Page 1
Product Manual 02022 (Revision B) Original Instructions MSLC Master Synchronizer and Load Control 9907-004 (4-Wire Wye) 9907-005 (3-Wire Delta, 120 V) 9907-006 (3-Wire Delta, 240 V) Installation and Operation Manual...
Page 2
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, no responsibility is assumed by Woodward unless otherwise expressly undertaken.
Start-up On- and off-highway Mobile Applications: Unless Woodward's control functions as the supervisory control, customer should install a system totally independent of the prime mover control system that...
Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715 , Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules.
Page 8
MSLC Master Synchronizer and Load Control Manual 02022 Woodward...
Application The MSLC is a microprocessor-based overall plant load control designed for use in a system with Woodward DSLC™ (Digital Synchronizer and Load Control) controls on each generator to provide utility synchronizing, paralleling, loading, and unloading of a three-phase generating system.
4–20 mA (1–5 Vdc) remote process reference. The output of the process control, like the import/export control, is the percentage of rated load setpoint to the individual generators in isochronous load sharing. Woodward...
Chapter 9 provides a troubleshooting guide. Due to the extensive built-in diagnostics, MSLC installation may be tested and verified quickly. Chapter 10 describes how to return the control to Woodward in the event of damage or failure of an internal component. ...
MSLC Master Synchronizer and Load Control Manual 02022 Figure 1-4. Typical Wiring Connections (9907-005 for open delta, 120 V switchgear configuration) Woodward...
Manual 02022 MSLC Master Synchronizer and Load Control Figure 1-5. Typical Wiring Connections (9907-006 for open delta, 240 V switchgear configuration) Woodward...
Electrical Connections This section covers typical wiring connections, as shown in Figure 1-3. For other applications, contact Woodward Governor Company for assistance. Connect the terminals as shown in Figure 1-3. When making the connections, observe the following: ...
50 mm (2 inches). The other end of the shields must be left open and insulated from any other conductor. Do NOT run shielded signal wires along with other wires carrying large currents. See Woodward application note 50532, Interference Control in Electronic Governing Systems for more information.
150 Vac RMS on inputs labeled 120V, or 300 Vac RMS on inputs labeled 240V respectively. Local bus phase rotation must correspond to the phase rotation of the utility or tie bus for proper synchronization. Woodward...
The discrete outputs are the relay driver output commands from the MSLC. Each optically isolated discrete output is designed 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 particular application. Woodward...
Make connections to terminals 24–27 as shown in Figure 1-3. Alarm Relay Make the alarm relay connection as shown in Figure 1-3 to terminal 28 of the MSLC. Alarm conditions are selectable by the user (see tables in Chapter 3). Woodward...
Ramp Pause Contact Connect the load ramp pause switch contact to terminal 51. When closed, this contact will hold any load ramp in progress at its current setting until the contact is opened. Woodward...
The following requirements must be met: 1. Use only recommended shielded twisted pair cabling for the LonWorks network. Correct cable is available from Woodward, Belden, or other suppliers providing an equivalent cable. Belden...
Check for shield faults by measuring the resistance from control terminals to chassis. If a resistance less than infinite is obtained, remove the connections from each terminal one at a time until the resistance is infinite. Check the last line removed to locate the fault. Woodward...
When the self-test is complete, the screen will be blank. Press the ID key to display the part number and revision level of the software in the control. Refer to this number and revision level in any correspondence with Woodward Governor Company.
“Turtle Down” or “Rabbit Down” keys to decrease the value. The “Rabbit Up” and “Rabbit Down” keys will make the rate of change faster than the “Turtle Up” and “Turtle Down” keys. This is useful during initial setup where a value may need to be changed significantly. Woodward...
9. Network Service Pin 10. Revert Status Lock In Last Hardware Lock In Last 11. Net Dropout Time 0.50 50.00 5.00 12. Utility Breaker Open Logic Direct Indirect Indirect * NOTE: Use kV only when Primary Voltage is greater than 33 kV. Woodward...
18. Slip Frequency –1.0 Slow 5.0 Fast Hz (Fast or Slow) 19. System Load –100 +120 20. System PF 0.5 Lagging 0.5 Leading Lagging, Leading * NOTE: Active Power is positive when exporting power, and negative when importing power. Woodward...
Sync NV Update Lost Invalid Resp Alloc Invalid Domain Read Past EndOfMsg Write Past EndOfMsg Addr Table Index Incomplete Msg Update On Output NV No Msg Avail Illegal Send Unknown PDU Invalid NV Index Divide by Zero Invalid Appl Error Woodward...
If the slip frequency reference is negative (slow) the local bus voltage may not be greater than the utility voltage. This ensures that the initial reactive power flow is in the same direction as the initial real power flow. Woodward...
Page 36
Imp/Exp Stability (integral term) compensates for lags in the load control loop. It prevents slow hunting and controls damping (overshoot or undershoot) after a load disturbance. Imp/Exp Derivative adjusts the rate of change in the load command during a load transient. Woodward...
Page 37
15. Raise Load Rate is the rate at which the control changes the load reference when the set point raise switch is activated. 16. Lower Load Rate is the rate at which the control changes the load reference when the set point lower switch is activated. Woodward...
Page 38
31. Gen Load Switch 2 PU sets the percentage system load level at which load switch #2 discrete output is activated. 32. Gen Load Switch 2 DO sets the percentage system load level at which load switch #2 discrete output is de-activated. Woodward...
Page 39
15. Low Limit Alarm specifies if the process low limit alarm will activated (de- energize) the alarm relay. 16. Process Switches specifies if the process high and low limits will activate the high and low limit discrete outputs. Woodward...
Page 40
VARs being absorbed/generated across the utility tie. It is recommended that the Constant Generator Power Factor control mode be used in applications where the total generator kVAR capacity is less than the kVAR load of the system. Woodward...
Page 41
Process Action specifies if the process variable is direct or indirect acting. If the process variable increases when the associated generators' load increases, the action is direct. Conversely, if the process variable decreases when the associated generators' load increases, the action is indirect. Woodward...
Page 42
This is referred to as the “Hardware Loop” (displayed as Loop 4 in menu 0 of the DSLC hand held programmer). Woodward...
Page 43
INDIRECT If set for Indirect, the Breaker Open Command Output will be normally energized, and will de-energize to issue a utility breaker open command. The Utility Breaker Open command is issued during normal operation in Utility Unload mode. Woodward...
Page 44
CT Phase A displays the sensed phase A current. When currents are applied to the control, adjust the displayed value to equal the actual phase A current. NOTE: This must be calibrated as part of the installation on the actual switchboard. Woodward...
Page 45
COMMANDS menu item if the control is set for command inputs from hardware, but a valid message is being seen on the network. The DI Commands monitor shows only the status of the USE_DS command inputs. The USE_CBAUX and USE_PS, USE_RR status is not indicated by this display. Woodward...
Page 46
10. Phase B PF is the power factor on phase B of the utility bus. 11. Phase C is the voltage on phase C of the utility bus. 12. Phase C is the current on phase C of the utility bus. Woodward...
Page 47
PF Reference is the internal reference setpoint of the MSLC. Synchronizer Timeout is the status of the alarm for exceeding the synchronizer timeout interval. Sync Reclose Limit is the status of the alarm for exceeding the synchronizer close attempts limit. Woodward...
Page 48
12. Lower Voltage is the status of the voltage lower contact input. 13. Test Key must be set to 49 to allow closing of discrete outputs for test purposes. In addition, all discrete inputs must be open to allow testing of discrete outputs. Woodward...
Page 49
Transmit Errors is the number of CRC (Cyclic Redundancy Check) errors detected during packet reception. These may be due to collisions or noise on the transceiver input. Pressing the “.” key will retrieve the current number of transmission error statistics. Woodward...
Page 50
16. Hardware Loop is a TRUE/FALSE indication which, when true, indicates a network command input failure has occurred, causing the MSLC control to lock into the current hardware input operating commands. See Chapter 3, “Menu 5 Configuration” section, for more details on network command operations. Woodward...
MSLC will be controlling. Prestart Load Limits and Switches Setup Set all load limits and switches according to the descriptions above and the specific plant application. Document these values in the worksheet in Appendix A for future reference and installations. Woodward...
To assist in setup and adjustments, you can monitor synchronizer mode of operation on Menu 8 and Synchronizer Mode and Slip Frequency and Synchroscope values on Menu 7. Woodward...
Set the Slip Frequency Ref set point to 0.0 Hz to select phase matching. Close the synchronizer Check Mode switch. With utility and bus active, adjust the synchronizer Gain set point for stable control of the utility frequency as indicated by the synchroscope's holding steady at zero phase. Woodward...
Page 54
Repeat steps 5 and 6 if necessary to get the desired performance. Verify synchronizer performance under all expected operating conditions, such as synchronizing at higher or lower speeds. Woodward...
Page 55
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 to step 6. Otherwise, repeat steps 4 and 5. Woodward...
Page 56
Set the Sync Timeout to the maximum number of seconds the synchronizer should attempt to achieve synchronization. Set to 0 for no timeout. If an alarm is desired when the Sync Timeout interval expires, set the Sync Timeout Alarm set point to Enabled. Woodward...
If the voltage cycles through the window without settling into it, the voltage adjusting potentiometer on the DSLC controls may need to be adjusted. See the DSLC manual. Set the synchronizer to “OFF”, manually lower the local bus voltage until it is approximately 5% lower than the utility voltage. Woodward...
Temporarily issue a lower set point command, and then a raise set point command. Verify that the load command changes appropriately and that the engines in isochronous load sharing respond appropriately. Woodward...
Page 59
0% or 100%. Temporarily issue a lower set point command, and then a raise set point command. Verify that the load command changes appropriately and that the engines in isochronous load sharing respond appropriately. This completes the import/export setup. Woodward...
Page 60
If it is desired that the Alarm output will also de-energize the alarm relay when load reaches the Low Limit PU, set the Low Limit Alarm set point to Enabled. The alarm will be automatically cleared when load increases to above the Low Limit DO switch point. Woodward...
Set the Process High Limit PU and DO set points to the desired values. The Process High Limit PU set point must be set to limit the range of the process reference even if the alarm will not be used. Woodward...
Failure to save the set points before removing power from the control causes them to revert to the previously saved settings. Disconnect the Hand Held Programmer from the control. Close the cover over J1 and re-tighten the retaining screw. Woodward...
Permissive mode enables the synch-check function for proper synchronization, but synchronizer operation does not affect the engine's speed or generator voltage. If phase, frequency, and voltage are within proper limits, the synchronizer issues the breaker closure command. Woodward...
Manual 02022 MSLC Master Synchronizer and Load Control Figure 5-2. Synchronizer Wiring Diagram (120 V wye configuration shown) Woodward...
Page 66
This will ensure that the initial power flow is out of or into the plant. The slip frequency method of paralleling is selected when the slip frequency reference is set to a non-zero value. Woodward...
Page 67
“OFF” and then back to “RUN” before the control will again attempt synchronization. An alarm is provided which if enabled will energize the alarm relay driver, terminal 24, if the a sync timeout occurs. The sync timeout function is disabled by setting it to zero. Woodward...
Reactive Power Q = ( S - P ) Power Factor pf = Phase Angle Frequency f = where T is the sampling period. The sampling period is derived from the zero crossings of the A phase voltage signal. Woodward...
DSLC controls will control to this percentage of their rated loads, and the MSLC will adjust this system load up or down to achieve the proper import/export level. For safety, the MSLC is limited to controlling generators between 0% and 100%. Woodward...
It will then issue a local generator bus breaker open command. This will transfer the plant load back to the utility power grid. Woodward...
Page 71
The local plant unload is accomplished by switching to base load mode and supplying a continuous set point lower command. The ramp pause command will pause all ramps in any mode. Woodward...
MSLC controls only those DSLC controls which are in isochronous load sharing. Any DSLC controls which are in base load mode will control the reactive power on their associated generators in accordance with their own internal reference and chosen mode of VAR/PF control. Woodward...
The MSLC system load command is obeyed only by the associated DSLC controls which are in isochronous load sharing. Base load or process control mode will ignore the MSLC load command signal and maintain its set base load reference. Woodward...
LonWorks-compatible devices through a custom installation. This chapter provides information on network specifications and the optional capabilities of the MSLC. Contact the Woodward Governor Company for full information on optional devices to take advantage of these features. Figure 9-1. Typical LON Setup...
+1.0). Power factor is further encoded such that 1.0 represents 0.0 lagging power factor, +1.0 represents 0.0 leading power factor, and 0.0 represents a power factor of 1.0. (Note: power factor across the utility tie is available at a 200 ms rate.) Woodward...
(does not have 20-40 Vdc applied). A bit value of “1” indicates that the specified input is active. The bit representation is: 0—Synchronizer Check Mode 1—Synchronizer Permissive Mode 2—Synchronizer Run Mode 3—Circuit Breaker Auxiliary Contact 4—Utility Unload 5—Import/Export Control 6—Process Control 7—Ramp Pause 8—Set Point Raise 9—Set Point Lower 10—Voltage Raise Woodward...
Page 78
The load control state is updated once per second. The value representation is: 0—Offline 1—Baseload 2—Baseload Lower 3—Baseload Raise 4—Baseload Remote 5—Utility Unload 6—Process Ramp 7—Process Control 8—Process Lower 9—Process Raise 10—Process Remote 11—Import/Export Ramp 12—Import/Export Control 13—Import/Export Lower 14—Import/Export Raise 15—Import/Export Remote Woodward...
The hardware discrete inputs must not be used when the network input is used. Changing any hardware discrete input causes the MSLC to look at all the hardware discrete inputs. Woodward...
Network Bus Length: 500 m (+20 to +85 °C) typical 150 m (+40 to +85 °C) typical Maximum Stub Length: 300 mm (+40 to +85 °C) 600 mm (0 to +70 °C) Network Termination: Required at both ends of the network Woodward...
Failure to display this message indicates either the control or Hand Held Programmer has failed. Replace the MSLC or Hand Held Programmer. Select the Diagnostics menu by pressing “0”. The Self Test Result should display a value of 49. If any other value is displayed, replace the control. Woodward...
Page 82
Vdc). Adjust the Process Cal set point for 20.0 ± 0.1 mA. Be sure to save the calibration information by pressing the “SAVE” key on the Hand Held Programmer. Repeat the above process input tests to verify correct calibration over the input range. Woodward...
Page 83
This section tests the operation and calibrates the Utility Potential Inputs. Both the high voltage (240 Vac) and low voltage (120 Vac) inputs may be optionally tested. Calibration of the input must be done for the appropriate voltage used in service. Woodward...
Select Menu 6 Synchroscope set point. With the voltage input to the Bus and Utility Phase A inputs connected in parallel, adjust the Synchroscope value to 0.0 ± 0.1 degrees. LonWorks Network Menu 0 (Diagnostics Menu), beginning with item 3, contains information to aid in verifying operation and troubleshooting of network operation. Woodward...
Page 85
The number of errors from message collisions is a function of the number of messages presented to the network. More than five or ten errors per second indicates the network function should be checked. Woodward...
Page 86
If no custom installation has been done and sufficient errors are occurring to cause load sharing problems, contact Woodward Governor Company. Missed Messages is the number of times the network processor received more messages at one time than it could process.
Page 87
If problems still exist, you may disconnect or replace a MSLC or other device attached to the network to investigate its effect on the network. If a custom installation has been done, it will be necessary to use the installation network management tool to properly install a replacement device on the network. Woodward...
Page 88
Menu 5 to ensure that they are linearly across their the same. entire range (Menus 6 & 7) *—NOTE 1: Installing PROMs backwards will result in the destruction of the chips. PROMs that have been powered up while installed backwards will need to be replaced. Woodward...
Woodward systems and components for the retrofits and overhauls, long term service contracts, emergency repairs, etc. You can locate your nearest Woodward distributor, AISF, RER, or RTR on our website at: www.woodward.com/directory...
Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat Rate Repair option with the exception that the unit will be returned to you in “like- new” condition and carry with it the full standard Woodward product warranty (Woodward Product and Service Warranty 5-01-1205). This option is applicable to mechanical products only.
Engineering Services Woodward offers various Engineering Services for our products. For these services, you can contact us by telephone, by email, or through the Woodward website. Technical Support ...
MSLC Master Synchronizer and Load Control Manual 02022 How to Contact Woodward For assistance, call one of the following Woodward facilities to obtain the address and phone number of the facility nearest your location where you will be able to get information and service.
__________% Gen Load Switch 1 DO __________% Gen Load Switch 2 PU __________% Gen Load Switch 2 DO __________% Process Control Menu 3 Process Control Gain __________ Process Stability __________Seconds Process Derivative __________Seconds Process Deadband __________mA Process Droop __________% Woodward...
PF Reference 0.0 lag | 0.0 lead Const-Gen-PF-Ref __________ PF Deadband __________ Voltage Low Limit __________V, kV Voltage Low Alarm Enabled | Disabled Voltage High Limit __________V, kV Voltage High Alarm Enabled | Disabled Voltage Switches Enabled | Disabled Woodward...
Line-to-Line | Line-to-Neutral | Volts | Kilovolts System Frequency 50 Hz | 60 Hz Process Action Direct | Indirect Network Address __________ Network Service Pin __________ Revert Status Hardware|Lock In Last Net Dropout Time _________seconds Util Breaker Open Logic Direct | Indirect Woodward...
12 to 40 Vdc Burden 10 mA nominal Relay Driver Outputs Voltage 12 to 40 Vdc Current 200 mA sink (max) Analog Inputs Current 4 to 20 mA Voltage 1 to 5 Vdc 243 current mode Resistance 10 k voltage mode Woodward...
Test Methods US MIL-STD-810C, Method 516.2, Shock Procedure I, Figure 516.2-2, basic design test Procedure II, transit drop test Procedure V, bench handling test Electromagnetic Susceptibility Test Method ANSI/IEEE C37.90.2 Electrostatic Discharge 6000 Volts Electrical Transients Test Method ANSI C37.90.1-1989 Woodward...
MSLC Menu Summary 1—Synchronizer 4—VAR/PF Control 8—Control Status Monitor Sync Gain VAR/PF Control Mode Synchronizer Mode Sync Stability VAR/PF Gain Load Control Mode Slip Frequency Ref VAR/PF Stability Import/Export Ref Slip Window Rated kVARS Process Reference Max Phase Window kVAR Reference Load Command Output Voltage Matching PF Reference...
Page 100
Email and Website—www.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website.
Need help?
Do you have a question about the MSLC 9907-004 and is the answer not in the manual?
Questions and answers