Woodward Generator Load Sensor
Woodward Generator Load Sensor
Woodward Generator Load Sensor
(Revision F)
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
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 1983
All Rights Reserved
Manual 82313 Generator Load Sensor
Contents
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Generator Load Sensor Manual 82313
ii Woodward
Manual 82313 Generator Load Sensor
Woodward iii
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iv Woodward
Manual 82313 Generator Load Sensor
Chapter 1.
General Information
Description
The Generator Load Sensor provides isochronous and droop load-sharing
capability for the 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 Sensor can include the Woodward
SPM-A Synchronizer, Paralleling Phase Switch, Process and Import Export
Control, and Precision Frequency Control. Figure 1-1 shows a typical system
using a Generator Load Sensor.
Additional Information
The literature listed here contains information on the 8290-048, Generator Load
Sensor and associated equipment. These publications are available on the
Woodward website (www.woodward.com).
Publication
82493 EPG 512/524 & 1712/1724 Electrically Powered Governor
82384 SPM-A Synchronizer
82461 Paralleling Phase Switch
82010 Process and Import Export Control
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Chapter 2.
Theory of Operation
Introduction
The Generator Load Sensor 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
Sensor 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 Sensor. 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 17 through 20 provide for
selection of input voltages of either 95 to 130 Vac or 190 to 260 Vac. The plant
wiring diagram (Figure 3-3) shows these connections and jumpers. Do not
connect inputs to Terminals 17 through 20.
Power Sensor
Generator kilowatt load is measured by the power sensor circuit of the Load
Sensor. 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) (PT) and the current input comes from the
current transformer (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. The load signal voltages, at full load, of all
generator sets in the system must be equal. The controller circuit of each Load
Sensor 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 82313 Generator Load Sensor
Droop Operation
In droop operation, a portion of the output voltage of the Load Sensor is fed back
to the controller circuit; this voltage is proportional to the load sensed. This
voltage is used by the controller circuit to reduce the output voltage of the
controller circuit by a percentage determined by the DROOP potentiometer. Load
Sensor output is reduced, and actuator shaft position is changed according to the
desired droop percentage.
When a generator set using the Generator Load Sensor 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 Sensor at the summing point, in order to synchronize the generator set with
the bus.
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Chapter 3.
Installation
Mounting
Figure 3-2 is an outline drawing of the Generator Load Sensor. 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 3-3 is the plant wiring diagram for the Generator Load Sensor. 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 Governor
Installation Guide, also contains general information on wiring for electronic
controls.
Some of the wiring to the Load Sensor must be twisted-pair, shielded; these
wires are shown in Figure 3-3. This shielding prevents the wires from picking up
stray signals which could cause erratic control operation. Ground the shield to
the system ground as shown in the plant wiring diagram (Pin 12 or Pin 22 on this
(control). The shield on a length of shielded wire must be connected to ground 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.
Power Supply
There are no separate power connections to the Load Sensor; the unit takes its
power from the potential transformer connections.
Output
Connect the wiring between the output of the Load Sensor and the auxiliary input
of the speed control. Use twisted- pair, shielded wire.
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Manual 82313 Generator Load Sensor
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 16. 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 twisted-pair, shielded
wire.
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Installation Check
Before initial operation of the Generator Load Sensor, make the following visual
and electrical checks.
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.
Electrical Checks
Do not start the turbine until the control has been checked for
correct installation and operation. To prevent the possibility of
damage to equipment or injury to personnel, DO NOT permit the
engine or turbine to start during any of the static check and
calibration procedures.
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Manual 82313 Generator Load Sensor
Chapter 4.
Calibration
Introduction
Use this calibration procedure after an Generator Load Sensor 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 17, 18, 19, and 20
to match your potential transformer secondary voltage. See the plant wiring
diagram (Figure 3-3).
2. Remove wires from terminals 10 and 11, and from terminals 23 and 24.
6. Check the load signal voltage between terminals 21 and 22. Adjust the
LOAD GAIN potentiometer for a 6.0 Vdc Load Signal. If this voltage is not
obtainable proceed to step 11.
8. Check the voltage between terminals 21 and 22. 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.
10. Check the voltage between terminals 21 and 22. This voltage should be 0.0
± 0.25 Vdc. If this voltage is not correct, the Load Sensor unit is faulty;
return it to Woodward for repair.
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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 21 and 22. 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.
15. Disconnect the wire from terminal 5 that comes from the Phase A CT and
connect both wires from this CT to Terminal 4.
17. Measure the load signal at terminals 21 and 22. 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 V in
step 13, the reading in this step should be 4 V.
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.
21. Disconnect the wire from terminal 7 that comes from the Phase B CT and
connect both wires from this CT to Terminal 6.
23. Measure the load signal at terminals 21 and 22. 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 V in
step 13, the reading in this step should be 4 V.
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.
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Manual 82313 Generator Load Sensor
27. Disconnect the wire from terminal 9 that comes from the Phase C CT and
connect both wires from this CT to Terminal 8.
29. Measure the load signal at terminals 21 and 22. If the phase A and 8 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 V in step 13,
the reading in this step should be 4 V.
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.
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
sensor 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 sensor, 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 sensor, with the correct polarity, and are now labeled with their
correct designations.
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Generator Load Sensor Manual 82313
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 4-1 is recommended. By connecting a burden
resistor (a 0.5 , 20 W resistor), across each current transformer, that current
transformer can be disconnected from the Load Sensor after removing all load.
The connections between the terminal strip and the Load Sensor 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.
For this procedure, the generator set must be running isochronously, not
paralleled, and with a power factor of unity (1.0 ±0.1).
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 the phase A input terminals 4
and 5.
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7. Measure the load signal voltage between terminals 21 and 22 and record
this voltage.
8. Shut the generator set down and reverse the phase A wires on terminals 4
and 5.
10. Measure the load signal voltage between terminals 21 and 22 and record
this voltage.
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.
14. Measure the load signal voltage between terminals 21 and 22 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 21 and 22 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 21 and 22 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 21 and 22 and record
this voltage.
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
Sensor.
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29. Measure the load signal voltage between terminals 21 and 22 and record
this voltage.
30. Shut the generator set down and reverse the phase 8 wires on the CT input
terminals.
32. Measure the load signal voltage between terminals 21 and 22 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
Sensor.
36. Measure the load signal voltage between terminals 21 and 22 and record
this voltage.
37. Shut the generator set down and reverse the phase B CT wires on the CT
input terminals
39. Measure the load signal voltage between terminals 21 and 22 and record
this voltage.
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.
44. Measure the load signal voltage between terminals 21 and 22 and record
this voltage.
45. Shut the generator set down and reverse the phase C CT wires on the CT
input terminals.
47. Measure the load signal voltage between terminals 21 and 22 and record
this voltage.
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.
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Manual 82313 Generator Load Sensor
2. Measure the load signal voltage and adjust the LOAD GAIN potentiometer
for 6.0 ± 0.1 Vdc.
If the load signal voltage can not be raised to 6 V, 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.
It may be necessary to reduce the load signal voltage of each unit in the system
to as low as 3 V in cases of extremely poor system dynamics. If your system
requires a load signal voltage as low as 3 V, consult Woodward for suggestions
for possible remedies.
Droop Adjustment
Droop is usually expressed as a percentage. The droop in a load sensor is
calculated by the following formula.
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.
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Generator Load Sensor Manual 82313
2. Start the engine and adjust the RATED SPEED potentiometer on the EPG
for rated speed with no load.
4. Open the OPEN FOR DROOP switch (or remove the wires from terminals
15 and 16.
5. Synchronize the generator with the bus and parallel it with the bus.
* 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.
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Manual 82313 Generator Load Sensor
Chapter 5.
Troubleshooting
2. Improper engine operation. If the droop occurs near the full load
Operate the engine and observe point only, it is possible the engine is not
speed while applying load. Note producing the horse-power called for by
the position of the actuator the fuel control, or is being overloaded.
terminal shaft. Either is indicated if the fuel control is at
maximum fuel position.
Load Signal voltage is low. 1. Incorrect phasing of CT & PT Perform phasing check. If phasing check
Adjusting LOAD GAIN won’t wiring. indicates need, perform procedure for
raise it. correcting phase wiring.
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Generator Load Sensor Manual 82313
Symptoms Cause Test/Remedy
Load Signal voltage is too CT output too high. Check for 5 A CT output at full load. (CT
high. Adjusting LOAD GAIN must be between 3 and 7 A at full load.)
won’t lower it. Change to a higher primary current CT.
Engine does not properly 1. Engine not receiving fuel as Check for maximum voltage to the
share load with other units. called for by governor. actuator. If voltage to the actuator is
correct but the actuator output shaft is
not at maximum position, an actuator or
speed control problem if indicated or the
linkage or fuel system is restricted.
3. Unequal load gain voltages. Check that load gain setting of all load
sharing units is correct. See load gain
adjustment in Chapter 4. Adjust as
necessary.
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Manual 82313 Generator Load Sensor
Chapter 6.
Product Support and Service Options
OEM or Packager Support: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.
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Generator Load Sensor Manual 82313
Replacement/Exchange: Replacement/Exchange is a premium program
designed for the user who is in need of immediate service. It allows you to
request and receive a like-new replacement unit in minimum time (usually within
24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime.
This option allows you to call your Full-Service Distributor in the event of an
unexpected outage, or in advance of a scheduled outage, to request a
replacement control unit. If the unit is available at the time of the call, it can
usually be shipped out within 24 hours. You replace your field control unit with
the like-new replacement and return the field unit to the Full-Service Distributor.
Flat Rate Repair: Flat Rate Repair is available for many of the standard
mechanical products and some of the electronic products in the field. This
program offers you repair service for your products with the advantage of
knowing in advance what the cost will be.
Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat
Rate Repair option, with the exception that the unit will be returned to you in “like-
new” condition. This option is applicable to mechanical products only.
When shipping the item(s), attach a tag with the following information:
return number;
name and location where the control is installed;
name and phone number of contact person;
complete Woodward part number(s) and serial number(s);
description of the problem;
instructions describing the desired type of repair.
Packing a Control
Use the following materials when returning a complete control:
protective caps on any connectors;
antistatic protective bags on all electronic modules;
packing materials that will not damage the surface of the unit;
at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
a packing carton with double walls;
a strong tape around the outside of the carton for increased strength.
Replacement Parts
When ordering replacement parts for controls, include the following information:
the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
the unit serial number, which is also on the nameplate.
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Manual 82313 Generator Load Sensor
Engineering Services
Woodward’s Full-Service Distributors offer various Engineering Services for our
products. For these services, you can contact the Distributor by telephone or by
email.
Technical Support
Product Training
Field Service
Technical Support is available from your equipment system supplier, your local
Full-Service Distributor, or from many of Woodward’s worldwide locations,
depending upon the product and application. This service can assist you with
technical questions or problem solving during the normal business hours of the
Woodward location you contact.
You can also contact the Woodward Customer Service Department at one of the
following Woodward facilities to obtain the address and phone number of the
nearest facility at which you can obtain information and service.
For the most current product support and contact information, please visit our
website directory at www.woodward.com/directory.
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Technical Assistance
If you need to contact technical assistance, you will need to provide the following information.
Please write it down here before contacting the Engine OEM, the Packager, a Woodward
Business Partner, or the Woodward factory:
General
Your Name
Site Location
Phone Number
Fax Number
Number of Cylinders
Type of Fuel (gas, gaseous, diesel,
dual-fuel, etc.)
Power Output Rating
Application (power generation, marine,
etc.)
Control/Governor Information
Control/Governor #1
Serial Number
Control/Governor #2
Serial Number
Control/Governor #3
Serial Number
Symptoms
Description
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.
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Manual 82313 Generator Load Sensor
Woodward 23
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