Woodward DSLC Digital Synchronizer and Load Controller: Installation, Operation, and Troubleshooting Guide

Current Transformer (CT) Connection:

The CT connection must be correct, and the corresponding phase CT and PT must be connected to the same phase terminal controlled by DSLC

It is necessary to observe the correct polarity

Provide 5A RMS full load current for optimal system performance

There is a risk of fatal electric shock if any wires connected to the generator CT terminal are disconnected while the engine is running

3、 System configuration and calibration

3.1 Use of Handheld Programmer

A handheld programmer is a small computer terminal that connects to the DSLC control RS-422 diagnostic and service port. Its main functions include:

After completing the power on self-test, press the ID key to display the control software part number and revision level

Four line backlit LCD display screen, capable of viewing two functions or menu items simultaneously

Access ten settings menus through numeric keys 1-0

Use the 'up/down arrow' keys to navigate through the menu

Use the "Turtle" key (slow) and the "Rabbit" key (fast) to adjust the set value

Press the 'Save' button to store the set values in the EEPROM memory

3.2 Detailed explanation of menu system

Menu 1- Synchronizer Settings:

Contains 16 parameters including synchronization gain, stability, slip frequency reference, voltage matching, and dead bus closure, used to optimize synchronization performance.

Menu 2- Load Control:

Contains 30 parameters including load control gain, stability, mode selection, rated load, base load, unloading trip, etc., used for precise control of generator load.

Menu 3- Process Control (Full Function Model):

Contains 16 parameters including process control gain, stability, dead zone, reference value, etc., used for process control applications.

Menu 4- Reactive Power/Power Factor Control (Full Function Model):

Contains 17 parameters including control mode, gain, stability, rated reactive power, reference value, etc., used for reactive power or power factor control.

Menu 5- Configuration:

Contains 9 parameters including PT winding ratio, CT rated value, PT voltage input, system frequency, etc., used for basic system configuration.

Menu 6- Calibration:

It includes 13 calibration items such as process input, remote input, speed bias output, and voltage bias output to ensure measurement accuracy.

Menu 7- Generator Electrical Parameters:

Provide 20 real-time monitoring parameters including active power, apparent power, reactive power, power factor, and voltage and current of each phase.

Menu 8- Control Status Monitor:

Display 13 status information including synchronizer mode, load control mode, load reference, process reference, etc.

Menu 9- Discrete Input/Output:

Display the status of all switch inputs and relay outputs, with a total of 25 monitoring points.

Menu 0- Diagnosis:

Provide 14 diagnostic information including diagnostic results, ROM checksum, number of active DSLCs, and network error statistics.

3.3 Initial setup program

Pre startup setup steps:

Connect the handheld programmer to provide power supply for DSLC control

Verify that the diagnostic result (menu 0) is 49, indicating that it has passed the self-test

Select menu 5, set the configuration key to 49, and configure basic parameters

Set all parameters of synchronizer menu 1 according to the worksheet

Set all parameters of load control menu 2 and initially use proportional load control mode

Set all parameters of process control menu 3 (if used)

Set all parameters of reactive power/power factor control menu 4 and initially disable this function

4、 Adjustment and optimization

4.1 Synchronizer Adjustment

Phase matching synchronizer settings:

Set the slip frequency reference to 0.0Hz and select phase matching

Turn off the synchronizer check mode switch

Adjust synchronous gain to achieve stable frequency control

Verify the performance of the synchronizer under different operating conditions

Slip frequency synchronizer setting:

Complete phase matching synchronizer setup

Set the required slip frequency reference value

Adjust synchronization gain and stability to achieve smooth phase rotation

Verify the performance of the synchronizer under various operating conditions

Voltage matching adjustment:

For voltage regulators using MOP: Adjust the voltage ramp time and verify the voltage matching function

For direct voltage bias input: adjust the voltage range potentiometer and set the desired voltage range

Set voltage high and low limits and alarm function

4.2 Load Control Adjustment

Proportional base load control setting:

Set the load control gain to 0.25

Carefully set the engine speed to achieve synchronous speed

Close the base load switch contactor, open the load/unload and process contactors

Select the synchronizer operation mode to connect the generator in parallel with the busbar

Verify load stability and control performance

Integral based load control setting:

Complete proportional load control settings

Set the load control mode to integral

Adjust load control gain, stability, and derivative parameters

Verify control stability under various load conditions

Timed load distribution adjustment:

Verify that the rated load setting is correct