Solenoid Troubleshooting Guide
Contents
1. Follow these precautions when working with or near the control 1 Before doing maintenance on the electronic control discharge the static electricity on your body to ground by touching and holding a grounded metal object pipes cabinets equipment etc 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 Keep plastic vinyl and Styrofoam materials such as plastic or Styrofoam cups cup holders cigarette packages cellophane wrappers vinyl books or folders plastic bottles and plastic ash trays away from the control the modules and the work area as much as possible 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 e 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 e 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 A CAUTION To prevent damage to electronic components caused by improper handling2. Table 4 NO RUN Solenoid pulls in but will not hold in Step Condition Action Measure the hold coil voltage refer to Solenoid Voltage Check section If voltage is in range refer to Step 2 If voltage is out of range bench test the solenoid refer to Solenoid Bench Testing section Check linkage assembly for correct length and or binding Adjust linkage if needed refer to Solenoid Linkage Adjustment section If the linkage checks OK bench test the solenoid refer to Solenoid Bench Testing section Table 5 NO SHUTDOWN Solenoid pulls in but does not return to shutdown Step Condition Action Measure the hold coil voltage with the ignition switch in the OFF position If voltage is in range refer to Step 2 If voltage is out of range test the solenoid refer to Solenoid Bench Testing section Check linkage assembly for correct length and or binding Adjust linkage if needed refer to Solenoid Linkage Adjustment section If the linkage checks OK bench test the solenoid refer to Solenoid Bench Testing section NOTE Be aware that there can be non solenoid related causes for this condition such as alternator circuit feeding back through the hold coil or OEM wiring problem Woodward 17 Solenoid Troubleshooting Guide Manual 36541 Solenoid Voltage Check Improper voltage affects the solenoid s work output Low voltage reduces the wor
3. to prevent damage to these parts e Discharge body static before handling the control with power to the control turned off contact a grounded surface and maintain contact while handling the control e Avoid all plastic vinyl and Styrofoam except antistatic versions around printed circuit boards e Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices IMPORTANT DEFINITIONS A WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION indicates a potentially hazardous situation which if not avoided could result in damage to equipment NOTE provides other helpful information that does not fall under the warning or caution categories l Revisions Text changes are indicated by a black line alongside the text Woodward Governor Company reserves the right to update any portion of this publication at any time Information provided by Woodward Governor Company is believed to be correct and reliable However no responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken Woodward 2005 All Rights Reserved Manual 36541 Solenoid Troubleshooting Guide Contents ee ee ELECTROSTATIC DISCHARGE AWARENESS ccseeeeesseeeeeeesseneeeeesesneeneeneenes Il CHAPTER 1 GENERAL INFORMATION ssssssssunsssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn na 1 Solenoid
4. Measurement Range Model Pull Coil Resistance Hold Coil Resistance No Voltage White Black Wire Red Black Wire 12 0 308 0 376 14 365 14 655 EES 24 1 280 1 255 48 897 59 763 1503ES 12 0 348 0 426 13 45 16 43 12 0 232 0 284 9 819 12 001 TES 24 0 878 1 073 46 548 56 892 1751ES 12 0 232 0 284 9 82 12 00 1756ES 24 0 878 1 073 46 55 56 89 1752ES 12 0 195 0 239 10 04 12 27 1755ES 24 0 735 0 899 37 22 45 49 1753ES 12 0 324 0 396 12 97 15 85 1757ES 24 1 208 1 477 54 73 66 89 12 0 248 0 302 17 48 21 36 2001ES 24 0 936 1 144 71 03 86 79 SB 2776 12 0 240 0 294 16 77 20 49 12 0 179 0 219 13 33 16 29 SES 24 0 577 0 706 48 78 59 62 12 0 175 0 213 12 75 15 59 SES 24 0 554 0 678 46 76 57 15 12 0 175 0 213 12 75 15 58 2003ES 24 0 554 0 678 46 76 57 15 24 0 895 1 093 35 76 43 70 12 0 221 0 258 5 761 7 041 SE 24 0 798 0 976 21 08 25 76 14 Woodward Manual 36541 Solenoid Troubleshooting Guide Table 1B Coil Resistance Internally Switched Solenoids Measurement Range Between Pos and Neg Terminals Dem Voltage Pull Coil Resistance Hold Coil Resistance 12 0 359 0 438 15 28 18 67 24 1 350 1 650 89 10 108 90 1502 32 2 466 3 014 145 35 177 65 48 4 563 5 577 359 73 439 67 64 7 884 9 636 394 65 482 35 12 0 261 0 319 14 13 17 27 1504 24 0 977 1 193 58 90 71 98 36 2 430 2 970 114 12 139 48 12 0 232 0 284 9 82 12 00 1
5. amp L WASHER hae RIGHT ANGLE SWIVEL SWIVEL X CHECK ALIGNMENT PIVOT Figure 9 Solenoid with Connecting Rod 20 Woodward Manual 36541 Solenoid Troubleshooting Guide Table 7 Linkage Adjustment Step Action 1 Examine the linkage and look for signs of corrosion rust oil and dirt all of which can contribute to unacceptable performance of the solenoid Make sure linkage moves freely without binding If the linkage feels tight check for bent linkage misaligned bracket improper spring on control lever swivel head hitting control lever etc Loosen linkage as needed The linkage and the plunger must all move freely with your fingers Turn the Key Switch to Run On position NOTE Take precautions during these checks to prevent pull coil burnout For internally switched solenoids manually push the linkage all the way in The plunger should hold in place If the plunger does not hold in measure resistance across the positive and negative terminals The reading should match the hold coil resistance listed in the Solenoid Coil Resistance Check section If the reading is not correct the plunger is not activating the internal switch and linkage adjustment is too short Adjust linkage until the plunger holds in For externally switched solenoids manually push the linkage as far as it will go The plunger should hold in place If the plunger does not hold in linkage adjustment is too shor
6. your nearest Woodward distributor or service facility Woodward 25 Solenoid Troubleshooting Guide Manual 36541 Engineering Services Woodward Industrial Controls Engineering Services offers the following after sales support for Woodward products For these services you can contact us by telephone by email or through the Woodward website e Technical Support e Product Training e Field Service Contact information Telephone 1 970 482 5811 Toll free Phone in North America 1 800 523 2831 Email icinfo woodward com Website www woodward com Technical Support is available through our many worldwide locations or our authorized distributors depending upon the product This service can assist you with technical questions or problem solving during normal business hours Emergency assistance is also available during non business hours by phoning our toll free number and stating the urgency of your problem For technical support please contact us via telephone email us or uSe our website and reference Customer Services and then Technical Support Product Training is available at many of our worldwide locations standard classes We also offer customized classes which can be tailored to your needs and can be held at one of our locations or at your site This training conducted by experienced personnel will assure that you will be able to maintain system reliability and availability For information concerning traini
7. Number When shipping the item s attach a tag with the following information e name and location where the control is installed e name and phone number of contact person e complete Woodward part number s and serial number s e description of the problem e instructions describing the desired type of repair CAUTION To prevent damage to electronic components caused by improper handling read and observe the precautions in Woodward manual 82715 Guide for Handling and Protection of Electronic Controls Printed Circuit Boards and Modules Packing a Control Use the following materials when returning a complete control protective caps on any connectors e antistatic protective bags on all electronic modules e packing materials that will not damage the surface of the unit e atleast 100 mm 4 inches of tightly packed industry approved packing material a packing carton with double walls e a strong tape around the outside of the carton for increased strength 24 Woodward Manual 36541 Solenoid Troubleshooting Guide Return Authorization Number When returning equipment to Woodward please telephone and ask for the Customer Service Department 1 800 523 2831 in North America or 1 970 482 5811 They will help expedite the processing of your order through our distributors or local service facility To expedite the repair process contact Woodward in advance to obtain a Return Authorization Number a
8. a piece of equipment it is important to take a systematic step by step approach to narrow and identify the probable cause of the problem Troubleshooting is a process in which trail fixing should not be attempted Many times troubleshooting is a matter of finding out what is not wrong with the system Therefore begin with the most obvious and proceed step by step in an orderly fashion Be aware that when several items of equipment are connected together it is not easy to pinpoint the one item that is faulty Also be aware that in many cases the problem may be that the operator is not using the equipment properly or that there is some misadjustment Woodward 7 Solenoid Troubleshooting Guide Manual 36541 Approach each situation using the following precautions e Understand the problem e Check the symptoms to determine probable cause e Take appropriate action to fix the problem Once the repairs are completed test to see if the equipment is functioning normally If not look for other probable causes and take corrective action until the system is returned to service Safety Precautions Nothing is more important than safety The simple rule of safety is that if you think safety is for the other person let the job be too Keep in mind that beside yourself you are also responsible for the safety of everyone around you e Information provided in this guide is intended for use by qualified technicians Attempti
9. after pulling the plunger to the bottomed out position For both internally switched and externally switched solenoids it is recommended that engine cranking be limited to three 30 second attempts with a cool down period of two minutes 120 seconds between each cranking attempt After three cranking attempts total elapsed time of 5 minutes the solenoid must be allowed to cool down to ambient temperature before making further cranking attempts 6 Woodward Manual 36541 Solenoid Troubleshooting Guide Chapter 2 Basic Troubleshooting CX General Guidelines Any troubleshooting process involves the following steps e Reviewing customer complaint to understand the problem e Analyzing information and symptoms to determine probable cause e Taking appropriate corrective action to fix the problem This section contains some basic troubleshooting instructions Chapter 3 contains detailed step step instructions for diagnosing and troubleshooting solenoid related problems Tools and Equipment The use of a digital multimeter is recommended for troubleshooting Other tools usually found in a mechanic s tool box should be sufficient for most repairs e Wire cutters strippers e Screwdrivers e Adjustable wrenches e Soldering iron The following parts are not essential but may be needed e Tie wraps e Electrical tape e Wire e Crimp ons Troubleshooting Techniques In order to efficiently troubleshoot a system or
10. or pulls the throttle control lever to a preset position With an externally switched solenoid a timing device such as a Coil Commander to switch from the pull coil to the hold coil is needed to limit the pull coil on time As an alternative an internally switched solenoid can also be used Shutdown solenoids are prone to failure because of over cranking by the operator resulting in overheating while throttle solenoids are prone to failure because of likely problems in the system Coil Protection In an internally switched dual coil solenoid the pull coil is energized at the same time as the hold coil with the key switch in the Run position The plunger switches off the pull coil when it bottoms out provided there is enough voltage and the linkage is adjusted correctly In an externally switched dual coil solenoid the hold coil is designed to be energized continuously with the key switch in the Run position There is little or no danger of the hold coil failing The pull coil is designed to be energized for a short time during engine cranking with the key switch in the Start position Thus the pull coil current is considerably higher 80 50 amps depending on the model than that of the hold coil Energizing the pull coil causes a significant rise in the internal temperature of the solenoid Burnout of the coil can occur with excessive engine cranking Therefore the pull coil must be turned off as soon as possible
11. switch caps and either screw or blade type terminals See Figure 3 1 Pigtail leaded termination designed for leads to be fitted to a connector 2 Switch cap with spade type terminals designed for harness leads to be connected without soldering 3 Switch cap with screw type terminals designed for harness leads to be be screwed on Switch cap with Switch cap with spade type terminals screw type terminal Figure 3 Terminations on Externally Switched Solenoids 4 Woodward Manual 36541 Solenoid Troubleshooting Guide Pull vs Push Solenoids Solenoids can be pull type or push type In a pull type solenoid which is the more common type when the solenoid is energized the plunger pulls in towards the solenoid Pull type solenoids can be internally or externally switched In a push type solenoid when the solenoid is energized the plunger pushes out away from the solenoid All push type solenoids are externally switched Both pull and push type solenoids are constructed in a similar manner and operate on the same principle It is usually the application mounting considerations and direction of plunger motion needed that determine what type of solenoid will be used POLL Model TS eg Plunger Pulls Ir PUSH N CH d Li lunger Pushes Out Figure 4 Pull and Push Type Solenoids Energized to Run vs Energized to Stop Applications Solenoids can be used in both Energized to Run ETR and Energized
12. to Stop ETS Applications In Energized to Run applications which are more common the equipment is turned on when the solenoid is energized In Energized to Stop applications the equipment is turned off when the solenoid is energized For example in marine applications it is desirable to keep the engine running at all times while at sea Therefore the engine fuel control lever is held in the run position To stop the engine a solenoid is energized long enough to stop fuel completely and shut the engine off When de energized the solenoid returns the lever to its minimum fuel lever for the next engine start In ETR applications the solenoid is on continuously and therefore the ES solenoid requires some form of coil protection such as a Coil Commander unit to protect from engine over cranking In ETS operation since the application is being turned off the need for protection is minimum Woodward 5 Solenoid Troubleshooting Guide Manual 36541 Shutdown vs Throttle Choke Applications Shutdown applications control via the fuel shutoff lever The lever controls fuel flow to the engine or application Usually a relay in the engine start system switches from the pull coil to the hold coil However over cranking by the operator can burn out the solenoid and therefore including a timing device is preferred as a safety measure Throttle Choke applications use a solenoid to increase the amount of fuel going to the engine It pushes
13. with the key in run position go to the NO RUN Table 4 If the solenoid pulls in but does not return to the shutdown position when switched off engine will not shut off go to the NO SHUTDOWN Table 5 If the solenoid pulls in and operates normally but the engine will not start the problem is probably application related a Check fuel pump and injectors b Check air cleaner and filter c Check switches and system grounds d Check relays at least 60 A e Refer to the OEM manual NOTE Remember to limit cranking to three 30 second attempts with a cool down period of two minutes 120 seconds between each cranking attempt After three cranking attempts the solenoid must be allowed to cool down to ambient temperature 512 minutes total elapsed time before any further attempts are made 16 Woodward Manual 36541 Solenoid Troubleshooting Guide Table 3 NO START Solenoid does not pull in Step Condition Action Measure solenoid pull coil voltage refer to Solenoid Voltage Check section If voltage is in range refer to Step 2 If voltage is out of range bench test the solenoid refer to Solenoid Bench Testing section Check linkage assembly for correct length and or binding Adjust linkage if needed refer to Solenoid Linkage Adjustment section If the linkage checks OK bench test the solenoid refer to Solenoid Bench Testing section
14. 751 24 0 878 1 073 46 55 56 89 36 6 363 7 777 226 26 276 54 12 0 324 0 396 12 97 15 85 1753 24 1 208 1 477 54 72 66 89 64 8 730 10 670 296 10 361 40 1755 12 0 195 0 239 10 04 12 27 24 0 754 0 922 47 94 58 60 2001 12 0 248 0 303 17 48 21 36 24 0 936 1 144 71 01 86 81 o 12 0 179 0 219 13 33 16 29 24 0 577 0 706 48 78 59 62 12 0 185 0 227 6 50 7 94 24 0 703 0 859 37 27 45 55 Sieg 24 0 496 0 606 18 90 23 10 12 0 185 0 227 6 50 7 94 24 0 703 0 850 37 27 45 55 24 0 358 0 438 23 98 19 62 Woodward 15 Solenoid Troubleshooting Guide Manual 36541 Solenoid Operation on the Engine or Application The procedure outlined below refers to shutdown applications that are the most common solenoid applications For other type of applications use the installed switching mechanism relay switch etc to energize and de energize the solenoid Use Table 2 below to observe solenoid operation on the engine and follow the suggested course of action Table 2 Solenoid Operation of the Engine Step Condition Corrective Action With one person at the key switch and one person watching the solenoid inspect the shutdown system during several cycles of the ignition switch Check for complete shutoff lever travel from stop to run position If the solenoid does not pull in engine will crank but not start go to the NO START Table 3 If the solenoid pulls in but will not hold in engine stops
15. H NUMBER PIN XXXXXXXXXX SN XXXXX VDC XX www woodward com CUSTOMER PART NUMBER SALES ORDER NUMBER VOLTAGE Figure 5 Woodward Solenoid Label Woodward 9 Solenoid Troubleshooting Guide Manual 36541 Part Number Descriptor Below is an explanation of a part number descriptor found on a typical solenoid Example Part Number 12A2U1B1S1A Reading from left to right 12 Indicates volts a solenoid can be 12 Vdc or 24 Vdc A indicates the mounting style A Flanged B Threaded C Based 2 Indicates plunger type 2 Ext Thread 1 4 28 3 Ext Thread M 6 6 Int Thread 1 4 28 7 Int Thread M 6 U Indicates grounding G Grounded U Ungrounded 1 Indicates termination type 1 Screw 2 Spade C Connector L 3 Wire Leads B1 Indicates boot type B1 Constant Volume B2 Bellows S1 Indicates return spring forces Consult the factory for ratings A Indicates special options A Aux Terminal C Conduct Cover CC Coil Commander Consult the factory for additional information or explanation 10 Woodward Manual 36541 Solenoid Troubleshooting Guide Chapter 3 Detailed Troubleshooting ss Se Preliminary Check The purpose of this check is to do a quick visual scan of the setup and look for some obvious damage or problem Frequently such an inspection can save a technician valuable time and effort 1 Check for broken parts Inspect the rubber boot A torn boot can allow dirt to enter and
16. M wooDWARD Troubleshooting Guide Solenoid Troubleshooting Guide Internally amp Externally Switched Solenoids Push amp Pull Type Solenoids Manual 36541 WARNING Read this entire manual and all other publications pertaining to the work to be performed before installing operating or servicing this equipment Practice all plant and safety instructions and precautions Failure to follow instructions can cause personal injury and or property damage The engine turbine or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury loss of life or property damage The overspeed shutdown device must be totally independent of the prime mover control system An overtemperature or overpressure shutdown device may also be needed for safety as appropriate OG CAUTION 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 In systems where large inductive loads are switched on the DC power buss surge impulse energy will be present due to the switching To address surge energy affects on the control appropriate suppression devices must be installed in the DC power buss prior to the control s power connection Electronic controls contain static sensitive parts Observe the following precautions
17. Operation EE 1 Single Coil Solenoid E 1 Dual Coil Solengid sirieni osanaan aiaa aaa ae 2 Three Methods for Turning Off the Pull Col 3 Externally Switched Solenoid Terminations cccccesceceeceeeeeeeeeseeeeeeeeees 4 Pull vs PUSH Solenoids cceeceeeseeceeeeeeeeeeeeeaeceeaeeceaeeesaaeeeeaaeseeeeeseaeeesaeeseneeesaees 5 Energized to Run vs Energized to Stop Applcatons esenee ennenen 5 Shutdown vs Throttle Choke Applicatons 6 CSOT BPRS eegenen 6 CHAPTER 2 BASIC TROUBLESHOOTING ccseeeessesteneesseneeeenseneneenseneenennes 7 General Ee ie H Troubleshooting Techniques ceecccceeeesseeeeeenneeeeeeaeeeseeaaeeeeeeaaeeeeeeaaeeeeseaeeeeeeaas 7 Safety PrECAUTONS 90 daaa anaana aeaiiai aa aada aaan aana 8 Solenoid Troubleshooting Process 8 Identifying Solenoid Tvpe nnen nenn 9 Part Number Descripior seerder EEN 10 CHAPTER 3 DETAILED TROUBLESHOOTING sscssesteeeeeseeneeeeneeneeneeneeneeees 11 Preliminary Gheck ts issccccsve iiris aniona ad atlas ender ce ita aaa 11 Power to the Solenoid c ciccc 0ciidsssgecetbaasiuctessteuelcnagaurtsnsteeessasadeeteactenelsicetedltaatenesds 11 Wiring to the S Terminal of Giarter e 12 Solenoid Coil Resistance Check 13 Table 1A Coil Resistance Externally Switched Solenoids 0ss0sseeeseeees 14 Table 1B Coil Resistance Internally Switched Golenode 15 Solenoid Operation on the Engine or Application cccceeeseeeeeeeeeseeeeeneeeeees 16 Table 2
18. Solenoid Operation of the Engine sssseesseessesseeseeeresereserese nees 16 Table 3 NO START rniret Zeg deeg Eed eege EN 17 Trable 4 NO RUN sscecsteceeetaacelates tenietsanesthed cturietanecthinetiiebteneeccerstentadvedgieus 17 Table 5 NO SHUTDOWN AA 17 Solenoid Voltage Check 18 Table 6 Solenoid Voltage esne senreenn nten nenntnnnnnnennnenn nenn 19 Solenoid Linkage Adjustment eecceeeeeceeeeeeeeeeeceeeeeaaeeeeaeeseeeeeseaeeesaaeeeeneeeeaes 20 Table 7 Linkage Adjustment eee ceeeeeeeeeeeeeeeeeeeaeeeeeeaaeeeeeeaaeeeeeeaaeeeenaas 21 Overload Protection cccecccecececeenceceeeeeeeaeeeeeeeeeeeeeeaeeeeaaeseeaeeseaneesaeeseaaesseneessaees 22 Solenoid Bench Testing nenn nenn 22 CHAPTER 4 SERVICE OPTIONS cissstccsscsatseiecseteccrnendecedravasseecnsdsscnnerancaincdie 23 Product Service Rule TEE 23 Returning Equipment for Repair eceeeeeeeeeeeeeeeeceeeeeeeeeeeeeeeeeeeseeeeeeeseneeeeeeeeaees 24 Replacement EE 25 How to Contact Woodward 25 Engineering Services seseeeseeeseeeseresinest tnst nsstnsstnssrnnsrnnstensrenstnnsrensnnnsnnnnnnnnn ennt 26 Tecnnical Ee EE 27 Woodward i Solenoid Troubleshooting Guide Manual 36541 Electrostatic Discharge Awareness All electronic equipment is static sensitive some components more than others To protect these components from static damage you must take special precautions to minimize or eliminate electrostatic discharges
19. ank the engine for a few values 10 Vdc for 12 Vdc units during seconds until you get a steady and 20 Vdc for 24 Vdc units cranking reading on the meter the solenoid may not pull in Attach the clips of a voltmeter to The voltage must be a the Hold and Common wires in minimum of 75 of rated 2 the harness Hold the run stop voltage Check the lever in the stop position Turn hold in the Key Switch to Start and If the voltage is below these voltage crank the engine for a few values 10 Vdc for 12 Vdc units available to seconds until you get a steady and 20 Vdc for 24 Vdc units the solenoid reading on the meter the plunger will not hold in at during the moment cranking stops cranking and the Key Switch is released to the Run On position Attach the clips of a voltmeter to The voltage must not be below 3 the Hold and Common wires in and must remain at a Check the the harness Turn the Key minimum of 75 of rated hold in Switch to Run On and check voltage voltage the voltage Check continuity available to between the Start and On If the voltage is below these the solenoid positions on the key switch values 10 Vdc for 12 Vdc units when NOT and 20 Vdc for 24 Vdc units cranking the plunger will not hold in Attach the clips of a multimeter There should NOT be any 4 to the Pull and Common wires in voltage because the Pull in coil Check the the harness and check the is only energized when the Key v
20. arter Wiring the solenoid to the S terminal of the starter or to the relay that is connected to the S terminal will VOID the manufacturer s warranty for the solenoid Perform the following test to determine if the pull coil is incorrectly wired to the S terminal of the starter 1 2 3 Turn the ignition switch to the OFF position Disconnect the solenoid electrical connector from the OEM wiring harness Locate the pin on the OEM side of the connector that is opposite the white wire pull coil of the solenoid side of the connector Place one lead of the multimeter on this pin Place the other lead of the multimeter on the S terminal of the starter Measure the resistance between these two points The resistance should be infinite open circuit if the solenoid is wired correctly If the resistance is not infinite the solenoid is incorrectly wired to the S terminal of the starter Re wire the solenoid correctly Refer to the publication SE 3024 for recommended wiring schemes Figure 6 Connection to the S Terminal is Not Recommended 12 Woodward Manual 36541 Solenoid Troubleshooting Guide Solenoid Coil Resistance Check Make sure the solenoid is at room temperature 70 F 21 C before checking the resistance Disconnect solenoid electrical connector from the wiring harness connector if solenoid is installed on the application Use an ohmmeter capable of measurin
21. g at least tenths of ohms or better Zero adjust the meter before measuring For internally switched solenoids pull the plunger all the way out and then check the reading between positive and negative terminals for pull coil resistance Now manually move the plunger all the way in to activate the internal switch Hold the plunger in this position and check the reading again between the positive and negative terminals to obtain hold coil resistance For externally switched solenoids pull coil resistance is read between White and Black wires and hold coil resistance is read between Red and Black wires For externally switched solenoids with switch caps and screw or blade type terminals use the label to identify and measure the pull coil and hold coil resistance Refer to the coil resistance chart 1A or 1B for the correct values NOTE Some specially manufactured solenoid units may not follow the general wire color scheme presented here FLUKE 87 RE AUS MULTIMETER H S GIN mW FANGE GOLD C LO CRE ai we PEAK MIN MAX w OL Ae gt Wf A MA mV he ae g SS Il L Figure 7 An Ohmmeter to Measure Resistance is Recommended Woodward 13 Solenoid Troubleshooting Guide Table 1A Coil Resistance Externally Switched Solenoids Manual 36541
22. g out and reaching the cutoff switch or low voltage On externally switchrd units the most common reason for a burnt coil is overcranking 3 Arrange by using a block or some other means to restrict the stroke of the solenoid to about 1 maximum Using a power supply apply nominal power 12 Vdc for a 12 Vdc unit and 24 Vdc for a 24 Vdc unit to the solenoid and see if the solenoid works NOTE Make sure the power supply is functioning properly If the solenoid works it is acceptable as manufactured This completes the bench testing process Reinstall the solenoid on the application 22 Woodward Manual 36541 Solenoid Troubleshooting Guide Chapter 4 Service Options Product Service Options The following factory options are available for servicing Woodward equipment based on the standard Woodward Product and Service Warranty 5 01 1205 that is in effect at the time the product is purchased from Woodward or the service is performed e Replacement Exchange 24 hour service e Flat Rate Repair e Flat Rate Remanufacture If you are experiencing problems with installation or unsatisfactory performance of an installed system the following options are available e Consult the troubleshooting guide in the manual e Contact Woodward technical assistance see How to Contact Woodward later in this chapter and discuss your problem In most cases your problem can be resolved over the phone If not you can select which co
23. hould be followed Both approaches are equally valid and it is generally at the technician s discretion to determine the best possible approach to use for each specific situation In some instances one approach may be more practical than the other For example if the solenoid is especially difficult to remove and re install it may be better to investigate all possible engine related causes before removing the solenoid for bench testing At other times especially from the solenoid manufacturer s perspective it may make more sense to bench test the solenoid first and eliminate it as the source of the problem before investigating other causes Geiting Started Before beginning the actual troubleshooting complete the following 1 Identify and learn about the type of engine or application on which the solenoid is installed consult with the customer 2 Identify the type of solenoid being used Refer to Safety Precautions section Refer to Chapter 3 to begin step by step testing and troubleshooting Identifying Solenoid Type It is important to correctly identify the type of solenoid unit you have This can help during troubleshooting and when communicating with the factory about a problem The label on the solenoid contains a model number descriptor and a part number descriptor The part number descriptor specifies the type of features the solenoid has WOODWARD MODEL NUMBER Nb woopwarp SOLENOID MODEL EE WOODWARD SE
24. increase the drag or friction on the plunger 2 Check for blown fuse broken wires or loose connections Check for burned out solenoid coil usually evident by pungent odor 3 Check the solenoid mounting Look for loose mounting screws that can cause misalignment resulting in reduced solenoid force 4 Check the location Although the solenoid is designed to operate in harsh environments locations with excessive heat buildup constant exposure to liquid and particulate contaminants can effect the solenoid operation Power to the Solenoid 1 Disconnect the solenoid from the linkage and the control lever Apply power and see if the solenoid pulls in If the solenoid pulls in it is getting power to operate 2 If the solenoid does not pull in check voltage at the connector and confirm at least 10 Vdc is being delivered to a 12 Vdc system and 20 Vdc toa 24 Vdc system This is the minimum acceptable voltage 3 If the voltage reading is not acceptable check the wiring harness and make sure battery voltage at the battery posts is within manufacturer s specifications Replace battery if needed 4 Ifthe voltage readings are acceptable but the solenoid does not pull in prepare to remove the solenoid from the application and test it on the bench Woodward 11 Solenoid Troubleshooting Guide Manual 36541 WARNING A Make sure the solenoid is NOT wired to the S terminal of the starter Wiring to the S Terminal of St
25. k output When the voltage is excessive it overheats the solenoid and destroys the insulation on the coil and burns out the solenoid Use Table 6 to check if the solenoid is getting proper voltage The solenoid must remain in circuit connected to the wiring harness when checking the voltage For externally switched solenoids you can make a jumper harness with mating connectors as shown in Figure 8 to check the voltage while keeping the solenoid connected to the wiring harness For internally switched solenoids use the positive and negative terminals to check the voltage For externally switched solenoids the typical wiring scheme is as follows Solenoid Wire Markin Solenoid Wire Color Hold Red Pull White Common Black NOTE Some specially manufactured solenoid units may not follow the general wire color scheme presented above Insulation removed from wire Figure 8 Jumper Harness 18 Woodward Manual 36541 Solenoid Troubleshooting Guide Table 6 Solenoid Voltage Step Action Response Attach the clips of a voltmeter to The voltage must be a 1 the Pull and Common wires in minimum of 75 of rated Check pull the harness Hold the run stop voltage in voltage lever in the stop position Turn available to the key Switch to Start and If the voltage is below these solenoid cr
26. l Number If you have an electronic or programmable control please have the adjustment setting positions or the menu settings written down and with you at the time of the call Woodward 27 We appreciate your comments about the content of our publications Send comments to icinfo woodward com Please include the manual number from the front cover of this publication W wooDwarRD PO Box 1519 Fort Collins CO 80522 1519 USA 1000 East Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 e Fax 1 970 498 3058 Email and Website www woodward com Woodward has company owned plants subsidiaries and branches as well as authorized distributors and other authorized service and sales facilities throughout the world Complete address phone fax email information for all locations is available on our website 05 10 M
27. lly switched 3 wire solenoid is used in applications STARTER RELAY where an operator driver manually turns a key switch that temporarily energizes the pull coil to pull in the plunger The most popular application is for start stop control of engines in trucks and mobile equipment where moisture dirt dust and high vibration are present The sealed 3 wire solenoid is well suited for these harsh conditions SOLENOID EXTERNAL SWITCHING WITH TIMER MODULE With the addition of a Woodward pull coil timer module the externally switched 3 wire solenoid can be used not only in SUE operator driver controlled ee s vehicles but also in unattended equipment throttle and choke controls The timer ensures that the pull coil is turned off within approximately 1 1 2 seconds after energizing which prevents overheating of the coil in situations such as abusive overcranking of an engine INTERNAL SWITCHING The internally switched solenoid utilizes a mechanical double contact switch mounted on the rear of the solenoid to turn off the pull coil Best suited for applications such as standby generator sets or other applications where vibration dirt moisture and excessive cycling are not present Woodward 3 Solenoid Troubleshooting Guide Manual 36541 Externally Switched Solenoid Terminations Externally switched solenoids are available with the standard leads termination They are also available with
28. nd arrange for issue of a purchase order for the item s to be repaired No work can be started until a purchase order is received NOTE We highly recommend that you make arrangement in advance for return shipments Contact a Woodward customer service representative at 1 800 523 2831 in North America or 1 970 482 5811 for instructions and for a Return Authorization Number Replacement Parts When ordering replacement parts for controls include the following information e the part number s XXXX XXXX that is on the enclosure nameplate e the unit serial number which is also on the nameplate How to Contact Woodward In North America use the following address when shipping or corresponding Woodward Governor Company PO Box 1519 1000 East Drake Rd Fort Collins CO 80522 1519 USA Telephone 1 970 482 5811 24 hours a day Toll free Phone in North America 1 800 523 2831 Fax 1 970 498 3058 For assistance outside North America call one of the following international Woodward facilities to obtain the address and phone number of the facility nearest your location where you will be able to get information and service Facility Phone Number Brazil 55 19 3708 4800 India 91 129 230 7111 Japan 81 476 93 4661 The Netherlands 31 23 5661111 You can also contact the Woodward Customer Service Department or consult our worldwide directory on Woodward s website www woodward com for the name of
29. ng please contact us via telephone email us or use our website and reference Customer Services and then Product Training Field Service engineering on site support is available depending on the product and location from one of our many worldwide locations or from one of our authorized distributors The field engineers are experienced both on Woodward products as well as on much of the non Woodward equipment with which our products interface For field service engineering assistance please contact us via telephone email us or use our website and reference Customer Services and then Technical Support 26 Woodward Manual 36541 Solenoid Troubleshooting Guide Technical Assistance If you need to telephone for technical assistance you will need to provide the following information Please write it down here before phoning General Your Name Site Location Phone Number Fax Number Prime Mover Information Engine Turbine Model Number Manufacturer Number of Cylinders if applicable Type of Fuel gas gaseous steam etc Rating Application Control Governor Information Please list all Woodward governors actuators and electronic controls in your system Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Seria
30. ng repairs without the proper training tools and equipment can result in personal injury and or property damage e Some of the procedures described in this guide require the use of specialized tools or equipment Make sure the proper tools or equipment are available before attempting repairs e Be aware of the work environment rotating equipment and hazardous exhaust fumes etc Be sure protective shields are in place and the work area is properly ventilated e Wear eye and ear protection when needed Wear protective shoes as required by job conditions e Be aware of high voltages and take adequate precautions to avoid getting shocked e When you need to replace parts use only the recommended replacement parts Do not use parts of inferior quality e Observe all cautionary notices to reduce or avoid the risk of personal injury or equipment damage e Work carefully around machinery that is in operation Solenoid Troubleshooting Process Solenoid troubleshooting can be approached in a couple of ways 1 You can decide to remove the solenoid from the installation and bench test it first After making sure the solenoid is working you can re install the solenoid and test it on the application OR 2 You can test the solenoid while still installed on the application and remove it for bench testing only after eliminating other possible sources of trouble 8 Woodward Manual 36541 Solenoid Troubleshooting Guide Which approach s
31. noid This type of solenoid uses two separate coil windings to allow the solenoid to be held energized for longer periods The first wound coil pull coil operates at a high current level to provide maximum pull or push The second wound coil hold coil simply holds the plunger in after it has completed its stroke and bottomed out Since the current required to hold the plunger is low typically 1 2 amps the hold coil can be energized continuously without overheating This unique design results in a highly efficient and compact solenoid approximately one half the size of a comparable single coil unit RUGGED CONSTRUCTION HEAVY PLASTIC HARD CHROME HOUSING CRIMPED OVER PROTECTIVE HOUSING PLATED PLUNGER TOP AND BOTTOM U BRASS SLEEVE TWO TERMINALS PLUS PLUNGER GUIDE AN AUXILIARY TERMINAL DOUBLE BREAK HEAVY DUTY SWITCH FLEXIBLE DUST BOOT RETURN SPRING OPTIONAL STEEL HOUSING PRACTICALLY INDESTRUCTIBLE PULL COIL PERMANENTLY SEALED STRONG STEEL AGAINST DIRT AND MOISTURE HOLD COIL MOUNTING BRACKET Figure 2 Components of a Dual Coil Solenoid 2 Woodward Manual 36541 Solenoid Troubleshooting Guide Three Methods for Turning Off the Pull Coil After energizing and pulling in the plunger the pull coil in a dual coil solenoid must be turned off as soon as possible to prevent overheating The three basic methods for switching off the pull coil are discussed below EXTERNAL SWITCHING The externa
32. nt list price of a new unit Return Shipment Authorization Label To ensure prompt receipt of the core and avoid additional charges the package must be properly marked A return authorization label is included with every Replacement Exchange unit that leaves Woodward The core should be repackaged and the return authorization label affixed to the outside of the package Without the authorization label receipt of the returned core could be delayed and cause additional charges to be applied Woodward 23 Solenoid Troubleshooting Guide Manual 36541 Flat Rate Repair Flat Rate Repair is available for the majority of standard products in the field This program offers you repair service for your products with the advantage of knowing in advance what the cost will be All repair work carries the standard Woodward service warranty Woodward Product and Service Warranty 5 01 1205 on replaced parts and labor Flat Rate Remanufacture Flat Rate Remanufacture is very similar to the Flat Rate Repair option with the exception that the unit will be returned to you in like new condition and carry with it the full standard Woodward product warranty Woodward Product and Service Warranty 5 01 1205 This option is applicable to mechanical products only Returning Equipment for Repair If a control or any part of an electronic control is to be returned to Woodward for repair please contact Woodward in advance to obtain a Return Authorization
33. oltage voltage Switch is in the Start position between the Pull and If there is a voltage reading Common disconnect the solenoid to wires when prevent burn out Inspect NOT application wiring to locate the cranking protien NOTE Gi Remember to limit cranking to three 30 second attempts with a cool down period of two minutes 120 seconds between each cranking attempt After three cranking attempts the solenoid must be allowed to cool down to ambient temperature 512 minutes total elapsed time before any further attempts are made Woodward 19 Solenoid Troubleshooting Guide Manual 36541 Solenoid Linkage Adjustment The solenoid linkage connects the solenoid plunger shaft to the engine control lever The linkage must have minimal friction binding and backlash in order to assure accurate responsive performance of the application The setting of the linkage is critical to both the solenoid operation and to the performance of the application The linkage consists of rotating joints fastening hardware and where required a control lever Figure 9 displays various parts of a typical linkage Linkage Adjustment A misaligned linkage may not allow the plunger to bottom out Failure to bottom out will cause an internally switched solenoid to burn out and an externally switch solenoid to drop out LEVER POSITION SOLENOID SOLENOID ENERGIZED DE ENERGI ZED CONNECT ING 1 STROKE ADJUST SCH NUT
34. read and observe the precautions in Woodward manual 82715 Guide for Handling and Protection of Electronic Controls Printed Circuit Boards and Modules Woodward Manual 36541 Solenoid Troubleshooting Guide Chapter 1 General Information Solenoid Operation Single Coil Solenoid A solenoid is a device that converts electrical energy into mechanical force The basic single coil solenoid is made of a free moving steel plunger that sits within a wound coil of copper wire When electric current is introduced a magnetic field forms which draws the plunger in The exposed end of the plunger can be attached to equipment and when the solenoid is activated the plunger will move to open close turn on or turn off that equipment Solenoids are configured in many ways for different applications and operating characteristics In most automotive applications solenoids are used for operating engine run stop levers throttle control levers chokes valves and clutches and to protect expensive diesel equipment from overspeed low lube pressure and high temperature Figure 1 shows the various parts of a basic single coil solenoid copper Coll xposed End Spring ese f Plunger Source Droe Plunger movement Figure 1 Basic Single Coil Solenoid Woodward 1 Solenoid Troubleshooting Guide Manual 36541 Dual Coil Solenoid The dual coil solenoid offers high actuation force in a small package compared to a single coil sole
35. t for push type solenoids the linkage adjustment is too long Adjust linkage until the plunger holds in Manually move linkage from shutdown to maximum fuel ensuring solenoid spring will return linkage to shut down position and full travel of linkage is smooth uninhibited and does not exceed specified stroke When a connecting rod is used the stroke is adjusted by turning the rod on its threads and locking the rod in place with a lockwasher and nut The solenoid should be energized during this adjustment Use this procedure with ES solenoids only if the linkage length is incorrect When bead chain or cable is used the solenoid should be energized and the bead chain or cable length adjusted to give the desired lever position Plunger travel must be checked especially when a bead chain or cable is used in a connecting device The plunger travel must be limited to the solenoid s rated stroke when it is de energized An L bracket can be used to limit the plunger travel Woodward 21 Solenoid Troubleshooting Guide Manual 36541 Overload Protection Internally Switched Solenoids Woodward recommends using an overload device to protect solenoids from permanent overload damage Since customers can choose from a number of devices available on the market for example circuit breakers specific troubleshooting procedures cannot be outlined here Externally Switched Solenoids Woodward recommends using a
36. timer device such as a Coil Commander to protect solenoids from permanent damage Coil Commanders limit pull coil on time to prevent solenoid burnout due to engine overcranking and misaligned linkages NOTE Gi When using a Coil Commander module there will be a voltage loss to the solenoid Application must supply additional voltage above the minimum hot solenoid pull in voltage Please consult the factory with questions regarding Coil Commanders Solenoid Bench Testing Use the procedure outlined below to bench test the solenoid 1 Carefully remove the solenoid from the application Clean any debris from the solenoid Remove and inspect the boot to see if foreign matter may have entered inside Remove the plunger and inspect Clear the cavity of any debris or foreign material Assemble solenoid back together and make sure plunger moves freely Ensure the return spring is not preventing the plunger from bottoming out by becoming compressed to solid Correct situation if needed 2 Check solenoid coil resistance to determine if the coil is good refer to Solenoid Coil Resistance Check section If the resistance readings are incorrect the coil is probably defective Replace solenoid and determine why the coil may have burnt out The probable cause is usually misadjustment or low voltage On internally switched units the most common reasons for a burnt coil is misadjustment that prevents the plunger from bottomin
37. urse of action you wish to pursue based on the available services listed in this section Replacement Exchange Replacement Exchange is a premium program designed for the user who is in need of immediate service It allows you to request and receive a like new replacement unit in minimum time usually within 24 hours of the request providing a suitable unit is available at the time of the request thereby minimizing costly downtime This is also a flat rate structured program and includes the full standard Woodward product warranty Woodward Product and Service Warranty 5 01 1205 This option allows you to call in the event of an unexpected outage or in advance of a scheduled outage to request a replacement control unit If the unit is available at the time of the call it can usually be shipped out within 24 hours You replace your field control unit with the like new replacement and return the field unit to the Woodward facility as explained below see Returning Equipment for Repair later in this chapter Charges for the Replacement Exchange service are based on a flat rate plus shipping expenses You are invoiced the flat rate replacement exchange charge plus a core charge at the time the replacement unit is shipped If the core field unit is returned to Woodward within 60 days Woodward will issue a credit for the core charge The core charge is the average difference between the flat rate replacement exchange charge and the curre
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