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Manual 02007

DSLC Digital Synchronizer and Load Control

Woodward

101

Process Reference

__________ mA

Raise Reference Rate

__________ mA/Second

Lower Reference Rate

__________ mA/Second

High Limit PU

__________ mA

High Limit DO

__________ mA

High Limit Alarm

Enabled | Disabled

Low Limit PU

__________ mA

Low Limit DO

__________ mA

Low Limit Alarm

Enabled | Disabled

Process Switches

Enabled | Disabled

VAR/Power Factor Control Menu 4

VAR/PF Control Mode

Disabled | PF Control | VAR Control

VAR/PF Gain

__________

VAR/PF Stability

__________ Seconds

Rated KVARS

__________ kVAR

KVAR Reference

__________ kVAR Generate | Absorb

PF Reference

__________ Lagging | Leading

PF Deadband

__________

Voltage Reference

__________ Volts | kV

Voltage Trim

Enabled | Disabled

Voltage Regulation

__________ %

Voltage Low Limit

__________ Volts | kV

Voltage Low Alarm

Enabled | Disabled

Voltage High Limit

__________ Volts | kV

Voltage High Alarm

Enabled | Disabled

Voltage Switches

Enabled | Disabled

Voltage Range Alarm

Enabled | Disabled

Voltage Ramp Time

__________ Seconds

Summary of Contents for DSLC

Page 1: ...Installation and Operation Manual DSLC Digital Synchronizer and Load Control Manual 02007 Revision D...

Page 2: ...orized modifications i constitute misuse and or negligence within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage and ii invalidate product certificati...

Page 3: ...Voltage Regulator Output 18 Process Control Input 19 Remote Load Setting Input 19 Installation Checkout Procedure 20 CHAPTER 3 CALIBRATION AND ADJUSTMENT 21 Introduction 21 Using the Hand Held Progra...

Page 4: ...Bench Tests 85 LonWorks Network 89 CHAPTER 10 SERVICE OPTIONS 94 Product Service Options 94 Woodward Factory Servicing Options 95 Returning Equipment for Repair 96 Replacement Parts 96 Engineering Se...

Page 5: ...orrection 15 Figure 2 2 DSLC Control in a Parallel Bus Utility Parallel Application 19 Figure 3 1 Hand Held Programmer Functions 22 Figure 4 1 Synchronizer Block Diagram 61 Figure 4 2 Synchronizer Wir...

Page 6: ...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 a...

Page 7: ...trols VAR or power factor PF control full function models only Built in diagnostics Multi function adjustable high and low limit alarms and load switch with relay driver outputs Digital communications...

Page 8: ...load sharing or process control A ramp pause switch input allows holding of the load ramp for warm up or other purposes The base load control is selectable as either a proportional or integrating cont...

Page 9: ...imit until process control is obtained When unloading from the process control an adjustable unload ramp provides time controlled unloading to the unload trip level When load reaches the unload trip l...

Page 10: ...d wiring including each major group of connections along with any special instructions Chapter 3 covers DSLC control configuration setup and adjustment The chapter explains the purpose of each set poi...

Page 11: ...Manual 02007 DSLC Digital Synchronizer and Load Control Woodward 5 Figure 1 1a DSLC Control wye version shown...

Page 12: ...DSLC Digital Synchronizer and Load Control Manual 02007 6 Woodward Figure 1 1b DSLC Control Dimensions wye version shown...

Page 13: ...Manual 02007 DSLC Digital Synchronizer and Load Control Woodward 7 Figure 1 2 Hand Held Programmer...

Page 14: ...DSLC Digital Synchronizer and Load Control Manual 02007 8 Woodward Figure 1 3a DSLC Plant Wiring Diagram for 120 240 V wye switch gear configurations...

Page 15: ...Manual 02007 DSLC Digital Synchronizer and Load Control Woodward 9 Figure 1 3b DSLC Plant Wiring Diagram for 120 V open delta switch gear configurations...

Page 16: ...DSLC Digital Synchronizer and Load Control Manual 02007 10 Woodward Figure 1 3c DSLC Plant Wiring Diagram for 240 V open delta switch gear configurations...

Page 17: ...Manual 02007 DSLC Digital Synchronizer and Load Control Woodward 11 Figure 1 4 Control Options...

Page 18: ...voltage high current devices Allow adequate space in front of the unit for servicing Do not install where objects can be dropped on the terminals Ground the chassis for proper safety and shielding Th...

Page 19: ...e 50532 Interference Control in Electronic Governing Systems for more information Where shielded cable is required cut the cable to the desired length and prepare the cable as instructed below 1 Strip...

Page 20: ...est performance of the system The following sections describe the potential connections for the synchronizer and power sensor functions Various DSLC controls have been designed to accommodate PTs wire...

Page 21: ...d as a low side driver capable of sinking a maximum of 200 mA The use of drivers allows the user to supply relays of a contact rating appropriate for the application Figure 2 1 Temporary Wiring for Tr...

Page 22: ...discrete inputs are the switch input commands to the DSLC control Discrete inputs are optically isolated from the control and require 10 mA at 24 Vdc each to activate Discrete inputs may be powered b...

Page 23: ...7 the Base Load contact input terminal 50 and the Load Unload contact inputs terminal 51 The status of these three contact inputs determines the five load control operating modes CB Aux Base Load Load...

Page 24: ...ielded YQ28863 Plenum 22 AWG shielded 2 Maximum cable length for a LonWorks 1 25 Mbps network is 500 m 1640 ft 3 Stubs or wiring drops connecting intermediate devices to the main cable are limited to...

Page 25: ...t be installed across terminals 37 and 38 For a 1 5 Vdc transmitter the jumper should not be installed Connect the cable shields to ground at the DSLC control end only Remote Load Setting Input To avo...

Page 26: ...stments in the next chapter 1 Check for correct wiring in accordance with the wiring diagram Figure 1 3 2 Check for broken terminals and loose terminal screws 3 Check for shield faults by measuring th...

Page 27: ...he display permits you to look at two separate functions or menu items at the same time Use the Up Down Arrow key to toggle between the two displayed items the first letter of the active menu item wil...

Page 28: ...kward through the menu The menus are continuous that is pressing the Down Arrow key at the last menu item takes the menu to the first item or pressing the Up Arrow key at the beginning of the menu tak...

Page 29: ...Sync Reclose Alarm Enabled Disabled Enabled 14 Sync Timeout 0 1000 0 seconds 15 Sync Timeout Alarm Enabled Disabled Disabled 16 Auto Re Synchronize Enabled Disabled Disabled Menu 2 Load Control 1 Loa...

Page 30: ...000 0 025 8 Voltage Reference 50 0 300xPT ratio 70xPT ratio V L L L N 9 Voltage Trim Enabled Disabled Disabled 10 Voltage Regulation 1 0 10 0 2 0 11 Voltage Low Limit 50 300xPT ratio 60xPT ratio V L L...

Page 31: ...ge 40xPT ratio 300xPT ratio n a volts 17 Synchroscope 180 180 n a degrees 18 Slip Frequency 1 0 slow 5 0 fast n a Hz 19 System Load 100 120 n a 20 System PF 0 0 leading 0 0 lagging n a Menu 8 Control...

Page 32: ...Voltage Raise Relay Energized De energized 17 Voltage Lower Relay Energized De energized 18 High Limit Relay Energized De energized 19 Low Limit Relay Energized De energized 20 Load Switch Relay Energ...

Page 33: ...Router Authentication Self Inst Semaphore Read Write Semaphore Appl Signature Bad Router Firmware Unknown 13 Net Interface Errors 0 65535 14 A D Errors 0 65535 Menu Set Point Descriptions Menu 1 Synch...

Page 34: ...the breaker closure relay driver output low energized Failure to receive the CB Aux contact signal during this interval results in a failed close attempt The breaker closure relay driver returns high...

Page 35: ...load control responds to a load error Gain is set to provide stable load control For integrating load control mode use 0 05 as the initial load control gain In proportional load control mode the load...

Page 36: ...e or the load indicated for load sharing whichever is less NOTE If the load reference reaches zero and generator load does not drop to the Unload Trip the CB Open relay driver will not de energize Thi...

Page 37: ...Alarm specifies if the high limit alarm will activate de energize the alarm driver terminal 28 21 Low Limit PU is the generator where if enabled the Low Limit discrete output is energized and if enabl...

Page 38: ...Process Reference is the internal reference for the process control 8 Raise Reference Rate is the rate at which the process reference is increased when the raise command input is activated 9 Lower Ref...

Page 39: ...ce specifies the bus voltage reference for VAR PF sharing when in isochronous load sharing mode 9 Voltage Trim enables or disables the isochronous load sharing mode voltage trim function When disabled...

Page 40: ...yed on the Hand Held Programmer as volts line to neutral volts line to line kilovolts line to neutral or kilovolts line to line 6 System Frequency is set to nominal system operating frequency 50 60 Hz...

Page 41: ...B phase voltage When potentials are applied to the control adjust until the displayed value is equal to the actual generator B phase voltage as seen on the DSLC terminals 8 PT Phase C displays the sen...

Page 42: ...the power factor on the generator B phase 11 Phase C Volts is the voltage on the generator C phase 12 Phase C Amperes is the amperes on the generator C phase 13 Phase C PF is the power factor on the g...

Page 43: ...f the alarm generated when generator voltage is below the Low Voltage Limit set point 12 High Voltage Limit is the status of the alarm generated when generator voltage exceeds the High Voltage Limit s...

Page 44: ...D is the status of the CPU OK LED Menu 0 Diagnostics 1 Diagnostic Result is the result of power up diagnostics A value of 49 indicates no problems found Any other value indicates an internal failure i...

Page 45: ...ackets due to insufficient application buffers or due to excess traffic on the channel Messages will be lost when power is initially applied to a DSLC control while power up diagnostics are being perf...

Page 46: ...s used 7 Network Address Prestart Synchronizer Setup Set all Synchronizer Menu 1 set points according to the descriptions above and the work sheet Leave unknown values such as Gain and Stability at th...

Page 47: ...f the input circuits of the engine speed control 2 Open the isoch droop switch in series with the CB Aux contact input to terminal 47 of the DSLC control If such a switch is not installed temporarily...

Page 48: ...ate the engine speed required to pick up 50 and 100 of rated load Example Rated frequency 60 0 Hz Desired droop 5 0 05 or 3 0 Hz Desired test frequency 60 0 Hz Load x 3 0 Hz at 50 0 5 load 60 0 0 5 x...

Page 49: ...breaker manufacturer Add delay time for any interposing relays if required 5 Set CB Close Hold Time to the time desired for the DSLC control to hold the breaker closure signal This time should at lea...

Page 50: ...y into phase lock If the synchronizer action is too slow increase Sync Gain by a factor of two If increasing Sync Gain results in unstable operation reduce the value by at least one half and proceed t...

Page 51: ...two Repeat until the synchronizer picks up correct phase rotation at a satisfactory rate 4 Observe the smoothness of phase rotation If a slow hunt is observed as indicated by slowing and speeding up...

Page 52: ...e greater than the time required to recharge the circuit breaker arming mechanism 7 If an alarm is desired when the maximum Close Attempts has been reached set Sync Reclose Alarm to Enabled 8 Set the...

Page 53: ...r by pressing the Up Down Arrow key Select Menu 7 and display the bus voltage set point 3 Use Voltage Raise or Lower to adjust the generator voltage until generator Phase A voltage is approximately 5...

Page 54: ...mum generator voltage desired 5 Close the Lower Voltage contact input to the DSLC control Observe the Voltage Lower Relay set point on Menu 9 indicates Energized when the Lower Voltage contact input i...

Page 55: ...he desired values Voltage adjustments by the Synchronizer and VAR PF Control will not adjust voltage beyond these limits 2 If the High Voltage Alarm or the Low Voltage Alarm are desired when generator...

Page 56: ...control should be used when paralleling with a frequency stable bus or when the process control will be used The following procedure is used to set up the proportional base load control mode A utility...

Page 57: ...n Otherwise proceed to Isochronous Load Sharing Adjustment Integrating Base Load Control Setup The following procedure is used to setup the integrating base load control mode The integrating control i...

Page 58: ...tive may be increased to increase the rate of change in Speed Bias Output during a transient This completes the integrating load control setup Continue with Isochronous Load Sharing Adjustments or Fin...

Page 59: ...ith the system until the system load exceeds that unit load percentage 8 Close the Load Unload switch contact The unit should ramp until the unit load percentage equals the system load percentage and...

Page 60: ...ints Raise Rate and Lower Rate set points may be adjusted to achieve satisfactory performance 5 Open the Raise Load and Lower Load contacts The Load Control Mode should indicate Base Load The load ref...

Page 61: ...Gain Process Stability Process Derivative Process Deadband Process Droop and Process Filter to their default values 2 Set Menu 5 Configuration Key to 49 Set Menu 5 Process Control Action to Direct or...

Page 62: ...ons Slower but more stable performance can be obtained 10 Introduce Process Droop if required to increase stability of the process control loop 11 In most systems it will not be necessary to change Pr...

Page 63: ...ust the voltage regulator stability to achieve desired results Consult the voltage regulator manual for instructions 1 Verify that the voltage matching adjustments above have been done 2 Select Menu 4...

Page 64: ...tained 12 Select the desired operating mode either PF Control or VAR Control Set the appropriate reference for the desired operating point 13 Ramp load up and down throughout the expected normal load...

Page 65: ...acement control is necessary or for start up of another similar unit Power down the control for about 10 seconds Restore power and verify that all set points are as recorded CAUTION SAVE SET POINTS To...

Page 66: ...conditions are verified by the synchronizer functions Figure 4 1 shows the functional block diagram of the synchronizer for reference during the following descriptions Operating Modes The operation o...

Page 67: ...Manual 02007 DSLC Digital Synchronizer and Load Control Woodward 61 Figure 4 1 Synchronizer Block Diagram...

Page 68: ...DSLC Digital Synchronizer and Load Control Manual 02007 62 Woodward Figure 4 2 Synchronizer Wiring Diagrams wye and open delta...

Page 69: ...verifying that they also indicate a dead bus bus input less than 40 Vac L N and do not hold a lock the requesting unit then holds lock permission and may attempt to close its circuit breaker The lock...

Page 70: ...ntage above bus voltage The automatic voltage matching function may be enabled or disabled with a set point When enabled voltage matching will occur in both the Check and Run modes and is verified onl...

Page 71: ...tage matching function is enabled The generator voltage must be within the specified voltage window above bus voltage before the breaker closure command may be given To minimize transients the breaker...

Page 72: ...oltage variations Automatic ramping functions provide bumpless transfer of load when adding or removing generator capacity to a system or changing the mode of load control operation Power Sensor Theor...

Page 73: ...s then converted and an interrupt is generated when all inputs are converted The microprocessor then reads the digital values from A D registers This procedure is repeated at regular intervals to prov...

Page 74: ...peed setting Figure 5 1 Droop Mode Isochronous Isochronous means repeating at a single rate or having a fixed frequency or period A generating set operating in the isochronous mode will operate at the...

Page 75: ...s of each droop unit are adjusted so that each generates a fixed amount of power as illustrated in Figure 5 3 The output power of the swing machine will change to follow changes in the load demand Max...

Page 76: ...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...

Page 77: ...isolated system The advantage of base loading over droop is that when separating from a utility there is no frequency change Simply removing the bias signal on breaking from the utility returns the sy...

Page 78: ...et to a specific load The second mode can also be used when a controlled unload is desired without taking the generator set off line The DSLC control also includes a ramp pause function that allows fo...

Page 79: ...Manual 02007 DSLC Digital Synchronizer and Load Control Woodward 73 Figure 5 5 Load Control Plant Wiring Diagrams wye and open delta...

Page 80: ...d trip level When the Load Unload contact connected to terminal 51 is closed the load ramp starts and the unit load is increased to match the base load set point The base load can be adjusted up or do...

Page 81: ...er Trip Menu 2 to ENABLE selects terminal 25 as the reverse power trip output The load switch will not operate based on the Load Switch PU and Load Switch DO settings when the Reverse Power Trip is en...

Page 82: ...R or PF control mode is selected the control function is set to Auto by closing both the Voltage Raise and Voltage Lower contacts The VAR PF control is disabled when both switch contacts are open Manu...

Page 83: ...or sharing is automatically selected Power factor sharing adjusts the voltage regulators so that all generators carry the same proportion of reactive load by balancing the power factor on all units A...

Page 84: ...equal to the internal or remote process reference If the process input and process reference are not equal the control ramps the load reference in the appropriate direction to reduce the difference er...

Page 85: ...Manual 02007 DSLC Digital Synchronizer and Load Control Woodward 79 Figure 7 1 Process Control Block Diagram...

Page 86: ...r factor sharing occurs see Figure 8 1 Figure 8 1 Typical LON Setup The network may also include a Woodward Master Synchronizer or Master Synchronizer and Load control MSLC One of the optional devices...

Page 87: ...DATA 2 Long int 16 BIT DATA 3 Long int 16 BIT DATA 4 Long int 16 BIT DATA 5 Long int 16 BIT DATA 6 Long int 16 BIT DATA 7 Long int 16 BIT The following signals are available through the LonWorks netwo...

Page 88: ...f set VOLTAGE_LOW_LIMIT alarm is active 0x0100 If set VOLTAGE_HIGH_LIMIT alarm is active 0x0200 Not used 0x0400 Not used 0x0800 Not used 0x1000 Not used 0x2000 Not used 0x4000 This bit is not set but...

Page 89: ...process_remote 16 0x4000 This bit is set to indicate that this is the third type of electrical parameter out 0x8000 This bit is set to indicate that this is the third type of electrical parameter out...

Page 90: ...rate The process input has a times 1000 scaling that is 20000 would represent 20 0 mA and 4000 would represent 4 0 ma net_discrete_in is a network input from a remote sequencer The input must be in th...

Page 91: ...uring bench tests Several of the tests cannot be done when the DSLC control is in operation The internal test software verifies that bus and generator potentials are dead prior to executing the test o...

Page 92: ...l 2 to terminal 44 the Synchronizer Check Mode switch input Verify that the Check Switch indication on Menu 9 indicates Closed Repeat the above step for each of the remaining discrete inputs terminals...

Page 93: ...Key to 49 Connect a dc voltmeter to terminals 32 and 33 Select Speed Bias Output on Menu 6 Verify that the speed bias output is at 0 Cycle the power to the DSLC control to reset the speed bias output...

Page 94: ...e input set point to 240 Vac or 120 Vac according to the DSLC being tested Set to 120 Vac for 120 V open delta DSLC versions Set to 240 Vac for 240 V open delta DSLC versions Connect the generator pot...

Page 95: ...6 and set the Calibration Key to 49 Read the PT Phase A set point Select the Bus Voltage set point and adjust to be 0 1 of the voltage read for the Generator phase A Voltage Select Menu 6 Synchroscop...

Page 96: ...nication with each other do the tests described below under Installation Verification below If Active DSLCs still indicates the wrong value after doing the above steps continue with the tests describe...

Page 97: ...s at one time than it could process It is possible that enough DSLC controls may send out their load sharing information at nearly the same time that Rcv Transaction Full errors may occur Frequent err...

Page 98: ...es not power up No input power supply Check 24 V power supply Input power supply polarity reversed Ensure proper polarity of 24 V power supply Software PROMs installed backwards or in wrong slot U32 U...

Page 99: ...tment procedure in Chapter 3 Cross current compensation installed on voltage regulators Remove cross current compensation from the voltage regulator circuit Unit carries improper proportion of load du...

Page 100: ...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...

Page 101: ...r 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 u...

Page 102: ...ls 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...

Page 103: ...equipment with which our products interface For information on these services please contact us via telephone email us or use our website and reference www woodward com support and then Customer Supp...

Page 104: ...l 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 Con...

Page 105: ...abled Disabled Breaker Delay __________ Seconds C B Close Hold Time __________ Seconds Close Attempts __________ Reclose Delay __________ Seconds Sync Reclose Alarm Enabled Disabled Sync Timeout _____...

Page 106: ...W High Limit Alarm Enabled Disabled Low Limit PU __________ kW Low Limit DO __________ kW Low Limit Alarm Enabled Disabled Load Limit Switches Enabled Disabled Load Switch PU __________ kW Load Switch...

Page 107: ...ntrol Menu 4 VAR PF Control Mode Disabled PF Control VAR Control VAR PF Gain __________ VAR PF Stability __________ Seconds Rated KVARS __________ kVAR KVAR Reference __________ kVAR Generate Absorb P...

Page 108: ...on Menu 5 PT Winding Ratio __________ 1 CT Rating __________ 5 PT Voltage Input _____120 _____240 Vac Voltage Display V Line to Line V Line to Neutral kV Line to Line kV Line to Neutral System Frequen...

Page 109: ...iesel Corporation DDEC III control and any other control requiring a 0 5 Vdc input 500 Hz PWM Compatible with Woodward GenDec controls and with Caterpillar speed controls 1 5 Vdc Compatible with Woodw...

Page 110: ...guration 120 Vac input terminals 7 to 12 9 to 12 and 11 to 12 65 to 150 Vac 240 Vac input terminals 6 to 12 8 to 12 and 10 to 12 150 to 300 Vac 120 Vac Open Delta PT Configuration 65 to 150 Vac termin...

Page 111: ...e 55 to 105 C Humidity Operating 95 at 38 C Mechanical Vibration Level 2 5 G Frequency 24 to 2000 Hz Mechanical Shock Test Methods US MIL STD 810C Method 516 2 Shock Procedure I Figure 516 2 2 basic d...

Page 112: ...ept dead bus closing The format of the data available over the Echelon network on the obsolete part numbers is different The format used in the obsolete controls sends one message for each variable on...

Page 113: ...tion Key 2 PT Winding Ratio 3 CT Rating 4 PT Voltage Input 5 Voltage Display 6 System Frequency 7 Process Control Action 8 Network Address 9 Network Service Pin 6 Calibration 1 Calibration Key 2 Proce...

Page 114: ...2 1519 USA 1000 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...

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