Installation and Operation Manual

Load Sharing Module

Analog Output
CE Compliant

Manual 02029 (Revision B)

 WARNING—DANGER OF DEATH OR PERSONAL INJURY
WARNING—FOLLOW INSTRUCTIONS
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.
WARNING—OUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify
that you have the latest revision, be sure to check the Woodward website:
www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The
latest version of most publications is available at:
www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get
the latest copy.
WARNING—OVERSPEED PROTECTION
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.
WARNING—PROPER USE
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or property
damage, including damage to the equipment. Any such unauthorized modifications: (i)
constitute "misuse" and/or "negligence" within the meaning of the product warranty
thereby excluding warranty coverage for any resulting damage, and (ii) invalidate product
certifications or listings.

CAUTION—POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY

CAUTION—BATTERY CHARGING
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.
CAUTION—ELECTROSTATIC DISCHARGE
Electronic controls contain static-sensitive parts. Observe the following precautions to
prevent damage to these parts.
• Discharge body static before handling the control (with power to the control turned off,
contact a grounded surface and maintain 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.

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 or property.
• A NOTE provides other helpful information that does not fall under the warning or caution
categories.

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 1996
All Rights Reserved
Manual 02029 Load Sharing Module (Analog Output)

Contents

ELECTROSTATIC DISCHARGE AWARENESS .................................................. II

CHAPTER 1. GENERAL INFORMATION ........................................................... 1
Description..............................................................................................................1
Additional Information.............................................................................................1
Declaration of Incorporation ...................................................................................1
CHAPTER 2. INSTALLATION.......................................................................... 5
Mounting .................................................................................................................5
Electrical Wiring......................................................................................................5
Installation Check ...................................................................................................7
CHAPTER 3. CALIBRATION........................................................................... 8
Introduction.............................................................................................................8
Phasing Check .......................................................................................................9
Phase Correction Procedure ................................................................................10
Load Gain Adjustment ..........................................................................................13
Droop Adjustment.................................................................................................14
CHAPTER 4. THEORY OF OPERATION ......................................................... 16
Introduction...........................................................................................................16
Power Supply .......................................................................................................16
Power Sensor .......................................................................................................16
Controller Circuit...................................................................................................16
Isochronous Load Sharing ...................................................................................18
Droop Operation ...................................................................................................18
CHAPTER 5. TROUBLESHOOTING ............................................................... 19
Introduction...........................................................................................................19
CHAPTER 6. SERVICE OPTIONS ................................................................. 21
Product Service Options.......................................................................................21
Returning Equipment for Repair...........................................................................22
Replacement Parts ...............................................................................................23
How to Contact Woodward...................................................................................23
Engineering Services ...........................................................................................24
Technical Assistance............................................................................................25

Illustrations and Tables

Figure 1-1. Typical System Using Load Sharing Module.......................................2

Figure 1-2. Outline Drawing of Load Sharing Module............................................3
Figure 1-3. Plant Wiring Diagram ...........................................................................4
Figure 2-1. Open Delta Connection .......................................................................6
Figure 3-1. Temporary CT Connection ................................................................11
Figure 3-2. Droop Adjustment ..............................................................................15
Figure 4-1. Block Diagram....................................................................................17

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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.

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.).

2. 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.

3. 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.

4. 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.

CAUTION—ELECTROSTATIC DISCHARGE
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.

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Manual 02029 Load Sharing Module (Analog Output)

Chapter 1.
General Information

Description
The 9907-026 Load Sharing Module provides isochronous and droop load-
sharing capability for Woodward 701, EPG, and 2301A electronic speed controls,
and electrically powered governors in generator set applications. Additional
equipment in the control system with the Load Sharing Module can include the
Woodward SPM-A Synchronizer, Paralleling Phase Switch, Process and
Import/Export Control, and Precise Frequency Control. Figure 1-1 shows a
typical system using a Load Sharing Module.

Additional Information
The literature listed here contains information on the 9907-026 Load Sharing
Module and associated equipment and can be ordered from any Woodward
location listed on the back page.

Manual
82493 1712/1724 Electrically Powered Governor
82384 SPM-A Synchronizer
82461 Paralleling Phase Switch
82010 Process and Import/Export Control

Declaration of Incorporation
In accordance with the EMC Directive 89/336/EEC and its amendments, this
controlling device, manufactured by the Woodward Governor Company, is
applied solely as a component to be incorporated into an engine prime move
system. Woodward declares that this controlling device complies with the
requirements of EN50081-2 and EN50082-2 when put into service per the
installation and operating instructions outlined in the product manual.

NOTICE: This controlling device is intended to be put into service only upon
incorporation into an engine prime mover system that itself has met the
requirements of the above Directive and bears the CE mark.

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Load Sharing Module (Analog Output) Manual 02029

Figure 1-1. Typical System Using Load Sharing Module

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Manual 02029 Load Sharing Module (Analog Output)

Figure 1-2. Outline Drawing of Load Sharing Module

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Load Sharing Module (Analog Output) Manual 02029

Figure 1-3. Plant Wiring Diagram

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Manual 02029 Load Sharing Module (Analog Output)

Chapter 2.
Installation

Mounting
Figure 1-2 is an outline drawing of the Load Sharing Module. Mount the unit near
the electronic speed control. It may be mounted in any position. Provide
adequate ventilation for cooling and space for installation and servicing. Ambient
temperature must be between –40 and +75 °C (–40 and +167 °F).

Electrical Wiring
Figure 1-3 is the plant wiring diagram for the Load Sharing Module. This drawing
shows the connections that must be made to this unit, but does not show the
actual wiring for a particular system. For this information, see the plant wiring
diagram for your specific system. Woodward manual 25070, Electronic Control
Installation Guide, also contains general information on wiring for electronic
controls.

Some of the wiring to the Load Sharing Module must be shielded, twisted-pair.
These wires are shown in Figure 1-3. The shielding prevents the wires from
picking up stray signals which could cause erratic control operation. Ground the
shield to the system common as shown in the plant wiring diagram (pin 12 on
this control). The shield on a length of shielded wire must be connected to
common at one end only; do not ground the shields on both ends of a wire. Do
not run a shielded wire inside a conduit with a wire which is carrying high current.
Do not attempt to tin the braided shields.

Make all wiring connections with insulated terminals.

Power Supply
There are no separate power connections to the Load Sharing Module; the unit
takes its power from the potential transformer connections.

Output
Connect the wiring between the output of the Load Sharing Module and the
auxiliary input of the speed control. Use twisted-pair, shielded wire.

Current Transformers (CTs)

Connect the wiring from the current transformers as shown in the plant wiring
diagram. This shows normal current sensing connection using three CTs. Figure
2-1 shows an open delta connection, an alternate method of current sensing
using only two CTs.

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Load Sharing Module (Analog Output) Manual 02029

Figure 2-1. Open Delta Connection

Potential Transformer (PT)

Connect the wiring from the potential transformer (or transformers) as shown in
the plant wiring diagram.

Droop Contacts
Because the load-sharing-line relay is contained in the control, no relay is
required between the control and the load-sharing-line bus. Use shielded cable
and connect the load-sharing lines directly to terminals 10 (+) and 11 (–).
Connect the shield to terminal 12.

The droop contact for selecting droop or isochronous operation is wired in series
with the circuit-breaker auxiliary contact to terminal 13. When both the droop
contact and circuit-breaker auxiliary contact are closed, the control is in the
isochronous load-sharing mode. In this mode the internal load-sharing-line relay
is energized, the droop signal is disabled (permitting isochronous load sharing),
and the load-matching circuit is connected to the load-sharing lines.

The control is in the droop mode when EITHER the droop contact or the circuit-
breaker auxiliary contact is open. If the droop contact is open, the control
remains in the droop mode even when the circuit-breaker auxiliary contact is
closed.

SPM Synchronizer
Connect the wiring to the SPM Synchronizer (if used). Use shielded, twisted-pair
wire.

Load Sharing Lines

Connect the wiring for the load sharing lines. Use shielded, twisted-pair wire.
Load Sharing lines are not required if the Load Sharing Module is to be used in
the droop mode only.

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Manual 02029 Load Sharing Module (Analog Output)

Installation Check
Before initial operation of the Load Sharing Module, make the following visual
checks.

1. Check that the control is securely mounted.

2. Check that all electrical connections are correctly made and that all terminal
screws are tight.

3. Check that shielded wire is installed on the wires indicated in the plant
wiring diagram, and that all shields are grounded on one end only.

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Load Sharing Module (Analog Output) Manual 02029

Chapter 3.
Calibration

Introduction
Use this calibration procedure after a Load Sharing Module is installed on a
generator set, to obtain the needed operating characteristics during load sharing.

1. Check that the correct jumpers are installed on terminals 15, 16, 17, and 18
to match your potential transformer secondary voltage. See the plant wiring
diagram (Figure 1-3).

2. Remove wires from terminals 10 and 11, and from terminals 24 and 25.

3. Select isochronous operation by shorting terminals 13 and 14.

WARNING—START-UP
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 property damage.

4. Start the engine and apply full load to the generator set.

NOTE
The most accurate calibration is made at full load. However, if it is not
possible to run the generator set at full load, run it at less than full load, and
reduce the voltage readings given in this calibration procedure
proportionally. For example, run a 2 kW gen-set at 1 kW and divide all
voltages given in this calibration procedure by 2. If you reduce the load in
this manner, however, be sure to reduce it by the same amount throughout
this calibration procedure.

5. Set the LOAD GAIN potentiometer fully clockwise.

6. Check the load signal voltage between terminals 22 and 23. Adjust the
LOAD GAIN potentiometer for a 6.0 Vdc load signal. If this voltage is not
obtainable, proceed to step 11.

7. Set the LOAD GAIN potentiometer fully counterclockwise.

8. Check the voltage between terminals 22 and 23. If the proper current
transformer is being used, and if the power factor is unity, this voltage
should be 3.4 ±0.25 Vdc. If this voltage is not correct, proceed to step 11.

9. Remove the load from the generator set.

10. Check the voltage between terminals 22 and 23. This voltage should be 0.0
±0.25 Vdc. If this voltage is not correct, the Load Sharing Module unit is
faulty; return it to Woodward for repair.

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Manual 02029 Load Sharing Module (Analog Output)

Phasing Check
For this check, the generator set must be running isochronously, not paralleled,
and with a power factor of unity (1.0 ±0.1).

11. Check that the potential connections are made as follows and correct them
if they are not.
Phase A to Terminal 1
Phase B to Terminal 2
Phase C to Terminal 3

12. Start the engine and apply full load to the generator set.

13. Using a dc voltmeter, measure the load signal at terminals 22 and 23.
Adjust the load gain potentiometer to give a 6 Vdc load signal. If 6 Vdc is not
obtainable, set the load signal as close as possible to 6 Vdc. Record this
voltage.

14. Shut down the generator set.

WARNING—HIGH VOLTAGE
Do not disconnect a current transformer from its burden resistor while the
engine is running. The current transformers can develop dangerously high
voltages if open circuited while the engine is running and may explode.

15. Disconnect the wire from terminal 5 that comes from the Phase A CT and
connect both wires from this CT to Terminal 4.

16. Start the generator set and apply full load.

17. Measure the load signal at terminals 22 and 23. If the phase B and C
current transformers are connected correctly, this voltage will be 1/3 lower
than the voltage recorded in step 13. For example; if the reading was 6 volts
in step 13, the reading in this step should be 4 volts.

18. Shut down the generator set.

19. Reconnect the Phase A CT wire to terminal 5.

20. If the reading in step 17 was correct, proceed to step 21. If the reading in
step 17 was not correct, proceed to the Phase Correction Procedure below.

21. Disconnect the wire from terminal 7 that comes from the Phase B CT and
connect both wires from this CT to Terminal 6.

22. Start the generator set and apply full load.

23. Measure the load signal at terminals 22 and 23. If the phase A and C
current transformers are connected correctly, this voltage will be 1/3 lower
than the voltage recorded in step 13. For example; if the reading was 6 volts
in step 13, the reading in this step should be 4 volts.

24. Shut down the generator set.

25. Reconnect the Phase B CT wire to terminal 7.

26. If the reading in step 23 was correct, proceed to step 27. If the reading in
step 23 was not correct, proceed to the Phase Correction Procedure below.

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Load Sharing Module (Analog Output) Manual 02029
27. Disconnect the wire from terminal 9 that comes from the Phase C CT and
connect both wires from this CT to Terminal 8.

28. Start the generator set and apply full load.

29. Measure the load signal at terminals 22 and 23. If the phase A and B
current transformers are connected correctly, this voltage will be 1/3 lower
than the voltage recorded in step 13. For example; if the reading was 6 volts
in step 13, the reading in this step should be 4 volts.

30. Shut down the generator set.

31. Reconnect the Phase C CT wire to terminal 9.

32. If the reading in step 29 was correct, the phasing is correct and there is no
need to perform the Phase Correction Procedure. If the reading in step 29
was not correct, proceed to the Phase Correction Procedure.

Phase Correction Procedure

If this procedure is followed, the correct connection of the current transformers is
assured; the correct CT will be connected to the correct input on the Load
Sharing Module with the correct polarity. Use this procedure only if the Phasing
Check above indicates that the phasing is incorrect.

A CT for any phase (A, B, or C), will produce the most positive load signal
voltage when it is connected, in the proper polarity, to the terminals on the Load
Sharing Module which correspond to the same phase. Any other connections of
this CT will produce a less positive load signal voltage. This procedure makes
trial connections of the first CT to all three CT inputs on the Load Sharing
Module, polarized both ways on each CT input. The load signal voltage is
recorded for each connection, and the CT is then connected to the CT input
terminals that produced the most positive load signal voltage, and with the
polarity that produced the most positive load signal voltage.

In a like manner, the second CT is tried on each of the two remaining CT input
terminals in each polarity, then connected, in the correct polarity, to the terminals
which produced the most positive load signal voltage.

The single remaining CT is then connected to the remaining CT input and the
load signal checked for each polarity. This CT is then connected to the CT input,
polarized so that it produces the most positive load signal voltage.

When the procedure is completed, all three CTs are connected to the proper CT
inputs on the Load Sharing Module, with the correct polarity, and are now labeled
with their correct designations.

The procedure for correcting phase wiring requires that the generator set be shut
down and the current transformers disconnected many times. For convenience
during the phasing check, the temporary method of connecting the current
transformers shown in Figure 3-1 is recommended. By connecting a burden
resistor (a 0.5 Ω, 20 W resistor), across each current transformer, that current
transformer can be disconnected from the Load Sharing Module after removing
all load. The connections between the terminal strip and the Load Sharing
Module can be changed with the generator set running; however, remove all load
before any changes in connections are made. Do not disconnect a wire from a
current transformer with load on the system. After the phase correction
procedure has been completed, remove the terminal strip and the resistors.
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Manual 02029 Load Sharing Module (Analog Output)
For this procedure, the generator set must be running isochronously, not
paralleled, and with a power factor of unity (1.0 ±0.1).

1. Make sure that the turbine is shut down.

2. Label each CT wire with the phase and polarity that you think it should be.
Even though this identification may prove to be wrong during this procedure,
this step is necessary so that the individual wires may be identified during
the description of the procedure.

3. Disconnect the phase B CT wires from terminals 6 and 7 and connect these
two wires together. Use a small screw and nut and tape the connection.

WARNING—HIGH VOLTAGE
Do not disconnect a current transformer from its burden resistor while the
engine is running. The current transformers can develop dangerously high
voltages if open circuited while the engine is running and may explode.

Figure 3-1. Temporary CT Connection

4. Disconnect the phase C CT wires from terminals 8 and 9 and connect these
two wires together. Use a small screw and nut and tape the connection.

5. Connect the two wires from the phase A CT to the phase A input terminals 4
and 5.

6. Start the engine and apply full load.

7. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.

8. Shut the generator set down and reverse the Phase A wires on terminals 4
and 5.

9. Start the engine and apply full load.

10. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.

11. Shut down the generator set.

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Load Sharing Module (Analog Output) Manual 02029
12. Remove the phase A CT wires from terminal 5 and 6 and connect the phase
A CT wires to the phase B input terminals 6 and 7.

13. Start the engine and apply full load.

14. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.

15. Shut the generator set down and reverse the phase A CT wires on terminals
6 and 7.

16. Start the engine and apply full load.

17. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.

18. Shut down the generator set.

19. Remove the phase A CT wires from terminal 6 and 7 and connect the phase
A CT wires to the phase C input terminals 8 and 9.

20. Start the engine and apply full load.

21. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.

22. Shut the generator set down and reverse the phase A wires on terminals 8
and 9.

23. Start the engine and apply full load.

24. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.

25. Shut down the generator set.

26. Remove the phase A CT wires from terminal 8 and 9 and connect the phase
A wires to the pair of terminals, in the same polarity, that produced the most
positive load signal voltage.

27. Untape and disconnect the Phase B CT wires. Connect the phase B CT
wires to one pair of the two remaining CT input terminals on the Load
Sharing Module.

28. Start the engine and apply full load.

29. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.

30. Shut the generator set down and reverse the phase B wires on the CT input
terminals

31. Start the engine and apply full load.

32. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.

33. Shut down the generator set.

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Manual 02029 Load Sharing Module (Analog Output)
34. Remove the phase B CT wires from the terminals they are connected to and
connect them to the remaining pair of CT input terminals on the Load
Sharing Module.

35. Start the engine and apply full load.

36. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.

37. Shut the generator set down and reverse the phase B CT wires on the CT
input terminals

38. Start the engine and apply full load.

39. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.

40. Shut down the generator set.

41. Remove the phase B CT wires from the CT input terminals and connect
these phase B CT wires to the pair of CT input terminals, in the same
polarity, that produced the most positive load signal voltage.

42. Untape and disconnect the wires from phase C CT. Connect these two
wires to the remaining pair of CT input terminals.

43. Start the engine and apply full load.

44. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.

45. Shut the generator set down and reverse the phase C CT wires on the CT
input terminals.

46. Start the engine and apply full load.

47. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.

48. Shut down the generator set.

49. Connect the phase C CT wires to the same pair of CT input terminals that
they are connected to, but in the polarity that produced the most positive
load signal voltage.

50. Label each wire with the designation of the terminal that it is now connected
to.

Load Gain Adjustment

For this procedure, the generator set must be running isochronously, not
paralleled, and with a power factor of unity (1.0 ±0.1).

1. Start the generator set and run at full load.

2. Measure the load signal voltage and adjust the LOAD GAIN potentiometer
for 6.0 ±0.1 Vdc.

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If the load signal voltage cannot be raised to 6 volts, and the phasing has
been checked and is correct, it will be necessary to use a lower load signal
voltage. Set the load signal voltages of all generator sets in the system to
the same voltage.

When paralleled, adjustment of a generator set's LOAD GAIN potentiometer

clockwise will cause that generator set to carry less load. If stability
problems occur when paralleled at a particular load signal voltage, reduce
the load signal voltage by adjusting the LOAD GAIN potentiometer and set
the load signal voltage of all other generator sets in the system to the same
voltage. When the load signal voltages of all generator sets in a system are
reduced, the load sharing gain will be reduced and this may result in some
loss of load sharing sensitivity.

It may be necessary to reduce the load signal voltage of each unit in the
system to as low as three volts in cases of extremely poor system
dynamics. If your system requires a load signal voltage as low as three
volts, consult the Woodward Governor Company for suggestions for
possible remedies.

NOTE
The most accurate calibration is made at full load. However, if it is not
possible to run the generator set at full load, run it at less than full load, and
reduce the voltage readings given in this calibration procedure
proportionally. For example, run a 2 kW gen-set at 1 kW and divide all
voltages given in this calibration procedure by 2. If you reduce the load,
however, be sure to reduce it the same amount throughout this calibration
procedure.

Droop Adjustment
Droop is usually expressed as a percentage. The droop in a Load Sharing
Module is calculated by the following formula.

No Load Speed – Full Load

% Droop =
No Load Speed

When the generator set is to be operated in the droop mode, the DROOP
potentiometer must be adjusted. The method of setting droop depends on
whether the load of the generator set is an isolated load or an infinite bus.

Setting Droop for an Isolated Load

1. Open the OPEN FOR DROOP SWITCH (or disconnect the wires from
terminals 15 and 16).

2. Start the engine and adjust the RATED SPEED potentiometer on the EPG
for rated speed with no load.

3. Apply full load.

4. Adjust the DROOP potentiometer to give the desired speed.

For example: operating at 60 Hz, 57 Hz at full load indicates 5% droop.

If only 50% loading is possible, 58.5 Hz would indicate 5% droop. See
Figure 3-2. Droop Adjustment.

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Manual 02029 Load Sharing Module (Analog Output)

Setting Droop for an Infinite Bus Load

1. With the generator not paralleled, adjust the RATED SPEED potentiometer
on the EPG to give a speed setting above 60 Hz by the percent droop
required.

For example: Droop of 5% would require raising the speed to 63 Hz.

2. Mark the potentiometer position and re-adjust the RATED SPEED

potentiometer for 60 Hz.

3. Turn the DROOP potentiometer fully clockwise (for maximum droop).

4. Open the OPEN FOR DROOP switch (or remove the wires from terminals
13 and 14).

5. Synchronize the generator with the bus and parallel it with the bus.

6. Return the RATED SPEED potentiometer to the mark made in step 2.

7. Adjust the DROOP potentiometer counter-clockwise, decreasing droop, until

100% load is achieved.

This completes the calibration of the Load Sharing Module.

If it is necessary to set the droop without pulling 100% load, set the RATED
SPEED potentiometer (in step 1) accordingly for desired percent droop.

For example: at 5% droop, running at only 50% load, the RATED SPEED
potentiometer would be set at 61.5 Hz. in step 1.

Figure 3-2. Droop Adjustment

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Chapter 4.
Theory of Operation

Introduction
This chapter describes the operation of the Load Sharing Module and its internal
circuits. Figure 4-1 is a block diagram of the Load Sharing Module.

The Load Sharing Module senses the power output of a generator and, through
paralleling lines which connect all the generator sets in the system, permits
isochronous load-sharing between these generator sets. The Load Sharing
Module also provides droop operation instead of isochronous load sharing,
making it possible to connect this generator set in the droop mode, in parallel
with either a generator set which is running isochronously, or with a bus.

Power Supply
The power supply generates a regulated dc voltage for the operation of the
circuits in the Load Sharing Module. The power supply gets its power from two of
the three phase-potential connections which are made to the output of the
generator set being controlled. Jumper wires on terminals 15 through 18 provide
for selection of input voltages of either 95 to 130 Vac or 190 to 260 Vac. The
plant wiring diagram (Figure 1-3) shows these connections and jumpers. Do not
connect inputs to Terminals 15 through 18.

Power Sensor
Generator kilowatt load is measured by the power sensor circuit of the Load
Sharing Module. The power sensor circuit senses both current amplitude and
phase between voltage and current of the generator output. The potential input
comes from the potential transformer(s) (PTs), and the current input comes from
the current transformers (CTs). The circuit uses these two inputs to generate a
load signal which is then filtered and sent to the controller circuit. The load signal
voltage of each generator set will be proportional to the load on that generator
set.

Controller Circuit
In the controller circuit, the load signal voltage is adjusted to match the other
generator sets in the system. At full load, the load signal voltages of all generator
sets in the system must be equal. The controller circuit of each Load Sharing
Module includes a potentiometer to adjust each generator set's load signal so
that the load signal voltage of each is the same at full load.

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Manual 02029 Load Sharing Module (Analog Output)

Figure 4-1. Block Diagram

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Load Sharing Module (Analog Output) Manual 02029

Isochronous Load Sharing

The controller circuit compares the voltage on the paralleling lines to the load
signal voltage for this generator set and generates an error voltage. This error
voltage goes through the summing point and the output terminals of the Load
Sharing Module to the speed control. The Load Sharing Module output biases
the speed loop of the speed control so that the fuel is increased or decreased in
order to keep the load signal voltage of this generator set equal to the voltage on
the paralleling lines, while not changing the common frequency of the generator
sets.

Droop Operation
In droop operation, a portion of the output voltage of the Load Sharing Module is
fed back to the controller circuit. This voltage is proportional to the load sensed
and is used by the controller circuit to reduce the output voltage of the controller
circuit by a percentage determined by the DROOP potentiometer. Load Sharing
Module output is reduced, and actuator shaft position is changed, according to
the desired droop percentage.

When a generator set using the Load Sharing Module is paralleled in droop with
other generator sets, the common load signal on the paralleling lines is not used.
The frequency of the generator set could, therefore, vary with load, so it must be
determined by a different means.

In an isolated system with two or more generator sets paralleled, if isochronous

speed control is required, one of the generator sets must be running in the
isochronous mode. This generator set determines the frequency of the system. If
this generator set is in droop and is paralleled with an infinite bus, either by itself
or with other generator sets, the bus determines the frequency. The DROOP
potentiometer and the SPEED potentiometer on the speed control determine the
amount of the load that is carried by the generator (when running in droop).

If an SPM-A Synchronizer is used with the system, it biases the output of the
Load Sharing Module at the summing point, in order to synchronize the
generator set with the bus.

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Manual 02029 Load Sharing Module (Analog Output)

Chapter 5.
Troubleshooting

Introduction
If the Load Sharing Module is determined not to be operating correctly, use the
following troubleshooting chart to find the problem. The causes for each
symptom are given with the most likely cause first.

NOTE
This troubleshooting section is intended only as a guide. There may be other
causes for a symptom than those given, and there may be repairs not given
which may be more suited to the particular situation.

Symptoms Cause Test/Remedy

Undesirable speed 1. Droop mode switch is open Jumper Load Sensor terminals 13
decrease with load or auxiliary contract is open. and 14.
increase. Load Sensor is in droop
mode. Observe engine operation. Replace
wiring or switch as required. (The
Load Sharing Module will be in droop
when the circuit breaker auxiliary
contact is open. See Droop Switch
under Electrical Wiring section of
Installation chapter.)

2. Improper engine operation. If the droop occurs near the full load
Operate the engine and point only, it is possible the engine is
observe speed while applying not producing the power called for by
load. Note the position of the the fuel control, or is being
actuator terminal shaft. overloaded. Either is indicated if the
fuel control is at maximum fuel
position.

3. Faulty engine or speed If speed decreases with load, either

control. Disconnect the load engine operation or the speed
sensor from the speed control may be faulty. You may be
control. Load the engine as a exceeding the load rating of the
single, isolated unit. engine or there may be insufficient
fuel flow.
Erratic Load 1. Open or intermittent wire. Check all wiring for continuity and
Sensor Operation. tight connections. Repair if
necessary.

2. EMI (Electromagnetic Remove ground loops. Shield all

Interference). wiring, grounding shield at one end
only. Route wiring and controls away
from high current wires and noise
sources. (Equipment containing
SCRs is especially noisy.) Keep wire
lengths to a minimum. Route wiring
through conduit when possible. Use
single point grounds. Take control
power right off battery. (Do not use
distribution points or take off starter.)
Run additional equipment off
separate battery wires.

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Load Sharing Module (Analog Output) Manual 02029

Symptoms Cause Test/Remedy

Load Signal Incorrect phasing of CT and Perform phasing check. If phasing
voltage is low. PT wiring. check indicates need, perform
Adjusting LOAD procedure for correcting phase
GAIN won't raise wiring.
it.
Insufficient CT output. Check for 5 amp CT output at full
load. (CT must be between 3 and 7
amps at full load.) Change to a lower
primary current CT.
Load Signal CT output too high. Check for 5 amp CT output at full
voltage is too high. load. (CT must be between 3 and 7
Adjusting LOAD amps at full load.) Change to a
GAIN won't lower higher primary current CT.
it.
Engine does not 1. Engine not receiving fuel Check for maximum voltage to the
properly share as called for by governor. actuator. If voltage to the actuator is
load with other correct but the actuator output shaft
units. is not at maximum position, an
actuator or speed control problem is
indicated, or the linkage or fuel
system is restricted.

2. Unequal speed settings. Be sure that speed settings of all

units at no load are identical. Adjust
as necessary.

3. Unequal load gain Check that load gain setting of all

voltages. load sharing units is correct. See
Load Gain Adjustment in Chapter 3.
Adjust as necessary.

4. Improper load sensing Perform the transformer Phasing

phasing. Check in Chapter 3. Correct wiring
as necessary.

5. Circulating currents Properly adjust the generator voltage

between generators (noted controls.
by unequal power factors
between generators).
Engine does not Terminals 13 and 14 not Jumper Load Sensor terminals 13
properly share shorted. Load Sensor in and 14. Observe engine operation.
load with other droop. Replace wiring or switch as required.
units.

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Manual 02029 Load Sharing Module (Analog Output)

Chapter 6.
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:
• Replacement/Exchange (24-hour service)
• Flat Rate Repair
• Flat Rate Remanufacture

If you are experiencing problems with installation or unsatisfactory performance

of an installed system, the following options are available:
• Consult the troubleshooting guide in the manual.
• 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 course 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 current 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.

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Load Sharing Module (Analog Output) Manual 02029

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
Number. When shipping the item(s), attach a tag with the following information:
• 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.

CAUTION—ELECTROSTATIC DISCHARGE
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;
• 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.

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Manual 02029 Load Sharing Module (Analog Output)

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, and 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:
• the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
• 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 your nearest Woodward distributor or service facility.

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Load Sharing Module (Analog Output) Manual 02029

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.

• Technical Support
• Product Training
• Field Service

Contact information:
Telephone—+1 (970) 482-5811
Toll-free Phone (in North America)—1 (800) 523-2831
Email—[email protected]
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 training, 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.

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 Manual 02029 Load Sharing Module (Analog Output)

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

Serial 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.

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Load Sharing Module (Analog Output) Manual 02029

26 Woodward
 We appreciate your comments about the content of our publications.
Send comments to: [email protected]
Please include the manual number from the front cover of this publication.

PO Box 1519, Fort Collins CO 80522-1519, USA

1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811 • Fax +1 (970) 498-3058
Email and Website—www.woodward.com

Woodward has company-owned plants, subsidiaries, and branches,

as well as authorized distributors and other authorized service and sales facilities throughout the world.
Complete address / phone / fax / email information for all locations is available on our website.

06/5/F