Woodward 9905-096 | 2301A Series High-Performance Load Sharing & Speed Control Module for Industrial Prime Movers

Description

Product Overview

Key Technical Specifications

• Input Voltage: 12–60 Vdc (nominal 24/48 Vdc) – ultra-wide range supporting low-voltage (mobile/vehicle) to high-voltage (industrial DC bus) systems.
• Control Modes:
  • Isochronous Mode: Maintains constant prime mover speed (±0.1% tolerance) for standalone/isolated bus operation.
  • Droop Mode: Adjusts speed based on load (adjustable droop percentage, 0–20%) for parallel operation (wider range than standard 2301A models).
• Actuator Compatibility: Works with Woodward proportional actuators (e.g., EG-3P, EG-6P, PG-PL, EPG-2) for fuel/steam valve positioning.
• Operating Temperature: -40°C to +85°C (-40°F to +185°F) – extended range for arctic/offshore/high-heat environments.
• Certifications: CE, UL, CSA, ATEX (Zone 2/22) – compliant with international safety and hazardous-area standards.
• Dimensions: Compact form factor (~300 mm × 220 mm × 95 mm) – fits standard industrial cabinets.
• Weight: ~4.5 kg (9.9 lbs) – rugged yet lightweight for harsh-environment handling.
• Diagnostic Features: 12 onboard LEDs (power, run, sync, fault, mode, actuator status, etc.) and non-volatile fault log (stores last 50 events with timestamps).
• Output Signal: 0–200 mA (sink) or 4–20 mA (source) – dual-mode output for versatile actuator compatibility.
• Protection Ratings: IP55 (dust/water jet resistant) – suitable for outdoor/marine installations.

  

  WOODWARD 9905-001-G

Field Application & Problem Solved

• Ultra-Wide Voltage Incompatibility: Standard 2301A modules (10–40 Vdc) fail in 12 Vdc (vehicles) or 60 Vdc (industrial DC buses). The 9905-096’s 12–60 Vdc range ensures compatibility.
• Harsh Environment Limitations: Base models (e.g., 9905-003) lack IP55 sealing or extended temperature tolerance (-40°C to +85°C), failing in arctic/offshore sites.
• Insufficient Diagnostics: Limited LED indicators and small fault logs (e.g., 10 events) complicate troubleshooting in remote locations. The 9905-096’s 12-LED panel and 50-event log enable rapid root-cause analysis.
• Unstable Speed/Load: Mitigates grid frequency deviations (±0.1% speed accuracy) and uneven load distribution (±1% accuracy in droop mode), critical for remote grid stability.

• Remote Mining/Oil/Gas Sites: Mobile diesel generators with 12–48 Vdc battery systems (wide voltage support).
• Arctic Offshore Platforms: Gas turbine control in -40°C environments (extended temperature resilience).
• Marine Auxiliary Power: Shipboard generators with 24/32/48 Vdc DC buses (dual-mode output compatibility).
• High-Temperature Refineries: Steam turbine control in 85°C ambient conditions (IP55 dust/water resistance).

Installation & Maintenance Pitfalls (Expert Tips)

1. Ultra-Wide Voltage Validation:
   • Confirm input voltage (12–60 Vdc) matches the system’s DC bus. Use a multimeter to check for voltage spikes (e.g., engine cranking at 12 Vdc dropping to 8 Vdc) and ensure the module’s low-voltage cutoff (10 Vdc) is not triggered.
2. Droop Mode Calibration for Parallel Systems:
   • For N generators in parallel, set droop percentage to 100%/N (e.g., 4 generators = 25% droop each). Use Woodward’s handheld programmer (Model 8923-xxxx) to fine-tune.
3. Advanced Diagnostic Utilization:
   • Map the 12 LEDs to system states (e.g., green = sync ready, red = overspeed fault). Regularly download the 50-event fault log via USB to identify recurring issues (e.g., sensor drift at low temps).
4. Harsh Environment Hardening:
   • Install in a NEMA 4X cabinet with desiccant packs for high-humidity sites. For arctic use, add a thermostatically controlled heater (10 W) to prevent internal condensation.

     

     WOODWARD 9905-001-G

Technical Deep Dive & Overview

1. Signal Reception:
   • Accepts inputs from:
     • Speed sensor​ (magnetic pickup/encoder) for prime mover RPM (supports 0–10 kHz signals).
     • Load sensor​ (current transformer) for generator output current (0–5 A range).
     • Operator inputs​ (membrane keypad) for speed setpoint, droop, and diagnostic access (replaces front-panel potentiometers for durability).
2. Processing & Control:
   • Analog circuitry with adaptive PID algorithms​ (adjusts gains based on load) calculates fuel/steam flow. Isochronous mode locks speed; droop mode (0–20%) adjusts for load.
3. Advanced Diagnostics:
   • 12 LEDs provide real-time status (e.g., “actuator fault,” “sensor loss”). A non-volatile flash memory stores 50 faults with timestamps, error codes, and system parameters.
4. Output & Actuation:
   • Dual-mode output (0–200 mA sink or 4–20 mA source) drives actuators. Includes galvanic isolation (1500 VAC) to protect against surge damage.
5. Environmental Resilience:
   • Conformal-coated PCB, sealed connectors (IP55), and temperature-compensated components ensure operation from -40°C to +85°C.

• Ultra-Wide Voltage Range: 12–60 Vdc vs. 9905-092’s 12–48 Vdc and 9905-068’s 20–40 Vdc.
• Extended Droop Range: 0–20% vs. standard 0–10% for flexible parallel load sharing.
• Superior Diagnostics: 12 LEDs + 50-event log vs. 8 LEDs + 10-event log (9905-092).
• Harsh-Environment Rating: IP55 + ATEX vs. IP20 (base models) or IP54 (9905-003-L).

Final Notes

• Choose 9905-096 if: You need 12–60 Vdc compatibility, harsh-environment resilience (-40°C to +85°C, IP55), or detailed diagnostics (50-event log).
• Consider Alternatives: For basic synchronization, use 9905-002; for enhanced SPM-A diagnostics, use 9905-228.