Woodward 723 PLUS Applications Manual
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Woodward 723 PLUS Applications Manual

Standard generator control lon load sharing
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See also: Technical Manual , Operation & Installation Manual
Product Manual 91623
(Revision NEW)
Original Instructions
723PLUS Standard Generator Control
LON Load Sharing
8280-1099
Woodward manual 02877 is also required.
Application Manual

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  • Page 1 Product Manual 91623 (Revision NEW) Original Instructions 723PLUS Standard Generator Control LON Load Sharing 8280-1099 Woodward manual 02877 is also required. Application Manual...
  • Page 2 Revisions—Changes in this publication since the last revision are indicated by a black line alongside the text. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly undertaken.

  • Page 3: Table Of Contents

    Product Support Options ..................58   Product Service Options ..................58   Returning Equipment for Repair ................59   Replacement Parts ....................59   Engineering Services .................... 60   Contacting Woodward’s Support Organization ............ 60   Technical Assistance .................... 61   Woodward...
  • Page 4 723PLUS Standard Generator Control LON Load Sharing Manual 91623 Illustrations and Tables Figure 5-1a. Functional Block Diagram 9971-4050 ..........47   Figure 5-1b. Functional Block Diagram 9971-4050 ..........48   Figure 5-1c. Functional Block Diagram 9971-4050 ..........49   Woodward...

  • Page 5: Warnings And Notices

    Start-up On- and off-highway Mobile Applications: Unless Woodward's control functions as the supervisory control, customer should install a system totally independent of the prime mover control system that...

  • Page 6: Electrostatic Discharge Awareness

    Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. 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.

  • Page 7: List Of Abbreviations

    Power Supply Unit Power Take Off Revolutions per Minute (can also be expressed as “1/s”) Real Power Sensor Shutdown Starboard SPM-A Woodward Synchronizer Power Management Analog Terminal Block Tie Breaker UPCI Universal PC Interface Volts (alternating current) Volts (direct current)
  • Page 8 723PLUS Standard Generator Control LON Load Sharing Manual 91623 Woodward...

  • Page 9: Chapter 1. General Information

    Manual 91623 723PLUS Standard Generator Control LON Load Sharing Chapter 1. General Information Introduction The Woodward part numbers belonging to the “Standard Generator Control LON Load Sharing” are the following:  System: 8280-1099  Hardware: 723PLUS Low Voltage: 9906-619 ...

  • Page 10: Chapter 2. Inputs And Outputs

    DEBUG mode. Currently, this control feature is not used. Synchronizer Speed Bias (–5 V ~ +5 V) The synchronizer speed bias input is a bi-polar voltage input. The Woodward SPM-A synchronizer makes a suitable match for this control feature. The voltage will be scaled into a bi-polar speed bias (rpm), with a corresponding “Synchronizer Gain”...

  • Page 11: Analog Outputs

    Menus. Generator Load Input (4–20 mA) The Generator Load must be a real power measurement input. The Woodward RPS is a suitable choice for this control input. The generator load input is used extensively in the control for load sharing and droop operation.
  • Page 12 (actuator position) when the input failed. Load Limiter This copies and outputs the Load Limiter [%] input Remote Base-Load Reference This copies and outputs the Remote Base-Load [%] input. Reactive Power This copies and outputs the Reactive Power [kVar] input. Woodward...

  • Page 13: Discrete Inputs

    Raises the speed reference ramp. Active in Speed Control mode when above Idle speed. It overrides the Rated Speed feature. Lower Speed Raises the speed reference ramp. Active in Speed Control mode when above Idle speed. It overrides the Rated Speed feature. Woodward...
  • Page 14 GCB Closed Feedback of the generator circuit breaker status. This signal must be as fast as possible for best load rejection performance. TBR #1 Closed Feedback of the tie-breaker #1 status. TBR #2 Closed Feedback of the tie-breaker #2 status. Woodward...

  • Page 15: Relay Driver Outputs / Led Driver Outputs

    SERVICE Menu. Analog Input #1~4 Fault These signals indicate an out-of-range failure (wire break) for analog input #1~4. GCB Closed Feedback of the generator circuit breaker status. TBR #1 Closed Feedback of the tie-breaker #1 status. Woodward...
  • Page 16 Load reference ramp <=unload setpoint. Stopped Engine speed < stop speed setpoint Speed > Setpoint # X Engine speed >= respective setpoint Any LON fault Indicates any LON network communication failure (latched). Speed Sensor #X Fault Indicates a speed sensor failure (latched). Woodward...

  • Page 17: Chapter 3. Description Of Operation

    LON communications are OK (not using the LSL) and the Base- Load contact is closed or both Raise & Lower Load are closed. The Load reference ramp will follow the Remote Base-Load setpoint input until either the Unload setpoint is reached or any of the Load-Limits have been reached. Woodward...

  • Page 18: Load-Sharing Control (Lon)

    Load-Sharing Control (LSL) For downward compatibility with legacy Woodward controls, one can configure this control to operate in load sharing mode using the Woodward Load Sharing Lines (LSL). The LSL's shall be daisy chained from each engine control to an other.

  • Page 19: Start Sequence & Start Fuel Limiter

    When the start-sequence is initiated, a startup timer is started. When this timer expires, the speed override is removed from both speed sensors. When speed is still below the minimum speed threshold, a major alarm will shutdown the engine, indicating this startup attempt has failed. Woodward...

  • Page 20: Synchronizing

    The Load limiter input is not a true fuel limiter, since it does not operate on the LSS bus directly. It limits the Load reference ramp, and therefore is only active in Load control mode. There is also a Load limiter setpoint, adjustable from the SERVICE Menu. Woodward...

  • Page 21: Load Rejection

    For each Dynamic Set, The P, I and S_D_R can be setup as:  a single figure, or  a 6 point Curve based on Load input [%], or  a 6 point Curve based on Actuator output [%],  a 6 point Curve based on Speed input [%] Woodward...
  • Page 22 There are also a few dynamic parameters for the Load Control, which allows adjusting the system stability, and the balance between speed & load control. The speed control PID operates with a “normalized” speed error (error is divided by RATED speed), typically resulting in higher P gains. Woodward...

  • Page 23: Lon, Load Sharing, & Setup

    ID#11 = 3 ID#15 = 0 ID#4 = 1 ID#8 = 0 ID#12 = 0 ID#16 = 0 All engine controls must have the same system bus segment definition in order for the LON Load Sharing to work properly. Woodward...

  • Page 24: Initializing The Lon Network

    If engines need to be taken out for a longer time, we advise changing the Node ID & bus segment configuration. This has to be changed and kept the same for each 723PLUS control in the LON network. Woodward...

  • Page 25: Chapter 4. Configure And Service Menus

    (0, 2) SS #2 Filter Tau [s] (0, 10) 0.010 SpdSensing Mode (TRUE,FALSE) TRUE Torsional Filtering ? (TRUE,FALSE) FALSE Torsional Ratio [%] (0,100) Grid Frequency [Hz] (0, 1000) #Teeth SS #1/2 Sets the number of teeth for the gear-wheel Woodward...
  • Page 26 When set to 0, the function will output XXXXXXXX DfltVal and there will never be a signal failure. When 5 is selected. the function will be mapped to its corresponding Modbus address. There will be a signal failure when the Modbus communication fails. Woodward...
  • Page 27 For all output channels, the output range is: 0% = 4 mA, 100% = 20 mA Scaling of individual signal engineering units to % can be performed in the SERVICE Menu. The XXXXXXXX DfltVal will be output when the AOX Sel# is set to 0. Woodward...
  • Page 28 When set to 0, the function will output XXXXXXXX INVERT. When 9 is selected. the function will be mapped to its corresponding Modbus address. By default, inputs are NO/Close for action. When XXXXXXXX INVERT is TRUE, the discrete input function changes to NC/Open for action. Woodward...
  • Page 29 Assigns any of the above signals to relay output #1~3. When 0 is selected, DOX NC/Open for Action ? will be output. LEDX Sel# Assigns any of the above signals to 723PLUS LED#1~4. When 0 is selected, LEDX NC/Open for Action ? will be output. Woodward...
  • Page 30 Charge Air Press Fault (0, 2) Load Fault (0, 2) Load Limit Fault (0, 2) Rem Load Setp Fault (0, 2) kVar Fault (0, 2) Modbus Fault (0, 2) 0 = No Alarm, 1 = Minor Alarm, 2 = Major Alarm Woodward...
  • Page 31 Description Range Nominal Actual Modbus ASCII/RTU ? (1, 2) Modbus Net Address (1, 247) Modbus ASCII/RTU ? 1 = Modbus ASCII protocol, 2 = Modbus RTU protocol Modbus Net Address Defines the Modbus network address for this slave Modbus. Woodward...

  • Page 32: Service Mode

    Charge Air Press [bar] Charge Air Press Lim [%] Load [%] Load [kW] Load Limit [%] Remote Load Ref [%] Reactive Power [kVar] Fuel Limit [%] My Busses Avg Load [%] Busses Total LS Load [%] All Busses Total Load [%] Woodward...
  • Page 33 Tie Breaker #1 closed Tie Breaker #2 closed Tie Breaker #1 (LON) Tie Breaker #2 (LON) Speed Control active Load Control active Isochronous Mode selected Droop Mode selected Load-Sharing Control active Base-Load Control active Dynamics Select set #2 Dynamics Select set #3 Woodward...
  • Page 34 (TRUE, FALSE) FALSE Reset Alarms[F,T,F] This software reset command can be used to clear (latching) alarms for which the cause has disappeared. The signal shall be toggled from FALSE to TRUE and back to FALSE to generate a reset pulse. Woodward...
  • Page 35 Reset on Start Automatically issue Reset command on engine starting. Reset on Stop Automatically issue Reset command on engine stopping. Enable Auto Reset Control issues Reset commands automatically. Auto Reset Time [s] Repetition time for the automatic Reset pulse feature. Woodward...
  • Page 36 Speed PID S_D_R Sets the Speed Derivative Ratio for the speed PID. When S_D_R = 1 to 100, D = 1 / ( S_D_R x I ), (PID is Feedback Dominant). When S_D_R = 0.01 to 1, D = S_D_R / 1 (PID is Input Dominant). Woodward...
  • Page 37 1-2 I X6 [%,rpm] (0.0, 5000.0) 1000 1-2 I Y6 (0.0, 50.0) This menu defines the Curve based Integral Gain. These are applicable when Dyn#1 Curve Select has been set to 2,3 or 4 in menu *Dynamics 1 * Woodward...
  • Page 38 Dyn#2 Curve Select Select where P, I and S_D_R are coming from: 1=single figures, 2=Load Curve, 3=Actuator Curve, 4=Speed Curve Please refer to application note 83402, PID Control, to learn more about adjusting the dynamic settings for the load sharing PID. Woodward...
  • Page 39 Speed PID S_D_R Sets the Speed Derivative Ratio for the speed PID. When S_D_R = 1 to 100, D = 1 / ( S_D_R x I ), (PID is Feedback Dominant). When S_D_R = 0.01 to 1, D = S_D_R / 1 (PID is Input Dominant). Woodward...
  • Page 40 2-2 I X6 [%,rpm] (0.0, 5000.0) 1000 2-2 I Y6 (0.0, 50.0) This menu defines the Curve based Integral Gain. These are applicable when Dyn#2 Curve Select has been set to 2,3 or 4 in menu *Dynamics 2 * Woodward...
  • Page 41 Dyn#3 Curve Select Select where P, I and S_D_R are coming from: 1=single figures, 2=Load Curve, 3=Actuator Curve, 4=Speed Curve Please refer to application note 83402, PID Control, to learn more about adjusting the dynamic settings for the load sharing PID. Woodward...
  • Page 42 Speed PID S_D_R Sets the Speed Derivative Ratio for the speed PID. When S_D_R = 1 to 100, D = 1 / ( S_D_R x I ), (PID is Feedback Dominant). When S_D_R = 0.01 to 1, D = S_D_R / 1 (PID is Input Dominant). Woodward...
  • Page 43 3-2 I X6 [%,rpm] (0.0, 5000.0) 1000 3-2 I Y6 (0.0, 50.0) This menu defines the Curve based Integral Gain. These are applicable when Dyn#3 Curve Select has been set to 2,3 or 4 in menu *Dynamics 3 * Woodward...
  • Page 44 These features can be used to optimize the PID settings while running the engine in a steady state condition. Please refer to application note 83402, PID Control, to learn more about adjusting the dynamic settings for the load sharing PID. Woodward...
  • Page 45 The Overspeed Setpoint shall be set between Rated Setpoint and Overspeed Test Setpoint. Stop Speed Setpoint [rpm] When the engine speed drops below this threshold for 5 seconds, the engine is considered stopped and only now it is possible to reset major alarms. Woodward...
  • Page 46 This is the speed reference rate when going from Idle to Rated speed by either contact input or start sequence. Analog SpdSet Rate [rpm/s] This is the speed reference rate when remote speed setpoint is activated. Digital SpdSet Rate [rpm/s] This is the speed reference rate when Raise/Lower discrete inputs are used. Woodward...
  • Page 47 Defines the 4-point start fuel limit curve. Engine speed is the input to this curve and each next speed point shall be higher than the previous speed point. Per speed point an adjustable fuel limit [%] can be set. Woodward...
  • Page 48 Sets the actuator limit during the activation of the KickDown function. Actuator Return Rate [%/s] Sets the rate at which the KickDown actuator limit ramps out of the way and normal PID control can take over again, when KickDown gets deactivated. Woodward...
  • Page 49 Defines the absolute maximum actuator position for this engine, active in droop and in isochronous load sharing mode. Charge Air Limit#X [bar], Charge Air Limit#X [%] Defines the 4 point curve of Boost pressure versus fuel limit, to try to minimize overfueling the engine. Woodward...
  • Page 50 Adjust for stable Load Control & Load Sharing operation When the speed control PID settings have been optimized for droop operation in a multiple engine system, when switching to load control mode, the P-Gain shall be adjusted for stable load control. Woodward...
  • Page 51 Fuel Limiter Inp [%] EngLoad [%] Displays the final load as being used in the load controller. This can be the EngLoad input signal, but also the actuator based calculated backup load when the EngLoad input has failed or is not configured. Woodward...
  • Page 52 My Busses Avg Load 20 mA [%] (-9999, 9999) Busses Tot LS Load 4 mA [%] (-9999, 9999) Busses Tot LS Load 20 mA [%] (-9999, 9999) 2000 Busses Total Load 4 mA [%] (-9999, 9999) Busses Total Load 20 mA [%] (-9999, 9999) 2000 Woodward...
  • Page 53 Set Download Mode ? This sets the 723PLUS com port J1 usage setting: 1 = Servlink, 2 = Hand-Held After every reboot of the 723PLUS control, Set Download Mode ? is set back to 2, which is Hand-Held usage. Woodward...

  • Page 54: Chapter 5. Functional Block Diagram

    723PLUS Standard Generator Control LON Load Sharing Manual 91623 Chapter 5. Functional Block Diagram This chapter contains Functional Block Diagram 9971-4050. Woodward...

  • Page 55: Figure 5-1A. Functional Block Diagram 9971-4050

    723PLUS Standard Generator Control LON Load Sharing Bias Calc [rpm] Load Setpoint Logic LOAD MODE Unit #1 ~ #16 Unit #1 ~ #16 Control Mode [LON] [LON] Speed Ctrl Load Ctrl BaseLd Ctrl 100% Communications 4-20mA Figure 5-1a. Functional Block Diagram 9971-4050 Woodward...

  • Page 56: Figure 5-1B. Functional Block Diagram 9971-4050

    723PLUS Standard Generator Control LON Load Sharing Manual 91623 % -> mA Load Rejection logic Starting Logic & Speed Reference Ramp Fuel Limiting +/- 5V 4-20mA 4-20mA 4-20mA Figure 5-1b. Functional Block Diagram 9971-4050 Woodward...

  • Page 57: Figure 5-1C. Functional Block Diagram 9971-4050

    723PLUS Standard Generator Control LON Load Sharing Bias Calc [rpm] Load Setpoint Logic LOAD MODE Unit #1 ~ #16 Unit #1 ~ #16 Control Mode [LON] [LON] Speed Ctrl Load Ctrl BaseLd Ctrl 100% Communications 4-20mA Figure 5-1c. Functional Block Diagram 9971-4050 Woodward...

  • Page 58: Chapter 6. Modbus Signals List

    Discrete Inputs - Load Lower 1:0008 Discrete Inputs - Droop 1:0009 Discrete Inputs - Isochronous 1:0010 Discrete Inputs - Idle 1:0011 Discrete Inputs - Rated 1:0012 Discrete Inputs - Unload 1:0013 Discrete Inputs - BaseLoad 1:0014 Discrete Inputs - GCB Closed Woodward...
  • Page 59 ALM - LON Fault NODE10 1:0059 ALM - LON Fault NODE11 1:0060 ALM - LON Fault NODE12 1:0061 ALM - LON Fault NODE13 1:0062 ALM - LON Fault NODE14 1:0063 ALM - LON Fault NODE15 1:0064 ALM - LON Fault NODE16 Woodward...
  • Page 60 SEQUENCE - Starting to Idle 1:0109 SEQUENCE - Running >= Idle 1:0110 LoadRef - Load at Limit 1:0111 LoadRef - Unloaded 1:0112 LoadRef - Soft-Loading 1:0113 Control - Speed in control 1:0114 Control - Max Actuator Lim in control Woodward...
  • Page 61 BaseLoad mode NODE09 1:0156 BaseLoad mode NODE10 1:0157 BaseLoad mode NODE11 1:0158 BaseLoad mode NODE12 1:0159 BaseLoad mode NODE13 1:0160 BaseLoad mode NODE14 1:0161 BaseLoad mode NODE15 1:0162 BaseLoad mode NODE16 1:0163 SpeedControl mode NODE01 1:0164 SpeedControl mode NODE02 Woodward...
  • Page 62 GCB Closed NODE07 1:0202 GCB Closed NODE08 1:0203 GCB Closed NODE09 1:0204 GCB Closed NODE10 1:0205 GCB Closed NODE11 1:0206 GCB Closed NODE12 1:0207 GCB Closed NODE13 1:0208 GCB Closed NODE14 1:0209 GCB Closed NODE15 1:0210 GCB Closed NODE16 Woodward...
  • Page 63 3:0037 Value - 3:0038 Value - 3:0039 Value - 3:0040 Value - 3:0041 Value - 3:0042 Value - 3:0043 Value - 3:0044 Value - 3:0045 Value - 3:0046 Value - 3:0047 Value - 3:0048 Value - 3:0049 Value - Woodward...
  • Page 64 LON - Grid Frequency [Hz] NODE11 3:0094 LON - Grid Frequency [Hz] NODE12 3:0095 LON - Grid Frequency [Hz] NODE13 3:0096 LON - Grid Frequency [Hz] NODE14 3:0097 LON - Grid Frequency [Hz] NODE15 3:0098 LON - Grid Frequency [Hz] NODE16 Woodward...
  • Page 65 Analog Writes Address Description Units Multiplyer 4:0001 Remote Speed Ref [%] 4:0002 SPMA [%] 4:0003 Charge Air Press [%] 4:0004 Load [%] 4:0005 Load Limit [%] 4:0006 Remote Load Ref [%] 4:0007 Reactive Power [%] 4:0008 Fuel Limit [%] Woodward...

  • Page 66: Chapter 7. Product Support And Service Options

    A current list of Woodward Business Partners is available at www.woodward.com/directory. Product Service Options Depending on the type of product, the following options for servicing Woodward products may be available through your local Full-Service Distributor or the OEM or Packager of the equipment system.

  • Page 67: Returning Equipment For Repair

    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.

  • Page 68: Engineering Services

    Field Service engineering on-site support is available, depending on the product and location, from one of our Full-Service 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.

  • Page 69: Technical Assistance

    723PLUS Standard Generator Control LON Load Sharing Technical Assistance If you need to contact technical assistance, you will need to provide the following information. Please write it down here before contacting the Engine OEM, the Packager, a Woodward Business Partner, or the Woodward factory: General...
  • Page 70 Email and Website—www.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website.

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