Product Manual 26011 (Revision C) : Load Sharing Module
Product Manual 26011 (Revision C) : Load Sharing Module
Product Manual 26011 (Revision C) : Load Sharing Module
(Revision C)
Original Instructions
This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, on the publications
Revisions page of the Woodward website:
www.woodward.com/publications
Revisions—Changes in this publication since the last revision are indicated by a black line
alongside the text.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Copyright © Woodward 1999
All Rights Reserved
Manual 26011 Load Sharing Module
Contents
Woodward i
Load Sharing Module Manual 26011
ii Woodward
Manual 26011 Load Sharing Module
Woodward iii
Load Sharing Module Manual 26011
iv Woodward
Manual 26011 Load Sharing Module
Chapter 1.
General Information
Introduction
The Woodward Load Sharing Module is made for use with engines equipped with
speed controls that accept a ±3 Vdc speed setting. The Load Sharing Module
allows use of Woodward power generation accessories and allows load sharing
between engines equipped with speed controls that are not manufactured by
Woodward and engines controlled with Woodward electronic controls, or controls
using other Woodward load sharing modules.
Description
The Load Sharing Module provides isochronous and droop load-sharing
capability for engines in generator set applications. Additional equipment in the
control system can include the Woodward SPM-A Synchronizer, Paralleling
Phase Switch, Import/Export Control, Precision Frequency Control, Automatic
Generator Loading Control, and Automatic Power Transfer and Loading Control.
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2 Woodward
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Chapter 2.
Installation
Introduction
This section contains general installation instructions for the Load Sharing
Module. Environmental precautions and location considerations are included to
determine the best location for the Load Sharing Module. Additional information
includes unpacking instructions, electrical connections, and an installation check-
out procedure.
Unpacking
Before handling the Load Sharing Module, read page ii, Electrostatic Discharge
Awareness. Be careful when unpacking the Load Sharing Module. Check the unit
for signs of damage such as bent or dented panels, scratches, and loose or
broken parts. Notify the shipper of any damage.
Location Considerations
Consider these requirements when selecting the mounting location:
Figure 1-2 is an outline drawing of the Load Sharing Module. Install the unit as
close as practical to the electronic engine control, but not on the engine itself. It
may be installed in any position.
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Load Sharing Module Manual 26011
Wiring for the Load Sharing Module must be suitable for at least 90 °C (194 °F)
and also be suitable for the maximum installed operating temperature.
The Load Sharing Module must be permanently connected and employ fuses or
circuit breakers in each of the PT lines to limit current to the LSM PT inputs to no
more than 5 A.
All terminal block screws must be tightened to 0.56 to 0.79 N·m (5.0 to 7.0 lb-in).
Power Requirements
The Load Sharing Module is powered from the potential transformer connections.
Jumpers are used to set the module for the voltage being produced by the
generator. Jumper terminals 15 to 16 and 17 to 18 when the generator is
producing 95 to 130 Vac. Jumper terminal 16 to 17 when the generator is
producing 190 to 260 Vac. Potential transformer burden is 1.6 W per phase with
230 Vac input and 0.4 W per phase with 115 Vac input.
The unit is shipped with terminals 15–16 and 17–18 jumpered for 95 to 130 volt
generation. To change to 190–260 volt generation, remove both jumpers and
install one of the jumpers across terminals 16–17. The other jumper is then not
used.
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Manual 26011 Load Sharing Module
Shielded Wiring
All shielded cable must be twisted conductors with either a foil or braided shield.
Do not attempt to tin (put solder on) the braided shield. All signal lines should be
shielded to prevent picking up stray signals from adjacent equipment. Connect
the shields to the terminals indicated in the plant wiring diagram. Wire exposed
beyond the shield must be as short as possible.
The other end of the shields must be left open and insulated from any other
conductor. Do not run shielded signal wires with other wires carrying large
currents. See Application Note 50532, EMI Control for Electronic Governing
Systems, for more information.
Where shielded cable is required, cut the cable to the desired length and prepare
the cable as instructed below and shown in Figure 2-1.
1. Strip outer insulation from both ends, exposing the braided or spiral wrapped
shield. Do not cut the shield on the end nearest to the Load Sharing Module.
Cut off the shield on the end away from the unit.
2. Use a sharp, pointed tool to carefully spread the strands of the shield.
3. Pull the inner conductors out of the shield. Twist braided shields to prevent
fraying.
4. Connect lugs to the shield and to the control wires. Number 6 slotted or
round crimp-on terminals are used for most installations. Connect the wires
to the appropriate terminals on the module.
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Generator Connections
Use 1 mm² (18 AWG) or larger wire for all PT and CT connections.
Connect the PT output from the A leg to terminal 1. Connect the PT output from
the B leg to terminal 2. Connect the PT output from the C leg to terminal 3. Size
the potential transformers to produce 100–240 Vac.
Current Transformers
Power source current transformers should be sized to produce 5 A secondary
current with maximum generator current (3–7 A secondary current at full load is
acceptable). CT burden is 0.1 VA. To prevent lethal high voltage from developing
on leads to the terminals, the Load Sharing Module contains internal burden
which must be connected across the power source current transformers
whenever the unit is running. Ammeters may be installed on the leads from the
current transformers.
The Load Sharing Module 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
Load Sharing Module remains in the droop mode even when the circuit breaker
auxiliary contact is closed. If droop is not desired when the auxiliary contact is
open, turn the droop potentiometer fully counterclockwise.
Use a single pole, single-throw switch with a 0.1 A minimum rating for the “open
for droop” switch.
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Manual 26011 Load Sharing Module
Synchronization Connections
If an SPM-A synchronizer is used, connect twisted-pair 0.5 mm² (20 AWG) or
larger shielded wire from the synchronizer to terminals 24(+) and 25(–). Tie the
shield to the closest chassis screw. Do not connect the shield at the synchronizer
end of the wiring.
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Chapter 3.
Setup and 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 load sharing line terminals 10 and 11, and from the
SPM-A Synchronizer (if used) at terminals 24 and 25.
6. Check the load signal voltage between terminals 22 and 23. Adjust the
LOAD GAIN potentiometer for 6.0 Vdc signal. If this voltage is not
obtainable, set the load signal as close as possible to 6 Vdc.
8. 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 is faulty or
there may still be load on the generator.
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Phasing Check
For this check, the generator set must be running isochronously, not paralleled,
and with a power factor greater than 0.8.
9. 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
10. Start the engine and apply full load to the generator set.
11. 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.
13. Disconnect the wire from terminal 5 that comes from the phase “A” CT and
connect both wires from this CT to terminal 4.
15. 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 approximately 4 volts.
18. If the reading in step 15 was correct, proceed to Load Gain Adjustment later
in this chapter. Otherwise, perform the following Phase Correction
Procedure.
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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 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 completion of the procedure
remove the terminal strip and the resistors.
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Manual 26011 Load Sharing Module
For this procedure, the generator set must be running isochronously, not
paralleled, and with a power factor greater than 0.8.
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.
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 phase “A” input terminals 4
and 5.
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.
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9. Start the engine and apply full load.
10. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.
12. Remove the phase “A” CT wires from terminal 4 and 5 and connect the
phase “A” CT wires to the phase “B” input terminals 6 and 7.
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.
17. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.
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.
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.
24. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.
26. Remove the phase “A” CT wires from terminal 8 and 9 and connect the
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.
29. Measure the load signal voltage at 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.
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Manual 26011 Load Sharing Module
31. Start the engine and apply full load.
32. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.
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.
36. Measure the load signal at terminals 22 and 23 and record this voltage.
37. Shut the generator set down and reverse the phase “B” wires on the CT
input terminals.
39. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.
41. Remove the phase “B” CT wires from the CT input terminals and connect
the wires to the pair of terminals, in the same polarity, that produced the
most positive load signal voltage.
42. Untape and disconnect the Phase “C” CT wires. Connect the phase “C” CT
wires to remaining pair of CT input terminals on the Load Sharing Module.
44. Measure the load signal voltage at terminals 22 and 23 and record this
voltage.
45. Shut the generator set down and reverse the phase “C” wires on the CT
input terminals.
47. Measure the load signal voltage between terminals 22 and 23 and record
this voltage.
49. Remove the phase “C” CT wires from the CT input terminals and connect
the wires to the pair of terminals, in the same polarity that produced the
most positive load signal voltage.
50. Label each wire with the designation of the terminal to which it is now
connected. Be sure and remove the original designations to avoid future
confusion.
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2. Measure the load signal voltage and adjust the LOAD GAIN potentiometer
for 6 ± 0.1 Vdc.
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 full load signal voltages of all generator sets in the system to the same
voltage.
Droop Adjustment
Droop is usually expressed as a percentage. Droop percentage is calculated by
dividing the difference between the no load speed and the full load speed by the
rated speed.
The DROOP potentiometer only needs to be adjusted when the generator set is
to be operated in droop mode. The method of setting droop depends on whether
the load on the generator set is an isolated load or an infinite bus. Once adjusted,
the droop potentiometer will not have to be readjusted unless a different droop
percentage is desired.
2. Start the engine and adjust the speed for rated with no load.
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Manual 26011 Load Sharing Module
4. Synchronize the generator with the bus and parallel it with the bus.
If it is necessary to set the droop without pulling 100 percent load, set the engine
speed accordingly for the desired percent of droop at the load to be pulled. For
example: Five percent droop at 50 percent load will require a no load rated speed
of 61.5 Hz, not 63 Hz, on a 60 Hz system.
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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 1-4 is a block diagram of the circuits in the module.
The Load Sharing Module senses the power output of a generator and provides
a ±3 Vdc signal to the speed control to adjust the power output of the engine-
generator set to match the reference power level. The Load Sharing Module can
also produce a droop condition (instead of isochronous load-sharing), making it
possible to connect the generator set in parallel with either a generator set which
is running isochronously, or with an infinite 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 load is measured by the power-sensor circuit of the Load Sharing
Module. The power-sensor circuit senses current amplitude, and produces a load
signal proportional to the current amplitude times the power factor. The potential
input comes from potential transformers (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 percentage of rated load
on the generator set.
Ammeters and voltmeters may be driven with the same PT and CT wires.
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Manual 26011 Load Sharing Module
Droop Operation
In droop operation, a portion of the load signal voltage is fed to the controller
circuit. This voltage is used by the comparator circuit to reduce the control output
by a percentage determined by the DROOP potentiometer. The output is
reduced, and the speed control reduces engine power output 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 will 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 (constant speed) mode. This
generator set maintains the frequency of the system. If a generator set is in
droop and is paralleled with an infinite bus, the bus determines and maintains the
frequency. The DROOP percentage and the speed setting on the engine speed
control determine the amount of the load that is carried by the generator, when
running in droop.
Auxiliary Equipment
The Woodward SPM-A synchronizer functions by biasing the output of the Load
Sharing Module. All other Woodward auxiliary generating control equipment
functions by biasing the voltage on the load-sharing lines.
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Chapter 5.
Troubleshooting
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Manual 26011 Load Sharing Module
SYMPTOMS CAUSE TEST/REMEDY
Load Signal voltage is CT output too high. Check for 5 amp CT output at
too high. Adjusting full load. (CT output must be
LOAD GAIN will not between 3 and 7 amps at full
lower it. load.) Change to a higher
primary current CT if necessary.
Engine does not Engine not responding Check for maximum voltage
properly share load to signal from Load from terminals 22 to 23. If
with other units. Sharing Module. possible check the voltage from
terminal 20 to 19. If the Load
Sharing Module is putting out a
maximum signal, the problem is
either in the wiring to the engine
control, the engine control, or the
engine.
Unequal speed Be sure the speed settings of all
settings. off-line units at no load are
identical. Adjust as necessary.
Resynchronize.
Unequal load gain Check that load gain settings of
voltages. all load sharing units are correct.
See load gain adjustment in
Chapter 3. Adjust as necessary.
Improper load sensing Perform the transformer phasing
phasing. check in Chapter 3. Correct as
necessary.
Engine does not Circulating currents Properly adjust the generator
properly share load between generators. voltage regulators.
with other units. (Noted by unequal
power factors between
generators.)
Engine does not Terminals 13 and 14 Jumper Load Sharing Module
properly share load not shorted. Load terminals 13 and 14. Observe
with other units. sharing module is in engine operation. Replace wiring
droop. or switch as required.
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Chapter 6.
Service Options
OEM and Packager Support: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.
You can locate your nearest Woodward distributor, AISF, RER, or RTR on our
website at:
www.woodward.com/directory
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Manual 26011 Load Sharing Module
This option allows you to call your Full-Service Distributor in the event of an
unexpected outage, or in advance of a scheduled outage, to request a
replacement control unit. If the unit is available at the time of the call, it can
usually be shipped out within 24 hours. You replace your field control unit with
the like-new replacement and return the field unit to the Full-Service Distributor.
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 within 60 days, a credit for the core charge will be issued.
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.
When shipping the item(s), attach a tag with the following information:
return authorization number;
name and location where the control is installed;
name and phone number of contact person;
complete Woodward part number(s) and serial number(s);
description of the problem;
instructions describing the desired type of repair.
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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.
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.
Engineering Services
Woodward offers various Engineering Services for our products. For these services,
you can contact us by telephone, by email, or through the Woodward website.
Technical Support
Product Training
Field Service
Technical Support is available from your equipment system supplier, your local Full-
Service Distributor, or from many of Woodward’s worldwide locations, depending
upon the product and application. This service can assist you with technical
questions or problem solving during the normal business hours of the Woodward
location you contact. Emergency assistance is also available during non-business
hours by phoning Woodward and stating the urgency of your problem.
For information on these services, please contact us via telephone, email us, or
use our website: www.woodward.com.
24 Woodward
Manual 26011 Load Sharing Module
You can also locate your nearest Woodward distributor or service facility on our
website at:
www.woodward.com/directory
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:
Your Name
Site Location
Phone Number
Fax Number
Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, gaseous, steam, etc)
Rating
Application
Control/Governor #1
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Control/Governor #2
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Control/Governor #3
Woodward Part Number & Rev. 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 Manual 26011
Appendix.
LSM Control Specifications
INPUTS
3-phase PT Inputs 100–120 or 200–240 Vac line-to-line, 50–400
Hz. PT input burden is 1.6 W per phase at 240
Vac, 0.4 W per phase at 120 Vac.
Droop SwitchThe external droop switch is to be wired in series with the auxiliary
circuit breaker contact between terminals 13 and
14. Droop mode is selected when either the
droop switch or the auxiliary circuit breaker is
open.
OUTPUTS
Load Signal DC signal proportional to total real current
measured by the Load Sharing Module. Load
Gain adjustable over minimum range of 0.86 to
2.0 Vdc/Arms.
ADJUSTMENTS
Droop Provides 0 to 10% speed reduction* between no
load and full load conditions.
26 Woodward
Manual 26011 Load Sharing Module
ENVIRONMENTAL
Operating Temperature –40 to +70 °C (–40 to +158 °F).
Installation
Overvoltage Category Category III.
DIMENSIONS
Linear (maximum) Length: 273.6 mm (10.77 in)
Width: 214.1 mm (8.43 in)
Height: 59.2 mm (2.33 in)
*—When used with a speed control having a gain of 3.3% speed change/volt.
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Load Sharing Module Manual 26011
28 Woodward
Declarations
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