Woodward DSLC-2 User manual

37443A
Manual
Software Version 1.14xx
Manual 37443A
DSLC-2
Digital Synchronizer and Load Control

Manual 37443A DSLC-2 - Digital Synchronizer and Load Control
Page 2/226 © Woodward
WARNING
Read this entire manual and all other publications pertaining to the work to be performed before instal-
ling, operating or servicing this equipment. Practice all plant and safety instructions and precautions.
Failure to follow instructions can cause personal injury and/or property damage.
The engine, turbine or other type of prime mover should be equipped with an overspeed (overtempera-
ture or overpressure, where applicable) shutdown device(s), that operates totally independently of the
prime mover control device(s) to protect against runaway or damage to the engine, turbine or other
type of prime mover with possible personal injury or loss of life should the mechanical-hydraulic gov-
ernor(s) or electric control(s), the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s)
or the controlled device(s) fail.
Any unauthorized modifications to or use of this equipment outside its specified mechanical, electrical
or other operating limits may cause personal injury and/or property damage, including damage to the
equipment. Any such unauthorized 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 certifications or listings.
CAUTION
To prevent damage to a control system that uses an alternator or battery-charging device, make sure
the charging device is turned off before disconnecting the battery from the system.
Electronic controls contain static-sensitive parts. Observe the following precautions to prevent dam-
age to these parts.
•
Discharge body static before handling the control (with power to the control turned off, contact a
grounded surface and maintain contact while handling the control).
•
Avoid all plastic, vinyl and Styrofoam (except antistatic versions) around printed circuit boards.
•
Do not touch the components or conductors on a printed circuit board with your hands or with
conductive devices.
OUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify that you
have the latest revision, be sure to check the Woodward website:
http://www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The latest
version of most publications is available at:
http://www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get the latest
copy.
Important definitions
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, could result in damage to equipment.
NOTE
Provides other helpful information that does not fall under the warning or caution categories.
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, Woodward assumes no responsibility unless otherwise expressly undertaken.
© Woodward
All Rights Reserved.

Manual 37443A DSLC-2 - Digital Synchronizer and Load Control
© Woodward Page 3/226
Revision History
Rev.
Date
Editor
Changes
NEW
11-03-24
TE
New Release
A
11-05-13
TE
•Minor corrections
New features
Requirements: Digital synchronizer and load control (DSLC-2)with software revision 1.1404 or
higher and device revision A or higher.
•Modbus communication: Loss of connection. Refer to “Loss Of Connection” on page 192
for details.
Content
CHAPTER 1. GENERAL INFORMATION .....................................................................................11
Document Overview...............................................................................................................................11
Application..............................................................................................................................................12
Synchronizer ..........................................................................................................................................12
Load Control...........................................................................................................................................13
Process Control......................................................................................................................................14
Var/PF Control .......................................................................................................................................14
DSLC-2 / MSLC-2 Systems ...................................................................................................................15
CHAPTER 2. INSTALLATION....................................................................................................17
Electrostatic Discharge Awareness .......................................................................................................17
Unpacking ..............................................................................................................................................18
Location..................................................................................................................................................18
Housing..................................................................................................................................................19
Dimensions ..................................................................................................................................19
Installation....................................................................................................................................20
Terminal Arrangement.................................................................................................................21
Wiring Diagrams.....................................................................................................................................22
Connections ...........................................................................................................................................24
Power Supply...............................................................................................................................25
Voltage Measuring.......................................................................................................................26
Current Measuring.......................................................................................................................37
Power Factor Definition................................................................................................................39
Discrete Inputs.............................................................................................................................41
Relay Outputs ..............................................................................................................................43
Analog Inputs...............................................................................................................................45
Analog Outputs............................................................................................................................46
Interfaces .....................................................................................................................................47
CHAPTER 3. CONFIGURATION &OPERATION........................................................................... 49
Configuration Via PC..............................................................................................................................49
Install ToolKit Configuration And Visualization Software.............................................................49
Install ToolKit Software................................................................................................................49
Install ToolKit Configuration Files ................................................................................................50
Starting ToolKit Software.............................................................................................................51
Configure ToolKit Software..........................................................................................................52
Connect ToolKit And The DSLC-2 Unit .......................................................................................53
View DSLC-2 Data With ToolKit..................................................................................................54
Configure The DSLC-2 With ToolKit............................................................................................55
The DSLC-2 Version Page ..........................................................................................................56

Manual 37443A DSLC-2 - Digital Synchronizer and Load Control
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Menu (Setpoint) Description.................................................................................................................. 57
DSLC-2 – Homepage.................................................................................................................. 57
Menu 1 – Synchronizer ............................................................................................................... 61
Menu 2 – Load Control................................................................................................................ 65
Menu 3 – Process Control........................................................................................................... 69
Menu 4 – Var / PF Control........................................................................................................... 71
Menu 5 – Configuration............................................................................................................... 77
Menu 6 – Analog Inputs / Outputs............................................................................................... 89
Menu 7 – Electrical Parameters ................................................................................................ 100
Menu 8 – Control Status Monitor............................................................................................... 103
Menu 9 – Discrete Inputs / Relay Outputs ................................................................................ 106
Menu 0 – Diagnostics................................................................................................................ 109
Overview Pages ........................................................................................................................ 111
Prestart Setup Procedure.................................................................................................................... 117
Configuration Menu................................................................................................................... 117
Prestart Segmenting Setup ....................................................................................................... 118
Prestart Synchronizer Setup ..................................................................................................... 122
Prestart Load Control Setup...................................................................................................... 122
Prestart Process Control Setup................................................................................................. 122
Prestart Var/Power Factor Control Setup.................................................................................. 122
DSLC-2 Control Adjustments .............................................................................................................. 123
Load Control Droop Adjustment................................................................................................ 125
With Load Bank......................................................................................................................... 125
Without Load Bank.................................................................................................................... 125
Synchronizer Adjustments................................................................................................................... 127
Preliminary Synchronizer Adjustments...................................................................................... 127
Phase Matching Synchronizer................................................................................................... 127
Slip Frequency Synchronizer .................................................................................................... 128
Final Synchronizer Setup .......................................................................................................... 129
Voltage Matching Adjustments............................................................................................................ 130
Preliminary Voltage Matching Setup......................................................................................... 130
Voltage Matching With MOP Driven Voltage Regulator............................................................ 130
Voltage Matching Using Voltage Bias Output ........................................................................... 130
Final Voltage Matching Setup ................................................................................................... 131
Load Control Adjustment..................................................................................................................... 133
Preliminary Setup...................................................................................................................... 133
Isochronous Load Sharing Adjustment ..................................................................................... 133
Integrating Base Load Control Setup........................................................................................ 134
Remote Load Reference Signal Setup...................................................................................... 135
Final Load Control Setup........................................................................................................... 136
Process Control Adjustment................................................................................................................ 137
Var/PF Control Adjustment.................................................................................................................. 139
CHAPTER 4. SYNCHRONIZER DESCRIPTION...........................................................................141
Introduction.......................................................................................................................................... 141
Functional Description......................................................................................................................... 141
Operating Modes....................................................................................................................... 141
Measurement Connections (Examples).................................................................................... 143
Dead Bus Closing – Multiple Units............................................................................................ 155
Dead Bus Closing – Single Unit................................................................................................ 156
Voltage Matching....................................................................................................................... 156
Phase Matching Synchronizing................................................................................................. 157
Slip Frequency Synchronizing................................................................................................... 157
Permissive Mode / Synch-Check Function ............................................................................... 157
GCB Maximun Closing Attempts............................................................................................... 157
Auto Re-Synchronization........................................................................................................... 157
Reclose Limit Alarm................................................................................................................... 158
Synchronizer Timer ................................................................................................................... 158
Logic Charter GCB Closure....................................................................................................... 159

Manual 37443A DSLC-2 - Digital Synchronizer and Load Control
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CHAPTER 5. REAL POWER CONTROL DESCRIPTION .............................................................. 160
Introduction...........................................................................................................................................160
Power Management Concepts.............................................................................................................160
Droop .........................................................................................................................................160
Droop Tracking ..........................................................................................................................161
Isochronous ...............................................................................................................................161
Droop/Isochronous Load Sharing On An Isolated Bus..............................................................162
Isochronous Load Sharing On An Isolated Bus.........................................................................163
Base Load On An Isolated Bus..................................................................................................163
Base Load..................................................................................................................................163
Load Control Mode Switching....................................................................................................164
Soft Loading Into A Load Sharing System.................................................................................165
Soft Unloading From A Load Sharing Or A Base Loaded System............................................165
Base Loading Against A Utility...................................................................................................166
Base Load And Load Sharing Systems.....................................................................................167
Controlled By MSLC-2 Utility Mode ...........................................................................................167
Reverse Power Relay Description .......................................................................................................168
CHAPTER 6. VAR/POWER FACTOR CONTROL DESCRIPTION................................................... 169
Introduction...........................................................................................................................................169
Var Control...........................................................................................................................................171
Var Sharing ..........................................................................................................................................172
Power Factor Control ...........................................................................................................................172
CHAPTER 7. PROCESS CONTROL DESCRIPTION .................................................................... 173
Introduction...........................................................................................................................................173
Description ...........................................................................................................................................173
CHAPTER 8. NETWORK /SYSTEM DESCRIPTION.................................................................... 175
Introduction...........................................................................................................................................175
Description ...........................................................................................................................................175
Applications Without Segmenting..............................................................................................175
Applications With Segmenting...................................................................................................177
Not Supported Applications .......................................................................................................179
Remote Control By PLC.......................................................................................................................180
Interface Connection Via RS-485 With Modbus Protocol..........................................................180
Interface Connection Via Ethernet By Modbus/TCP Stack .......................................................181
CHAPTER 9. DIAGRAMS ....................................................................................................... 182
Diagram Frequency / Active Power Controller.....................................................................................182
Diagram Voltage / Reactive Power Controller .....................................................................................183
CHAPTER 10. INTERFACE..................................................................................................... 184
Interface Overview...............................................................................................................................184
Ethernet Load Sharing.........................................................................................................................185
Multi-Master Principle ................................................................................................................185
Load Share Monitoring...............................................................................................................185
General Load Share Information ...............................................................................................185
Modbus Communications.....................................................................................................................186
General Information...................................................................................................................186
Address Range..........................................................................................................................187
Visualization...............................................................................................................................188
Configuration..............................................................................................................................189
DSLC-2 Interface Remote Control.............................................................................................190
Changing Parameter Settings Via Modus............................................................................................196
Parameter Setting......................................................................................................................196
Remotely Resetting The Default Values....................................................................................198
Modbus Parameters.............................................................................................................................200
Serial Interface 1........................................................................................................................200
Serial Interface 2........................................................................................................................200
Network B – Modbus..................................................................................................................200

Manual 37443A DSLC-2 - Digital Synchronizer and Load Control
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APPENDIX A. TECHNICAL DATA............................................................................................201
Environmental Data............................................................................................................................. 203
Accuracy.............................................................................................................................................. 204
APPENDIX B. USEFUL INFORMATION.....................................................................................205
Connecting 24 V Relays............................................................................................................ 205
APPENDIX C. DATA PROTOCOLS ..........................................................................................206
Data Protocol 5200.............................................................................................................................. 206
APPENDIX D. PARAMETER OVERVIEW ..................................................................................213
Introduction.......................................................................................................................................... 213
Parameter List Columns............................................................................................................ 213
Parameter List ..................................................................................................................................... 214
APPENDIX E. SERVICE OPTIONS...........................................................................................221
Product Service Options...................................................................................................................... 221
Returning Equipment For Repair......................................................................................................... 221
Packing A Control...................................................................................................................... 222
Return Authorization Number RAN........................................................................................... 222
Replacement Parts .............................................................................................................................. 222
How To Contact Woodward................................................................................................................. 223
Engineering Services........................................................................................................................... 224
Technical Assistance........................................................................................................................... 225

Manual 37443A DSLC-2 - Digital Synchronizer and Load Control
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Figures and Tables
Figures
Figure 1-2: Multiple generators in isolated operation with tie-breaker..................................................................................... 15
Figure 1-3: Multiple generators in isolated and utility parallel operation with utility- and tie-breaker..................................... 16
Figure 2-1: Housing DSLC-2 - dimensions............................................................................................................................... 19
Figure 2-2: Housing - drill plan ................................................................................................................................................ 20
Figure 2-3: DSLC-2 - terminal arrangement............................................................................................................................. 21
Figure 2-4: Wiring diagram - DSLC-2 - 1/2 ............................................................................................................................. 22
Figure 2-5: Wiring diagram - DSLC-2 - 2/2 ............................................................................................................................. 23
Figure 2-6: Power supply.......................................................................................................................................................... 25
Figure 2-7: Power supply - crank waveform at maximum load ................................................................................................ 25
Figure 2-8: Voltage measuring - generator ............................................................................................................................... 26
Figure 2-9: Voltage measuring - generator windings, 3Ph 4W OD .......................................................................................... 27
Figure 2-10: Voltage measuring - generator measuring inputs, 3Ph 4W OD............................................................................ 27
Figure 2-11: Voltage measuring - generator windings, 3Ph 4W............................................................................................... 29
Figure 2-12: Voltage measuring - generator measuring inputs, 3Ph 4W................................................................................... 29
Figure 2-13: Voltage measuring - generator windings, 3Ph 3W............................................................................................... 30
Figure 2-14: Voltage measuring - generator measuring inputs, 3Ph 3W................................................................................... 30
Figure 2-15: Voltage measuring - busbar.................................................................................................................................. 31
Figure 2-16: Voltage measuring - busbar measuring inputs, 1Ph 2W (phase-neutral).............................................................. 32
Figure 2-17: Voltage measuring - busbar measuring inputs, 1Ph 2W (phase-phase)................................................................ 33
Figure 2-18: Voltage measuring – auxiliary busbar.................................................................................................................. 34
Figure 2-19: Voltage measuring - auxiliary busbar PT windings, 3Ph 4W............................................................................... 35
Figure 2-20: Voltage measuring - auxiliary busbar measuring inputs, 3Ph 4W........................................................................ 35
Figure 2-21: Voltage measuring - auxiliary busbar PT windings, 3Ph 3W............................................................................... 36
Figure 2-22: Voltage measuring - auxiliary busbar measuring inputs, 3Ph 3W........................................................................ 36
Figure 2-23: Current measuring - generator.............................................................................................................................. 37
Figure 2-24: Current measuring - generator, L1 L2 L3............................................................................................................. 38
Figure 2-25: Current measuring - generator, phase Lx.............................................................................................................. 38
Figure 2-26: Power measuring - direction of power.................................................................................................................. 39
Figure 2-27: Discrete inputs - alarm/control input - positive signal.......................................................................................... 41
Figure 2-28: Discrete inputs - alarm/control input - negative signal......................................................................................... 41
Figure 2-29: Relay outputs........................................................................................................................................................ 43
Figure 2-30: Analog inputs - wiring two-pole senders.............................................................................................................. 45
Figure 2-31: Analog inputs - wiring two-pole senders, external jumper used for current input................................................ 45
Figure 2-32: Analog controller output - Wiring and external jumper setting............................................................................ 46
Figure 2-33: RS-485 interface #1 - overview............................................................................................................................ 47
Figure 2-34: RS-485 Modbus - connection for half-duplex operation ...................................................................................... 47
Figure 2-35: RS-485 Modbus - connection for full-duplex operation....................................................................................... 47
Figure 2-36: RS-232 interface - overview................................................................................................................................. 48
Figure 2-37: RJ-45 interfaces - overview.................................................................................................................................. 48
Figure 3-1: ToolKit - visualization screen ................................................................................................................................ 54
Figure 3-2: ToolKit - analog value trending screen .................................................................................................................. 54
Figure 3-3: ToolKit - configuration screen ............................................................................................................................... 55
Figure 3-4: ToolKit -version page............................................................................................................................................. 56
Figure 3-5: ToolKit - home page............................................................................................................................................... 57
Figure 3-7: ToolKit - home page - generator ............................................................................................................................ 60
Figure 3-8: ToolKit - home page - segments............................................................................................................................. 60
Figure 3-9: ToolKit – synchronizer........................................................................................................................................... 61
Figure 3-11: ToolKit – load control.......................................................................................................................................... 65
Figure 3-13: ToolKit – process control..................................................................................................................................... 69
Figure 3-15: ToolKit – var / pf control...................................................................................................................................... 71
Figure 3-17: ToolKit – configuration........................................................................................................................................ 77
Figure 3-19: ToolKit – interfaces.............................................................................................................................................. 83
Figure 3-21: ToolKit – system management............................................................................................................................. 86
Figure 3-23: ToolKit – analog inputs / outputs......................................................................................................................... 89
Figure 3-24: ToolKit – analog inputs........................................................................................................................................ 90
Figure 3-25: ToolKit – relevant fields for remote load reference input..................................................................................... 91
Figure 3-26: ToolKit – relevant fields for remote process reference input................................................................................ 91
Figure 3-27: ToolKit – process signal input.............................................................................................................................. 92
Figure 3-28: ToolKit – reactive load input................................................................................................................................ 93
Figure 3-29: ToolKit – analog output ....................................................................................................................................... 95

Manual 37443A DSLC-2 - Digital Synchronizer and Load Control
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Figure 3-31: ToolKit – electrical parameters .......................................................................................................................... 100
Figure 3-33: ToolKit – control status monitor........................................................................................................................ 103
Figure 3-35: ToolKit – discrete inputs / relay outputs............................................................................................................. 106
Figure 3-37: ToolKit – diagnostics ......................................................................................................................................... 109
Figure 3-39: ToolKit – DSLC-2 overview page 1................................................................................................................... 111
Figure 3-40: ToolKit – DSLC-2 overview page 2................................................................................................................... 113
Figure 3-41: ToolKit – DSLC-2 overview page 3 – MSLC-2................................................................................................. 115
Figure 3-42: Example of an online diagram............................................................................................................................ 118
Figure 3-43: Example of an online diagram with segment numbers and segment connector feedbacks................................. 119
Figure 3-44: Example of an online diagram with according network..................................................................................... 120
Figure 3-45: Example of an online diagram with all required information to setup the units................................................. 121
Figure 4-1: Synchronizer block diagram................................................................................................................................. 142
Figure 4-2: Low voltage system 480 V / 277 V – 3-phase with neutral.................................................................................. 143
Figure 4-3: Low voltage system 480 V / 277 V – 3-phase with neutral.................................................................................. 144
Figure 4-4: Low voltage system 480 V – 3-phase with neutral............................................................................................... 145
Figure 4-5: Low voltage system 600 V / 346 V – 3-phase...................................................................................................... 146
Figure 4-6: Low voltage system 600 V / 346 V – 3-phase...................................................................................................... 147
Figure 4-7: Low voltage system 600 V / 346 V – 3-phase...................................................................................................... 148
Figure 4-8: Low voltage system 600 V / 346 V – 3-phase with neutral.................................................................................. 149
Figure 4-9: Low voltage system 600 V / 346 V – 3-phase with neutral.................................................................................. 150
Figure 4-10: Low voltage system 600 V / 346 V – 3-phase with neutral................................................................................ 151
Figure 4-11: Low voltage system 600 V / 346 V – 3-phase with neutral................................................................................ 152
Figure 4-12: Middle voltage system 20 kV – 3-phase without neutral ................................................................................... 153
Figure 4-13: Middle voltage system 20 kV – 3-phase without neutral ................................................................................... 154
Figure 4-14: Dead bus closing – Example of dead busbar closure arbitration........................................................................ 155
Figure 4-15: Dead bus closing – Example of single dead busbar closure arbitration.............................................................. 156
Figure 4-16: Logic charter GCB closure................................................................................................................................. 159
Figure 5-1: Isochronous mode ................................................................................................................................................ 161
Figure 5-2: Droop/isochronous load sharing........................................................................................................................... 162
Figure 5-3: Isochronous load sharing...................................................................................................................................... 163
Figure 5-4: Reverse power trip ............................................................................................................................................... 168
Figure 7-1: Diagram process control....................................................................................................................................... 174
Figure 8-1: Multiple generators in isolated operation without tie-breakers............................................................................. 176
Figure 8-2: Multiple generators in isolated / parallel to utility operation without tie-breakers............................................... 176
Figure 8-3: Isolated operation with multiple generator and tie-breaker .................................................................................. 177
Figure 8-4: Isolated / utility parallel operation with multiple generator and tie-breaker......................................................... 177
Figure 8-5: Isolated / utility parallel operation with multiple generator, tie-breaker and generator group breaker................. 178
Figure 8-6: Isolated operation with multiple generator and tie-breaker (ring option)............................................................. 178
Figure 8-7: Not supported application .................................................................................................................................... 179
Figure 8-8: Not supported application .................................................................................................................................... 179
Figure 8-9: Visualization and remote control by PLC via RS-485 interface........................................................................... 180
Figure 8-10: Visualization and remote control by PLC via Ethernet Modbus/TCP interface ................................................. 181
Figure 9-1: Diagram frequency / active power controller ....................................................................................................... 182
Figure 9-2: Diagram voltage / reactive power controller........................................................................................................ 183
Figure 10-1: DSLC-2 - interface overview (housing - side view)........................................................................................... 184
Figure 10-2: Modbus - visualization configurations............................................................................................................... 188
Figure 10-3: Modbus - sending binary digital orders over interface....................................................................................... 191
Figure 10-4: Modbus – loss of connection.............................................................................................................................. 193
Figure 10-7: Modbus - configuration example 1..................................................................................................................... 196
Figure 10-8: Modbus - configuration example 2..................................................................................................................... 197
Figure 10-9: Modbus - configuration example 3..................................................................................................................... 197
Figure 10-10: Modbus - remote control parameter 1701 ........................................................................................................ 198
Figure 10-11: Modbus - write register - enable the resetting procedure via RS-232 or Modbus TCP/IP................................ 198
Figure 10-12: Modbus - remote control parameter 1701 ........................................................................................................ 199
Figure 10-13: Modbus - write register - resetting the default values....................................................................................... 199
Figure 10-14: Interference suppressing circuit - connection................................................................................................... 205

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Tables
Table 1-1: Manual - overview................................................................................................................................................... 11
Table 2-1: Conversion chart - wire size .................................................................................................................................... 24
Table 2-2: Power supply - terminal assignment........................................................................................................................ 25
Table 2-3: Voltage measuring - terminal assignment - generator voltage................................................................................. 26
Table 2-4: Voltage measuring - terminal assignment - generator, 3Ph 4W OD........................................................................ 28
Table 2-5: Voltage measuring - terminal assignment - generator, 3Ph 4W............................................................................... 29
Table 2-6: Voltage measuring - terminal assignment - generator, 3Ph 3W............................................................................... 30
Table 2-7: Voltage measuring - terminal assignment - busbar voltage ..................................................................................... 31
Table 2-8: Voltage measuring - terminal assignment - busbar, 1Ph 2W (phase-neutral).......................................................... 32
Table 2-9: Voltage measuring - terminal assignment - busbar, 1Ph 2W (phase-phase)............................................................ 33
Table 2-10: Voltage measuring - terminal assignment - auxiliary busbar voltage .................................................................... 34
Table 2-11: Voltage measuring - terminal assignment - auxiliary busbar, 3Ph 4W.................................................................. 35
Table 2-12: Voltage measuring - terminal assignment - auxiliary busbar, 3Ph 3W.................................................................. 36
Table 2-13: Current measuring - terminal assignment - generator current................................................................................ 37
Table 2-14: Current measuring - terminal assignment - generator, L1 L2 L3........................................................................... 38
Table 2-15: Current measuring - terminal assignment - generator, phase Lx............................................................................ 38
Table 2-16: Power measuring - terminal assignment................................................................................................................ 39
Table 2-17: Discrete input - terminal assignment ½ ................................................................................................................. 41
Table 2-18: Discrete input - terminal assignment 2/2 ............................................................................................................... 42
Table 2-20: Relay outputs - terminal assignment...................................................................................................................... 43
Table 2-21: Analog inputs - terminal assignment - wiring two-pole senders............................................................................ 45
Table 2-22: Bias signal outputs - analog or PWM .................................................................................................................... 46
Table 2-23: RS-485 interface #1 - pin assignment.................................................................................................................... 47
Table 2-24: RS-232 interface - pin assignment......................................................................................................................... 48
Table 2-25: RJ-45 interfaces - pin assignment.......................................................................................................................... 48
Table 3-6: Parameter - homepage ............................................................................................................................................. 59
Table 3-10: Parameter – synchronizer....................................................................................................................................... 64
Table 3-12: Parameter – load control........................................................................................................................................ 68
Table 3-14: Parameter – process control................................................................................................................................... 70
Table 3-16: Parameter – var / pf control ................................................................................................................................... 76
Table 3-18: Parameter – configuration...................................................................................................................................... 81
Table 3-20: Parameter – configuration – interfaces .................................................................................................................. 85
Table 3-22: Parameter – configuration – system management.................................................................................................. 88
Table 3-30: Parameter – analog input / output.......................................................................................................................... 99
Table 3-32: Parameter – electrical parameters........................................................................................................................ 102
Table 3-34: Parameter – control status monitor...................................................................................................................... 105
Table 3-36: Parameter – discrete inputs / outputs................................................................................................................... 108
Table 3-38: Parameter – diagnostics....................................................................................................................................... 110
Table 3-29: Parameter – DSLC-2 overview page 1 ................................................................................................................ 112
Table 3-30: Parameter – DSLC-2 overview page 2 ................................................................................................................ 114
Table 3-30: Parameter – DSLC-2 overview page 3 – MSLC-2 .............................................................................................. 116
Table 4-1: Low voltage system 480 V / 277 V – 3-phase with neutral ................................................................................... 143
Table 4-2: Low voltage system 480 V / 277 V – 3-phase with neutral ................................................................................... 144
Table 4-3: Low voltage system 480 V – 3-phase with neutral................................................................................................ 145
Table 4-4: Low voltage system 600 V / 346 V – 3-phase ....................................................................................................... 146
Table 4-5: Low voltage system 600 V / 346 V – 3-phase ....................................................................................................... 147
Table 4-6: Low voltage system 600 V / 346 V – 3-phase ....................................................................................................... 148
Table 4-7: Low voltage system 600 V / 346 V – 3-phase with neutral ................................................................................... 149
Table 4-8: Low voltage system 600 V / 346 V – 3-phase with neutral ................................................................................... 150
Table 4-9: Low voltage system 600 V / 346 V – 3-phase with neutral ................................................................................... 151
Table 4-10: Low voltage system 600 V / 346 V – 3-phase with neutral ................................................................................. 152
Table 4-11: Middle voltage system 20 kV – 3-phase without neutral..................................................................................... 153
Table 4-12: Middle voltage system 20 kV – 3-phase without neutral..................................................................................... 154
Table 10-1: DSLC-2 - Interfaces - overview........................................................................................................................... 184
Table 10-2: Modbus - address range....................................................................................................................................... 187
Table 10-3: Modbus - address range block read...................................................................................................................... 188
Table 10-4: Modbus - address calculation .............................................................................................................................. 189
Table 10-5: Modbus - data types............................................................................................................................................. 189
Table 10-6: Modbus – sending setpoint sover interface.......................................................................................................... 190
Table 10-7: Modbus – sending binary digital orders over interface........................................................................................ 190
Table 10-8: Modbus – sending binary digital orders over interface........................................................................................ 192
Figure 10-5: Modbus - configuration example 1 - active power............................................................................................. 194
Figure 10-6: Modbus - configuration example 2 – power factor............................................................................................. 195
Table 10-9: Modbus – password for serial interface 1............................................................................................................ 196
Table 10-10: Modbus – generator rated voltage...................................................................................................................... 197

Manual 37443A DSLC-2 - Digital Synchronizer and Load Control
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Table 10-11: Modbus – generator voltage measuring............................................................................................................. 197
Table 10-12: Modbus – reset default values ........................................................................................................................... 198
Table 10-13: Modbus - serial interface 1 - parameters............................................................................................................ 200
Table 10-14: Modbus - serial interface 2 – parameters........................................................................................................... 200
Table 10-15: Modbus - TCP/IP Network B– parameters........................................................................................................ 200
Table 10-16: Interference suppressing circuit for relays......................................................................................................... 205

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Chapter 1.
General Information
Document Overview
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
This manual describes the Woodward DSLC-2TM Digital Synchronizer and Load Control.
Type
English
German
DSLC-2
DSLC-2 – User Manual
this manual

37443
-
MSLC-2 – User Manual
37444
-
Table 1-1: Manual - overview
Intended Use The unit must only be operated in the manner described by this manual. The prerequisite for a
proper and safe operation of the product is correct transportation, storage and installation as well as careful opera-
tion and maintenance.
NOTE
This manual has been developed for a unit fitted with all available options. Inputs/outputs, functions,
configuration screens and other details described, which do not exist on your unit, may be ignored.
The present manual has been prepared to enable the installation and commissioning of the unit. Due to
the large variety of parameter settings, it is not possible to cover every combination. The manual is
therefore only a guide.

Manual 37443A DSLC-2 - Digital Synchronizer and Load Control
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Application
≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡≡
The Woodward DSLC-2TM control is the direct successor of the microprocessor-based DSLCTM synchronizer and
load control designed for use on three-phase AC generators. The DSLC-2TM control combines synchronizer, load
sensor, load control, dead bus closing system, var, power factor and process control, all integrated into one po-
werful package.
Applications allow up to 32 generators to be paralleled and controlled. A dedicated Ethernet system provides
seamless communications between DSLC-2TM and MSLC-2TM units. A second Ethernet port is provided for cus-
tomer remote control and monitoring capability using Modbus TCP allowing DCS and PLC interfacing. Modbus
RTU is available through a separate RS-485 port.
DSLC-2 function summary
Original DSLC functions include:
•Selectable for phase matching or slip frequency synchronizing with voltage matching and automatic
dead bus closure capability
•Automatic generator loading and unloading for bumpless load transfer
•Droop, base load and isochronous load control capability
•Process control for cogeneration, import/export, pressure control or other processes
•Isochronous load sharing with other sets equipped with DSLC controls
•Var or power factor (PF) control
•Built in diagnostics
•Multifunction adjustable high and low limit alarms and load switch with relay outputs
•Digital communications network to provide load sharing, var/PF sharing and other information ex-
change between controls
•Reverse power relay
Additional DSLC-2 functions include:
•One dedicated Ethernet line for precise system communications between all DSLC-2’s and MSLC-2’s
on the system
•Ethernet Modbus/TCP for remote control and monitoring
•Serial Modbus RS-485 for remote control and monitoring
•Applications with up to 32 DSLC-2 and 16 MSLC-2
•Automatic segment control (self recognizing of the segment)
•Process control with up to 32 DSLC-2 or 1 Master MSLC-2
•Full setup, metering and diagnostic capability through the PC program ToolKit
Synchronizer
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Either phase matching or slip frequency synchronizing may be selected. Phase matching provides rapid synchro-
nizing for critical standby power applications. Slip frequency synchronizing guarantees that initial power flow is
positive for all generators. For both synchronizing methods, the DSLC-2 control uses actual slip frequency and
breaker delay values to anticipate a minimum phase difference between bus and generator at actual breaker clo-
sure. The DSLC-2 control provides a safe automatic dead-bus closure function. Deadbus closing permission is
granted to only one DSLC-2 or MSLC-2 control in the whole system, through locking techniques done over the
communications network. This assures that a race condition will not cause two or more breakers to close simulta-
neously on the dead bus. Additional synchronizer features include voltage matching, time delayed automatic mul-
ti-shot reclosing, auto-resynchronizing and a synchronizer timeout alarm. Each of these features may be enabled
or disabled during setup.

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Load Control
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Load control begins at breaker closure when the load control function takes control of the DSLC-2 speed bias
output directly from the synchronizer. The matching of synchronizer slip frequency to initial load (unload trip
level) can result in a bumpless transfer to load control. On command, the adjustable ramp allows smooth, time-
controlled loading into base load, isochronous 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 an integrating controller. The
integrating base load control provides accurate load control when in parallel with a bus where frequency may
vary. The DSLC-2 control provides switch inputs to allow raising or lowering the internal digital base load refer-
ence. The control also provides an analog input for remote load setting.
When unloading, an adjustable unload ramp provides time controlled unloading to the unload trip level. When
load reaches the unload trip level, the control issues a breaker open command to separate the generator set from
the system. The ramp pause switch input is in effect while unloading to allow holding of the unload ramp for
cool-down or other purposes.
The load and unload ramps also provide smooth transition between base load, isochronous load sharing and
process control any time the operating mode is changed.
The DSLC-2 control includes several additional load control features:
•Load droop operation provides safe operation in parallel bus applications in the event of a circuit breaker
aux contact failure.
•A frequency trimmer function provides accurate frequency control in isochronous load sharing systems
by compensating for small variations in speed setting between units.
•Adjustable load switch output with independent pick-up and drop-out points provides a signal when the
specified load is exceeded. The load switch output can be selected as a reverse power trip.
•Load raise and lower inputs can be used to adjust speed before synchronizing.
•Voltage raise and lower inputs can be used to adjust voltage before synchronizing.
•A droop tracking function is available automatically by a network fault or by a discrete input.

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Process Control
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A cascade PID process controller is provided for cogeneration, import/export control, pond level maintenance,
pressure maintenance or other application. An adjustable bandwidth signal input filter, flexible PID controller ad-
justments and control selectable for direct or indirect action, allow the process control to be used in a wide variety
of applications.
The analog input “Process Signal Input” provides the real value for the DSLC-2 control. The control includes an
internal digital process reference which may be controlled by raise and lower load switch contact inputs or by the
analog input “Process Signal”.
Adjustable ramps allow smooth entry to or exit from the process control mode. When the process control mode is
selected, an adjustable ramp moves the load reference in a direction to reduce the process control error. When the
error is minimized or the reference first reaches either the specified high or low load pick-up limits, the process
controller is activated. When a limit is reached, the control will hold the load reference at that limit 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 level, the DSLC-2 control automatically issues a breaker
open command to remove the generator set from the system. The ramp pause switch input allows holding of the
unload ramp for cool-down or other purposes.
Additional functions include selectable and adjustable process high and low limit switches and alarm activation.
Var/PF Control
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The var/PF functions control the reactive power component of the generator in parallel systems. In an infinite bus
system, the controller compares either the kvar load or power factor (selectable) on the generator with an adjusta-
ble internal reference and makes corrections to the voltage regulator until the desired kvar load or power factor is
obtained. For higher performance, the “Voltage Bias” output, can be directly connected to compatible voltage
regulators with analog voltage setting input. The control has raise and lower voltage discrete inputs for manual
voltage adjustment. The control also has raise and lower contact outputs to activate a voltage regulator MOP
when an analog input is not provided on the AVR.
The var/PF controller will limit the generators kvar output to the generator rated reactive power setpoint when
connected to an infinite bus. A DSLC-2 must be in baseload or process control or a MSLC-2 must be in control.
This will protect the generator when connected to an infinite source. This feature is not active when the DSLC-2
is in the load sharing mode (isolated).
The DSLC-2 control provides var sharing between multiple units when in an isolated bus application. The control
computes an average var value for the system and uses it as the reference input to the var controller. The control
includes an adjustable voltage reference and voltage trim function in the sharing function to maintain system vol-
tage. The analog input “Reactive Load” is activated by closing both the voltage raise and lower discrete inputs.
This allows remote control of the PF reference setpoint when in power factor control. Each power factor setpoint
either external or internal is calculated to a var load setpoint. var load setpoints are restricted within the range -10
% to 100 % generator rated reactive power.
The DSLC-2 control has a selectable voltage range alarm which is activated if the analog output to the voltage
regulator reaches high or low saturation. The DSLC-2 control also has selectable and adjustable high and low
voltage limit switches and alarm outputs.

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DSLC-2 / MSLC-2 Systems
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The network addressing of the DSLC-2 / MSLC-2 allows up to 32 DSLC-2s and 16 MSLC-2s in an application.
A DSLC-2 and MSLC-2 application can handle 8 segments. Discrete inputs inform the DSLC-2s and MSLC-2s
which segments each generator and utilities are operating on. If a MSLC-2 receives a discrete input to activate
segment 1 and 2, it will share this information with all controls over the Ethernet bus. It is not necessary to pro-
vide a segment activation discrete input to all controls. Segmenting allows the DSLC-2s and MSLC-2s to remain
connected thru the Ethernet bus, but be operating on separate load buses.
The DSLC-2 / MSLC-2 system can be applied according to following rules:
•The maximum number of DSLC-2s (Gen-CB) is 32.
•The maximum number of MSLC-2s (Utility- or Tie-CB) is 16.
•The maximum number of segments is 8.
•The segment numbers have to follow a line, which can finally be closed to a ring.
•Only one MSLC-2 can be used as master control, when multiple MSLC-2 are resided in one segment.
oThe MSLC-2 with the lower device number will control if multiple Utility MSLC-2s are active
on the same segment
•The generator is not counted as a segment.
•The utility is not counted as a segment.
NOTE
If different MSLC-2s, located in different segments, are connected via a tie-MSLC-2, more than one
MSLC-2 is now located in the same segment. The result is the MSLC-2 with the lowest device number
becomes the master of all MSLC-2s located in this segment.
Examples:
Figure 1-2: Multiple generators in isolated operation with tie-breaker

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Figure 1-3: Multiple generators in isolated and utility parallel operation with utility- and tie-breaker

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Chapter 2.
Installation
Electrostatic Discharge Awareness
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All electronic equipment is static-sensitive, some components more than others. To protect these components
from static damage, you must take special precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
Before doing maintenance on the electronic control, discharge the static electricity on your body to ground by
touching and holding a grounded metal object (pipes, cabinets, equipment, etc.).
Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic materials. Wear
cotton or cotton-blend materials as much as possible because these do not store static electric charges as
easily as synthetics.
Keep plastic, vinyl and Styrofoam materials (such as plastic or Styrofoam cups, cigarette packages, cellophane
wrappers, vinyl books or folders, plastic bottles, etc.) away from the control, modules and work area as
much as possible.
Opening the control cover may void the unit warranty.
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 precautions:
•Ensure that the device is completely voltage-free (all connectors have to be disconnected).
•Do not touch any part of the PCB except the edges.
•Do not touch the electrical conductors, connectors or components with conductive devices or with bare
hands.
•When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in until you
are ready to install it. Immediately after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
CAUTION
To prevent damage to electronic components caused by improper handling, read and observe the pre-
cautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed
Circuit Boards and Modules.
NOTE
The unit is capable to withstand an electrostatic powder coating process with a voltage of up to 85 kV
and a current of up to 40 µA.

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Unpacking
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Before unpacking the control, refer to the inside front cover of this manual for WARNINGS and CAUTIONS. Be
careful when unpacking the control. Check for signs of damage such as bent or dented panels, scratches, loose or
broken parts. If any damage is found, immediately notify the shipper.
Location
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When selecting a location for mounting the DSLC-2 control, consider the following:
•Protect the unit from direct exposure to water or to a condensation-prone environment.
•The continuous operating range of the DSLC-2 control is –40 to +70 °C (–40 to +158 °F).
•Provide adequate ventilation for cooling. Shield the unit from radiant heat sources.
•Do not install near high-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.
•The control must NOT be mounted on the engine.

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Housing
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Dimensions
Figure 2-1: Housing DSLC-2 - dimensions
Protective Earth

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Installation
The unit is to be mounted to the switch cabinet back using four screws with a maximum diameter of 6 mm. Drill
the holes according to the dimensions in Figure 2-2 (dimensions shown in mm).
Figure 2-2: Housing - drill plan