Manual 26288 2301D/2301D-EC Digital Control

As the filter frequency is reduced, steady state stability improves but transient
performance may worsen. As the filter frequency is increased, steady state
stability worsens but transient performance may improve.

NOTE
If the calculated firing frequency is greater that 15.9 Hz, then disable the
filter by setting the filter cutoff frequency at or above 15.9 Hz.

Figure 4-3. Speed Filter

08 BUMP ACT TRIGGER (T THEN F) dflt = FALSE (FALSE, TRUE)

Allows you to test your dynamics settings by temporarily applying a decreased
fuel demand transient to stimulate a control response. Both the magnitude (Act
Bump Level) and duration (Act Bump Duration) of the transient may be set. The
actuator bump must be enabled in the ACTUATOR BUMP menu. To initiate an
actuator bump, toggle Bump Act to TRUE then back to FALSE while the engine
is operating in a normal steady state loaded or unloaded condition.

Figure 4-4 illustrates prime mover starts with the RAMP TIME set to minimum
(no ramp), step loadings at four different RESET settings, and stable, steady-
state running conditions. These are typical performance curves on a naturally
aspirated (non-turbocharged) diesel engine.

NOTE
Optimum performance is not necessarily obtained with the GAIN set to
maximum (stable). In some cases, the gain must be reduced slightly to
ensure stability under widely-varying conditions.

NOTE
Be prepared to change the dynamics settings since the actuator bump
transient may stimulate instability.

NOTE
BUMP ENABLE must be set TRUE to enable the BUMP ACT function. See the
ACTUATOR BUMP SETUP menu.

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Figure 4-4. Typical Transient Response Curves

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I**Dynamics #2**
The Dynamics 2 control parameters are adjusted the same as Dynamics 1
described above. To enable the use of two sets of dynamics, it is necessary to
set Enable 2nd DYNAMICS w/CB below to TRUE. These parameters are in
control only when the CB Aux contact input is closed or if a discrete input is
configured for Select 2nd Dynamics and this input is closed.

NOTE
I**Dynamics #2** parameters 04 thru 10 have the same effect on speed control
response as H**Dynamics #1** parameters 01 thru 07 described above.

01 ENABLE DYNAMICS 2 W/CB dflt = FALSE (FALSE, TRUE)

02 DELAY DYN 2 ENABLE (SEC) dflt = 0.00 (0.00, 20.00)
This is the delay time before dynamics #2 are used by the speed control when
the "CB Aux Droop contact" or "Select 2nd Dynamics" input is activated.

03 DELAY DYN 1 ENABLE (SEC) dflt = 0.00 (0.00, 20.00)

This is the delay time before Dynamics #1 are used by the speed control after
the "CB Aux Droop contact" or "Select 2nd Dynamics" input is de-activated.
04 PROP GAIN 2 dflt = 2.00 (0.001, 100.00)

05 RESET 2 dflt = 1.00 (0.01, 100.00)

06 ACTUATOR COMPENSATION 2 dflt = 0.1f0 (0.01, 100.00)

07 WINDOW WIDTH 2 (RPM) dflt = 60.00 (1.00, 200.00)

08 GAIN RATIO 2 dflt = 1.00 (1.00, 10.00)

09 SPEED FILTER FREQ 2 (HZ) dflt = 20.00 (4.00, 20.00)

10 BUMP ACT TRIG (T THEN F) dflt = FALSE (FALSE, TRUE)

J**Dynamics #1 5 Pt Gain**
This menu and control function is enabled when Configure Menu: A**SPEED
CONTROL FUNCTIONS** parameter 07 ENABLE 5 SLOPE GAIN MAP is TRUE
and provides a 5-point curve as a function of prime mover load for the variable
GAIN set point. The Breakpoint parameter is based on what is set in Configure:
parameter ‘08 SEL GAIN FUNCTION (1,3)’. The prime mover Fuel Demand %
(1) or generator kilowatt % (2) or engine speed (3) is used as the load/rpm axis.
It is useful in applications that have a non-linear fuel valve (such as butterfly
valves). A plot of the fuel system must be determined to properly adjust the gain
of the control to match the gain of the system at all loads. See the Gas Engine
Setup and Control Gain Programming Steps sections below.

01 BREAKPOINT 1A (%LD OR RPM) dflt = 99.60 (0.00, 5000.00)

Set at the min load point no-load fuel demand or 0% KW.

02 GAIN @BREAKPOINT 1A dflt = 2.0 (0.001, 100.00)

The no load GAIN value.

03 BREAKPOINT 1B (%LD OR RPM) dflt = 99.70 (0.01, 5000.00)

The Fuel demand % or KW% at the next load breakpoint.

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04 GAIN @BREAKPOINT 1B dflt = 2.0 (0.001, 100.00)
The GAIN value when the load is at breakpoint B.

05 BREAKPOINT 1C (%LD OR RPM) dflt = 99.80 (0.01, 5000.00)

The load % for breakpoint C.

06 GAIN @BREAKPOINT 1C dflt = 2.0 (0.001, 100.00)

This is the GAIN value when the load is at breakpoint C.

07 BREAKPOINT 1D (%LD OR RPM) dflt = 99.90 (0.01, 5000.00)

The load % for breakpoint D.

08 GAIN @BREAKPOINT 1D dflt = 2.0 (0.001, 100.00)

The GAIN value when the load is at breakpoint D.

09 BREAKPOINT 1E (%LD OR RPM) dflt = 100.00 (0.01, 5000.00)

The load % for breakpoint E.

10 GAIN @BREAKPOINT 1E dflt = 2.0 (0.001, 100.00)

The GAIN value when the load is at breakpoint E.

11 RESET 1 dflt = 1.0 (0.01, 100.00)

This compensates for the lag time of the engine. It adjusts the time required for
the control to return the speed to zero error after a disturbance. Reset is adjusted
to prevent slow hunting and to minimize speed overshoot after a load
disturbance.

12 ACT COMPENSATION dflt = 0.10 (0.01, 100.00)

This compensates for the actuator and fuel system time constant. Increasing
compensation increases actuator activity and transient performance.

13 WINDOW WIDTH 1 (RPM) dflt = 60.00 (1.00, 200.00)

The magnitude (in rpm) of speed error at which the control automatically
switches to fast response. The control uses the absolute value of speed error to
make this switch. The absolute value is the difference between the speed
reference and the speed. A window width that is too narrow results in cycling that
always factors in the gain ratio (see Figure 4-2).

14 GAIN RATIO 1 dflt = 1.00 (1.00, 10.00)

The ratio of the gain setting at steady state to the gain setting during transient
conditions. The gain ratio operates in conjunction with the Window Width and
gain adjustments by multiplying the gain set point by the gain ratio when the
speed error is greater than the window width. This makes the control dynamics
fast enough to minimize engine-speed overshoot on start-up and to reduce the
magnitude of speed error when loads are changing. This allows a lower gain at
steady state for better stability and reduced steady-state actuator linkage
movement (see Figure 4-2).

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15 SPEED FILTER FREQ 1 (HZ) dflt = 20.00 (4.00, 20.00)
Adjusts the cutoff frequency of a low pass filter used on the engine speed
sensing input (see Figure 4-3). To use this feature set the cutoff frequency below
15.9 Hz. The filter is used to attenuate engine firing frequencies. To calculate the
desired filter cutoff point, use the following formulas:

camshaft frequency = (engine rpm)/60 [for 2-cycle engines]

= (engine rpm)/120 [for 4-cycle engines]

firing frequency = camshaft frequency x number of cylinders

Initially set the filter frequency to the firing frequency.

As the filter frequency is reduced, steady state stability improves but transient
performance may worsen. As the filter frequency is increased, steady state
stability worsens but transient performance may improve.

NOTE
If the calculated firing frequency is greater that 15.9 Hz, then disable the
filter by setting the filter cutoff frequency at or above 15.9 Hz.

16 BUMP ACT TRIG (T THEN F) dflt = FALSE (FALSE, TRUE)

Allows you to test your dynamics settings by temporarily applying a decreased
fuel demand transient to stimulate a control response. Both the magnitude (Act
Bump Level) and duration (Act Bump Duration) of the transient may be set. The
actuator bump must be enabled in the ACTUATOR BUMP SETUP menu. To
initiate an actuator bump, toggle Bump Act to TRUE then back to FALSE while
the engine is operating in a normal steady state loaded or unloaded condition.

K**Dynamics #2 5 Pt Gain**
The Dynamics 2 control parameters are adjusted the same as Dynamics 1
described above. These parameters are in control only when the CB Aux contact
input is closed, or if a discrete input is configured for Select 2nd Dynamics and
this input is closed.

NOTE
K**Dynamics #2 5 Pt Gain** parameters 04 thru 19 have the same effect on speed
control response as J**Dynamics #2 5 Pt Gain** parameters 01 thru 16 described
above.

01 ENABLE DYNAMICS 2 W/CB dflt = FALSE (FALSE, TRUE)

When TRUE, the second set of dynamics is enabled when the circuit breaker
auxiliary contact or Select 2nd Dynamics contact is closed. When this prompt is
FALSE, only Dynamics 1 with be used to set speed control response.

02 DELAY DYN 2 ENABLE (SEC) dflt = 0.00 (0.00, 20.00)

A delay time, in seconds, that dynamics #1 will continue to be used by the speed
control after the CB contact.

03 DELAY DYN 1 ENABLE (SEC) dflt = 0.00 (0.00, 20.00)

The delay time that dynamics #2 will continue to be used before switching to
dynamics #1.

04 BREAKPOINT 2A (%LD OR RPM) dflt = 99.60 (0.01, 5000.00)

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05 GAIN @BREAKPOINT 2A dflt = 2.0 (0.001, 100.00)

06 BREAKPOINT 2B (%LD OR RPM) dflt = 99.70 (0.01, 5000.00)

07 GAIN @BREAKPOINT 2B dflt = 2.0 (0.001, 100.00)

08 BREAKPOINT 2C (%LD OR RPM) dflt = 99.80 (0.01, 5000.00)

09 GAIN @BREAKPOINT 2C dflt = 2.0 (0.001, 100.00)

10 BREAKPOINT 2D (%LD OR RPM) dflt = 99.90 (0.01, 5000.00)

11 GAIN BREAKPOINT 2D dflt = 2.0 (0.001, 100.00)

12 BREAKPOINT 2E (%LD OR RPM) dflt = 100.00 (0.01, 5000.00)

13 GAIN BREAKPOINT 2E dflt = 2.0 (0.001, 100.00)

14 RESET 2 dflt = 1.00 (0.01, 100.00)

15 ACTUATOR COMPENSATION 2 dflt = 0.10 (0.01, 100.00)

16 WINDOW WIDTH 2 (RPM) dflt = 60.00 (1.00, 200.00)

17 GAIN RATIO 2 dflt = 1.0 (1.00, 10.00)

18 SPEED FILTER FREQ 2 (HZ) dflt = 20.00 (4.00, 20.00)

19 BUMP ACT TRIG (T THEN F) dflt = FALSE (FALSE, TRUE)

Gas Engine Setup

The butterfly valve position of a gas engine is not linear in comparison to engine
power output. In naturally-aspirated (non-turbocharged) engines, the position of the
valve in comparison to engine output appears on a chart similar to Figure 4-5.

Turbocharged engines distort this curve, particularly as turbo pressure builds to

the point of operating the waste gate. A turbocharged gas engine will likely have
a butterfly position chart similar to Figure 4-6.

Figure 4-5. Non-linear Valve Power Curve

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Figure 4-6. Non-linear Valve Power Curve for Turbocharged Engine

Note that in both charts the valve position falls on a curve. The menu does not
permit the construction of a curve. However, with four slope segments (5 break
points) available, a rough approximation of the curve can be created (see Figure
4-7).

2 Series1

0
0 20 40 60 80 100 120
Fuel Demand

Figure 4-7. Linearized Gain Plot

Diesel Engine Setup

Most Diesel engine fuel controls are nearly linear. The dynamics maps may still
be used to accommodate non-linear conditions caused either by the fuel system
or by linkage between the actuator and the rack. For gain settings that are not
used, set the associated breakpoint at 100%.

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Control Gain Programming Steps

1. Gain programming is needed whenever the gain of the engine and fuel
system is non-linear. This usually occurs in gas engine applications. A plot of
the fuel system must be determined to properly adjust the gain of the control
to match the gain of the system at all loads.

The plot reflects the actuator output, as seen in A**DISPLAY MENU**,

versus the engine load as load is varied from no load to full load.

To construct a gain plot:

a. Set the Gain A breakpoint for 100%. This ensures that there will not be
any confusion with other settings while plotting the system
characteristics. Only Gain A, Reset, and Actuator Compensation will be
used.
b. Start the engine and obtain good control at no load using Gain A,
Stability, and Actuator Compensation. Record these settings and the
actuator output as displayed in A**DISPLAY MENU**.
c. Load the engine with as many load points as are practical. At each load
point, Gain A may need to be varied to maintain engine stability. Do not
change Reset or Actuator Compensation after the first setting in step b.
Should it be necessary to change these settings to obtain good control,
repeat all previous steps until only Gain is changed at each load step.
At each load point, record the Fuel Demand % that is displayed in
A**DISPLAY MENU**. Also record the engine load (KW) and Gain A at
each point. If KW percent is selected for the X axis of the curve, the
ratio of KW to Rated KW times 100 will be used as the load percent
value. The actuator bump feature can be used to make small fuel
changes about the load point to verify stability.

The table below aids in collecting the data for the Gain Plot. When
entering the values into the control, the software will not allow
overlapping the breakpoint values (that is, Breakpoint A must be less
than breakpoint B, which must be less than breakpoint C, etc).

Gain settings reflect the sensitivity of the engine load to fuel demand as
shown in Figure 4-7. Flat portions of the engine plot will require
relatively small values of gain, steep portions of the plot will require
larger gain numbers (actuator has to move a lot to pickup small amount
of load).

d. Create a plot of the system by plotting PID GAIN as a function of load.

A typical result is shown in Figure 4-7.

The following table may help in the construction of the plot. Use as
many load steps as possible, it is not necessary to use all 20 points
given below.

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Gain (for good Actuator or kW Output or

Load/RPM Point
control) Speed
Load/RPM Point 1
Load/RPM Point 2
Load/RPM Point 3
Load/RPM Point 4
Load/RPM Point 5
Load/RPM Point 6
Load/RPM Point 7
Load/RPM Point 8
Load/RPM Point 9
Load/RPM Point 10
Load/RPM Point 11
Load/RPM Point 12
Load/RPM Point 13
Load/RPM Point 14
Load/RPM Point 15
Load/RPM Point 16
Load/RPM Point 17
Load/RPM Point 18
Load/RPM Point 19
Load/RPM Point 20

2. Set Gain A to the value recorded at point 1b. This should give good control at
no load.
3. Use the plot of the engine to determine the linearity of the fuel system. This
curve should be linearized between inflection points as shown in Figure 4-7.
4. Set the Gain A Breakpoint for the actuator output at or slightly below the load
value at the min load point. Set the GAIN value at breakpoint A.
5. Set the Gain B Breakpoint at the point slightly above the first inflection point
in the load plot. Gain B should now be adjusted to obtain good control at the
inflection point B. Note: you may already have obtained the correct value in
Step 1c.

WARNING—OVERSPEED
Be prepared to change the dynamics settings since the actuator bump
transient may stimulate instability, which could result in an overspeed
condition.

NOTE
BUMP ENABLE must be set to TRUE to enable the BUMP ACT function. See
the ACTUATOR BUMP menu.

L**FUEL LIMITERS 1/2**

Fuel limiters restrain the fuel demand from the control to the actuator.

01 START FUEL LIMIT (%FD) dflt = 100.00 (15.00, 110.00)

This limits the percent fuel demand when the engine is started. The limit is
usually set at the fuel level required to start the engine. The limiter is disabled
when the engine fuel is controlled by speed (see Figure 4-8). The limiter begins
out of the way at 100% with no speed. Upon speed exceeding the failed speed
sense percent, the START FUEL LIMIT immediately limits the fuel to the start
fuel limit level. The limiter then ramps at START RAMP RATE (%FD/S) until the
speed has reached 95% of reference and the Speed Control PID is in control for
1 second.

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Figure 4-8. Start Limit Function

02 START RAMP RATE (%FD/S) dflt = 10.00 (1.00, 180.00)

Establishes the start limiter ramping rate at which the fuel demand increases to
assist starting in colder ambient conditions.

03 SOFT START FUEL LIMIT ON dflt = FALSE (FALSE, TRUE)

When set TRUE enables a ramp to the start fuel limit. When the engine is started
and MPU is sensed, the fuel demand ramps from zero at the “Start Ramp Rate
(%FD/S), until the start fuel limit is reached. The fuel demand will stop ramping
until the speed reaches 95% of the speed reference, at which time the PID will
take control. This option is usually used with slow speed natural gas engines.
This feature allows the manifold air pressure time to build, while waiting on the
turbo to build enough air pressure.

S O F T S T A R T F U N C T IO N
1 00

MAX
FUEL
LIM IT

START START
FUEL RAMP
LIM IT (% /
SEC)

SPEED T IM E SPEED
GREATER EQ UALS
THEN SPEED
5% O F REFERENCE
RATED

Figure 4-9. Soft Start Fuel Limit Function

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04 MAX FUEL LIMIT (%FD) dflt = 100.00 (50.00, 110.00)
Sets the maximum percent fuel demand. Maximum (100%) is based on 200 mA.
This is an electronic rack stop which is active in all modes of operation.

05 ENABLE IDLE LIMITER ? dflt = FALSE (FALSE, TRUE)

Set to TRUE to enable the Idle Fuel Limiter . Set to FALSE to disable the Idle
Fuel Limiter. This option, when enabled, will limit the Fuel Demand at a fixed
value [06 IDLE FUEL LIMITER (%fd)], only while the Idle / Rated contact is in the
Idle position. This feature can be used to limit fuel on natural gas engines, so that
the engine is not flooded on start-up.

06 IDLE FUEL LIMITER (%FD) dflt = 100.00 (0.00, 100.00)

Sets the maximum percent fuel demand when the Idle / Rated Contact is in the
Idle position. Maximum (100%) is based on 200 Ma.

07 ENABLE TORQUE LIMITER ? dflt = FALSE (FALSE, TRUE)

Set to TRUE to enable the TORQ LIMIT CURVE. Set to FALSE to disable the
TORQUE LIMIT CURVE.

08 MIN SPEED TORQUE LIMIT dflt = 300.00 (0.00, 4000.00)

This sets the first break point of the TLC. It should be adjusted to the rpm which
represents the first break point. Typically this is set at minimum speed. The limit
on fuel demand below this point is extrapolated from this point and the SPEED
BRKPOINT TORQ LIM below.

09 TORQUE LIMIT MIN SPEED dflt = 100.00 (0.00, 100.00)

This sets the maximum fuel demand at the minimum speed setpoint.

10 SPEED BRKPOINT TORQ LIM dflt = 800.00 (0.00, 4000.00)

This sets the speed break point of the TLC. It should be adjusted to the rpm
which represents the torque limit breakpoint.

11 TORQUE LIMIT BREAKPOINT dflt = 100.00 (0.00, 100.00)

This sets the maximum fuel demand at the speed break point.

12 MAX SPEED TORQUE LIMIT dflt = 1000.00 (0.00, 4000.00)

This sets the maximum speed point of the TLC. It should be adjusted to the
maximum rpm which represents the maximum fuel break point.

13 TORQUE LIMIT MAX SPEED dflt = 100.00 (0.00, 100.00)

This sets the maximum fuel demand at the maximum speed point.

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TORQUE LIMITER FUNCTION

TORQUE 100
LIMIT
MAX
SPEED

TORQUE
LIMIT
BREAK
% FUEL POINT
DEMAND

TORQUE
LIMIT
MIN
SPEED
0

MIN SPEED MAX

SPEED BRKPOINT SPEED
TORQUE TORQUE TORQUE
LIMIT LIMIT LIMIT

SPEED

Figure 4-10. Torque Limiter Function

M**FUEL LIMITERS 2/2**

01 ENABLE MAP LIMITER ? dflt = FALSE (TRUE, FALSE)
When set TRUE the Manifold Air pressure limiter is active.

02 PRESSURE X1 dflt = 6.000 (–1000.00, 1000.00)

This sets the pressure at the first breakpoint. The limit on fuel demand below this
point is extrapolated from this point and the pressure X2 below.

03 MAP LIMIT Y1 dflt = 100.000 (0.00, 100.00)

This sets the maximum fuel demand at the first pressure setpoint.

04 PRESSURE X2 dflt = 8.000 (–1000.00, 1000.00)

This sets the pressure at the second breakpoint.

05 MAP LIMIT Y2 dflt = 100.000 (0.00, 100.00)

This sets the maximum fuel demand at the second pressure setpoint.

06 PRESSURE X3 dflt = 10.000 (–1000.00, 1000.00)

This sets the pressure at the third breakpoint.

07 MAP LIMIT Y3 dflt = 100.000 (0.00, 100.00)

This sets the maximum fuel demand at the third pressure setpoint.

08 PRESSURE X4 dflt = 15.000 (–1000.00, 1000.00)

This sets the pressure at the fourth breakpoint.

09 MAP LIMIT Y4 dflt = 100.000 (0.00, 100.00)

This sets the maximum fuel demand at the fourth pressure setpoint.

10 PRESSURE X5 dflt = 20.000 (–1000.00, 1000.00)

This sets the pressure at the maximum breakpoint.
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11 MAP LIMIT Y5 dflt = 100.000 (0.00, 100.00)
This sets the maximum fuel demand at the maximum pressure setpoint.

12 MAP NEAR FUEL LIMIT % dflt = 5.000 (0.00, 10.00)

When the maximum air pressure limit comes within the range of this setting the
overload contact is initiated.

13 MAP DELAY TIME CONTACT dflt = 0.500 ( 0.00, 30.00)

When the maximum air pressure limit is within the near fuel limit range for longer
then this delay time an overload contact is activated.

14 MAP OVERLOAD PULS TIME dflt = 0.500 (0.00, 100.00)

This is the time for the overload contact to be active. In Configure Menu
D**Discrete Out Options** a discrete output can be setup at parameter 8
(Overload Contact).

MAP LIMITER FUNCTION

100

MAP LIMIT Y3
MAP LIMIT Y4

MAP LIMIT Y5

% FUEL MAP LIMIT Y2

DEMAND

MAP LIMIT Y1

P P P P P
R R R R R
E E E E E
S S S S S
S S S S S

X X X X X
1 2 3 4 5
MANIFOLD AIR PRESSURE

Figure 4-11. MAP Limiter Function

N**LOAD SETTINGS**
The Load Setting section is the set-up of the generator load control parameters.

01 LOAD DROOP PERCENT dflt = 5.000 (0.00, 12.00)

is the percentage of rated speed the speed reference will droop when the
generator load is increased to maximum load. Set to desired droop percent.

02 LOAD LEVEL VOLTAGE dflt = 6.000 (0.10, 9.00)

Sets the voltage level of the load.

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03 LOAD SHARE GAIN dflt = 1.000 (0.01, 10.00)
Sets the loadsharing gain. A too-high gain will result in unstable load sharing
between the units.

04 ENABLE ACT POS DROOP dflt = FALSE (TRUE, FALSE)

This enables the actuator position droop feature. Actuator position droop is a
feature that gives the control a speed droop percentage based on the actuator
position (fuel demand). This feature would be used if the control was not capable
of receiving a PT and CT signal for KW droop, or if for testing purposes.

05 ACT POSITION DROOP % dflt = 0.00 (0.00, 100.00)

The actuator dependant droop percentage setting, for proper droop control set
the below parameters 06 and 07 first. If load (kW) droop is used (GEN PT and
GEN CT are connected) set this parameter to 0.

06 ACT OUT AT RATED NO LOAD dflt = 20.00 (0.00, 100.00)

The setting where droop is calculated from. Adjust this setting at the same
reading of the Fuel Demand % when engine is running at rated rpm but with no
load.

07 ACT OUT RATED FULL LOAD dflt = 80.00 (0.00, 100.00)

Adjust this setting at the same reading of the Fuel Demand % when engine is
running at rated rpm but with full load.

08 BASE LOAD MINIMUM (KW) dflt = 20.000 (10.00, 30000.00)

The minimum value the base load reference will ramp to when the external lower
switch at terminal 36 is closed.

09 BASE LOAD REFERENCE (KW) dflt = 50.000 (0.00, 30000.00)

Enter the internal Baseload set point. This sets the initial internal set point of the
Baseload Reference Ramp when the Load Control enters Base Load mode.

10 BASE LOAD MAXIMUM (KW) dflt = 110.000 (10.00, 30000.00)

The maximum value the base load reference will ramp to when the external raise
switch at terminal 35 is closed.

11 BASELOAD RAISE TIME (SEC) dflt = 60.000 (1.00, 600.00)

The time for the reference to ramp from baseload minimum to baseload load
maximum values entered above.

12 BASELOAD LOWER TIME (SEC) dflt = 60.000 (1.00, 600.00)

The time for the reference to ramp from baseload maximum to baseload load
minimum values entered above.

13 UNLOAD TRIP LEVEL (KW) dflt = 5.000 (0.00, 30000.00)

Enter the unload trip level set point. This sets the load level that the unit unloads
to following an Unload command. When the Load switch is opened to unload, the
generator unloads to this KW value. The Discrete output 4 will then change state
momentarily to give a breaker open command.

14 LOADING RATE (KW/SEC) dflt = 20.000 (1.00, 600.00)

Enter the loading rate. This sets the rate at which the Load Ramp will increase
for soft loading.

15 UNLOADING RATE (KW/SEC) dflt = 20.000 (1.00, 600.00)

Enter the unloading rate. This sets the rate at which the Load Ramp will
decrease for soft unloading.

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16 ENABLE FAST LOAD RATE dflt = FALSE (TRUE, FALSE)
Set to TRUE if the function to activate a faster loading ramp rate than the
LOADING RATE entered above when the system load level is high.

17 FAST RAMP ENABLE LOAD (%) dflt = 80.000 (1.00, 110.00)

When the system load, as measured through the load sharing lines, is
determined to by above this percentage the soft load ramp rate will switch to a
faster rate to allow this oncoming unit to pick up it share of the load faster.

18 FAST RAMP RATE (KW/SEC) dflt = 60.000 (1.00, 600.00)

Enter the loading rate at which the load will increase when the system load is
above the percentage entered above.

O**ACTUATOR BUMP SETUP**

01 BUMP ENABLED dflt = FALSE (TRUE, FALSE)
Set to TRUE to enable the actuator bump for 60 minutes. Set to FALSE to
disable this function. When this prompt is set FALSE, the Actuator Bump tunable
in the Dynamics sections described above is disabled.

02 ACT BUMP LEVEL (%FD) dflt = 1.000 (0.00, 25.00)

This is the % fuel demand for the desired bump level.

03 ACT BUMP DURATION (SEC) dflt = 0.110 ( 0.08, 2.00)

The desired bump duration in seconds.

04 BUMP ACT TRIGGER (T THEN F) dflt = FALSE ( TRUE, FALSE)

Allows you to test your dynamic settings by temporarily applying a decrease fuel
demand transient to stimulate a control response. To initiate an actuator bump,
toggle Bump Act to TRUE then back to FALSE while the engine is operating in a
normal steady state loaded or unloaded condition.

P**ANALOG INPUTS SETTINGS**

This group of Service settings set the parameters of the two analog inputs at
terminals 19 through 24.

01 AI 1 CONFIGURED FOR: (monitor)

This will display the function Analog Input #1 at terminal 19–21 was set for in the
Configure mode.

02 AI 2 CONFIGURED FOR: (monitor)

This will display the function Analog Input #2 at terminal 22–24 was set for in the
Configure mode.

03 SPEED w/ RMT IN@MIN(RPM) dflt = 800.000 (0.00, 4000.00)

Sets the speed reference value when the remote reference input is at the low
value for the selected range. This value may be less than or greater than the
value entered when the input is at maximum.

04 SPEED w/ RMT IN@MAX(RPM) dflt = 1000.000 (0.00, 4000.00)

Sets the speed reference value when the remote reference input is at the
maximum value for the selected range.

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05 RMT SPEED REF INPUT (RPM) (monitor)
Displays the speed reference based on analog input #2.

NOTE
This displayed value is the result of the input parameter, it is not limited by
the ramp times or switch input logic.

06 RMT SPDREF INC TIME(SEC) dflt = 30.000 (1.00, 300.00)

Sets the time for the speed reference to ramp from the 4 mA speed setting to the
20 mA speed setting.

07 RMT SPDREF DEC TIME(SEC) dflt = 30.000 (1.00, 300.00)

Sets the time for the speed reference to ramp from the 20 mA speed setting to
the 4 mA speed setting.

08 BSLOAD W/RMT IN@MIN (KW) dflt = 20.000 (0.00, 30000.00)

Sets the Base Load reference value when the remote reference input is at the
low value for the selected range. This value may be less than or greater than the
value entered when the input is at maximum.

09 BSLOAD W/RMT IN@MAX (KW) dflt = 90.000 (10.00, 30000.00)

Sets the Base Load reference value when the remote reference input is at the
maximum value for the selected range.

10 RMT BSLOAD REF INPUT (KW) (monitor)

Displays the baseload reference based on the analog input.

NOTE
This displayed value is the result of the input parameter, it is not limited by
the ramp times or switch input logic.

11 RMT BSLOAD INC TIME(SEC) dflt = 60.000 (1.00, 600.00)

Sets the time for the Base load reference, ramp from the 4 mA setting to the
20 mA setting.

12 RMT BSLOAD DEC TIME(SEC) dflt = 60.000 (1.00, 600.00)

Sets the time for the Base load reference to ramp from the 20 mA setting to the
4 mA setting.

13 REMOTE AUX SCALE(%/VOLT) dflt = 3.000 (0.10, 5.00)

Sets the gain of the remote input when used to bias speed from a remote control
device. The normal scale is 3.0% speed change per volt input. The analog input
range is ±2.5 V.

14 SYNC INPUT SCALE(%/VOLT) dflt = 0.70 (0.10, 5.00)

Sets the gain of the synchronizer input when used to bias speed from a speed
and phase matching device. The normal scale is 0.7% speed change per volt
input. The analog input range is ±2.5 V.

15 MAP LIMITER INPUT MIN dflt = 0.0 (–10000, 10000)

Sets the manifold air pressure value at 4 mA. This is the setting for the value of
the pressure sensor at 4 mA.

16 MAP LIMITER INPUT MAX dflt = 20.0 (–10000, 10000)

Sets the manifold air pressure value at 20mA. This is the setting for the value of
the pressure sensor at 20 mA.

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Q**DISCRETE OUT SETTINGS *8

The 2301D, 2301D-EC has four discrete output driver channels. Terminals 41,
42, 43 and 44 are configurable and can be programmed to perform one of the
following functions.

And any of the four relays can also be programmed to function as a level switch.
When programmed as a level switch the relay will change state when the
selected parameter reaches the programmed level (energizes when value is
higher the programmed level).

01 RELAY 1 SELECTED AS (monitor)

Displays the function selected for terminal 41. This relay is selected in the
Configure Menu D**DISCRETE OUT OPTIONS**.

02 RELAY 1 LEVEL SW (1-6) dflt = 1 (1, 6)

Select one of the following parameters for discrete output at terminals 41 when it
was selected as a level switch.
1 NOT USED
2 ACTUAL SPEED
3 SPEED REFERENCE
4 START LIMITER SETPOINT
5 ACTUATOR DEMAND
6 GENERATOR OUT (LOAD SENSOR)

03 RELAY 1 LEVEL SELECT FOR (monitor)

Displays the level function selected for terminal 41.

04 RELAY 1 ON LEVEL = dflt = 0.000 (-32000.00, 32000.00)

Enter the level switch ON setting in engineering units. There is an ON and an
OFF setting for each level switch option. This allows you to program the desired
hysteresis for the function selected.

05 RELAY 1 OFF LEVEL = dflt = 0.000 (-32000.00, 32000.00)

Enter the level switch OFF setting in engineering units (must be less than the
‘Relay On Level’).

06 RELAY 2 SELECTED AS (monitor)

Displays the function selected for terminal 42. This relay is selected in the
configure menu D**DISCRETE OUT OPTIONS**.

07 RELAY 2 LEVEL SW (1-6) dflt = 1 (1, 6)

Select one of the following parameters for discrete output at terminals 42 when it
was selected as a level switch.
1 NOT USED
2 ACTUAL SPEED
3 SPEED REFERENCE
4 START LIMITER SETPOINT
5 ACTUATOR DEMAND
6 GENERATOR OUT (LOAD SENSOR)

08 RELAY 2 LEVEL SELECT FOR (monitor)

Displays the level function selected for terminal 42.

09 RELAY 2 ON LEVEL = dflt = 0.000 (-32000.00, 32000.00)

Enter the level switch ON setting in engineering units. There is an ON and an
OFF setting for each level switch option. This allows you to program the desired
hysteresis for the function selected.

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10 RELAY 2 OFF LEVEL= dflt = 0.000 (-32000.00, 32000.00)
Enter the level switch OFF setting in engineering units.
(Must be less than the ‘Relay On Level’).

11 RELAY 3 SELECTED AS (monitor)

Displays the function selected for terminal 43. This relay is selected in the
configure menu D**DISCRETE OUT OPTIONS**

12 RELAY 3 LEVEL SW (1-6) dflt = 2 (1, 6)

Select one of the following parameters for discrete output at terminals 43 when it
was selected as a level switch.
1 NOT USED
2 ACTUAL SPEED
3 SPEED REFERENCE
4 START LIMITER SETPOINT
5 ACTUATOR DEMAND
6 GENERATOR OUT (LOAD SENSOR)

13 RELAY 3 LEVEL SELECT FOR (monitor)

Displays the level function selected for terminal 43.

14 RELAY 3 ON LEVEL = dflt = 0.000 (-32000.00, 32000.00)

Enter the level switch ON setting in engineering units. There is an ON and an
OFF setting for each level switch option. This allows you to program the desired
hysteresis for the function selected.

15 RELAY 3 OFF LEVEL = dflt = 0.000 (-32000.00, 32000.00)

Enter the level switch OFF setting in engineering units (must be less than the
‘Relay On Level’).

16 RELAY 4 SELECTED AS (monitor)

Displays the function selected for terminal 44. This relay is selected in the
configure menu—D**DISCRETE OUT OPTIONS**

17 RELAY 4 LEVEL SW (1-6) dflt = 1 (1, 6)

Select one of the following parameters for discrete output at terminals 44 when it
was selected as a level switch.
1 NOT USED
2 ACTUAL SPEED
3 SPEED REFERENCE
4 START LIMITER SETPOINT
5 ACTUATOR DEMAND
6 GENERATOR OUT (LOAD SENSOR)

18 RELAY 4 LEVEL SELECT FOR (monitor)

Displays the level function selected for terminal 44

19 RELAY 4 ON LEVEL = dflt = 0.000 (-32000.00, 32000.00)

Enter the level switch ON setting in engineering units. There is an ON and an
OFF setting for each level switch option. This allows the user to program the
desired hysteresis for the function selected.

20 RELAY 4 OFF LEVEL = dflt = 0.000 (-32000.00, 32000.00)

Enter the level switch OFF setting in engineering units.
(Must be less than the ‘Relay On Level’).

21 BREAKER OPEN TIME (SEC) dflt = 1.000 (0.80, 60.00)

Sets the time the automatic circuit breaker command time is will change states
(depending on the configuration of CB Open Relay Normally Energized).
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22 RAMP @ MIN,CB DELAY(SEC) (monitor)
The time delay the load/unload ramp is at minimum value and the generator KW
has not reached the unload KW trip level.

R**ANALOG OUTPUT SETTINGS**

This section sets the parameter to be sent to the analog output driver and the
desired scaling of the output.

01 ANALOG OUTPUT SEL (1-9) dflt = 1 (1, 9)

Select one of the following parameters for 4–20 mA output at terminals 16,17,
and 18.
1. Engine Speed
2. Speed Reference
3. Fuel Demand %
4. Unit Load %
5. System Load %
6. Analog Input #1
7. Analog Input #2
8. Speed Reference Bias
9. Baseload Reference (kW)

02 ANALOG OUTPUT SELECTION (monitor)

Displays the analog output selection.

03 ANOUT, 4 MA OFFSET dflt = 0.000 (-200.00, 200.00)

Adjusted for the value of the displayed parameter when the analog output will be
4 mA. If the analog output is reading Engine Speed or Speed Reference, this
value will be set to the zero speed, or the minimum value of the readout.

04 ANOUT, 20MA GAIN dflt = 900.000 (-200.00, 32000.00)

Adjusted for the value of the displayed parameter when the analog output will be
20.0 mA. If the analog output is reading Engine Speed or Speed Reference, this
value will be set to the rated speed, or the maximum value of the readout.

05 ANALOG OUT 1 (%) (monitor)

Displays the analog output %, 0% is 4 mA, and 100% is 20 mA.

S**RELAY AND ANOUT TESTS**

This section allows the operator to test the relay driver outputs and the analog
output by artificially forcing its signal. The engine must be shut down at minimum
fuel. If the test is enabled, the actuator output will be held to minimum.

01 ENABLE MANUAL DRIVR TEST dflt = FALSE (TRUE, FALSE)

When the engine is at zero speed and minimum actuator output tune this to
TRUE. The status below will read ‘Test On’

02 FORCE OUTPUT STATUS (monitor)

Displays the test status.

03 TURN ON DO1 dflt = FALSE (TRUE, FALSE)

Tune to TRUE to turn the driver output #1 on.

04 DISCRETE OUTPUT #1 (monitor)

Displays the output status of output #1

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05 TURN ON DO2 dflt = FALSE (TRUE, FALSE)
Tune to TRUE to turn the driver output #2 on.

06 DISCRETE OUTPUT #2 (monitor)

Displays the output status of output #2.

07 TURN ON DO3 dflt = FALSE (TRUE, FALSE)

Tune to TRUE to turn the driver output #3 on.)

08 DISCRETE OUTPUT #3 (monitor)

Displays the output status of output #3

09 TURN ON DO4 dflt = FALSE (TRUE, FALSE)

Tune to TRUE to turn the driver output #4 on.

10 DISCRETE OUTPUT #4 (monitor)

Displays the output status of output #4

11 TURN ON CB AUX RELAY dflt = FALSE (TRUE, FALSE)

Tune to TRUE to energize the internal load sharing relay, observe the green LED
next to terminals 9 and 10.

12 LOAD SHARE RELAY (monitor)

Displays the status of the load share relay.

13 ADJUST ANALOG OUTPUT (%) dflt = 0.000 (0.00, 100.00)

Adjust 0 to 100 for analog output at 16 and 17 to change from 0 to 20mA.

14 ANALOG OUT (%) (monitor)

Displays the status of the analog output.

15 ADJUST ACTUATOR OUTPUT (%) dflt = 0.000 (0.00, 100.00)

Adjust 0 to 100 for actuator output at 13 and 14 to change from 0 to 200mA.

16 ACTUATOR OUTPUT (mA) (monitor)

Displays the status of the actuator output.

T**KW INPUT CALIBRATION**

This section calibrates the 2301D, 2301D-EC internal load sensor to correspond
its output to measured kilowatts. This calibration allows the control to calculate
the 100% load gain voltage, droop %, and load sharing ratio. For proper
calibration the generator load should be as close as possible to required
generator voltage and unity power factor.

01 KW INPUT CALIBRATN ZERO dflt = 0.000 (-20.00, 20.00)

Adjust until the KW reading below is zero when the generator output is zero.

02 KW INPUT CALIBRATN GAIN dflt = 13.000 (5.00, 40.00)

Adjusted to match the load sensor output to the external instrumentation
readings.

03 GEN OUTPUT (READ KW) (monitor)

The output of the engine sensed load (should match external instrumentation).

04 LOAD SIGNAL OUT (Vdc) (monitor)

Converts the generator kW into the load Gain voltage value.

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U**DISPLAY PID PARAMETERS**

This is a display of the input to the PID control. The values entered in the
Dynamic tuning section are normalized values and the values displayed here can
be used for stability analysis if needed.

01 DYNAMICS 2 ENABLED (monitor)

indicates the system is in the isochronous mode (CB aux is closed) and
Dynamics 2 values are input to the PID controller.

02 PID GAIN VALUE (monitor)

is the proportional value into the PID.

03 PID INTEGRAL GAIN VALUE (monitor)

is the Integral value into the PID, Reset rate.

04 PID SDR VALUE (monitor)

is the derivative or lead term into the PID.

V**ANALOG IN/OUTPUT CALIB**

01 AnIN 1, Offset dflt = 0.000 (–100.00, 100.00)
Sets the offset of analog input 1.

02 AnIN 1, Gain dflt = 1.000 (0.00, 10.00)

Sets the gain for analog input 1.

03 AnIN 1, mA / Volt (monitor)

Shows the actual input value for input 1.

04 AnIN 2, Offset dflt = 0.000 (–100.00, 100.00)

Sets the offset of analog input 2.

05 AnIN 2, Gain dflt = 0.000 (0.00, 10.00)

Sets the gain for analog input 2.

06 AnIN 2, mA / Volt (monitor)

Shows the actual input value for input 2.

07 Actuator, Offset dflt = 0.000 (–100.00, 100.00)

Sets the offset for the actuator output. This value should never need adjustment.

08 Actuator, Gain dflt = 0.000 (–100.00, 100.00)

Sets the gain for actuator output. This value should never need adjustment.

09 Actuator Output (monitor)

Shows the actual milliamp output value of the actuator.

10 Anout 4–20 mA, Offset dflt = 0.000 (–100.00, 100.00)

Sets the offset of analog output.

11 Anout 4–20 mA, Gain dflt = 0.000 (–100.00, 100.00)

Sets the gain of analog output.

12 Anout 4–20 mA, output (monitor)

Shows the actual output value.

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W**LOADPULSE SETTINGS**
To enable the Loadpulse, the kW calibration should be OK since the logic uses
the load change as a parameter.

The Loadpulse logic has been tested in August 2002 on a DG-set with a W200
engine. Activating the loadpulse logic did not result in significant improvement of
load-acceptance. There was improvement on the load-rejection tests.

01 ENABLE LOADPULSE dflt = FALSE (TRUE, FALSE)

This parameter enables (TRUE) or disables (FALSE) the Loadpulse logic.

The Loadpulse logic measures how fast the engine load changes in time. When
a large increase in engine load is detected, the speed reference is increased
momentarily to compensate for a drop in speed.

If a large decrease in engine load is detected, the speed reference is decreased

momentarily to compensate for a large speed overshoot.

02 SCALE LOADPULSE dflt = 1.000 (0.01, 10.00)

This allows for scaling of the kW signal.

03 LOW LVL ON dflt = –50.000 (–10000.00, 10000.00)

This represents the level (of change in engine load) at which the Loadpulse logic
is activated, for large load rejections. When this level is reached, then value
entered In SUBTR FRM SP is subtracted from the speed reference (or actuator
output).

04 HI LVL ON dflt = 50.000 (–10000.00, 10000.00)

This represents the level (of change in engine load) at which the Loadpulse logic
is activated, for large load acceptances. When this level is reached, then value
entered In ADD TO SP is added to the speed reference (or actuator output).

05 OFFSET dflt = 0.000 (–100.00, 100.00)

This represents the value to which the SUBTR FRM SP or ADD TO SP will
return. Normally, this value should be set at 0.0.

06 RATE TO SP dflt = 50.000 (0.00, 100.00)

This determines how fast (in rpm/s for speed reference, or actuator %/s) the
value entered in OFFSET is reached, from value entered in ADD TO SP or
SUBTR FRM SP.

07 SUBTR FRM SP dflt = –50.000 (–100.00, 100.00)

This represents the value that is subtracted from the current speed reference, or
from the actuator output in case of a large load rejection. This step is momentary
and will return to the value entered in OFFSET. The rate with which this happens
can be modified in RATE TO SP.

08 ADD TO SP dflt = 50.000 (–100.00, 100.00)

This represents the value added to the current speed reference, or from the
actuator output if a large load acceptance occurs. This step is momentary, and
returns to the value entered in OFFSET. The rate at which this occurs can be
modified in RATE TO SP. See Figure 4-12.

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Figure 4-12. LP Ramp

X**ADAPTIVE FILTER SET**

01 ADAPTIVE FILTER ENABLE dflt = TRUE (TRUE, FALSE)
Enables / Disables the Adaptive Filter used with Configure Menu B**ENG—GEN
CNTRL FUNCTIONS, 02 SPEED SENSING TYPE, #5—Adaptive Speed
Sensing.

02 ADAPTIVE FILTER GAIN dflt = 0.25 (0.01, 1.00)

This value is typically left at the default value.

Y**APPLICATION INFO**
01 APP SOFTWARE NUMBER (monitor)
Indicates the number of the software in the control.

02 APP SOFTWARE REVISION (monitor)

Shows the revision of the software in the control.

03 APPLICATION NAME (monitor)

The name of the application.

Z**COMM PORT (MODBUS)**

These menu items are only applicable for the 2301D-EC. The menu is used to
setup the serial port for use with Modbus.

01 PORT FAIL (monitor)

indicates a hardware fault of RS-232/RS-422 communication port

02 LINK ERROR (monitor)

indicates Link Error sets TRUE when the slave fails to answer a data request in
specified number of time-out seconds

03 ERROR PERCENT (monitor)

Error Percent outputs reflects communication quality as a percentage by dividing
the number of exception errors detected by the total number of communication
transactions. This essentially gives the number of message/packet errors
detected.
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04 ERROR NUMBER (monitor)
Error Number outputs the code number of the communication/exception error
that occurred.

CODE NAME MEANING

00 NO ERROR Error free
The following are returned to the master.
01 ILLEGAL Message function received is not an allowable action for
FUNCTION addressed slave. (Unsupported or illegal function code).
02 ILLEGAL Address referenced in data field is not an allowable address for
DATA the addressed slave location. (Master requested data, which is
ADDRESS not configured from slave).
03 ILLEGAL Amount of data requested from slave was too large for slave to
DATA VALUE return in a single response. Woodward maximum is 118
registers.
The following are displayed only.
09 CHECKSUM Error in the checksum. Can indicate link quality and/or noise
ERROR problems.
10 GARBLED Data received by the slave, but it is too short to be a valid
MESSAGE Modbus message/command.

Table 4-1. Communication Error Code

05 BAUD RATE dflt = 10 (1, 10)

Sets the Baud rate, which defines the transfer rate for port communications:
1= 110
2= 300
3= 600
4= 1200
5= 1800
6= 2400
7= 4800
8= 9600
9= 19200
10= 38400

06 BAUD RATE IS SET FOR (monitor)

Shows the selected Baud rate.

07 DATA BITS dflt = 2 (1, 2)

Sets the Data bits input defines the protocol for the number of data bits in the
data packets:
1= 7
2= 8

08 DATA BITS ARE SET FOR (monitor)

Shows the selected data bits.

09 STOP BITS dflt = 1 (1, 3)

Sets the Stop bits, which defines the number of stop bits for the communications
protocol. Stop bits specify the time that elapses between transmitted characters.
1= 1 stop bit
2= 2 stop bits
3= 1.5 stop bits

10 STOP BITS ARE SET FOR (monitor)

Shows the selected stop bits setting.

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11 PARITY dflt = 1 (1, 3)
Sets the Parity input defines protocol for the parity. If you selected 8 data bits
select '1' for none:
1= OFF (none)
2= ODD
3= EVEN

12 PARITY IS SET FOR (monitor)

Shows the parity setting.

13 DRIVER dflt = 1 (1, 2)

Sets the Driver input defines the type of driver output for this port.
1= RS232
2= RS422

14 DRIVER IS SET FOR (monitor)

Shows the selected driver.

15 TIME OUT (SEC) dflt = 2.000 (0.00, 100.00)

Sets the Time-out Number of Seconds input defines the Modbus link dead time
allowed before a link error occurs.

16 NETWORK ADDRESS dflt = 1 (1, 247)

Sets the Network Address input defines the slave block address on the Modbus
network. The network address may depend on master device allowable
addresses.

17 ENABLE MODBUS CONTROL dflt = FALSE (TRUE, FALSE)

Set this value to TRUE to enable the Modbus command.

18 USE MODBUS ANALOG CNTRL dflt = FALSE (TRUE, FALSE)

Set this to TRUE if you want to use the analog Modbus speed setting/baseload
reference.

NOTE
When parameter 18 is set TRUE the analog inputs are disabled. If the
communication fails the speed setting/baseload setting will go to minimum.
The analog settings are not latched to the last value.

Saving The Tunable Values

When done with the tuning procedure, make sure that they are saved in the

control. This is accomplished by clicking on the “Save” icon. Failure to do

this might cause the control to reset back to the default numbers.

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Chapter 5.
Initial Control Settings

Initial Prestart Settings

WARNING—FOLLOW INSTRUCTIONS
Read this entire procedure before starting the prime mover.

1. RATED SPEED—Set to Generator synchronous speed.

2. Set the correct number of gear teeth in “Enter number of gear teeth”.
3. Select the proper speed function.
4. Set the overspeed setting, usually 110 to 115% of the rated speed. Make
sure that there is always a separate overspeed detection device to protect
the engine form overspeed!
5. For initial startup, configure the control for single slope gain dynamics. Turn
off DYNAMICS 2, use only Dynamics 1 adjustments for initial startup.
6. IDLE PROP GAIN – Set at 1.0
7. RATED PROP GAIN 1—Set at 2.0.
8. RESET 1—Set at 1.0.
9. ACTUATOR COMPENSATION 1—Set the ACTUATOR COMPENSATION
at 0.1 for diesel or fuel injected gasoline prime movers. Set the ACTUATOR
COMPENSATION at 0.35 for carbureted gas or gasoline prime movers.
10. Set GAIN RATIO 1 to 1.0 to disable the effect of window width and gain ratio.
11. ACCEL RAMP TIME—Set at 20 sec.
DECEL RAMP TIME—Set at 20 sec.
12. LOW IDLE SPEED—Set at idle speed rpm, (no lower than 20% of rated).
13. LOAD GAIN—Set at 1.0, or the value of other load sharing controls on a
common bus.
14. DROOP—Set at desired percentage.
15. START FUEL LIMIT—Set at 100%.
16. Be sure the actuator is connected to terminals 13 and 14 and the speed
signal connected to terminals 25 and 26.

Start-up Adjustments
1. Complete the Configuration Procedure in Chapter 4, and the initial prestart
settings above.

CAUTION—RATED SPEED & NUMBER OF GEAR TEETH

Be sure the Rated Speed and Number of Teeth are set correctly for your
application as described earlier in this chapter.

2. Close the Close For Rated contact. Set the control for isochronous operation
by closing the droop/CB Auxiliary and the generator Load contact.

NOTE
This is for initial prime mover start-up only. For normal start-up, the Close
for Rated contact (open for idle/close for rated) should be open if the prime
mover is to start at idle.

3. Apply input power to the control.

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4. Preset rated speed (optional).
When using a signal generator to verify the proper configuration setting: set
the signal generator for the frequency of the speed sensor at rated speed,
and connect it to terminals 25 and 26. (The rated speed frequency in Hz
equals the rated prime mover speed in rpm times the number of teeth on the
speed sensing gear divided by 60.) Put the Close For Rated contact in the
rated (closed) position. Connect a dc analog voltmeter to terminals 13(+)
and 14(–) to read actuator voltage. If the actuator voltage is at minimum
(minimum will be approximately 0 volts), slowly decrease the input
frequency (increase for reverse acting controls) until the voltage just begins
to move to maximum. If the actuator voltage is at maximum, slowly increase
the input frequency (decrease for reverse-acting controls) until the voltage
just begins to move to minimum. Continue to very slowly adjust the input
frequency in the appropriate direction, trying to stop the actuator voltage
between the minimum and maximum voltages. Because it is not possible to
stop the motion, cease adjusting when the voltage changes slowly. The
RATED SPEED configuration has been verified. No further adjustment
when the engine is running will be necessary.

5. Check the speed sensor.

Minimum voltage required from the speed sensor to operate the electronic
control is 1.0 Vrms, measured at cranking speed or the lowest controlling
speed. For this test, measure the voltage while cranking, with the speed
sensor connected to the control. Before cranking, be sure to prevent the
prime mover from starting. The frequency required to clear the Loss of
Speed shutdown is entered as a percent of rated speed during
configuration. For example, at 5% of 1800 rpm rated speed, the failed speed
sensing circuit is cleared at 90 rpm.

WARNING—EMERGENCY STOP
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.

6. Start the prime mover.

Adjust for Stable Operation

If prime mover operation is stable, go to the “Speed Setting Adjustment”
procedure. If the prime mover is hunting at a rapid rate, slowly decrease the
GAIN until performance is stable. If the prime mover is hunting at a slow rate,
increase the RESET until the prime mover stabilizes. If increasing the RESET
does not stabilize the prime mover, it also may be necessary to either:
• Slowly decrease the GAIN or
• Slowly decrease the GAIN and increase the ACTUATOR
COMPENSATION.

For the PID adjustment see Chapter 6, Alternate Dynamic Adjustments.

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Dynamic Adjustment
The object of the PROPORTIONAL GAIN, RESET, and ACTUATOR
COMPENSATION adjustment is to obtain the optimum, or desired, stable prime
mover speed response. Connect a dc analog voltmeter to terminals 13(+) and
14(–) to monitor the actuator voltage.

Increasing the setting of the GAIN to provides faster transient response

(decreases the magnitude of the speed change from a sudden change in load).
To achieve optimum response, slowly increase the GAIN until the voltage on the
voltmeter becomes slightly unstable, then slowly lower the GAIN as necessary to
stabilize the meter reading. Step load the generator, bump the actuator terminal
shaft, or use the software “Bump Act Trigger (T then F)”in the dynamics tuning
sections, to make sure that the prime mover returns to the proper speed with little
overshoot or undershoot of the speed setting. To reduce overshoot, increase the
RESET. If the prime mover is slow in returning to the proper speed, decrease the
RESET.

Actuator Compensation Adjustment

If the ACTUATOR COMPENSATION is set as described under Initial Prestart
Settings, no further adjustment is normally required. If a slow periodic instability
remains, slightly increase the ACTUATOR COMPENSATION, and repeat the
GAIN and RESET adjustments. Continue to increase the ACTUATOR
COMPENSATION and readjust the GAIN and RESET until stability is achieved. If
a fast instability or extremely active actuator is evident, slightly decrease the
ACTUATOR COMPENSATION. If necessary, the ACTUATOR
COMPENSATION may be set to .01. This may be required when engine
torsionals cause excessive fuel-linkage movement.

Ramp Time Adjustment

Adjust the ACCEL RAMP TIME to achieve satisfactory prime mover acceleration
to rated speed with minimum overshoot. The number entered is the time in
seconds to change speed from idle to rated.

Adjust the DECEL RAMP TIME to achieve satisfactory prime mover deceleration
to idle speed with minimum undershoot. The number entered is the time in
seconds to change speed from rated to idle.

Raise/Lower Time Adjustment

Adjust the RAISE SPEED TIME to achieve satisfactory prime mover acceleration
toward the raise speed limit with minimum overshoot. The number entered is the
time in seconds to change speed from LOWER SPEED LIMIT to RAISE SPEED
LIMIT.

Adjust the LOWER SPEED TIME to achieve satisfactory prime mover

deceleration toward the lower limit with minimum undershoot. The number
entered is the time in seconds to change speed from RAISE SPEED LIMIT to
LOWER SPEED LIMIT.

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Start Fuel Limit Adjustment

With the prime mover operating at rated speed and no load, note the Fuel
Demand % displayed on the HMI. Set the Start Fuel Level 10% higher than the
fuel demand noted above. Shut down the prime mover. Start the prime mover
and observe the start time, overshoot of speed setting, and smoke emissions
obtained. The Start Fuel Limit may be adjusted as required to optimize the prime
mover starting characteristics. When the prime mover start is initiated the fuel is
set to the start fuel limit, the fuel level is then increased at the rate set by Start
Ramp Rate (%FD/Sec). The fuel-limiting function is turned off automatically when
the speed control takes over.

NOTE
For prime movers not requiring start fuel limiting, the START FUEL LIMIT
function can be deactivated by setting the Start Fuel Limit to 110%.

Speed Sensor Check

Measure the voltage across terminals 25 and 26 to be sure there is a minimum of
1.0 Vrms at cranking speed, and a maximum of 25 Vrms at rated speed. If the
voltage exceeds 25 Vrms, increase the gap of the speed sensor, and be sure
that there is still a minimum of 1.0 Vrms at cranking speed.

Current Transformer (CT) Phasing Check

NOTE
This control contains internal current transformers. Due to their low
impedance, shorting their inputs is not effective. The current input must be
removed from the control and shorted externally.

WARNING—HIGH VOLTAGE
Never disconnect any wire attached to load sensor terminals 4 through 9
when the prime mover is running unless temporary 0.5 A, 20 W resistors are
installed as shown in Figure 5-1, and all load is removed. The current
transformers can develop dangerously high voltages when open circuited
while the prime mover is running.

1. Go to the T**KW INPUT CALIBRATION** sheet and observe 03 Gen

Output (read KW) , and LOAD SIGNAL OUT to measure the load sensor
output. The displayed values are not yet calibrated to read Kilowatts, but is
used here for indication.
2. Start the prime mover. With the generator operating in the isochronous mode
and not paralleled, load the generator to as near to full load as possible.
3. Use a clamp-on ammeter and measure the per phase current of the Current
transformer output. Check that current in each of the three CTs are equal. In
a balanced three phase system the Load Signal Out reading will be
approximately:

Load Signal Out = kW Input Calibration Gain X 0.1 X Amps (RMS reading of
one phase)

A clamp-on ammeter is recommended to eliminate the need to open CT

wiring to insert an ammeter in series with the CT output.

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4. If the Load Signal Out Reading is within 10% of the above calculation, the
PT/CT phasing is correct. If the phasing is incorrect, proceed to the Phase
Correction Procedure. If the phasing appears correct, skip the Phase
Correction Procedure and go to the Load Calibration Adjustment procedure.

NOTE
If after completing the LOAD SENSOR CALIBRATION and DROOP
adjustments, the control loading is extremely sensitive to changes in the
power factor when operating in parallel, complete the phase correction
procedure.

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 reading given in this calibration procedure
proportionally. For example: run a 200 kW generator set at 100 kW and
divide all voltages given in this calibration procedure by 2. If you reduce the
load in this manner, be sure to reduce it by the same amount throughout the
calibration procedure.

Phase Correction Procedure

NOTE
This procedure requires a minimum power factor of (.9). If a .9 power factor
cannot be obtained, tracing through the wiring is the only means of
correcting the current transformer phasing.

The highest positive reading of kW or Load Signal Out will be obtained when the
CTs are correctly matched to the load sensor terminals in both phase and
polarity. The following procedure will assure the correct connection of the current
transformers. It is required only if the phasing check indicates incorrect phasing,
or loading stability is extremely sensitive to the power factor.

Make trial connections of the first CT to all three load sensor inputs, polarized
both ways (a total of six connections). Record the Load Signal Out reading for
each connection. Connect the first CT to the terminals that produce the highest
positive reading, and with the polarity that produces the highest positive voltage.
The displayed Load Gain reading is limited to about 0.2, therefore a negative
reading indicates a phasing or polarity error.

Try the second CT on each of the remaining two CT input terminals, in each
polarity, and record the Load Signal Out reading. Connect the second CT to the
terminals that produce (and with the polarity that produces) the highest positive
reading.

Try the last CT on the remaining input terminals, polarized both ways, and record
the voltage. Connect the last CT in the polarity that produces the highest Load
Signal Out reading.

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The Phase Correction Procedure requires that the prime mover be shut down
many times to disconnect the current transformers. For convenience, a
temporary method of connecting the current transformers shown in Figure 4-1 is
recommended. Connecting a 0.5 A, 20 W burden resistor across each current
transformer allows the current transformers to be disconnected from the terminal
strip with the prime mover running, after removing all load.

WARNING—HIGH VOLTAGE
The current transformers can develop dangerously high voltages. Do not
disconnect a current transformer while the prime mover is running unless
temporary 0.5 A, 20 W resistors are installed as shown in Figure 5-1, and all
load is removed.

Figure 5-1. Temporary Wiring for Transformer Phase Correction

If the temporary burden resistors described above and shown in Figure 4-1 are
not used, the prime mover MUST be shut down in addition to removing the load
in the following procedure.

Monitor the load sensor output in this procedure by connecting an external

computer and entering the Watch Window sheet for T**KW INPUT
CALIBRATION**. Observe 03 Gen Output (READ KW) Load Sensor calibration
and monitoring. Since the kW calibration cannot be completed until the phasing
is correct, the value shown is for reference only. The Load Sensor of the 2301D,
2301D-EC will only read a small negative value.

1. Shut down the prime mover.

WARNING—HIGH VOLTAGE
The current transformers can develop dangerously high voltages. Do not
disconnect a current transformer while the prime mover is running unless
temporary 0.5 A, 20 W resistors are installed as shown in Figure 4-1, and all
load is removed.

2. Label each CT wire with the phase and polarity that you think it should be.
Even though this identification may prove to be incorrect, this step is
necessary so that the individual wires can be identified during the description
of the procedure.
3. Disconnect the phase B CT wires from terminals 6 and 7. Connect these two
wires together using a small screw and nut, and tape the connection.

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4. Disconnect the phase C CT wires from terminals 8 and 9. Connect and tape
these two wires together as in Step 3.
5. Connect the two wires from the phase A CT to the phase A input terminals 4
and 5.
6. Start the prime mover, apply full load, and monitor the load sensor output.
Start a list and record this value.
7. Unload the system and reverse the phase A CT wires on terminals 4 and 5.*
8. Apply full load, monitor the load sensor, and record this value.
9. Unload the system, remove phase A CT wires from terminals 4 and 5, and
connect them to phase B input terminals 6 and 7.*
10. Apply full load, monitor the load sensor, and record this value.
11. Unload the system and reverse the phase A CT wires on terminals 6 and 7.*
12. Apply full load, monitor the load signal, and record this value.
13. Unload the system, remove phase A CT wires from terminals 6 and 7, and
connect them to phase C input terminals 8 and 9.*
14. Apply full load, monitor the load sensor, and record this value.
15. Unload the system and reverse the phase A CT wires on terminals 8 and 9.*
16. Apply full load, measure the load signal, and record this reading.
17. Unload the system and compare the six readings taken.*
18. Remove the phase A CT wires from terminal 8 and 9 and connect the phase
A wires to the pair of terminals that produced the highest positive load value
and in the polarity that produced the highest positive load value.
19. Untape and disconnect the phase B CT wires. Connect the phase B CT
wires to one pair of the two remaining pairs of CT input terminals on the load
sensor.
20. Apply full load and measure the load signal. Start a new list and record this
reading.
21. Unload the system, and reverse the phase B CT wires on the same
terminals.*
22. Apply full load, measure the load signal, and record this reading.
23. Unload the system, remove phase B CT wires, and connect them to the
other pair of terminals.*
24. Apply full load, measure the load signal, and record this reading.
25. Unload the system and reverse phase B CT wires on the same terminals.*
26. Apply full load and measure the load signal. Record this reading, and
compare the four readings on the list.
27. Unload the system. Remove the phase B CT wires and connect them to the
pair of CT input terminals that produced the highest positive load signal
reading and with the polarity that produced the highest positive load signal
reading.*
28. Untape and disconnect the phase C CT wires. Connect these two wires to
the remaining pair of CT input terminals.
29. Apply full load, measure the load signal, and record this reading.
30. Unload the system and reverse the phase C CT wires on the same
terminals.*
31. Apply full load, measure the load signal, and record this reading.
32. Unload and shut down the system. Compare the two readings.*
33. Connect the phase C CT wires to the same pair of CT input terminals, but in
the polarity that produced the highest positive load signal reading.
34. Re-label each wire with the phase designation of the terminal that it is now
connected to.
35. Remove the burden resistors and terminal block.

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Load Calibration Adjustment

For this procedure, the generator must be running isochronously and not paralleled.

Start the prime mover and apply full load. With the Watch Window at T**KW
INPUT CALIBRATION**, observe 03 Gen Output (READ KW). If this reading
does not match external instrumentation, adjust calibration gain and offset until
Watch Window value matches metering. The values should match at all
intermediate points.

CAUTION—CURRENT TRANSFORMER SIZE

If values at full load (or a lower reading proportional to a load less than
100%) cannot be obtained, and the phasing has been checked and is correct,
the current transformers are probably the wrong size. The current-
transformer output must be from 3 to 7 A (5 A nominal) at full load.

When paralleled in isochronous mode or on an isolated bus, generator speeds

must be the same. If speed references are not equal, load sharing will not remain
proportional as the load varies. Any difference in loads between the units can be
corrected by adjusting the Load Gain. Increasing the LOAD GAIN will cause that
generator to carry less load. If stability problems occur when paralleled at a
particular load signal reading, reduce the reading by reducing the LOAD GAIN,
and reduce the load signal reading setting of all other generators in the system to
the same reading. When the load signal readings of all generators 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 reading of each unit in the system
to as low as 3 volts in cases of extremely poor system dynamics. If your system
requires a load signal reading as low as 3 volts, consult Woodward for
suggestions for possible remedies.

Droop Adjustment
Because of the calculation available in the control, the droop percentage entered
will result in the correct speed change if the KW sensor is properly calibrated.
The droop percent is automatically corrected for load gain voltage values. The
speed trim range can be configured to stop the speed reference at 100% load, or
if a F reference source is used its range can be set to give no load to full load
limits.

Figure 5-2. Droop Adjustment

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Chapter 6.
Alternate Dynamic Adjustments

Introduction
This procedure, based on the Zeigler-Nichols Method, is an empirical method to
find first-pass settings for gain, reset, and actuator compensation in a PID
controller. First, the controller is set up to act as a proportional-only controller by
removing the effect of the reset and actuator compensation terms. The system is
then bumped and the resulting response is examined. Gain is slowly increased
until the point of marginal stability is found. Once that point is found, some
calculations are done using the period of oscillation and the gain value. The
results of the calculations are gain, reset, and actuator compensation that can be
plugged into the control. This procedure has been used to find a good set of
initial settings for the PID controller. This section also describes adjusting some
other parameters to improve on the initial settings.

Adjustment
Setup
1. Complete the start-up adjustments described in Chapter 5, Initial Control
Settings. The engine should now be somewhat stable. The settings should
also be saved to EEPROM.
2. Copy the settings you have right now from 1st dynamics to 2nd dynamics.
Save these values to EEPROM. As you go through the following steps, you
will be trying to find the point of marginal stability. That means that you will
be very close to the point of instability. You are likely to adjust the gain a little
bit too far and go into an unstable condition. When that happens, you will see
the engine start to run away and approach overspeed or stall. The reason
the dynamic settings are copied from 1st dynamics to 2nd dynamics is to
allow you to quickly switch to settings that can control the engine and keep it
from running away or dying. We recommend you use either a jumper or a
switch to allow you to quickly select 2nd dynamics as you are performing this
procedure so that you are confident you always have the ability to control the
engine speed.
3. Connect a chart recorder to record engine speed. Analog output 1 default
configuration provides a 4–20 mA signal proportional to engine speed. If
necessary, set the CFIG ANALOG OUTPUTS to read engine speed on
another configurable analog output if analog output 1 is being used for
something else.
4. Enable slight Firing Torsional Filtering by setting the SPEED FILTER
frequency at 15.8 Hz. This setting is found in the Dynamics service menu. A
lower setting may be necessary if firing torsionals are exceptionally high due
to combustion instability, etc. However, a setting below 10 Hz is not
recommended.

Gain, Reset, and Actuator Compensation Adjustments

5. The engine should now be running at no load, idle speed. Start the chart
recorder. Remember, when doing any of these adjustments, you can get the
engine back to running stable by switching in the 2nd dynamics. Select 1st
dynamics now. Reduce the gain by 50%.

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6. Disable the Reset (integral) and Compensation (derivative) dynamic actions
by setting both to 0.01.
7. Disable Window Width by setting the Gain Ratio at 1.0 and the Window
Width at 60 rpm.
8. Disable Gain Slope by setting it at 0.0.
9. The engine should still be stable. If it is not, reduce the gain further.
10. With the engine running at no load, idle speed; increase the gain one click at
a time until a sustained speed oscillation is only just obtained. In between
clicks, use the actuator bump feature to introduce a very small bump to the
system (1% fuel demand, 0.020 seconds works well). The system
oscillations will either die out in a short amount of time (stable), stay at the
same amplitude for a long time (marginally stable), or keep increasing in
amplitude (unstable). To start with, you will most likely be in the stable range,
where the oscillations die out with time. As you increase the gain, you will
eventually go into the unstable region, where you might need to switch back
to 2nd dynamics to get the engine under control. Reduce the gain and switch
back to 1st dynamics. Keep slightly adjusting the gain up or down until you
find the setting that gives you the point of marginal stability. When you are
there, the oscillations will neither decrease nor increase in amplitude. If you
can maintain a constant amplitude for 30 seconds to a minute, you have
found the point. If the oscillations die out, your gain is too low. If they keep
getting bigger, your gain is too high. Adjust if required. The following trace
(Figure 5-1) is an example. Write down the Gain setting (5.92 in this
example) and call it Ku. This is needed to calculate final settings.

Figure 6-1. Trend Tool Trace Example 1

11. After recording the speed oscillations for 30–60 seconds, reduce the gain to
stop the oscillations.
12. Measure the elapsed time for several speed cycles and calculate the time
per cycle in seconds and call this value Pu. In the above trace, each vertical
grid line represents 3 seconds elapsed time, so 15 speed cycles occur in 47
seconds. Pu in this example is 47 divided by 15, which equals 3.133 seconds
per cycle.
13. Calculate dynamic settings as follows:

Gain = Ku divided by 1.7. In the above example this is 5.92/1.7 = 3.48.

Reset = 2 divided by Pu. In the above example this is 2/3.133 = 0.64.
Compensation = Pu divided by 8. In the above example this is 3.133/8 = 0.39.

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14. Enter the calculated Reset, Compensation, and Gain setting into the control.
Save these settings in the control. The assumption is these settings will
produce good performance as shown in Figure 5-2. If this is not the case,
recheck all readings and calculations or repeat this entire procedure.

Figure 6-2. Trend Tool Trace Example 2

15. Bump the actuator (you can use a larger bump this time) to test control
response. Figure 5-2 shows the expected response.

Figure 6-3. Trend Tool Trace Example 3

16. Initiate load steps on and off to confirm acceptable and stable response.
Figure 5-3 shows the expected response. Note how the fuel demand
increases/decreases quickly with negligible overshoot.
17. This usually concludes the dynamic adjustment for one set of dynamics.
These settings are typically robust. Overly aggressive adjustments should be
avoided if possible. The Reset and Compensation settings produced by this
procedure are normally not changed. Increases to the Gain may produce
some improvement in the load transient response, however Window Width
and Gain Ratio (to be described in the next few steps) may be more
effective. It is also our experience that these settings are good for rated
speed as well as idle speed. Verify this for yourself by changing to rated
speed and performing some load transients. If you feel that the response can
be improved, we recommend leaving Reset and Compensation as they are
and only adjusting Gain.
18. Repeat this procedure for other dynamic adjustment sets as considered
necessary for alternate fuel supplies or operating conditions.

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Gain, Window Width, and Gain Ratio Adjustments

19. When extra load transient response improvement is needed, adjust the Gain
and/or Gain Ratio and Window Width. The following traces show examples
of the process used to obtain optimum transient response settings. The step
that increases Gain may be skipped in favor of Window Width and Gain
Ratio adjustments only.

Figure 6-4. Trend Tool Trace Example 4

20. Figure 5-4 shows the transient response with the Gain Ratio and Window
Width disabled. In this example Gain is 1.235; Reset is 0.28, and
Compensation is 0.88. Load step is ~15%.

Figure 6-5. Trend Tool Trace Example 5

21. Figure 5-5 shows results of just increasing Gain from 1.235 to 3.0. Gain
Ratio and Window Width remain disabled. Peak rpm is reduced
approximately 10–12 rpm.

Figure 6-6. Trend Tool Trace Example 6

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22. Figure 5-6 shows results of ultimately increasing Gain Ratio from 1.0 to 3.0
and decreasing Window Width from 60 rpm to 5 rpm. Overall peak rpm has
been reduced approx 30 rpm. The fuel demand is steeper with little
overshoot and roll-off. The speed roll-off is extended slightly by the Window
Width and Gain Ratio settings. This is normal.
23. Begin the Window Width and Gain Ratio adjustment process by increasing
the Gain Ratio from 1.0 to 2.0, then reduce the Window Width from 60 rpm in
10-rpm increments. Actuate an actuator bump or load on and load off step
after each adjustment and observe the change in peak engine speed.
Initially, the window will be too wide to cause any change in peak speed.
Eventually a reduction will be observed. Be prepared to first reduce the Gain
Ratio, or second increase the Window Width, if severe instability occurs due
to cycling through the low gain region. Do not attempt smaller Window Width
settings if this occurs. It may be useful to set the alternate (1st or 2nd)
dynamics to produce a stable engine speed and to switch to these dynamics
should severe instability occur while setting Gain Ratio and Window Width.
Otherwise, continue the Window Width reduction and actuator bump
response down to 10 rpm, and then reduce to 5 rpm. Reductions below 5
rpm are not recommended. Increase the Gain Ratio as needed to obtain the
desired response. The objective is to set the smallest Window Width with the
highest Gain Ratio without going unstable. If the Gain Ratio setting that
causes severe instability is known, then the final setting should not be more
than half of this amount.
24. Eventually a point is reached where no further improvement is possible. The
fuel demand overshoot should be minimal. Reduce the Gain or Gain Ratio as
needed to reduce the fuel demand overshoot.

Gain Slope and Gain Break point Adjustments

25. Gain Slope is an adjustment that increases gain as load (fuel demand)
increases. This adjustment should not be changed from 0.0 until the
previously described adjustments have been made. While it is possible to set
a negative Gain Slope which decreases gain as load increases, it is
considered unnecessary and not recommended.
26. The objective of these adjustments is to add gain at high engine loads to
improve transient load response. If the transient load response is already
acceptable, no adjustments are needed. Otherwise proceed as follows:
27. Set the Gain Break point equal to the no-load minimum speed fuel demand.
The actual fuel demand minus the Gain Break point setting is multiplied by
the Gain Slope to add gain when load increases. When the actual fuel
demand is at no-load, the difference is zero, therefore zero gain is added at
no-load.
28. Set Gain Slope while the engine is operating at or near rated load. Gradually
increase the Gain Slope in 0.5 increments, and bump the actuator or make a
step load change to measure the transient response. Continue this process
until the desired transient load response is achieved or excessive instability
occurs. Should excessive instability occur, reduce the setting to one-half of
the setting that produced this instability.

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Chapter 7.
Troubleshooting

Introduction
The following troubleshooting guide is an aid in isolating trouble to the control
box, actuator, plant wiring, or elsewhere. Troubleshooting beyond this level is
recommended ONLY when a complete facility for control testing is available.

NOTE
The control can be damaged with the wrong voltage. When replacing a
control, check the power supply, battery, etc., for the correct voltage.

Troubleshooting Procedure
This chapter is a general guide for isolating system problems. The guide
assumes that the system wiring, soldering connections, switch and relay
contacts, and input and output connections are correct and in good working
order. Make the checks in the order indicated. Various system checks assume
that the prior checks have been properly done.

WARNING—EMERGENCY STOP
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.

Control Start-up
When the control is powered on, the CPU begins execution of a section of the
software program known as the boot code. This code performs hardware
diagnostics and checks that a valid application program has been installed.
During this period all control outputs will remain disabled. The boot code takes
approximately 30 seconds to execute. During this period the red status LED
should be on. When execution of the boot code has completed, control will be
transferred to the application program. When the application program begins, the
control outputs will be enabled and system control will begin. At that point the red
status LED will be turned off and should remain off as long as the control is
running.

If the control fails its self-test diagnostics during boot, fails its on-line self-tests
while running the application program, or fails in any other way that it can detect,
then the CPU will blink the red status LED to indicate the failure.

CAUTION—SHUT PRIME MOVER DOWN

To prevent damage to the prime mover, the prime mover must be shut down
for all system checks.

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Control Test and Calibration

General
Do the following checks on the 2301D, 2301D-EC control. Then verify the
functioning of set points and adjustments.

1. Connect a computer to the communication port. Start Watch Window HMI

software in accordance with the instructions in Chapter 4. Verify that correct
voltage and polarity are applied to the control.
2. Verify the controller ID on the 2301D, 2301D-EC Standard PC Interface by
clicking “Control” then “Properties”. The Application ID message (part
number with the revision level [new, A, etc]) should appear.
3. Select the 1st Dynamics Menu. Verify that all set points are as recorded
during installation. Repeat for the other menus. If any differences are found,
change the set point(s) to the correct value. Click the “SAVE VALUES” icon
on the Tool bar. Remove power from the control for at least 10 seconds.
Verify correct values were retained during power down. Failure indicates the
control has failed and should be replaced.

Discrete Inputs
Do the following test to verify the function of the discrete inputs. Do NOT do this
test with the engine running.

1. Repeat this step for all discrete inputs. Close the appropriate input. The
status in DISPLAY DIGITAL I/O should switch from OPEN to CLOSED. If the
value does not change when the contact is closed, the control has failed and
should be replaced.

Discrete Outputs
To Verify operation of the Discrete Outputs, go to the RELAY AND ANOUT
TESTS sheet. With the engine shut down, enable the manual relay driver test.
Open another inspector sheet, select DISPLAY DIGITAL I/O, and monitor the
discrete outputs DO1—DO4. From the relay test procedure, each discrete output
may be activated and its operation verified. If the output is activated, the same
voltage as applied at terminal 39 and 40 should be measured between terminal
39 and the appropriate output terminal (41–44). Testing of the internal CB Aux
relay may be done by observing the green LED near terminal 9 and 10, or
hearing an audible ‘click’. The manual relay test must be disabled (status “test
off”) or the control will hold the actuator current to minimum.

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Troubleshooting Charts
Symptom Cause Solution
Prime mover will not Supply voltage polarity reversed On power up the CPU status LED should
start. Actuator not (dc only), or no supply voltage. come on for 30 seconds.
moving to start fuel
position. Check for proper voltage from terminals
45(+) to 46(–). Reverse leads if polarity is
NOTE incorrect.
If the actuator moves to Actuator not responding to input If there is a voltage output at control
start position, a signal from control. terminals 13(+) and 14(–), but the actuator
problem with the prime does not move, the wiring to the actuator
mover fuel supply is NOTE should be checked for opens or shorts. With
indicated. The hydraulic actuator must the EG3P actuator, remember that
have oil pressure and gear terminals C and D of the mating plug should
rotation to operate (respond). be jumpered.

Make resistance checks at the actuator.

Coil resistance on Woodward actuators is
approximately 35 A. (Read with leads at
terminals 13 and 14 disconnected.)
Start fuel limit set too low. Check Fuel Demand % in the Display
Menu. If it is not going to Start Fuel value
when cranking, check to see Engine Speed
is reading cranking speed. If Fuel Demand
is reading 0, increase the Start Fuel Limit.
Actuator or linkage. Check actuator and linkage for proper
installation and operation. Problems may be
oil supply, direction of rotation, insufficient
drainage, linkage, worn actuator
components, or improper adjustment.
No actuator voltage at terminals Check for shorted or grounded actuator
13 and 14. leads by removing wires to terminals 13 and
14. Stop prime mover. Close the switch on
terminal 32 (Failed Speed Sensor
Override). Check for 18 to 22 V at terminals
13 and 14 for forward acting controls, and 0
to 1 volt for reverse acting controls.

Check that Display Menu is reading engine

speed during cranking. If no speed reading ,
check the MPU.

Check for at least 1 Vrms at terminals 28

and 29, and at least 5% of the minimum
rated speed frequency range.
Speed setting too low on initial Control may be configured for the wrong
start. speed range. Check that the number of
teeth and the rated speed have been
entered correctly. Speed setting may be
lower than cranking speed. Control should
be set for rated speed.
LOW IDLE SPEED setting may be Check that the LOW IDLE SPEED setting is
set too low. entered correctly.
Minimum Fuel contact open. See Check terminal 31. Minimum fuel contact
“MINIMUM FUEL CONTACT” in must be closed for normal operation. Check
Chapter 3. for 20 to 40 Vdc from terminal 31(+) to
30(–).

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Symptom Cause Solution

Prime mover will not Speed sensor signal not clearing Check wiring for proper connection. Check
start. Actuator not failed speed signal circuit. shields for proper installation. Check the
moving to start fuel Display Menu for Engine Speed reading.
position (continued).
Speed sensor not spaced properly—check
for at least 1.0V ac at terminals 25 and 26
during cranking. If less that 1.0 Vac,
magnetic pickup may be spaced too far
from gear. Make sure there are no metal
chips on end of pickup.

If no voltage is present, magnetic pickup

may be open-circuited or shorted. Make
resistance check with the leads
disconnected from control. Should be about
100 to 300 Α.

Failed speed signal circuit may be disabled

by connecting terminal 28 to terminal 32.

WARNING
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.
Faulty 2301D control. Replace.
Prime mover overspeeds Ramp adjustment. Increase RAMP TIME. This decreases
only on starts. acceleration rate (from idle to rated).
RATED SPEED setting too high. Check that RATED SPEED is entered as
described in Chapter 4. Verify the Fuel
Demand % drops to minimum (0%) when
engine speed is greater than speed
reference.
Dynamics adjustment. Dynamics may be adjusted for sluggish
operation, causing overspeed on start.
Adjust GAIN for fastest stable response.
RESET may be adjusted too low. Increase
RESET setting.
Determine if engine is Verify that fuel rack is not binding and
malfunctioning. linkage is properly adjusted. Determine if
the fuel rack is quickly following the actuator
input voltage. Check operation of overspeed
protection device(s).
Prime mover overspeeds Start Fuel Limit is inactive. Power up 2301D before cranking engine.
or causes excessive 2301D control. If the control does not cut back the actuator
smoke only on starts. voltage [terminals 13(+) and 14(-)] when
engine speed is greater than speed
reference, the control may be programmed
for the wrong speed range. If the voltage is
cut back, look for a problem in the linkage
or actuator.

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Symptom Cause Solution

Prime mover overspeeds Prime mover. Check for proper operation of prime mover
after operating at rated fuel system. If actuator moves toward
speed for some time. minimum fuel during overspeed, problem is
in fuel system.
Magnetic pickup and 2301D Check the magnetic pickup output voltage
control. at speeds above idle—at least 1.0 Vrms. If
magnetic pickup should fail and the override
failed speed signal circuit is disabled, the
2301D control will call for maximum fuel.
2301D control. Control the prime mover manually at rated
speed. If the Engine Speed reading in the
Display Menu does not match external
indicators, the control is not configured
properly. When the engine speed value is
greater than the speed reference value, the
output voltage should be zero. If speed
range is correct for the application, replace
the control.
Low speed is not NOTE The LOW IDLE SPEED setting may be
regulated by LOW IDLE On carbureted prime movers, below the minimum fuel position of the
SPEED. the minimum fuel stop rpm actuator or prime mover fuel stop. In this
setting will vary with prime case, the output voltage to the actuator will
mover temperature. An be zero.
improper cold setting may give
interference with the LOW IDLE The engine will be maintained at the
SPEED setting when the prime minimum fuel position by the actuator or the
mover is hot. prime mover minimum fuel stop. The
conditions above indicate that the prime
mover minimum fuel position should be
decreased by linkage adjustment (diesel
engine) or low idle set screw (gas engine),
or the LOW IDLE SPEED setting should be
raised. If this action does not correct the
problem, the 2301D control may be faulty.
Prime mover does not Faulty Close for Rated contact. Check Close for Rated contact. Remove
decelerate when Close wire from terminal 32. Prime mover should
for Rated contact is decelerate.
open. LOW IDLE SPEED set the same Check the Speed Settings Menu.
as rated
Generator Aux contact is closed. A faulty Close for Rated contact may remain
in the accelerate position with the contact
open.

In general, adjustment of LOW IDLE

SPEED will vary the speed of the prime
mover with the Close for Rated contact in
the decelerate (open) position. Adjustment
of LOW IDLE SPEED should not affect
prime mover speed when the Close for
Rated contact is closed.

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Symptom Cause Solution

Prime mover will not 2301D control. Adjust GAIN, RESET, and ACTUATOR
stabilize at rated no load COMPENSATION as described in “Adjust
speed. The instability for Stable Operation” and “Dynamic
may occur at no load or it Adjustment” in Chapter 4.
may vary with load Speed reference controls. Check display menu. The speed reference
Control may be erratic. value should be constant. If speed
reference is erratic, check remote input (if
used), intermittent raise/lower contact
inputs. The speed bias sum at no load
should be constant.
Improper linkage adjustment. Make sure that actuator moves
approximately 2/3 of its travel from no load
to full load. Be sure linkage is linear on
turbine, diesel, and fuel-injected prime
movers. Be sure linkage is non-linear on
carbureted prime movers. Refer to actuator
manual for proper installation.
Necessary external wires not The following tests will isolate noise and
properly shielded. interference.

Electrical noise, caused by wiring CAUTION

carrying an ac voltage, stray Do not perform these tests in other than
magnetic fields from transformers, single-unit operating configuration.
etc., can be picked up by
improperly shielded wire. Noise Jumper terminal 28 to terminal 33 and
will cause instability if picked up by remove wires to the Close for Rated
lines associated with the amplifier contact.
summing point such as external
speed trim, paralleling lines, droop Remove wires to terminals 10, 11, 34–38,
contact, magnetic pickup lines, 19, and 20. Jumper terminals 28 and 34.
and synchronizer input.
Remove the wires to the minimum fuel
contact at terminal 31.

Verify that the switchgear frame, governor

chassis, and prime mover have a common
ground connection. Temporarily remove the
battery charger cables from the control
battery system.

If the prime mover operation is significantly

improved by these modifications, replace
the wiring one at a time to locate the source
of the trouble.

External wiring may require additional

shielding or rerouting from high-current lines
or components.

If the problem cannot be resolved by these

checks, it will be necessary to remove the
2301D control from the switchgear.
Temporarily mount it next to the prime
mover and connect only a battery, magnetic
pickup, and actuator to the control (use a
separate battery placed next to the prime
mover). After starting the prime mover,
place a small jumper wire across terminals
28 to 33 and terminals 29 to 30 to cause the
prime mover to accelerate to rated speed. If
necessary, apply load to check stability.
(CONTINUED)

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Symptom Cause Solution

Prime mover will not (CONTINUED)
stabilize at rated no load
speed. The instability If stability occurs when the control is
may occur at no load or it mounted next to the prime mover, return
may vary with load the control to the switchgear. Run new
Control may be erratic magnetic pickup, actuator, and battery
(continued). power lines. Shield all wires to the control.
Route all wires through conduit or an outer
shield. Tie the outer shield to system
ground at end opposite of the control.
Prime mover will not Prime mover may not be receiving Check actuator linkage to fuel controlling
stabilize at rated no load fuel as called for by the actuator mechanism for any lost motion, binding, or
speed. The instability voltage. excessive loading. Verify a steady fuel
may occur at no load or it pressure of proper value.
may vary with load
Control may be erratic Check actuator per appropriate
(continued). actuator manual.
Prime mover not operating Prime mover may be causing speed
properly. variations. Control engine manually to
determine if instability is in prime mover or
governor control. Verify proper adjustment
of fuel control linkage.
Input voltage low. Check supply voltage. It should be at least
18 Vdc.
Prime mover does not Prime mover not receiving fuel as If voltage to actuator is maximum (minimum
share load with other called for by the governor. for reverse acting), visually determine if
units. actuator shaft is at maximum position. If it is
not, an actuator problem is indicated, or the
linkage or fuel system is restricted.
Unequal speed settings. Be sure that speed settings of all units at no
load are identical.
Unequal load gain voltages. With the prime mover operating in single
unit configuration, LOAD GAIN must be set
at 6.0 Vdc. See LOAD GAIN
ADJUSTMENT in Chapter 4.
Circuit breaker auxiliary contact or Check auxiliary circuit breaker and droop
droop contact is open. contacts. Check for 20 to 40 Vdc from
terminal 30 to 34 on low voltage controls.
Improper load sensing phasing. Perform phasing procedure in Chapter 4.
Circulating currents between Refer to appropriate voltage regulator
generators. manual.
Prime mover does not Actuator. If actuator has a ballhead backup, verify
maintain constant speed that its hydraulic governor section, speed
(isochronous). setting, and speed droop adjustments are
properly set (see the applicable governor
manual).
Prime mover. If the droop occurs near the full-load point
only, it is possible the prime mover is not
producing the horsepower called for by the
fuel control, or is being overloaded. Either
is indicated if the fuel control is at maximum
position.

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Chapter 8.
Communications

Modbus Communication
The 2301D control part numbers 8273-505 and 8273-507 can communicate with
plant distributed control systems or CRT-based operator control panels through
one Modbus communication port. The communication port supports RS-232 and
RS-422 communications using RTU Modbus transmission protocols.

To enable Modbus communication one of the discrete inputs B, C or D should be

configured for “Use Modbus” (Configure Menu C**Discrete In Options**). When
this input is activated the communication port is switched to the settings used in
Service Menu Z**COMM Port (Modbus)**.

Modbus utilizes a master/slave protocol which determines how a communication

network’s master and slave devices establish and break contact, how a sender is
identified, how messages are exchanged, and how errors are detected.

Monitor Only
The Modbus communication port is not programmed (factory default) although it
continues to update all information to all registers. This allows the 2301D to be
monitored but not controlled from an external device. By simply connecting a
monitoring device, configured to communicate through Modbus, and to the
2301D’s defaulted protocol settings (parity, stop bits, etc.), this device can be
used to monitor all the 2301D’s controlling parameters, modes, etc., without
affecting control. To use a 2301D port it must be configured properly.

Monitor And Control

To control the discrete inputs by Modbus, parameter 17 in Service Menu
Z**COMM Port (Modbus)** should be set TRUE. To use the analog Modbus
control, parameter 18 should be set TRUE.

Once a Modbus port is activated by the Modbus selector command, the 2301D
will accept an external network master device. This allows a Modbus-compatible
device to monitor and perform all 2301D mode parameters and commands. To
use a 2301D port it must be configured properly.

The Modbus control, when activated, are in paralleled with the Discrete Inputs
through an “OR” input. This means that the Discrete Inputs or the Modbus inputs
have control over the functions.

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Modbus Communication Mode

The 2301D control supports RTU Modbus transmission mode.

Characteristic RTU
Coding System 8-bit binary
Start Bits 1
Data Bits per Character 8
Parity none
Stop Bits 1
Baud Rate 110,300, 600, 1200, 1800, 2400, 4800,
9600, 19200, or 38400
Error Checking CRC (Cyclical Redundancy Check)

Table 8-1. RTU Modbus

In RTU mode, data is sent in 8-bit binary characters and transmitted in a

continuous stream.

The Modbus protocol allows one master and up to 247 slaves on a common
network. Each slave is assigned a fixed, unique device address in the range of 1
to 247. With the Modbus protocol, only the network master can initiate a
transaction. A transaction consists of a request from the master to a slave unit
and the slave’s response. The protocol and Modbus device number are set in the
Program Mode and can be adjusted in Service Mode.

The 2301D control is programmed to function as a slave unit only. As a slave

unit, the 2301D will only respond to a transaction request by a master device.
The 2301D can directly communicate with a DCS or other Modbus supporting
device on a single communications link, or through a multi-dropped network. If
multi-dropping is used, up to 246 devices (2301Ds or other customer devices)
can be connected to one Master device on a single network. The control address
is programmed under the 2301D’s communications block.

Each message to or from a master has a defined structure called the message
“frame”. A frame consists of the slave device address, a code defining the
requested data and error checking information (see Table 7-2).

Beginning SLAVE Function DATA Error End of

of Frame Address Code Check Frame
Code

RTU 3-Char 1 Char 1 Char 8 bits 1 Char 3-Char

Dead 8 bits 8 bits Data per 8 bits Dead
Time Char Time

Table 8-2. Modbus Frame Definition

The Modbus function code tells the addressed slaves what function to perform.
The following table lists the function codes supported by this control.

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Modbus Function Codes

Code Definition Reference Address
01 Read Digital Outputs 0XXXX
(Raise/Lower and Enable/Disable Commands)
02 Read Digital Inputs 1XXXX
(Status Indications / Alarms and Trips)
03 Read Analog Outputs 4XXXX
04 Read Analog Inputs 3XXXX
(Speed, Setpt, etc.)
05 Write Single Discrete Output 0XXXX
(Raise/Lower and Enable/Disable Commands)
08 Loopback Diagnostic Test N/A
(Subfunction 0 only)
15 Write Digital Outputs 0XXXX
16 Write Analog Outputs 4XXXX

Table 8-3. Modbus Function Codes

When a Modbus message is received, it is checked for any errors or invalid data.
If there is invalid data in the message, an error code is sent back to the master
and the control issues an alarm message. The error codes are defined in the
following table. The exception error status and respective error codes can be
viewed in the Service mode under Z**COM PORT (MODBUS)**.

If the control has not received a message for the configured time-out period, the
control will give and alarm with an error message, but no message is sent to the
master. This time-out is defaulted to 4 seconds and only applies to units using
both monitor and control (adjustable in Service Mode).

Port Adjustments
Before the 2301D will communicate with the master device, the communication
parameters must be verified. These values are set in Service Mode.

Parameter Port Adjustment Range

Baud Rate 110 to 38400
Data Bits 7 or 8
Stop Bits 1, 2 or 1.5
Parity NONE, ODD or EVEN
Driver RS232 or RS422

Table 8-4. Port Adjustments

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2301D Control Modbus Addresses

The Modbus communication ports in the 2301D are programmed for unique
Modbus addresses. A complete listing of these addresses for your application is
located at the end of this section in the manual. The Modbus address listing
consists of Boolean Writes, Boolean Reads, Analog Reads and Analog Writes. The
Boolean reads and writes are also referred to as input and holding coils. The
analog reads and writes are also referred to as input registers and holding
registers. All values that can be addressed by Modbus are considered to be
discrete and numeric. The discrete values are a 1 bit binary, on or off value and the
numerics are 16 bit values. Discrete values are sometimes referred to as coils or
digitals and numerics are referred to as registers or analogs. All read/write registers
are interpreted by the 2301D as signed 16 bit integer values. Since Modbus can
only handle integers, values that require a decimal point in the Modbus Master
Device are multiplied by a scaling constant before being sent by the 2301D. See
Appendix B for the default communication constants and ranges.

Boolean Writes
Boolean Writes are logic signals that are writable to the 2301D control. An
example of a Boolean write value would be raise or lower commands. A logical
true denoted by the value 1 will cause the command listed in the description to
be executed.

If a RUN (address 0.0002) command is given it will be latched. To reset the latch
remove the RUN contact and give a command to STOP (address 0.0003). This is
applicable for the following commands:

0.0002 Run (latch)

0.0003 Stop (reset latch)

0.0004 Failed Speed Override ON (latched)

0.0005 Failed Speed Override OFF (reset latch)

0.0006 Rated (latched)

0.0007 Idle (reset latch)

0.0010 Isoch (latched)

0.0011 Droop (reset latch)

0.0012 Baseload ON (latched)

0.0013 Baseload OFF (reset latch)

Boolean Reads
Boolean Reads are logic signals that are readable from, but not writable to, the
2301D. An example of a Boolean read value would be a turbine trip status
indication. The logic true will have the value 1 if the statement in the description
column is true and a 0 if false. The ‘1:’ term in the address identifies a logic true.
The 2301D supports Modbus function code 2, which involves reading selected
logic signals.

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Analog Reads
Input registers are analog values that are readable from, but not writable to, the
2301D. Turbine speed is an example of an analog read value. The values of the
input registers are stored internally to the control as floating point numbers
representing engineering units (kPa or rpm). The values transmitted are integers
ranging from –32767 to +32767. Since Modbus can only handle integers, values
that have a decimal point are multiplied by a constant before being sent by
Modbus. For example, these input registers may be listed as the Modbus value
`x100’ or `x10’ under the description heading to denote the value is multiplied by
a scaling constant. This will allow transmission of decimal parts of a unit if this is
necessary for better resolution.

See the 2301D Service Mode for default communication constants and ranges.
The 2301D supports Modbus function code 4, which involves reading selected
input registers.

Analog Writes
Holding registers are analog values that are writable to the 2301D. These values
can also be read by a device performing an error check. An example of an
analog write value would be a direct speed setpoint as opposed to raise and
lower commands. The values of the holding registers are also stored in the
control as numbers representing engineering units (kPa or rpm). The 2301D
supports Modbus function codes 3, 6, and 16. These correspond to reading
selected holding registers, writing to a single holding register and writing to
multiple holding registers respectively. Appendix B lists the addresses and
descriptions of all Boolean and analog reads and writes.

Modbus Scale Factors

Modbus has two limitations:
• only integers can be sent across
• the value is limited between –32767 and +32767.

These limitations can be overcome by scaling the value before it is sent across the
Modbus. The default scale factor for analog values is 1. The scale factor can be
changed in the Watch Window (INTFC.COM) between 1 and 1000. These scaled
parameters and their scale factor are available through the Modbus. Values that
require a decimal point must be multiplied by the scale factor (10, 100 or 1000)
before being sent across the Modbus. The value sent is then divided by the scale
factor in the Master. The Scale Factor adjusts all associated analog reads
accordingly. The Multiplier (scale factor) can be changed in the Watch Window.

Shutdown Command through Modbus

Two different types of shutdown commands (emergency and controlled) can be
issued through Modbus. The Emergency Shutdown command instantly takes the
actuator current to zero and activates the shutdown relay. The Controlled
Shutdown function is used to stop the engine in a controlled manner, as opposed
to an Emergency Trip. When a STOP command (controlled shutdown) is issued
the shutdown relay is not activated.

The Emergency Shutdown and Controlled Shutdown commands do not influence

the operation of the Trip Relay.
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Start Command Through Modbus

The start-up of a turbine is possible from a command through the Modbus. The
open/close of contact inputs (RUN/SHUTDOWN, etc.) serve as the independent
command in Modbus BW. These commands operate as a momentary input.
Which means the input from the Modbus commands are latching.

For More Modbus Information

Detailed information on the Modbus protocol is presented in “Reference Guide
PI-MBUS-300” published by AEC Corp./Modicon Inc., formerly Gould Inc. To
implement your own source code, you must register with Modicon. Registration
includes purchasing document PI-MBUS-303 and signing a non-disclosure
agreement. You can register to use Modbus at your nearest Modicon field office.
To find the office nearest you, contact Modicon Technical Support at
+1-800-468-5342 (in North America).

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Chapter 9.
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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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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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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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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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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Appendix A.
Service/Configuration Chart

Configure Menus
PROGRAMMED DEFAULT TUNABLE RANGE
CONFIGURE MENU
VALUE VALUE MIN. MAX.
A**SPEED CONTROL FUNCTIONS**
01 ENTER RATED SPEED (RPM) 900 0 4000
02 USE START SPEED FALSE TRUE FALSE
03 ENABLE 5 SLOPE GAIN MAP FALSE TRUE FALSE
04 SEL GAIN FUNCTION (1,3) 1 1 3
05 DISPLAY GAIN FUNCTION Monitor
06 ENABLE IDLE DROOP FALSE TRUE FALSE
07 OVERSPEED SETTING 2000.000 0.00 4000.00
08 RST TO RATED AT CB CLOSE TRUE TRUE FALSE
09 RST TO RATED INSTANT TRUE TRUE FALSE
10 ENABLE AUTO IDLE/RATED FALSE TRUE FALSE
11 REMOTE SPD LOCK IN LAST FALSE TRUE FALSE
12 REMOTE LOAD LOCK IN LAST FALSE TRUE FALSE
B**ENG—GEN FUNCTIONS**
01 ENTER NUM OF GEAR TEETH 60 15 500
02 SPD SENSING TYPE (1,4,5) 5 1 5
03 ENTER MUMB OF CYLINDERS 8 1 24
04 ENTER FAILED SPD SENSE % 5.0 2.0 50.0
05 MPU ALARM ARM TIME 10 0 120
06 ENTER RATED/MAX LOAD(KW) 500 10 30000
07 GRID FREQ IS 50Hz FALSE TRUE FALSE
08 2 CYCLE OR 4 CYCLE 1 1 2
C**DISCRETE IN OPTIONS**
01 SEL DI B FUNCTION (1-7) 3 1 8
02 DISPLAY DI B FUNCTION Monitor
03 SEL DI C FUNCTION (1-7) 6 1 8
04 DISPLAY DI C FUNCTION Monitor
05 SEL DI D FUNCTION (1-7) 7 1 8
06 DISPLAY DI D FUNCTION Monitor
07 ENABLE R/L WHEN LS? FALSE TRUE FALSE
08 RSE/LWR STOP IDL/RTD RMP TRUE TRUE FALSE
D**DISCRETE OUT OPTIONS**
01 IS SHUTDOWN RELAY NC? TRUE TRUE FALSE
02 IS ALARM RELAY NC? TRUE TRUE FALSE
03 RELAY 1 ENERGIZES (1-10) 2 1 14
04 RELAY 1 SELECTED FOR Monitor
05 RELAY 2 ENERGIZES (1-10) 3 1 14
06 RELAY 2 SELECTED FOR Monitor
07 RELAY 3 ENERGIZES (1-10) 9 1 14
08 RELAY 3 SELECTED FOR Monitor
09 RELAY 4 ENERGIZES (1-10) 7 1 14
10 RELAY 4 SELECTED FOR Monitor
11 CB OPEN RELAY NORM ENGZD FALSE TRUE FALSE
E**ANALOG INPUT OPTIONS**
01 CONFIGURATION ERROR ? Monitor
02 SEL AI #1 FUNCTION (1-7) 4 1 6
03 DISPLAY AI #1 FUNCTION Monitor
04 SEL AI #1 TYPE (1-3) 1 1 3
05 DISPLAY AI #1 TYPE Monitor
06 USE INPUT #1 FAIL TRIP FALSE TRUE FALSE
07 SEL AI #2 FUNCTION (1-7) 3 1 6
08 DISPLAY AI #2 FUNCTION Monitor

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PROGRAMMED DEFAULT TUNABLE RANGE
CONFIGURE MENU
VALUE VALUE MIN. MAX.
09 SEL AI #2 TYPE (1-3) 1 1 3
10 DISPLAY AI #2 TYPE Monitor
11 USE INPUT #2 FAIL TRIP FALSE TRUE FALSE
F**ACTUATOR OUT OPTIONS**
01 ACTUATOR OUT TYPE (1-3) 1 1 3
02 DISPLAY ACTUATOR TYPE Monitor
03 REVERSE ACTING ACTUATOR FALSE TRUE FALSE

Service Menus
PROGRAMMED DEFAULT TUNABLE RANGE
SERVICE MENU
VALUE VALUE MIN. MAX.
A**DISPLAY MENU**
01 ENGINE SPEED (RPM) Monitor
02 CALC GENERATOR FREQ (Hz) Monitor
03 SPEED REFERENCE (RPM) Monitor
04 FUEL DEMAND (%) Monitor
05 SPEED REF BIAS SUM (RPM) Monitor
06 LOAD BIAS (RPM) Monitor
07 SYNC BIAS (RPM) Monitor
08 BASE LOAD REF (KW) Monitor
09 GENERATOR OUT (KW) Monitor
10 LOAD SIGNAL OUT (VDC) Monitor
11 FUEL CONTROL MODE Monitor
12 LOAD CONTROL PARAMETER Monitor
13 ANALOG INPUT #1 = Monitor
14 ANALOG INPUT #2 = Monitor
B**DISPLAY LOAD INFO**
01 LOAD SENSOR INPUT (KW) = Monitor
02 LOAD SENSOR (%) = Monitor
03 LOAD SHARING BIAS (RPM)= Monitor
04 LOAD SIGNAL OUT (Vdc)= Monitor
05 SYSTEM LOAD 0-3 (Vdc) = Monitor
06 LOAD SHARING BIAS (%) = Monitor
C**SHUTDOWNS**
01 SHUTDOWN STATUS Monitor
02 FIRST SHUTDOWN Monitor
03 OVERSPEED Monitor
04 MPU FAIL Monitor
05 ANALOG INPUT #1 FAIL Monitor
06 ANALOG INPUT #2 FAIL Monitor
07 TEST MODE Monitor
08 EXTERNAL SHUTDOWN Monitor
09 RESET SHUTDOWN FALSE TRUE FALSE
D**ALARMS**
01 ALARM STATUS Monitor
02 FIRST ALARM Monitor
03 ANALOG INPUT #1 FAIL Monitor
04 ANALOG INPUT #2 FAIL Monitor
05 LOAD SENSOR FAIL Monitor
06 LOAD SHARE LINE FAIL Monitor
07 RESET ALARMS FALSE TRUE FALSE
E**DISPLAY DIGITAL I/O**
01 CLOSE RUN/OPEN SHTDWN A Monitor
02 DISCRETE INPUT B Monitor
03 DISCRETE INPUT C Monitor
04 DISCRETE INPUT D Monitor
05 RAISE SPEED/LOAD E Monitor
06 LOWER SPEED/LOAD F Monitor
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PROGRAMMED DEFAULT TUNABLE RANGE
SERVICE MENU
VALUE VALUE MIN. MAX.
07 LOAD GENERATOR G Monitor
08 SELECT BASE LOAD H Monitor
09 DISCRETE OUTPUT #1 Monitor
10 DISCRETE OUTPUT #2 Monitor
11 DISCRETE OUTPUT #3 Monitor
12 DISCRETE OUTPUT #4 Monitor
13 INTERNAL CB AUX RELAY Monitor
F**DISPLAY ANALOG I/O**
01 SPEED SENSOR INPUT (RPM) Monitor
02 LOAD SENSOR INPUT (KW) (monitor
03 ANIN #1, INPUT TYPE: (monitor
04 ANIN #1 (UNITS) (monitor
05 ANIN #2 INPUT TYPE: (monitor
06 ANIN #2 (UNITS) (monitor
07 LOAD SHARING LINES (VDC) Monitor
08 LOAD SHARING BIAS SIG(%) Monitor
09 ACTUATOR CURRENT (mA) Monitor
10 ANALOG OUT 1 (%) Monitor
11 LOAD SIGNAL OUT (Vdc) Monitor
G**SPEED SETTINGS**
01 START SPEED (RPM) 400.000 1.00 2100.00
02 RAISE SPEED LIMIT (RPM) 1000.000 0.00 4000.00
03 LOWER SPEED LIMIT (RPM) 800.000 0.00 4000.00
04 IDLE SPEED (RPM) 600.000 0.00 4000.00
05 ACCEL RAMP TIME (SEC) 20.000 1.00 300.00
06 DECEL RAMP TIME (SEC) 20.000 1.00 300.00
07 SPEED TRIM INC TIME(SEC) 30.000 1.00 300.00
08 SPEED TRIM DEC TIME(SEC) 30.000 1.00 300.00
09 IDLE DROOP BREAKPOINT 40.000 0.50 100.00
10 IDLE DROOP (%) 5.000 0.00 100.00
11 DELAY TIME IDLE TO RATED 5.000 0.00 600.00
H**DYNAMICS #1**
01 IDLE PROP GAIN 1
02 RATED PROP GAIN 1 1.000 0.01 100.00
03 RESET 1 2.000 0.01 100.00
04 ACTUATOR COMPENSATION 1 12.000 0.01 100.00
05 WINDOW WIDTH 1 (RPM) 60.000 1.00 200.00
06 GAIN RATIO 1 1.000 1.00 10.00
07 SPEED FILTER FREQ 1 (HZ) 20.000 4.00 20.00
08 BUMP ACT TRIG (T THEN F) FALSE TRUE FALSE
I**DYNAMICS #2**
01 ENABLE DYNAMICS 2 w/CB FALSE TRUE FALSE
02 DELAY DYN 2 ENABLE (SEC) 0.00 0.00 20.00
03 DELAY DYN 1 ENABLE (SEC) 0.00 0.00 20.00
04 PROP GAIN 2 4.000 0.01 100.00
05 RESET 2 2.000 0.01 100.00
06 ACTUATOR COMPENSATION 2 12.000 0.01 100.00
07 WINDOW WIDTH 2 (RPM) 60.000 1.00 200.00
08 GAIN RATIO 2 1.000 1.00 10.00
09 SPEED FILTER FREQ 2 (HZ) 20.000 4.00 20.00
10 BUMP ACT TRIG (T THEN F) FALSE TRUE FALSE
J**DYNAMICS #1, 5 PT GAIN**
01 BREAKPOINT 1A (%LD or RPM) 99.600 0.01 5000.00
02 GAIN @BREAKPOINT 1A 4.0 0.01 100.00
03 BREAKPOINT 1B (%LD or RPM) 99.700 0.01 5000.00
04 GAIN @BREAKPOINT 1B 4.0 0.01 100.00
05 BREAKPOINT 1C (%LD or RPM) 99.800 0.01 5000.00
06 GAIN @BREAKPOINT 1C 4.0 0.01 100.00
07 BREAKPOINT 1D (%LD or RPM) 99.900 0.01 5000.00
08 GAIN @BREAKPOINT 1D 4.0 0.01 100.00
09 BREAKPOINT 1E (%LD or RPM) 100.00 0.01 5000.00
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PROGRAMMED DEFAULT TUNABLE RANGE
SERVICE MENU
VALUE VALUE MIN. MAX.
10 GAIN @BREAKPOINT 1E 4.0 0.01 100.00
11 RESET 1 2.000 0.01 100.00
12 ACT COMPENSATION 12.000 0.01 100.00
13 WINDOW WIDTH 1 (RPM) 60.000 1.00 200.00
14 GAIN RATIO 1 1.000 1.00 10.00
15 SPEED FILTER FREQ 1 (HZ) 20.000 4.00 20.00
16 BUMP ACT TRIG (T THEN F) FALSE TRUE FALSE
K**DYNAMICS #2, 5 PT GAIN**
01 ENABLE DYNAMICS 2 w/CB FALSE TRUE FALSE
02 DELAY DYN 2 ENABLE (SEC) 0.000 0.00 20.00
03 DELAY DYN 1 ENABLE (SEC) 0.000 0.00 20.00
04 BREAKPOINT 2A (%LD or RPM) 99.600 0.01 5000.00
05 GAIN @BREAKPOINT 2A 4.0 0.01 100.00
06 BREAKPOINT 2B (%LD or RPM) 99.700 0.01 5000.00
07 GAIN @BREAKPOINT 2B 4.0 0.01 100.00
08 BREAKPOINT 2C (%LD or RPM) 99.800 0.01 5000.00
09 GAIN @BREAKPOINT 2C 4.0 0.01 100.00
10 BREAKPOINT 2D (%LD or RPM) 99.900 0.01 5000.00
11 GAIN BREAKPOINT 2D 4.0 0.01 100.00
12 BREAKPOINT 2E (%LD or RPM) 100.00 0.01 5000.00
13 GAIN BREAKPOINT 2E 4.0 0.01 100.00
14 RESET 2 2.000 0.01 100.00
15 ACT COMPENSATION 2 12.000 0.01 100.00
16 WINDOW WIDTH 2 (RPM) 60.000 1.00 200.00
17 GAIN RATIO 2 1.000 1.00 10.00
18 SPEED FILTER FREQ 2 (HZ) 20.000 4.00 20.00
19 BUMP ACT TRIG (T THEN F) FALSE TRUE FALSE
L**FUEL LIMITERS 1/2**
01 START FUEL LIMIT (%FD) 100.000 15.00 110.00
02 START RAMP RATE (%FD/S) 10.000 1.00 180.00
03 SOFT START FUEL LIMIT ON FALSE TRUE FALSE
04 MAX FUEL LIMIT (%FD) 100.000 50.00 110.00
05 ENABLE IDLE LIMITER ? FALSE TRUE FALSE
06 IDLE FUEL LIMITER (%FD) 100.00 0.00 100.00
07 ENABLE TORQUE LIMITER ? FALSE TRUE FALSE
08 MIN SPEED TORQUE LIMIT 300.000 0.00 4000.0
09 TORQUE LIMIT MIN SPEED 300.000 0.00 100.00
10 SPEED BRKPOINT TORQ LIM 800.000 0.00 4000.0
11 TORQUE LIMIT BREAKPOINT 100.000 0.00 100.00
12 MAX SPEED TORQUE LIMIT 1000.000 0.00 4000.0
13 TORQUE LIMIT MAX SPEED 100.000 0.00 100.00
M**FUEL LIMITERS 2/2**
01 ENABLE MAP LIMITER ? FALSE TRUE FALSE
02 PRESSURE X1 6.000 -1000.00 1000.00
03 MAP LIMIT Y1 100.000 0.00 100.00
04 PRESSURE X2 8.000 -1000.00 1000.00
05 MAP LIMIT Y2 100.000 0.00 100.00
06 PRESSURE X3 10.000 -1000.00 1000.00
07 MAP LIMIT Y3 100.000 0.00 100.00
08 PRESSURE X4 15.000 -1000.00 1000.00
09 MAP LIMIT Y4 100.000 0.00 100.00
10 PRESSURE X5 20.000 -1000.00 1000.00
11 MAP LIMIT Y5 100.000 0.00 100.00
12 MAP NEAR FUEL LIMIT % 5.000 0.00 10.00
13 MAP DELAY TIME CONTACT 0.500 0.00 30.00
14 MAP OVERLOAD PULS TIME 0.500 0.00 100.00
N**LOAD SETTINGS**
01 LOAD DROOP PERCENT 5.000 0.00 12.00
02 LOAD LEVEL VOLTAGE 6.000 0.10 9.00
03 LOAD SHARE GAIN 1.000 0.01 10.00
04 ENABLE ACT POS DROOP FALSE TRUE FALSE
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PROGRAMMED DEFAULT TUNABLE RANGE
SERVICE MENU
VALUE VALUE MIN. MAX.
05 ACT POSITION DROOP % 0.000 0.00 100.00
06 ACT OUT AT RATED NO LOAD 20.000 0.00 100.00
07 ACT OUT RATED FULL LOAD 80.000 0.00 100.00
08 BASE LOAD MINIMUM (KW) 20.000 10.00 30000.00
09 BASE LOAD REFERENCE (KW) 50.000 0.00 30000.00
10 BASE LOAD MAXIMUM (KW) 110.000 10.00 30000.00
11 BASELOAD RAISE TIME(SEC) 60.000 1.00 600.00
12 BASELOAD LOWER TIME(SEC) 60.000 1.00 600.00
13 UNLOAD TRIP LEVEL (KW) 5.000 0.00 30000.00
14 LOADING RATE (KW/SEC) 20.000 1.00 600.00
15 UNLOADING RATE (KW/SEC) 20.000 1.00 600.00
16 ENABLE FAST LOAD RATE FALSE TRUE FALSE
17 FAST RAMP ENABLE LOAD(%) 80.000 1.00 110.00
18 FAST RAMP RATE (KW/SEC) 60.000 1.00 600.00
O**ACTUATOR BUMP SETUP**
01 ACT BUMP ENABLE FALSE TRUE FALSE
02 ACT BUMP LEVEL (%FD) 1.000 0.00 25.00
03 ACT BUMP DURATION (SEC) 0.110 0.08 2.00
04 BUMP ACT TRIG (T THEN F) FALSE TRUE FALSE
P**ANALOG INPUTS SETTINGS**
01 AI 1 CONFIGURED FOR: Monitor
02 AI 2 CONFIGURED FOR: Monitor
03 SPEED w/ RMT IN@MIN(RPM) 800.000 0.00 4000.00
04 SPEED w/ RMT IN@MAX(RPM) 1000.000 0.00 4000.00
05 RMT SPEED REF INPUT(RPM) Monitor
06 RMT SPDREF INC TIME(SEC) 30.000 1.00 300.00
07 RMT SPDREF DEC TIME(SEC) 30.000 1.00 300.00
08 BSLOAD w/RMT IN@MIN (KW) 20.000 0.00 30000.00
09 BSLOAD w/RMT IN@MAX (KW) 90.000 10.00 30000.00
10 RMT BSLOAD REF INPUT(KW) Monitor
11 RMT BSLOAD INC TIME(SEC) 60.000 1.00 600.00
12 RMT BSLOAD DEC TIME(SEC) 60.000 1.00 600.00
13 REMOTE AUX SCALE(%/VOLT) 3.000 0.10 5.00
14 SYNC INPUT SCALE(%/VOLT) 0.700 0.10 5.00
15 MAP LIMITER INPUT MIN 0.000 -10000.0 10000.0
16 MAP LIMITER INPUT MAX 20.000 -10000.0 10000.0
Q**DISCRETE OUT SETTINGS**
01 RELAY 1 SELECTED AS Monitor
02 RELAY 1 LEVEL SW (1-6) 1 1 6
03 RELAY 1 LEVEL SELECT FOR Monitor
04 RELAY 1 ON LEVEL = 0.000 -32000.00 32000.00
05 RELAY 1 OFF LEVEL = 0.000 -32000.00 32000.00
06 RELAY 2 SELECTED AS Monitor
07 RELAY 2 LEVEL SW (1-6) 1 1 6
08 RELAY 2 LEVEL SELECT FOR Monitor
09 RELAY 2 ON LEVEL = 0.000 -32000.00 32000.00
10 RELAY 2 OFF LEVEL= 0.000 -32000.00 32000.00
11 RELAY 3 SELECTED AS Monitor
12 RELAY 3 LEVEL SW (1-6) 2 1 6
13 RELAY 3 LEVEL SELECT FOR Monitor
14 RELAY 3 ON LEVEL = 0.000 -32000.00 32000.00
15 RELAY 3 OFF LEVEL = 0.000 -32000.00 32000.00
16 RELAY 4 SELECTED AS Monitor
17 RELAY 4 LEVEL SW (1-6) 1 1 6
18 RELAY 4 LEVEL SELECT FOR Monitor
19 RELAY 4 ON LEVEL = 0.000 -32000.00 32000.00
20 RELAY 4 OFF LEVEL = 0.000 -32000.00 32000.00
21 BREAKER OPEN TIME (SEC) 1.000 0.80 60.00
22 RAMP @ MIN,CB DELAY(SEC) Monitor
R**ANALOG OUTPUT SETTINGS**
01 ANALOG OUTPUT SEL 9 (1-9) 1 1
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PROGRAMMED DEFAULT TUNABLE RANGE
SERVICE MENU
VALUE VALUE MIN. MAX.
02 ANALOG OUTPUT SELECTION Monitor
03 ANOUT, 4 MA OFFSET 0.000 -200.00 200.00
04 ANOUT, 20MA GAIN 9F00.000 -200.00 32000.00
05 ANALOG OUT 1 (%) Monitor
S**RELAY AND ANOUT TESTS**
01 ENABLE MANUAL DRIVR TEST FALSE TRUE FALSE
02 FORCE OUTPUT STATUS Monitor
03 TURN ON DO1 FALSE TRUE FALSE
04 DISCRETE OUTPUT #1 Monitor
05 TURN ON DO2 FALSE TRUE FALSE
06 DISCRETE OUTPUT #2 Monitor
07 TURN ON DO3 FALSE TRUE FALSE
08 DISCRETE OUTPUT #3 Monitor
09 TURN ON DO4 FALSE TRUE FALSE
10 DISCRETE OUTPUT #4 Monitor
11 TURN ON CB AUX RELAY FALSE TRUE FALSE
12 LOAD SHARE RELAY Monitor
13 ADJUST ANALOG OUTPUT (%) 0.000 0.00 100.00
14 ANALOG OUT (%) Monitor
15 ADJUST ACTUATOR OUT (%) 0.000 0.00 100.00
16 ACTUATOR OUTPUT (mA) Monitor
T**KW INPUT CALIBRATION**
01 KW INPUT CALIBRATN ZERO 0.000 -20.00 20.00
02 KW INPUT CALIBRATN GAIN 13.000 5.00 40.00
03 GEN OUTPUT (READ KW) Monitor
04 LOAD SIGNAL OUT (VDC) Monitor
U**DISPLAY PID PARAMETERS**
01 DYNAMICS 2 ENABLED Monitor
02 PID GAIN VALUE Monitor
03 PID INTEGRAL GAIN VALUE Monitor
04 PID SDR VALUE Monitor
V**ANALOG IN/OUTPUT CALIB**
01 AnIN 1, Offset 0.000 -100.00 100.00
02 AnIN 1, Gain 1.000 0.00 10.00
03 AnIN 1, mA / Volt Monitor
04 AnIN 2, Offset 0.000 -100.00 100.00
05 AnIN 2, Gain 0.000 0.00 10.00
06 AnIN 2, mA / Volt Monitor
07 Actuator, Offset 0.000 -100.00 100.00
08 Actuator, Gain 0.000 -100.00 100.00
09 Actuator output Monitor
10 Anout 4–20 mA, Offset 0.000 -100.00 100.00
11 Anout 4–20 mA, Gain 0.000 -100.00 100.00
12 Anout 4–20 mA, output Monitor
W**LOADPULSE SETTINGS**
01 ENABLE LOADPULSE FALSE TRUE FALSE
02 SCALE LOADPULSE 1.000 0.01 10.00
03 LOW LVL ON -50.000 -10000.00 10000.00
04 HI LVL ON 50.000 -10000.00 10000.00
05 OFFSET 0.000 -100.00 100.00
06 RATE TO SP 50.000 0.00 100.00
07 SUBTR FRM SP -50.000 -100.00 100.00
08 ADD TO SP 50.000 -100.00 100.00
X**ADAPTIVE FILTER SET**
01 ADAPTIVE FILTER ENABLE FALSE TRUE FALSE
01 ADAPTIVE FILTER GAIN 0.25 0.01 1.00
Y**APPLICATION INFO**
01 APP SOFTWARE NUMBER Monitor
02 APP SOFTWARE REVISION Monitor
03 APPLICATION NAME Monitor

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Manual 26288 2301D/2301D-EC Digital Control
PROGRAMMED DEFAULT TUNABLE RANGE
SERVICE MENU
VALUE VALUE MIN. MAX.
Z**COMM PORT (MODBUS)**
01 PORT FAIL Monitor
02 LINK ERROR Monitor
03 ERROR PERCENT Monitor
04 ERROR NUMBER Monitor
05 BAUD RATE 10 1 10
06 BAUD RATE IS SET FOR Monitor
07 DATA BITS 2 1 2
08 DATA BITS ARE SET FOR Monitor
09 STOP BITS 1 1 3
10 STOP BITS ARE SET FOR Monitor
11 PARITY 1 1 3
12 PARITY IS SET FOR Monitor
13 DRIVER 1 1 2
14 DRIVER IS SET FOR Monitor
15 TIME OUT (SEC) 2.000 0.00 100.00
16 NETWORK ADDRESS 1 1 247
17 ENABLE MODBUS CONTROL FALSE TRUE FALSE
18 USE MODBUS ANALOG CNTRL FALSE TRUE FALSE

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 2301D/2301D-EC Digital Control Manual 26288

Appendix B.
PID Examples

This is a list of some engines that this control was installed on, and the
associated PID (Gain, Reset, and Actuator Compensation) values that were
tuned in the control.

WARNING—OVERSPEED
These values are given for reference only for initial start-up. An improperly
calibrated control could cause an overspeed or other damage to the prime
mover.

WARNING—EMERGENCY STOP
Be prepared to make an emergency shutdown when starting the engine, to
protect against runaway or overspeed with possible personal injury, loss of
life, or property damage.

This list only contains a small sample of engines. Your engine make and model
may not be listed. If you want to put the PID values for your engine in this
manual, please contact Woodward.

Rated Speed Act.

Number of Number Gain Reset
Engine Type Application Speed Sensor Com.
Cylinders Of Teeth Value Value
(RPM) Selected Value
Clark
Compressor
TLA-6 6 300 360 5 0.5 0.16 0.1
Drive
(Nat. Gas)
DeLaval
Enterprise Power
16 450 60 5 3.5 2.4 0.2
DSRV -16 -4 Generation
(Diesel)
Caterpillar
Power
3304 4 1800 156 1 20.0 0.4 0.2
Generation
(Diesel)
Detroit
Diesel Power
4 1800 118 1 15.0 0.5 0.2
471-T Generation
(Diesel)

Table B-1. PID Examples

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PID Conversion Charts

Listed below are conversion charts that approximate the Gain, Reset and
Actuator Compensation potentiometer settings on a 2301A and convert them to
the equivalent Prop. Gain, Reset, and Actuator Compensation values in the
2301D.

2301A to 2301D Gain Conversion

20
18
16
14
2301D Value

12
10
8
6
4
2
0
0 1 2 3 4 5 6 7 8 9 10
2301A Gain Potentiometer Position (CCW = 0, CW = 10)

Figure B-1. Gain Potentiometer Conversion Chart

2301A to 2301D Reset Conversion

10
9
8
7
2301D Value

6
5
4
3
2
1
0
0 1 2 3 4 5 6 7 8 9 10
2301A Reset Potentionmeter Position (0 = CCW, 10 = CW)

Figure B-2. Reset Potentiometer Conversion Chart

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2301A to 2301D Act. Comp. Conversion

0.9

0.8

0.7
2301D Value

0.6

0.5

0.4

0.3

0.2

0.1

0
0 1 2 3 4 5 6 7 8 9 10
2301A Act. Comp. Potentiometer Position (0=CCW, 10 = CW)

Figure B-3. Actuator Compensation Potentiometer Conversion Chart

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Appendix C.
Modbus Communication List

This Modbus Communication List is applicable for software number 5418-161.

Boolean Writes
Addr Description
0:0001 Reset Control
0:0002 Run
0:0003 Stop
0:0004 Failed Speed Override ON
0:0005 Failed Speed Override OFF
0:0006 Rated Speed Reference
0:0007 Idle Speed Reference
0:0008 Raise Speed / Load
0:0009 Lower Speed / Load
0:0010 Isochronous Mode
0:0011 Droop Mode
0:0012 Load
0:0013 Unload
0:0014 Baseload ON
0:0015 Baseload OFF
0:0016 Select 2nd Dynamics
0:0017 De-Select 2nd Dynamics
0:0018 External / Modbus Shutdown
0:0019 Not Used
0:0020 Not Used
0:0021 Energize Modbus relay #1
0:0022 De-Energize Modbus Relay #1
0:0023 Energize Modbus relay #2
0:0024 De-Energize Modbus Relay #2
0:0025 Energize Modbus relay #3
0:0026 De-Energize Modbus Relay #3
0:0027 Energize Modbus relay #4
0:0028 De-Energize Modbus Relay #4
0:0029 Enable Remote Speed Setting
0:0030 Disable Remote Speed Setting
0:0031 Enable Remote Baseload Setting
0:0032 Disable Remote Baseload Setting

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Boolean Reads
Addr Description
1:0001 Shutdown Status
1:0002 Alarm Status
1:0003 Overspeed
1:0004 MPU Failure
1:0005 Analog input #1 failure (if configured)
1:0006 Analog input #2 failure (if configured)
1:0007 Test mode active
1:0008 External Shutdown
1:0009 Analog input #1 failure
1:0010 Analog input #2 failure
1:0011 kW input failure PT/CT
1:0012 Loadshare Input failure
1:0013 Speed PID In-control
1:0014 Start Limiter Active
1:0015 Maximum Fuel Limit
1:0016 Torque Limiter Active
1:0017 MAP Limiter Active
1:0018 Level SW#1 ON
1:0019 Level SW#2 ON
1:0020 Level SW#3 ON
1:0021 Level SW#4 ON
1:0022 Discrete Input A State
1:0023 Discrete Input B State
1:0024 Discrete Input C State
1:0025 Discrete Input D State
1:0026 Discrete Input E State
1:0027 Discrete Input F State
1:0028 Discrete Input G State
1:0029 Discrete Input H State
1:0030 Relay Output #1 State
1:0031 Relay Output #2 State
1:0032 Relay Output #3 State
1:0033 Relay Output #4 State
1:0034 CPU Failure
1:0035 Remote Speed Control State
1:0036 Remote Load Control State
1:0037 Load Share Relay State
1:0038 Run Engine State
1:0039 Stop Engine State
1:0040 Rated Speed State
1:0041 Idle Speed State
1:0042 Raise Speed State
1:0043 Lower Speed State
1:0044 Isoch Mode State
1:0045 Droop Mode State
1:0046 Load Generator State
1:0047 Unload Generator State
1:0048 Baseload Mode State
1:0049 Second Dynamics State
1:0050 Failed MPU Override State
1:0051 Reset Alarms - Shutdown State

Analog Reads
Addr Description
3:0001 Shutdown first out Indication
3:0002 Alarm first out Indication
3:0003 Engine Speed (RPM)
3:0004 Speed Reference (RPM)
3:0005 Engine load (kW)
3:0006 Actuator Output (%)

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Manual 26288 2301D/2301D-EC Digital Control
3:0007 Speed PID Output (%)
3:0008 Analog Input #1
3:0009 Analog Input #2
3:0010 Speed Bias RPM
3:0011 Engine Load (%)
3:0012 Baseload Reference (kW)
3:0013 Load Bias (RPM)
3:0014 Sync Bias (RPM)
3:0015 Loadsharing Bias (%)

Analog Writes
Addr Description
4:0001 Remote Baseload Reference
4:0002 Remote Speed Reference

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 Appendix D.
2301D / 2301D-EC Control Specifications
Woodward Part Numbers:
8273-501 2301D Load Sharing and Speed Control, 24Vdc
input, Ordinary Locations
8273-503 2301D Load Sharing and Speed Control, 24Vdc
input, Hazardous Locations
8273-505 2301D-EC Load Sharing and Speed Control, 24Vdc
input, with Modbus, Ordinary Locations
8273-507 2301D-EC Load Sharing and Speed Control, 24Vdc
input, with Modbus, Hazardous Locations
8923-932 Watch Window / ServLink Installation

Power Supply Rating 18–40 Vdc (SELV)

Power Consumption less than or equal 20 W nominal
Input Supply Voltage Input Supply Current
18 V 589 mA
24 V (nominal) 431 mA
32 V 319.6 mA
Inrush Current 7 A for 0.1 ms (low-voltage model)
Inrush Current 22 A for 15 ms (high-voltage model)
Steady State Speed Band ±0.25% of rated speed
Magnetic Pickup 100–25 000 Hz (300–3600 rpm)
Discrete Inputs (8) 3 mA at 24 Vdc, impedance approximately 5.2 kΑ
Remote Reference Input 0–20 mA, 4–20 mA, 0–5 Vdc, 1–5 Vdc, or ±2.5 Vdc
externally powered
SPM-A Input ±2.5 Vdc, externally powered
Analog Output #1 0–20 mA, 4–20 or 0–200 mA to actuator, software
configurable
Analog Output #2 0–20 or 4–20 mA , internally powered, configurable
Discrete Outputs (4) , power by external +12
Vdc or +24 Vdc source, max output current 200 mA
Discrete Output Ratings Low-side drivers with overvoltage protection, 200
mA maximum
Communication Port (J2) RS-232, RS-422, 9-pin connector, 1200 to 38 400
baud, full duplex
Ambient Operating Temperature –40 to +70 °C (–40 to +158 °F)
Storage Temperature –40 to +105 °C (–40 to +221 °F)
Humidity Lloyd’s Register of Shipping, Test Specification No.
1, 1996, Humidity Test 1, 95% at +20 to +55 °C (+68
to +131 °F) condensing
Mechanical Vibration Lloyd’s Register of Shipping, Test Specification No.
1, Vibration Test 2 (5–25 Hz, ±1.6 mm, 25–100 Hz,
±4.0 g)
Mechanical Shock US MIL-STD 810C, Method 516.2, Procedure I
(basic design test), Procedure II (transit drop test,
packaged), Procedure V (bench handling)
Equipment Classification Class 1 (grounded equipment)
Declarations
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Phone +1 (970) 482-5811 • Fax +1 (970) 498-3058
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06/7/F