWM input
signal. These values set up the curve inputs. Allowed values: 0–100%.
These values must maintain a monotonic increase in their values, in order from lowest to highest. Also,
after the configuration is loaded into the control, power must be cycled on the control before the settings
take effect.
Actuator Position (%)

There are five breakpoint values that correspond to the modified actuator position command. These
values set up the curve outputs. Allowed values: 0–100%.
Analog (0.5 V) Settings

There are no additional settings when this mode is configured.
PWM Settings
Two additional configuration parameters appear when the position demand is set to PWM (see Figure 4-5).
PWM Pull Up Select

Selects the appropriate PWM source. This configures the L-Series input internally to provide the proper
pull-up logic. For details on selection of this parameter, refer to Chapter 3. Allowed values: Push-Pull,
High Side Drive, or Low Side Drive.
PWM Offset
Sets the PWM Duty cycle offset. This setting is provided to compensate for duty cycle variations in PWM
input frequencies, voltages, and types. Allowed values: –5.01 to +5.01%
Figure 4-5. Configuration Editor—PWM Settings
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Discrete Output Tab Sheet

This screen contains the discrete output configuration settings. If the discrete output is not used, then
these settings can be skipped.
Relay Output Configuration

The relay output can be configured to one of the following:
Normally On Sets the relay driver to a normally on mode that turns off for any of the faults
selected. This is the preferred, failsafe output configuration.
Normally Off Sets the relay driver to a normally off mode that turns on for any of the faults
selected.
It is recommended that the Relay Output be configured for the

failsafe ‘Normally On’ mode, to ensure maximum fault protection and
annunciation. Failure to follow these guidelines could, under
damage.
Relay Output Fault Selections

The list of faults displayed can be individually selected to activate the relay output. Any of the selected
faults will either turn the output off if configured for Normally On or turn the output on if configured for
Normally Off.
It is recommended that all faults be configured to activate the

discrete output, this ensures maximum fault annunciation.
Figure 4-6. Configuration Editor—Discrete Output Settings
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Alarm/Shutdown Tab Sheet

This screen contains the alarm and shutdown configuration settings.
Shutdown/Alarm Fault Selections

The list of faults displayed can be individually selected to either perform a Shutdown or just Alarm (no
action).
It is recommended that all faults be configured as shutdowns and

selecting ‘Enable Fault Latching’, this ensures maximum fault
protection. Failure to follow these guidelines could, under
damage.
Enable Fault Latching

This setting determines whether the faults are latching or non-latching. When set to latching, a reset
command is required to clear the fault.
Position Error Maximum (%)

Maximum deviation between the actual position and the position command. If the Error is exceeded for
longer than the Position Error Delay, then the Position Error fault is annunciated. Allowed values: 0–
100%.
Position Error Delay (sec)

There are 5 breakpoint values that correspond to the modified actuator position. Allowed values: 0–10
seconds.
Figure 4-7. Configuration Editor—Alarm/Shutdown Settings
Loading the Configuration (Save)

Select the File/Load to Control from the menu or Blue Arrow icon on the Configuration Editor to load the
changes into the control.
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Monitoring the Driver

The Service Tool has five different tab sheets to monitor driver parameters. The tab sheet screens
include:
 Overview (Figure 4-8)
 Alarms (Figure 4-9)
 Shutdowns (Figure 4-10)
 Internal Shutdowns (Figure 4-11)
 Identification (Figures 4-12)
Each screen displays the position setpoint and actual position values.
Position Setpoint
Displayed value of the position demand, in percent.
Actual Position
Displayed value of the actual position, in percent.
Status Bar Indications

At the bottom of the Service Tool window is a status bar. The status bar has two sections. The bottom left
section displays communication status and bottom right section displays alarm & shutdown status.
Communication Status
This section of the status bar shows the status of communication between the service tool and the L-
Series Driver. For more information, see Establishing Communication.
 Connected—The Service Tool is connected to and communicating with the driver.
 Not Connected—The Service Tool is not connected to the driver.
 Connecting—The Service Tool is attempting to connect to the driver. This message is displayed
when Connect is selected from the Communications menu or when attempting to re-establish
communication to the driver. If the connection is lost it will continuously attempt to re-connect.
Alarm Status
One or more alarms on the Alarms screen is active.
Shutdown Status
One or more shutdowns on the Shutdowns or Internal Shutdowns screen is active.
Overview Parameters Screen

To monitor the overview parameters, go to the Overview page on the main window.
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Figure 4-8. Service Tool—Overview Tab
Supply Voltage
Displayed value of the input power, in volts, as read by the processor.
Power Demand
Displayed value of the power demanded, in watts, as read by the processor. This is an indication of the
work output.
Electronics Temperature
Displayed value of the electronics temperature sensor, in degrees Celsius, as read by the processor. The
temperature sensor is physically located between the electronics module and the LAT motor.
PWM Input (Duty Cycle)

Displayed value of the PWM input, in percent duty cycle. This indication is displayed only when the
position demand is set to ‘PWM’.
AUX2 Input
Displayed value of the analog 0–5 V input, in volts. This indication is displayed only when the position
demand is set to ‘0.5 V’.
Discrete Output
On/Off status of the discrete output command. The indicator is illuminated when the channel is
commanded to ON and grayed-out when the command signal is OFF.
Run Enabled
Open (off) / Closed (on) indication of the Run Enable discrete input.
Full Travel Position Setpoint

Indication of the position setpoint in terms of total overall unit travel. Useful if a less than full-travel user-
calibrated range is used.
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Full Travel Actual Position
Indication of the actual position in terms of total overall unit travel. Useful if a less than full-travel user-
calibrated range is used.
Full Travel Sensor Position

Indication of the position in terms of total overall unit travel before linearization. This value will match the
TPS output.
Shutdown and Alarm Indications

The Shutdown and Alarm screens display the status is both active and logged fault conditions. The
logged indications provide a history of events even after the unit has been power-cycle of run again.
Indicates a logged alarm condition.
Indicates an active alarm condition.
Indicates a logged shutdown condition.
Indicates an active shutdown condition.
An active fault is one that is currently active or latched in the control. The latching/non-latching faults
configuration setting factors into this indication. If the fault is latching, then an active fault could either be
one that is still present or one that occurred but has not been reset. Latched faults can be cleared by
cycling power on the L-Series control or by selecting the ‘Reset Alarms and Shutdowns’ button on any of
the Alarm or Shutdown screens.
A logged fault is one that occurred but is no longer currently active or latched in the control. Logged faults
are permanently cleared by selecting the ‘Reset Logged Alarms and Shutdowns’ button on any of the
Alarm or Shutdown screens.
Alarms Screen
To monitor the alarm conditions, go to the Alarms page on the main window. The values displayed on this
screen dynamically change with the fault configuration. Refer to chapter 2 for a complete listing and
details of all the faults.
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Figure 4-9. Service Tool—Alarms Tab
Shutdowns and Internal Shutdowns Screens

To monitor the shutdown conditions, go to the Shutdowns and the Internal Shutdowns pages on the main
window. The values displayed on the Shutdowns screen dynamically change with the fault configuration.
Figure 4-10. Service Tool—Shutdowns Tab
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Figure 4-11. Service Tool—Internal Shutdowns Tab
Identification Screen
To monitor the L-Series product identification, go to the Identification page on the main window.
Figure 4-12. Service Tool—Identification Tab
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Tuning the PID

The Service Tool can be used to tune the PID or to just trend/monitor the PID output. To get to the PID
Tuning screen, select the Edit Position PID from the Tools menu selection.
The L-Series controller can be put into a manual control mode from this screen by selecting the “Enable
Manual Position Tuning’ checkbox (Figure 4-13). Once in manual mode, the position setpoint box is
highlighted and the value displayed is actively positioning the output. Use this command to create step
changes for the PID and monitor the response using the displayed trend.
Pressing the Properties button pops open the Properties Window (Figure 4-14). From this window the
user can adjust the trending window properties including the update rate and display range.
Figure 4-13. Service Tool—PID Tuning Window
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Figure 4-14. Service Tool—PID Tuning Properties Window
Position Calibration and Verification

Position calibration is available to map the position command input to the actual rotational travel of the
unit. It is only used when the full travel of the actuator is constrained or limited such that 0 to 60 degrees
of travel is not used. For example, an application-specific position calibration could map 0–100% position
command to 10–40 degrees actual rotation.
There are two methods available to perform a position calibration: Automatic or Manual. If the application
has hard stops that correspond to the actual min/max travel, then either Auto or Manual methods can be
used—although auto is easier. If hard stops are not available, then the auto method will give invalid
results and the manual method must be followed.
The Service Tool can be used to calibrate the control to end user stops (physical or soft) or to verify the
position calibration. To get to the Position Calibration screens select the desired function from Position
Calibration under the Tools menu selection.
Position Calibration is only used when the full travel of the actuator
is constrained or limited such that 0 to 60 degrees of travel is not
used.
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Calibration Sequence Overview

The following outlines the basic steps required to execute the position calibration.
Automatic Mode
1. Select Automatic Position Calibration Mode.
2. Select cw or ccw Direction.
3. L-Series automatically rotates in both cw and ccw directions until the stops are detected. The values
are then captured and stored.
4. When completed, cycle the power on the L-Series.
5. It is recommended that a Position Verification be performed to confirm the calibration is correct. See
Position Verification below.
Manual Mode
1. Determine to rotational travel limits. This can be done by positioning the unit to the minimum and
maximum positions and recording the position settings.
2. Select Manual Position Calibration Mode.
3. Select Direction.
4. Enter the pre-determined rotational travel limits values.
5. When completed, cycle the power on the L-Series.
6. It is recommended that a Position Verification be performed to confirm the calibration is correct. See
Position Verification below.
Position Verification
When the Verify Position screen is entered, the control is put into position control and the position is set to
the position the control was at when the screen was entered. The screen displays the “User” Requested
Position, Actual Position, Minimum Position, and Maximum Position (see figure 4-13). These User
Positions are calculated from the user-calibrated stops.
The Full Travel Actual Position is the full stroke factory position without user stops after software
linearization. The Full Travel Sensor Position is the full stroke factory position without user stops before
software linearization. The Full Travel Sensor Position will match the TPS Output Signal.
The Verify Position screen can be used to check the calibration or to get the minimum and maximum
position values for the manual calibration. If the Enable Requested Position Tuning box is checked the
valve can be positioned anywhere from 0 to 100% of the user minimum and maximum stops by entering a
value into the Requested Position. If the Enable Requested Position Tuning box is unchecked the valve
will go limp and can be physical positioned by hand.
If the full factory position calibration range is not being used (the
Manual or Automatic Calibration has been performed) and the
minimum position direction is changed, the calibration must be run
again for the Verify Position mode to work correctly.
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Figure 4-15. Service Tool—Verify Position Calibration
Manual Calibration
The manual calibration mode is used to set the minimum position and fail direction and to calibrate the
valve to user soft stops (inside of any physical stops). The first screen to appear when entering the
manual mode is used to set the minimum position and fail direction. This setting must be correct before
manually calibrating the valve.
Figure 4-16. Service Tool—Manual Position Calibration
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The next screen is used to set the minimum and maximum positions for the user soft stops. To find the
minimum and maximum soft stops use the verify position mode described above to position the valve and
use the Full Travel Actual Position reading for minimum and maximum position values.
Review ALL settings shown on ALL Configuration screens to verify

that all configuration settings are correct before loading settings to
the control. Configuration changes do not take effect until they are
loaded to the control.
Figure 4-17. Service Tool—Manual Position Calibration Settings
Automatic Calibration
The automatic calibration mode is used to set the minimum position and fail direction and to calibrate the
valve to user physical stops (mechanical hard stops). Like the manual mode, the first screen to appear is
used to set the minimum position and fail direction. This setting must be correct before automatic
calibration is performed.
After setting minimum position and fail direction the screen below will appear. The control is now moving
first to the ccw stop and then to the cw stop to get the physical minimum and maximum positions.
Review ALL settings shown on ALL Configuration screens to verify

that all configuration settings are correct before loading settings to
the control. Configuration changes do not take effect until they are
loaded to the control.
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Figure 4-18. Service Tool—Auto Position Calibration
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Chapter 5.
L-Series Control Specifications
Specifications
Power Supply 12/24 V systems (10–32 Vdc) reverse polarity protection, 2.5 A max
Power Consumption 32 W maximum
Torque Nominal: 0.34 Nm (0.25 lb-ft) at 25 °C
Maximum Transient (at 105 °C): 0.20 Nm (0.15 lb-ft)
Minimum Continuous (at 105 °C): 0.14 Nm (0.10 lb-ft)
Mass/Weight 425 g (15 oz)
Power-Up to Operation Time <250 ms
Performance
Positioning Accuracy ±2% (analog or PWM command), ±1.0% (CAN)–at 25 °C
±4% (analog), ±3.6% (PWM), ±3% (CAN)–over temperature range
Slew Time 10%–90% 33 ms
Overshoot 1%
Settling Time 10 ms
–6 db Roll-off at ±0.5% Input 32 Hz
–3 db Roll-off at ±2% Input 8 Hz
Environment
Ambient
Operating Temperature –40 to +105 °C (–40 to +221 °F)
Storage Temperature –40 to +125 °C (–40 to +257 °F)
EMC EN61000-6-2: Immunity for Industrial Environments
EN61000-6-4: Emissions for Industrial Environments
SAE J1113-21: Radiated Immunity (100 V/m)
SAE J1113-11: Conducted Transient Immunity – Pulse 5b, Suppressed Load
Dump (45 V)
Humidity US MIL-STD 810E, Method 507.3, Procedure III
Salt Spray US MIL-STD 810E, Method 509.3, Procedure I
Shock MS1-40G 11 ms sawtooth
Random Vibration Random: 0.3 G²/Hz, 10–2000 Hz (22.1 Grms) 3 h/axis
Sine: 5 G 2.5 mm peak-to-peak, 5–2000 Hz, 3 h/axis, 90 min dwells, 1
octave/min
Drop SAE J1211, Paragraph 4.8.3 (modified)
Thermal Shock SAE J1455, Paragraph 4.1.3.2
Ingress Protection IP56 per EN60529
Analog Command Input
Table 5-1. Analog Command Input
Parameter Value
Input Type 0–5 V, Single-Ended Input
Input Scaling 0.5 V = 0% and 4.5 V = 100% position
Max Input (Full Scale) 5 V ± 1%
Isolation None
Transient Protection According to EMC norm
Input Impedance 499 kΩ
Anti-Aliasing Filter 1 anti-aliasing pole at 0.5 ms (338 Hz)
Resolution 10 bits
±1.3% of full scale over the temperature
Accuracy
range of –40 to +125 °C, including drift
I/O Latency 6.5 ms
Calibration Method 2-point linear software calibration
Out of Range Signal < 0.2 V or > 4.8 V
Input protected against 32 Vdc steady
Overvoltage Protection
state
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PWM Command Input
Table 5-2. PWM Command Input
Parameter Value
Input Magnitude 5–32 V p-p
Frequency Range 300–1500 Hz
Duty Cycle Scaling 10% = fully closed and 90% = fully open
Isolation None
Input Impedance Push-Pull Mode 44 kΩ–113 kΩ
Input Impedance Open Collector Mode,
15 kΩ
High Side or Low Side.
Resolution 16 bits at 300 Hz, 14 bits at 1.5 kHz
±1% of full scale (duty cycle), over the
Accuracy temperature range of –40 to +125 °C,
including drift
I/O Latency 6.5 ms
Duty cycle offset adjustment is available
Calibration in Service Tool. This will tailor the input
to the signal source
Out of Range Frequency None
Out of Range Duty Cycle < 3% or > 97%
Discrete Input
Table 5-3. Discrete Input
Parameter Value
Input Current 0.5 mA @ 5 Vdc
Input Type Ground referenced discrete input
Delay Time for Shutdown < 200 ms for system to recognize
shutdown
Delay Time for Reset Detection < 1 s for valves to move to minimum
position
Max Voltage from + Connection 32 V (power input voltage)
Isolation None, Intended for use with external
relay or other dry contact
Input Thresholds > 3.1 Vdc = “ON” < 0.8 Vdc = “OFF”
Input Current 0.5 mA @ 5 Vdc
Discrete Output
Table 5-4. Discrete Output
Parameter Value
Output Type Low-side output driver
Max Contact Voltage (Open) 32 V
Max Current 0.5 A
Max Contact Voltage at 0.5 A (Closed) 1.5 V
Max Delay Time for Opening Contact 6.5 ms
Default at Power Up Configurable in software
Error Condition Configurable in software
OK Condition Configurable in software
Driving Inductive Loads Yes, internally protected low-side switch
Utilizes circuitry that will open the
contact when output contacts are short-
Protection
circuited. Self-resetting when fault is
removed
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TPS Output
Table 5-5. TPS Output
Parameter Value
Output Type 0–5 V, single-ended
0.75 V = full ccw position and
Output Scaling
4.25 V = full cw position
Isolation None
3 db Circuit Bandwidth 350 Hz
Transient Protection According to EMC norm
Output Impedance 2.8 kΩ (±1%)
Accuracy ±10% of full scale, @ 25 °C
Temperature Drift ±0.4% over the full temperature range
I/O Latency n/a–direct from position sensor
Sensor-in-place factory calibration.
Calibration Method
2-point linear
Out of Range Signal < 0.25 V or > 4.75 V
Output protected against 32 Vdc,
steady-state; if >28 V is applied to pin
Overvoltage Protection
2, a position-related error will be
annunciated
RS-232 Serial Communication Service Port
Table 5-6. RS-232 Serial Communication Service Port
Parameter Value
Isolation None
Baud Rate Fixed 19.2 Kbaud
Outputs are TTL level.
Requires external transceiver for
Electrical Interface
conversion to RS-232 levels for proper
communication
Pinout Tx = pin 4, Rx = pin 6, Gnd = pin 3
10 m (33 ft), not meant for permanent
Maximum Cable Length
connection (for service only)
Cable Type Straight-through (no crossover)
Electronics Temperature Sensor
Table 5-7. Electronics Temperature Sensor
Parameter Value
±2 °C at 25 °C ambient
Accuracy
±3 °C over full range (–40 to +125 °C)
I/O Latency 6.5ms
Software Execution Rates
Table 5-8. Software Execution Rates
Software Routine Nominal Software Execution Rate

Position Control Algorithms 1.6 ms
Position Demand Algorithms 6.5 ms
Analog Input Logic 6.5 ms
PWM Input Logic 6.5 ms
Serial Port background task
Run Enable Discrete Input 6.5 ms
Discrete Output 6.5 ms
Diagnostics 6.5 ms
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Figure 5-1. Bode Plot of L-Series Response
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Chapter 6.
Troubleshooting
Introduction
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 that 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.
The actions described in this troubleshooting section are not always

appropriate in every situation. Always make sure that any action
taken will not result in loss of equipment, personal injury, or loss of
life. Check with the local authority having jurisdiction.
The engine, turbine, or other type of prime mover should be

equipped with an independent fuel shut-off device to protect against
fuel leakage or damage to the prime mover with possible personal
Independent Fuel injury, loss of life, or property damage. The fuel shut off device must
be totally independent of the prime mover control system. An
Shutoff Required overtemperature or overpressure shutdown device may also be
(Overspeed / needed for safety, as appropriate.
Overtemperature /
Overpressure)
The L-Series wiring must be in accordance with North American

Class I, Division 2 or European Zone 2, Category 3 wiring methods as
applicable, and in accordance with the authority having jurisdiction.
The L-Series is used on prime movers that typically have a high

noise level. Always use appropriate hearing protection while working
around the L-Series.
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General System Troubleshooting Guide

The following is a general troubleshooting guide for areas to check which may present potential
difficulties. By making these checks appropriate to your engine/turbine before contacting Woodward for
technical assistance, your system problems can be more quickly and accurately assessed.
 Valves
 Is the wiring correct?
 Is the direction of the stroke correct?
 Is the direction of the failsafe shutdown correct?
 Does the valve move through its proper stroke smoothly?
 Does the valve travel its full stroke?
 Can mid-stroke be obtained and held?
 Does the valve fully seat (close)?
 Does the valve fully open?
Engine/Generator Troubleshooting
Table 6-1. Engine/Generator Troubleshooting Chart
Problem Possible Cause Suggested Test/Correction

Engine does not start Stuck throttle/frozen Move throttle by hand. Assess smoothness,
shaft friction, and return spring force.
Power not applied to Disconnect starter motor solenoid. Disconnect
control harness from governor. Activate application. Test
for +12/24 V between +12/24 V pin and ground
pin.
Run Enable not closed Verify status of input. Measure input. Verify input
and configuration using Service Tool.
No configuration or Using Service Tool, read configuration from
incorrect configuration in controller and evaluate parameters for
controller. correction.
Fault detected in Using Service Tool, read faults from controller.
controller. Verify/correct any shutdown conditions.
Engine unstable Improperly tuned Using Service Tool, tune the position dynamics.
enabloe.
Intermittent position Using Service Tool, verify fault indications.
command input signal.
Device sending position Measure input signal. Verify signal using Service
command is sending Tool.
oscillating signal.
Poor frequency control Improperly tuned Using Service Tool, tune the position dynamics.
dynamics.
Friction/dither Using Service Tool, adjust the Friction/Dither
improperly set. setting.
Unable to develop full Non-indexed linkage Manually verify full travel of throttle plate.
power slipped on shaft.
Fault detected in Using Service Tool, view status of fault codes.
controller. Take appropriate action for active faults.
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Table 6-1. Engine/Generator Troubleshooting Chart (cont’d.)
Problem Possible Cause Suggested Test/Correction

Not controlling at desired PWM input signal Measure input duty cycle and convert to
position setpoint inaccuracy. percentage. Verify controller signal using Service
Tool. If different, adjust the PWM Offset value in
the Configuration Editor.
Wiring fault or ground Check the wiring.
loop.
Look for loose connections and disconnected or
misconnected cables and connections.
Remove all wiring except the position command

and power input and verify
operation/functionality.
Analog input signal Measure the analog command voltage arriving at
inaccuracy. pin 10 to verify that it is at the expected value in
the range of 0.5 to 4.5 V. Use the service tool to
verify that AUX2 is being read correctly.
Output shaft is bound or Manually verify full shaft movement. Use the
sticking. “verify position” function of the service tool
(Chapter 4).
Discrete output not Wiring fault. Check the wiring leading to pin 9 for open
working connections or misconnections.
Verify that pin 9 is not connected directly to input

power or ground.
Configuration. Using the Service Tool, verify that the faults and
shutdowns are selected properly and that the
output is configured for expected operation
(either normally “on” or normally “off”).
Service Tool not Wiring fault. Check AUX3 and AUX4 for loose or mis-
communicating–‘Not connected connections.
Connected’ status
indicated Verify harness setup and connections (see
chapter 4)
Check that Service Tool is running.
Verify the port setting is correct.
Service Tool not Old version of Service Re-install Service Tool, get the latest version
communicating–‘Error Tool or file corruption or from the Woodward web site
message displayed on bad install. (www.woodward.com)
PC when trying to
connect
Service Tool will not Cap Lock is on. Password is case sensitive, make sure you enter
except password the password correctly using upper and lower
case.
If password is lost contact the OEM for retrieval.
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Electrical Troubleshooting Guide

Analog Input
If the Analog Input is not functioning properly, verify the following:
 Measure the input voltage. It should be in the range of 0.5–4.5 V.
 Check the values seen by the L-Series driver using the Service Tool and verify that it matches the
input signal.
 Verify that there are no or minimal ac components to the Analog Input signal. AC components can be
caused by improper shielding.
 Check the wiring. If the inputs are reading 0 or the engineering units that correspond to 0 V, look for
loose connections and disconnected / misconnected cables/connections.
 Check the software configuration to ensure that the input is configured properly as the Demand
Source.
PWM Input
If the PWM input is not functioning properly, verify the following:
 Measure the input voltage, frequency, and duty cycle.
 Check the values seen by the L-Series driver using the Service Tool and verify that is matches the
input signal.
 Check the wiring. Look for loose connections and disconnected / misconnected cables/connections.
 Check the software configuration to ensure that the input is configured properly as the demand
source.
Run Enable Discrete Input

If the run enable discrete input is not functioning properly, verify the following:
 Measure the input voltage on the terminal block. It should be in the range of 10–28 Vdc.
 Check the status of the input from the Overview screen of the Service Tool.
 Check the wiring, looking for loose connections or misconnected cables.
 Verify the input is properly configured.
Alarm or Shutdown Conditions

If the L-Series control has any alarm or shutdown conditions, refer to Chapter 2 for details on the exact
cause of the condition. The Service Tool must be used to determine the cause of any shutdown or alarm
condition.
Discrete Output
If the discrete output is not functioning properly, verify the following:
 Measure the output voltage on the terminal block. It should be in the range of 10–28 Vdc when the
output is off/false. The voltage will be in this range only if all shutdowns are false. This can be
verified through the Service Tool.
 Check the wiring, looking for loose connections or disconnected / misconnected cables.
 Verify the configuration of the output.
Service Tool
If the service tool is not functioning properly, review the installation information in Chapter 4. Verify the
following:
 Check the wiring, looking for loose connections or disconnected / misconnected cables.
 Check that Service Tool is running. Verify the Port setting is correct.
 Follow on-screen error messages. Re-install software as needed. The latest version of software is
available for download from the Woodward web site (www.woodward.com).
The L-Series actuator will not attempt to operate again, following a

detected error, until power to the valve is cycled. If an error persists,
the actuator must be replaced.
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Chapter 7.
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
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Replacement/Exchange: Replacement/Exchange is a premium program designed for the user who is in
need of immediate service. It allows you to request and receive a like-new replacement unit in minimum
time (usually within 24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime.
This option allows you to call your Full-Service Distributor in the event of an unexpected outage, or in
advance of a scheduled outage, to request a replacement control unit. If the unit is available at the time of
the call, it can usually be shipped out within 24 hours. You replace your field control unit with the like-new
replacement and return the field unit to the Full-Service Distributor.
Flat Rate Repair: Flat Rate Repair is available for many of the standard mechanical products and some
of the electronic products in the field. This program offers you repair service for your products with the
advantage of knowing in advance what the cost will be.
Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat Rate Repair option, with
the exception that the unit will be returned to you in “like-new” condition. This option is applicable to
mechanical products only.
There are no serviceable parts on the L-Series.
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.
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Engineering Services
Woodward’s Full-Service Distributors offer various Engineering Services for our products. For these
services, you can contact the Distributor by telephone or by email.
 Technical Support
 Product Training
 Field Service
Technical Support is available from your equipment system supplier, your local Full-Service Distributor,
or from many of Woodward’s worldwide locations, depending upon the product and application. This
service can assist you with technical questions or problem solving during the normal business hours of
the Woodward location you contact.
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 at www.woodward.com/directory, which also contains the most current product
support and contact information.
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 Industrial

Electrical Power Systems Engine Systems 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 (124) 4399500
Kempen---- +49 (0) 21 52 14 51 India --------------- +91 (124) 4399500 Japan---------------+81 (43) 213-2191
Stuttgart - +49 (711) 78954-510 Japan---------------+81 (43) 213-2191 Korea ---------------+82 (51) 636-7080
India --------------- +91 (124) 4399500 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
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Technical Assistance
If you need to contact technical assistance, you will need to provide the following information. Please write
it down here before contacting the Engine OEM, the Packager, a Woodward Business Partner, or the
Woodward factory:
General
Your Name
Site Location
Phone Number
Fax Number
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.
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Appendix A.
L-Series Configuration Summary
APPLICATION ________________________________________________
ACTUATOR SERIAL NUMBER ____________________________________

For details on individual settings, refer to Chapter 4.
Configuration Settings – Position Controller

Setup
Position Demand Selection PWM ____ 0..5 V ____
Fail Direction ccw ____ cw ____
Min Position Direction ccw ____ cw ____
Use Non-linear Actuator Curve? Yes ____ No ____
Dynamics
Proportional Gain (%) = ______________
Integral Gain (%) = ______________
Derivative Gain (%) = ______________
Friction / Dither Setting = ______________
PWM Input
PWM Drive Select Push-Pull ____ High Side ____ Low Side ____
PWM Offset (%) = ______________
Non-Linear Actuator Settings
Position Request (pt 0) (%) = ______________
Actuator Position (pt 0) (%) = ______________
Discrete Out
Discrete Out Normally On? Yes ____ No ____
Indicates Watchdog Reset? Yes ____ No ____
Indicates Brownout Reset? Yes ____ No ____
Indicates EE Prom Failure? Yes ____ No ____
Indicates Position Sensor Failure? Yes ____ No ____
Indicates Temperature Sensor Failure? Yes ____ No ____
Indicates Supply Voltage Fault? Yes ____ No ____
Indicates Relay Fault? Yes ____ No ____
Indicates Position Demand Failure? Yes ____ No ____
Indicates Overtemperature? Yes ____ No ____
Indicates Position Error? Yes ____ No ____
Indicates Run Enable Shutdown? Yes ____ No ____
Faults (Shutdown/Alarms)
Temp Sensor Failure Action Shutdown ____ Alarm ____
Supply Voltage Fault Action Shutdown ____ Alarm ____
Relay Fault Action Shutdown ____ Alarm ____
Position Demand Failure Action Shutdown ____ Alarm ____
Overtemperature Action Shutdown ____ Alarm ____
Position Error Action Shutdown ____ Alarm ____
Faults are Latched? Yes ____ No ____
Position Error Max (%) = ______________
Position Error Delay (sec) = ______________
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Revision History
New Manual—
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Declarations
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THIS PAGE INTENTIONALLY LEFT BLANK
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We appreciate your comments about the content of our publications.

Send comments to: [email protected]
Please reference publication 35154.
ËB35154è:-µºµ¸µ¸Î
PO Box 1519, Fort Collins CO 80522-1519, USA

1041 Woodward Way, Fort Collins CO 80524, USA
Phone +1 (970) 482-5811
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 35154

L-Series Position Controller

Installation and Operation Manual

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

Any unauthorized modifications to or use of this equipment outside its specified

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

Manual 35154 L-Series Position Controller RoHS Compliant

Manual 35154 L-Series Position Controller RoHS Compliant

Illustrations and Tables

Figure 2-1. L-Series Operation .............................................................................11

Table 3-1. Connector Pins ....................................................................................29

Manual 35154 L-Series Position Controller RoHS Compliant

Manual 35154 L-Series Position Controller RoHS Compliant

Warnings and Notices

Ensure that personnel are fully trained on LOTO procedures prior to

The engine, turbine, or other type of prime mover should be

The products described in this publication may present risks that

Manual 35154 L-Series Position Controller RoHS Compliant

Be prepared to make an emergency shutdown when starting the

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

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

Electrostatic Discharge Awareness

Follow these precautions when working with or near the control.

Manual 35154 L-Series Position Controller RoHS Compliant

European Compliance for CE Marking:

RoHS Directive: Declared to 2011/65/EC COUNCIL DIRECTIVE of the

Exemptions in Use: 6(a), 6(c), 7(a), 7(c)-I

ATEX Directive: Declared to Directive 2014/34/EU of the European

Other European and International Compliance:

Pressure Exempt per Article 1.2(j) of 2014/68/EU where pressure

North American Compliance:

Manual 35154 L-Series Position Controller RoHS Compliant

Connect ground terminal to earth ground.

Wiring must be in accordance with North American Class I, Division

Field wiring must be suitable for at least 105 °C.

The installer of the L-Series must take responsibility for meeting

The actuator should be protected from exposure to sunlight and rain.

EXPLOSION HAZARD—Do not connect or disconnect while circuit is

Substitution of components may impair suitability for Class I,

RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher

La substitution de composants peut rendre ce matériel

Manual 35154 L-Series Position Controller RoHS Compliant

Purpose and Scope

How to Use This Manual

Manual 35154 L-Series Position Controller RoHS Compliant

The gasket must be ordered separately.

Manual 35154 L-Series Position Controller RoHS Compliant

Service Tool Software

Detailed descriptions of software installation are available in Chapter 4.

Manual 35154 L-Series Position Controller RoHS Compliant

Customer Actual Position (0-5V)

Figure 2-1. L-Series Operation

Driver Input Power

Manual 35154 L-Series Position Controller RoHS Compliant

LCS Position Control Functional Overview

Serial Aux 4 Scaling & Fault F

12/24V Input Power +12/24V

Figure 2-2. L-Series Position Control Functional Overview