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Product Manual 26247

(Revision C)

Original Instructions

2301D and 2301D-EC Digital Load Sharing

and Speed Controls for Engines

Ordinary

Locations Hazardous Locations

2301D

8273-140

8273-141

2301D-EC

8273-138

8273-139

Installation and Operation Manual

Summary of Contents for 2301D

Page 1: ...vision C Original Instructions 2301D and 2301D EC Digital Load Sharing and Speed Controls for Engines Ordinary Locations Hazardous Locations 2301D 8273 140 8273 141 2301D EC 8273 138 8273 139 Installation and Operation Manual ...

Page 2: ...ed To verify that you have the latest revision be sure to check the publications page on the Woodward website www woodward com publications The current revision and distribution restriction of all publications are shown in manual 26311 The latest version of most publications is available on the publications page If your publication is not there please contact your customer service representative t...

Page 3: ...nal 31 13 Digital Inputs B C D Terminals 32 33 34 14 Failed Speed Override 14 Reset 14 Select 2nd Dynamics 15 Shutdown Internal 15 Shutdown External 15 Rated Speed 15 Idle Rated Software Switch 16 CB Aux Droop Contact 16 Raise Speed Load Contact Terminal 35 17 Lower Speed Load Contact Terminal 36 17 Load Generator Terminal 37 18 Base Load Terminal 38 18 Actuator Output 18 Analog Inputs 18 Analog I...

Page 4: ... OPERATION 77 Introduction 77 Speed Control 77 Control Dynamics 78 Minimum Fuel Function 79 Maximum Fuel Function 80 Start Limit Function 80 Torque Limiter 80 Manifold Air Pressure Limiter 81 Speed Load Reference and Ramps 81 Speed Reference and Ramp Functions 81 Speed Bias and Synchronizer Summing 83 Load Reference and Ramp Functions 83 Droop Function 85 Droop Isochronous Load Sharing on an Isola...

Page 5: ... 104 CHAPTER 9 PRODUCT SUPPORT AND SERVICE OPTIONS 105 Product Support Options 105 Product Service Options 105 Returning Equipment for Repair 106 Replacement Parts 106 Engineering Services 107 Contacting Woodward s Support Organization 107 Technical Assistance 108 APPENDIX A SERVICE CONFIGURATION CHART 109 Configure Menus 109 Service Menus 110 APPENDIX B MODBUS COMMUNICATION LIST 116 2301D 2301D E...

Page 6: ...Figure 3 3 Speed Filter 41 Figure 3 4 Typical Transient Response Curves 43 Figure 3 5 Non linear Valve Power Curve 47 Figure 3 6 Non linear Valve Power Curve for Turbocharged Engine 47 Figure 3 7 Linearized Gain Plot 48 Figure 3 8 Start Limit Function 50 Figure 3 9 LP Ramp 61 Figure 4 1 Temporary Wiring for Transformer Phase Correction 69 Figure 4 2 Droop Adjustment 71 Figure 5 1 Trend Tool Trace ...

Page 7: ...on Marine Compliance Bureau Veritas BV Rules Part C June 2000 Det Norske Veritas Standard for Certification No 2 4 2001 Germanischer Lloyd Additional Rules and Guidelines Part 1 2001 Lloyd s Register of Shipping Type Approval System Test Specification Number 1 2002 Registro Italiano Navale RINA Rules 2001 Part C NOTE Marine certifications apply to specific models only Connector J1 must not be used...

Page 8: ...m materials such as plastic or Styrofoam cups cup holders cigarette packages cellophane wrappers vinyl books or folders plastic bottles and plastic ash trays away from the control the modules and the work area as much as possible 4 Do not remove the printed circuit board PCB from the control cabinet unless absolutely necessary If you must remove the PCB from the control cabinet follow these precau...

Page 9: ...Vdc input Ordinary Locations 8273 141 2301D Load Sharing and Speed Control 24 Vdc input Hazardous Locations Modbus is a registered trademark of Schneider Automation Inc The control is housed in a sheet metal chassis and consists of a single printed circuit board The 2301D is set up and configured through an external computer connected at the 9 pin connector at the front of the control The configur...

Page 10: ...omputer during installation These 2301D controls operate with an input of 18 to 40 Vdc Applications Because of the configuration software available in the 2301D hardware application variations can now be selected using an external computer Changing the application to accommodate engine speed range gear teeth and selection of forward or reverse acting actuator is a matter of software setup rather t...

Page 11: ...ys available to assist you in selection of the correct control for your system or to answer questions concerning control installation operation or calibration Contact any Woodward office References The following publications contain additional product or installation information on Load Sharing and Speed Controls and related components They can be obtained at www woodward com publications Manual T...

Page 12: ...2301D 2301D EC Digital Control Manual 26247 4 Woodward Figure 1 1a 2301D Outline Drawing Ordinary Locations ...

Page 13: ...Manual 26247 2301D 2301D EC Digital Control Woodward 5 Figure 1 1b 2301D Outline Drawing Hazardous Locations ...

Page 14: ...2301D 2301D EC Digital Control Manual 26247 6 Woodward Figure 1 2a 2301D Plant Wiring Diagram sheet 1 ...

Page 15: ...GURABLE IDLE RATED DISCRETE INPUTS 24 VDC POWER USED WHEN POWERING DISCRETE INPUTS DISCRETE INPUTS WITH INTERNAL POWER SUPPLY CONFIGURABLE FAILSAFE OVERRIDE CONFIGURABLE CB AUX SPEED TRIM RAISE SPEED TRIM LOWER LOAD UNLOAD SELECT BASELOAD MINIMUM FUEL CLOSE TO RUN CONFIGURABLE IDLE RATED CONFIGURABLE FAILSAFE OVERRIDE CONFIGURABLE CB AUX SPEED TRIM RAISE SPEED TRIM LOWER LOAD UNLOAD SELECT BASELOA...

Page 16: ...2301D 2301D EC Digital Control Manual 26247 8 Woodward Figure 1 2c 2301D Plant Wiring Diagram notes ...

Page 17: ...current capacity of at least 900 mA for operating power If a battery is used for operating power an alternator or other battery charging device is necessary to maintain a stable supply voltage To prevent damage to the control make sure that the alternator or other battery charging device is turned off or disconnected before disconnecting the battery from the control Location Considerations This pr...

Page 18: ...utputs contact inputs and power supply wiring do not normally require shielding but can be shielded if desired The 2301D is designed for shield termination to earth ground at the control If intervening terminal blocks are used in routing a signal the shield should be continued through the terminal block If shield grounding is desired at the terminal block it should be ac coupled to earth All other...

Page 19: ...oth count into engine rpm Improper conversion could cause engine overspeed The speed range is factory set for 900 Hz 900 rpm 60 teeth Refer to Chapter 4 to change speed range and prevent possible overspeed Using the wrong speed range could cause an overspeed with resulting damage to equipment or personal injury or death Potential Transformer Connections Connect the potential transformer secondary ...

Page 20: ...rnal load control device terminals 34 and 37 must be connected to terminal 28 to connect the Load Matching Circuit to the load sharing lines The load sharing lines must be wired to the external load control device The circuit breaker auxiliary contact will then be connected to this device and not to the 2301D Power Supply Run the power leads directly from the power source to the control connecting...

Page 21: ...tact and connect the mated switch or relay contact to the corresponding discrete input terminal on the 2301D control In systems where the external low voltage dc power is not appropriate the discrete inputs may be powered by the internal 24 Vdc Discrete Input Power source at terminal 28 and 29 This source is capable of supplying 100 mA at a voltage level of 24 Vdc Connect the internal 24 Vdc volta...

Page 22: ...uts When the contact is open the control operates normally turning the control output off in the event of a loss of speed signal Closing the contact overrides the failed speed signal circuit as may be required for start up Prior to start up of the prime mover the speed signal is non existent On prime movers with cranking motors the cranking speed is usually sufficient to provide a speed signal so ...

Page 23: ...acts can be configured as External shutdown When the contact is open the control operates normally Closing the contact will cause the engine to go to 0 fuel demand on a forward acting actuator and 100 fuel demand on a reverse acting actuator Reverse acting actuators should always contain a mechanical ballhead governor When the contact is opened again a reset should be given before the engine can b...

Page 24: ...h or relay contacts are open the control will operate in Droop Mode A switch in series with the auxiliary contact on the generator circuit breaker will allow manually selecting Droop Mode or Base Load Isochronous Mode Open this switch for Droop Mode Close this switch for Base Load Isochronous Modes When both the droop contact and circuit breaker auxiliary contact are closed the control is in the i...

Page 25: ... open and by increasing the base load reference when in base load mode The speed reference ramp can increase only to a software adjusted RAISE SPEED limit The base load reference ramp can increase only to a software adjusted BASE LOAD MAXIMUM limit Both ramps increase at software adjusted rates De selecting the Rated Speed command described above takes command control away from the Raise Speed Loa...

Page 26: ...input TRUE isochronous load sharing with other units is disabled With the state of this contact FALSE isochronous load sharing with other units can occur The CB Aux Droop Contact discrete input must be TRUE for the Base Load input to affect the control Actuator Output The actuator wires connect to terminals 13 and 14 The current range to the actuator output is configured in software for a 0 200 mA...

Page 27: ...sure that the pressure sensor is supplied with the same voltage source as the 2301D control This is to prevent isolation problems No connection is required to this input if this function is not needed by the application set the function to 1 not used The 2301D control is designed to receive either 4 20 mA 0 5 Vdc 2 5 Vdc or 1 5 Vdc representing a minimum Remote Speed Load set point to a maximum Re...

Page 28: ...25 and 26 using shielded wire Connect the shield to terminal 27 making sure the shield has continuity the entire distance to the speed sensor and that the shield is insulated from all other conducting surfaces Relay Driver Outputs Terminals 41 44 The 2301D contains four discrete output driver channels The discrete outputs are low side drivers with a maximum output current of 200 mA The discrete ou...

Page 29: ...ol s serial communications port is used to configure and service the unit as well as communicate to a Human Machine Interface HMI or plant distributed control system DCS This port s protocol is switchable via the control s Modbus communications enable contact input When this contact input is open or has no connection to it the control s communications port communicates using an RS 232 driver and a...

Page 30: ...247 22 Woodward RS 232 See Figure 2 3 for cable connection Figure 2 3 RS232 Pin assignments for Serial Communication Cable RS 422 See Figure 2 4 for termination and cable connection example Figure 2 4 Typical RS422 Communications Connections ...

Page 31: ...its The preferred method to do this is to include a separate wire in the cable that connects the circuit grounds together Connect the shield to earth ground at one point only The alternate way is to connect all circuit grounds to the shield and then connect the shield to earth ground at one point only If the latter method is used and there are non isolated nodes on the party line connect the shiel...

Page 32: ... Multipoint Wiring Using Shielded Twisted pair Cable with a Separate Signal Ground Wire The SG signal ground connection is not required if signal ground is unavailable Figure 2 7 Alternate Multipoint Wiring Using Shielded Twisted pair Cable without a Separate Signal Ground Wire ...

Page 33: ...fuel or steam rack is at the minimum position If the actuator lever gets to its minimum position before completely shutting off fuel or steam the control may not be able to shut down the prime mover causing damage to equipment or injury or death 2 Check for correct wiring in accordance with the plant wiring diagram Figure 1 2 3 Check for broken terminals and loose terminal screws 4 Check the speed...

Page 34: ...he 2301D control on a prime mover The computer and Watch Window software is not required and not necessary for normal operation of the prime mover unless Modbus is being used for monitoring Watch Window was developed by Woodward to be a Servlink client software product that provides a generic PC interface to any control and is a very powerful setup testing and troubleshooting tool Watch Window pro...

Page 35: ...automatically be created from each Service and Configure Header programmed into the control Multiple inspectors can be created this way to allow for viewing more than one sheet at a time To enter the I O Lock mode and enable a configure value to be entered click on the I O Lock icon on the Tool Bar Because the values set in Configure are critical to engine operation it is not safe to operate the p...

Page 36: ...pm This value is used to set the 2301D speed sensor hardware to software conversion The rated speed can be varied in Service for testing If a rated speed other than values listed here is entered the calculated generator frequency shown in DISPLAY MENU may not be correct 02 ENTER NUM OF GEAR TEETH dflt 60 8 500 This is the number of teeth or holes of the gear or flywheel that the speed sensor is on...

Page 37: ...g 07 ENABLE 5 SLOPE GAIN MAP dflt FALSE TRUE FALSE Set to TRUE to permit the use of a 5 gain curve for setting the control gain as a function of prime mover load If Use 2nd Dynamics is also set TRUE the use of a second 5 gain curve is activated These two curves each provide 5 tunable gain settings at 5 tunable load dependent breakpoints If Enable 5 Slope Gain Map is set FALSE only a single gain va...

Page 38: ...o rated switch which activates rated after idle is reached and a certain time has expired Tunable in service mode B DISCRETE IN OPTIONS 01 SEL DI B FUNCTION 1 8 dflt 2 1 8 Used to select the function for digital input 2 B terminal 32 1 Not used 2 Failed speed override default 3 Reset 4 Select 2nd dynamics 5 Shutdown external On a forward acting actuator the fuel demand will go to 0 On a reverse ac...

Page 39: ...ammed to perform one of the following functions Any of the four relays can also be programmed to function as a level switch When programmed as a level switch the relay changes state when the selected parameter reaches the programmed level energizes when value is higher the programmed level Level Switch set up is in Menu Q Discrete Out Settings 01 IS SHUTDOWN RELAY NC dflt TRUE FALSE TRUE This opti...

Page 40: ...ay function for terminal 43 09 RELAY 4 ENERGIZES 1 14 dflt 7 1 14 Select one of the following parameters for discrete output at terminal 44 same as parameters in 03 RELAY 1 ENERGIZES 10 RELAY 4 SELECTED FOR monitor Displays the relay function for terminal 44 11 CB OPEN RELAY NORM ENGZD dflt FALSE FALSE TRUE When set TRUE sets the circuit breaker open relay to normally closed D ANALOG INPUT OPTIONS...

Page 41: ...t 3 2 5 Volt 4 1 5 Volt 10 DISPLAY AI 2 TYPE monitor Displays the type of input for analog input 2 11 USE INPUT 2 FAIL TRIP dflt FALSE FALSE TRUE When set TRUE a failure of the input signal gives a major alarm which shutdowns the engine When set FALSE only an alarm is given and the engine is not stopped E ACTUATOR OUT OPTIONS 01 ACTUATOR OUT TYPE 1 3 dflt 1 1 3 Selects the current range of the act...

Page 42: ... from the speed and phase match device input to the control 08 BASE LOAD REF KW monitor Displays the KW reference value of the baseload mode 09 GENERATOR OUT KW monitor Displays the generator load in kilowatts 10 LOAD SIGNAL OUT Vdc monitor Indicates the generator kW in units of load gain voltage The value will vary from 0 0 to the value entered in H LOAD SETTINGS LOAD GAIN VOLTAGE when the genera...

Page 43: ...dicates an overspeed 04 MPU FAIL 2 Monitor When TRUE indicates an MPU failure 05 ANALOG INPUT 1 FAIL 3 Monitor When TRUE indicates a signal input failure 06 ANALOG INPUT 2 FAIL 4 Monitor When TRUE indicates a signal input failure 07 TEST MODE 5 Monitor When TRUE indicates that the Test Mode is active 08 EXTERNAL SHUTDOWN 6 Monitor Indicates that an external shutdown is active one of the digital in...

Page 44: ...screte input A 02 DISCRETE INPUT B Monitor The status of discrete input B 03 DISCRETE INPUT C Monitor The status of discrete input C 04 DISCRETE INPUT D Monitor The status of discrete input D 05 RAISE SPEED LOAD E Monitor The status of discrete input E 06 LOWER SPEED LOAD F Monitor The status of discrete input F 07 LOAD GENERATOR G Monitor The status of discrete input G 08 SELECT BASE LOAD H Monit...

Page 45: ...ing string to indicate the input range selected for input 2 4 20 mA 0 5 V 2 5 V 1 5 V 06 ANIN 2 UNITS Monitor Displays the units of the input type above volts or mA of the analog Input 2 07 LOAD SHARING LINES Vdc Monitor Indicates the voltage present at terminals 10 and 11 08 LOAD SHARING BIAS SIG Monitor The error signal to the speed reference from the load sharing and or droop circuitry 09 ACTUA...

Page 46: ...SPEED RPM dflt 600 00 0 00 4000 00 This is the speed that the speed reference ramp goes to when the close for rated discrete input is OPEN It is normally the speed at which the engine is operated at start up It is also used during cool down Idle Speed is limited to a value between synchronous speed entered in configure and 20 of synchronous speed a 5 to 1 speed range Avoid critical speeds when set...

Page 47: ...age adjustment 13 IDLE DROOP dflt 0 00 0 00 100 00 Based on the control output current when it drops below the idle droop breakpoint The percentage is based on the idle speed set point To enable idle droop the parameter 11 Enable Idle Droop at Configure Menu A Engine Speed Control should be set TRUE 14 DELAY TIME IDLE TO RATED dflt 5 00 0 00 600 00 The delay time for the automatic idle to rated sw...

Page 48: ...width that is too narrow results in cycling that always factors in the gain ratio see Figure 3 2 05 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 t...

Page 49: ...orsens but transient performance may improve 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 3 3 Speed Filter 07 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 t...

Page 50: ... input is configured for Select 2nd Dynamics and this input is closed 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 contac...

Page 51: ...Manual 26247 2301D 2301D EC Digital Control Woodward 43 Figure 3 4 Typical Transient Response Curves ...

Page 52: ...EAKPOINT 1C LD OR RPM dflt 99 80 0 01 5000 00 The load for breakpoint C 06 GAIN BREAKPOINT 1C dflt 4 0 0 01 100 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 4 0 0 01 100 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 ...

Page 53: ...s but transient performance may worsen As the filter frequency is increased steady state stability worsens but transient performance may improve 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...

Page 54: ...0 06 BREAKPOINT 2B LD OR RPM dflt 99 70 0 01 5000 00 07 GAIN BREAKPOINT 2B dflt 4 0 0 01 100 00 08 BREAKPOINT 2C LD OR RPM dflt 99 80 0 01 5000 00 09 GAIN BREAKPOINT 2C dflt 4 0 0 01 100 00 10 BREAKPOINT 2D LD OR RPM dflt 99 90 0 01 5000 00 11 GAIN BREAKPOINT 2D dflt 4 0 0 01 100 00 12 BREAKPOINT 2E LD OR RPM dflt 100 00 0 01 5000 00 13 GAIN BREAKPOINT 2E dflt 4 0 0 01 100 00 14 RESET 2 dflt 2 00 ...

Page 55: ...es the position of the valve in comparison to engine output appears on a chart similar to Figure 3 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 3 6 Figure 3 5 Non linear Valve Power Curve Figure 3 6 Non linear Valve Power Curve for Turb...

Page 56: ...ed 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...

Page 57: ... 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 U...

Page 58: ... 3 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 for the start fuel limit 04 MAX FUEL LIMIT FD dflt 100 00 50 00 110 00 Sets the maximum percent fuel demand Maximum 100 is...

Page 59: ...nt 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 set point 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 se...

Page 60: ...closed 05 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 06 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 07 BASELOAD RAISE TIME S...

Page 61: ...ump 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...

Page 62: ...Displays the baseload reference based on the analog input 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 re...

Page 63: ...nction 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 t...

Page 64: ... 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 ...

Page 65: ...d parameter when the analog output will be 4 mA 04 ANOUT 20MA SCALE dflt 100 000 200 00 200 00 Adjusted for the value of the displayed parameter when the analog output will be 20 0 mA 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 it...

Page 66: ...nalog 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 internal load sensor to correspond its output to measured kilowatts This calibration allows the control to calculate the 100 load gai...

Page 67: ...N 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 1 000 0 00 10 00 Sets the gain for analog input 2 06 AnIN 2 mA Volt Monitor Shows the actual inpu...

Page 68: ... 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 Thi...

Page 69: ...used to setup the serial port for Modbus use 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 er...

Page 70: ...uality and or noise problems 10 GARBLED MESSAGE Data received by the slave but it is too short to be a valid Modbus message command Table 3 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 0...

Page 71: ...s 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 When set TRUE you are able to control using Modbus 18 USE MODBUS ANALOG CNTRL dflt FALSE TR...

Page 72: ...carbureted gas or gasoline prime movers 9 Set GAIN RATIO 1 to 1 0 to disable the effect of window width and gain ratio 10 ACCEL RAMP TIME Set at 20 sec DECEL RAMP TIME Set at 20 sec 11 LOW IDLE SPEED Set at idle speed rpm no lower than 20 of rated 12 LOAD GAIN Set at 1 0 or the value of other load sharing controls on a common bus 13 DROOP Set at desired percentage 14 START FUEL LIMIT Set at 100 15...

Page 73: ...k 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 entere...

Page 74: ... 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 th...

Page 75: ...peed Current Transformer CT Phasing Check 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 HIGH VOLTAGE Never disconnect any wire attached to load sensor terminals 4 through 9 when the prime mover is running unless temporary 0 5 20 W resistors are installed...

Page 76: ...ed 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 incorr...

Page 77: ... 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 Se...

Page 78: ... 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 sy...

Page 79: ...ing 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 shari...

Page 80: ...eans 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 kee...

Page 81: ...y 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 ...

Page 82: ...y 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 ...

Page 83: ...creases Gain may be skipped in favor of Window Width and Gain Ratio adjustments only Figure 5 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 5 5 Trend Tool Trace Example 5 21 Figure 5 5 shows results of just increasing Gain from 1 235 to...

Page 84: ... 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 poin...

Page 85: ...ads of all generators in the system to be shared proportionally During parallel operation of two or more generator or a generator paralleled against an infinite bus the control may be operated in Baseload mode During parallel operation of two or more generator or a generator paralleled against an infinite bus the control may be operated in Droop mode Speed Control The Speed Control system as shown...

Page 86: ...ion if not restricted However due to linkage adjustment or other restrictions in the external system minimum actuator position may not permit prime mover shutdown For controls with actuator current of 20 to 160 mA minimum fuel is defined as Actuator current less than 10 mA for forward acting controls Actuator current greater than 180 mA for reverse acting controls A contact to override the failed ...

Page 87: ...When the speed error exceeds an adjustable window width e g during a load transient the control automatically increases gain by an adjustable ratio This increased gain produces a faster fuel response and quickly restores engine speed at the speed reference The base gain is restored once the control senses a return to steady state operation This feature is available for all gain choices Furthermore...

Page 88: ... after the start fuel limit is triggered The rate can be set at zero to eliminate the ramp function When engine speed reaches 95 of the speed reference and the PID is in control of the fuel demand for 1 second the Start Limit Function will immediately increase to a maximum value of 100 When engine speed decreases below 5 of rated speed from a shutdown the Start Fuel Limit Function is disabled and ...

Page 89: ... the operation of the speed reference and ramp functions and their relation to each other Read this section carefully to be sure your sequencing provides the proper operating modes The control provides start idle lower limit raise limit and rated set points accel and decel times and raise and lower rates for local operation Accel time determines the time required for the engine to ramp from start ...

Page 90: ...ing operation is configured and enabled after the engine reaches rated speed the control will ramp speed to the reference value set by the Remote Reference input at the Remote Reference increase or decrease time settings The Remote Reference range is selectable and can be configured for one of four operating ranges from 4 to 20 mA 0 to 20 mA 1 to 5 V or 0 to 5 V The minimum input value 4ma 0mA 0 V...

Page 91: ...ference as required depending on its load control mode Load Reference and Ramp Functions This section describes the operation of the load reference and ramp functions and their relation to each other Droop operating mode has no ramp functions and is not included here Isochronous load sharing descriptions apply to two or more units paralleled on a common isolated bus or by accessory device with the...

Page 92: ...rip signal is issued after a tunable time delay In isolated bus applications a brief speed transient may occur when the load sharing relay closes following transfer from baseload back into isochronous load sharing It is possible for the control to be in base load control while supplying power to a load which is isolated from the infinite bus The capability of the engine generator must be considere...

Page 93: ...load T T T F F Base load ref will ramp to internal base load reference T T T F T Base load ref will ramp toward rated load T T T T F Base load ref will ramp toward the unload trip level T T T T T Base load ref will ramp to value of remote load set point T X F X X Base load control at the unload trip level T X T F X X Load will ramp to unload trip level and open gen breaker Legend F False T True X ...

Page 94: ...Aux contact is closed the control is in isochronous load control With only one unit on line the generator picks up the available load and remains at isochronous speed If other units are on line and the load command discrete input is open the load will immediately load to the Unload Trip Level setting When the Load contact connected to terminal 37 is closed the load matching circuit corrects the fu...

Page 95: ...ed in Figure 6 5 This reduction in speed is accomplished with negative feedback The feedback increases as the system is loaded Figure 6 5 Droop Mode Droop is expressed as the percentage reduction in speed that occurs when the generator is fully loaded With a given droop setting a generator set will always produce the same power output at a particular speed or frequency Droop is sometimes called th...

Page 96: ...nits some additional means must be used to keep each generator set from either trying to take all the load or from motoring Droop Isochronous Load Sharing on an Isolated Bus Droop isochronous load sharing combines the first two modes All generator sets in the system except one are operated in the droop mode The one unit not in droop is operated in the isochronous mode It is known as the swing mach...

Page 97: ...sochronous mode Load sharing is accomplished by adding a load sensor to each electric isochronous governor The load sensors are interconnected by the load sharing lines Any imbalance in load between units will cause a change to the regulating circuit in each governor While each unit continues to run at isochronous speed these changes force each machine to supply a proportional share of power to me...

Page 98: ...ed on the measured load in kW by the PT s and CT s terminals 1 to 9 of the 2301D is used With actuator droop the speed reference is decreased when the actuator output increases In Menu G Speed Setting the minimum and maximum actuator position settings are adjusted The droop function is active from this minimum position actuator at rated speed no load to the maximum actuator position actuator at ra...

Page 99: ...ct 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 c...

Page 100: ... 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 repla...

Page 101: ... 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 13 and 14 Check for shorted or grounded actuator leads by removing wires ...

Page 102: ...minal 28 to terminal 32 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 only on starts Ramp adjustment Increase RAMP TIME This decreases acceleration rate from low idle to rated RATED SPEED ...

Page 103: ...ontrol 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 regulated by LOW IDLE SPEED On carbureted pr...

Page 104: ...ver speed when the Close for Rated contact is closed Prime mover will not stabilize at rated no load speed The instability may occur at no load or it may vary with load Control may be erratic 2301D control Adjust GAIN RESET and ACTUATOR COMPENSATION as described in Adjust for Stable Operation and Dynamic Adjustment in Chapter 4 Speed reference controls Check display menu The speed reference value ...

Page 105: ...me 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 ...

Page 106: ...ator 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 con...

Page 107: ...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 sto...

Page 108: ...ice 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 connect...

Page 109: ...ge 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 Y 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...

Page 110: ...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 f...

Page 111: ...resenting 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 se...

Page 112: ...ommand in Modbus BW These commands operate as a momentary input 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 r...

Page 113: ...ould also be handled through the OEM or Packager Please review your equipment system documentation for details Woodward Business Partner Support Woodward works with and supports a global network of independent business partners whose mission is to serve the users of Woodward controls as described here A Full Service Distributor has the primary responsibility for sales service system integration so...

Page 114: ...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 for repair please contact your Full Service Distributor in advance to obtain Return Authorization and shipping instructions When shipping the item s attach a tag with the following information return number name and location where the control is i...

Page 115: ...nformation on these services please contact one of the Full Service Distributors listed at www woodward com directory Contacting Woodward s Support Organization For the name of your nearest Woodward Full Service Distributor or service facility please consult our worldwide directory published at www woodward com directory You can also contact the Woodward Customer Service Department at one of the f...

Page 116: ...s Type of Fuel gas gaseous diesel dual fuel etc Power Output Rating Application power generation marine etc Control Governor Information Control Governor 1 Woodward Part Number Rev Letter Control Description or Governor Type Serial Number Control Governor 2 Woodward Part Number Rev Letter Control Description or Governor Type Serial Number Control Governor 3 Woodward Part Number Rev Letter Control ...

Page 117: ...TIONS 01 SEL DI B FUNCTION 1 8 2 1 8 02 DISPLAY DI B FUNCTION Monitor 03 SEL DI C FUNCTION 1 8 6 1 8 04 DISPLAY DI C FUNCTION Monitor 05 SEL DI D FUNCTION 1 8 7 1 8 06 DISPLAY DI D FUNCTION Monitor C DISCRETE OUT OPTIONS 01 IS SHUTDOWN RELAY NC TRUE TRUE FALSE 02 IS ALARM RELAY NC TRUE TRUE FALSE 03 RELAY 1 ENERGIZES 1 14 2 1 14 04 RELAY 1 SELECTED FOR Monitor 05 RELAY 2 ENERGIZES 1 14 3 1 14 06 R...

Page 118: ... 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 1 Monitor 04 MPU FAIL 2 Monitor 05 ANALOG INPUT 1 FAIL 3 Monitor 06 ANALOG INPUT 2 FAIL 4 Monitor 07 TEST MODE 5 Monitor 08 EXTERNAL SHUTDOWN 6 Monitor 09 RESET SHUTDOWN FALSE TRUE FALSE D ALARMS 01 ALARM STATUS Monito...

Page 119: ...IME IDLE TO RATED 5 000 0 00 600 00 H DYNAMICS 1 01 PROP GAIN 1 2 000 0 01 100 00 02 RESET 1 2 000 0 01 100 00 03 ACTUATOR COMPENSATION 1 12 000 0 01 100 00 04 WINDOW WIDTH 1 RPM 60 000 1 00 200 00 05 GAIN RATIO 1 1 000 1 00 10 00 06 SPEED FILTER FREQ 1 HZ 20 000 4 00 20 00 07 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 ...

Page 120: ... ON FALSE TRUE FALSE 04 MAX FUEL LIMIT FD 100 000 50 00 110 00 05 ENABLE TORQUE LIMITER FALSE TRUE FALSE 06 MIN SPEED TORQUE LIMIT 300 000 0 00 4000 0 07 TORQUE LIMIT MIN SPEED 300 000 0 00 100 00 08 SPEED BRKPOINT TORQ LIM 800 000 0 00 4000 0 09 TORQUE LIMIT BREAKPOINT 100 000 0 00 100 00 10 MAX SPEED TORQUE LIMIT 1000 000 0 00 4000 0 11 TORQUE LIMIT MAX SPEED 100 000 0 00 100 00 M FUEL LIMITERS ...

Page 121: ...UT 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 LE...

Page 122: ... 03 AnIN 1 mA Volt Monitor 04 AnIN 2 Offset 0 000 100 00 100 00 05 AnIN 2 Gain 1 000 0 00 10 00 06 AnIN 2 mA Volt Monitor 07 Actuator Offset 0 000 100 00 100 00 08 Actuator Gain 1 000 100 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 1 000 100 00 100 00 12 Anout 4 20 mA output Monitor W LOADPULSE SETTINGS 01 ENABLE LOADPULSE FALSE TRUE FALSE...

Page 123: ...ward 115 SERVICE MENU PROGRAMMED VALUE DEFAULT VALUE TUNABLE RANGE MIN MAX 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 ...

Page 124: ...FF 0 0006 Rated 0 0007 Idle 0 0008 Raise 0 0009 Lower 0 0010 Isoch 0 0011 Droop 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 00...

Page 125: ... 1 0015 SPEED FUEL SEL_4 Maximum Fuel Limit 1 0016 SPEED FUEL SEL_6 Torque Limiter Active 1 0017 SPEED FUEL SEL_7 MAP Limiter Active 1 0018 LEVEL_SW SW1_LTCH LATCH Level SW 1 ON 1 0019 LEVEL_SW SW2_LTCH LATCH Level SW 2 ON 1 0020 LEVEL_SW SW3_LTCH LATCH Level SW 3 ON 1 0021 LEVEL_SW SW4_LTCH LATCH Level SW 4 ON 1 0022 HARDWARE BI_A BI_2301 Discrete Input A State 1 0023 HARDWARE BI_B BI_2301 Discre...

Page 126: ...W 3 0006 IO_SET ACT_DR A_SW Actuator Output 3 0007 SPEED PID_LSS MULTIPLY Speed PID Output 3 0008 HARDWARE ANIN_1 AI_2301 Analog Input 1 3 0009 HARDWARE ANIN_2 AI_2301 Analog Input 2 3 0010 SR SR_BIAS A_NAME Speed Bias RPM 3 0011 LSEN GEN_PCT1 A_NAME Engine Load 3 0012 BL BLREF_KW A_NAME Baseload Reference kW 3 0013 LSCON LS_ERROR2 A_NAME Load Bias RPM 3 0014 SR SYNC_B2 MULTIPLY Sync Bias RPM 3 00...

Page 127: ...Manual 26247 2301D 2301D EC Digital Control Woodward 119 ...

Page 128: ... 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 ove...

Page 129: ...Declarations ...

Page 130: ...East Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 Fax 1 970 498 3058 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 2012 8 Colorado ...

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Summary of Contents for 2301D

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