dse72/7300 series operators manual

DSE72/7300 Series Operators Manual ISSUE 11

DEEP SEA ELECTRONICS

DSE72/7300 Series Operators Manual

Document Number: 057-074

Author: Anthony Manton


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Deep Sea Electronics Plc Highfield House Hunmanby North Yorkshire YO14 0PH ENGLAND Sales Tel: +44 (0) 1723 890099 Sales Fax: +44 (0) 1723 893303 E-mail: [email protected]

Website: www.deepseaplc.com

DSE7200 & DSE7300 series Operators Manual © Deep Sea Electronics Plc All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means or other) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988. Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to Deep Sea Electronics Plc at the address above. The DSE logo and the names are UK registered trademarks of Deep Sea Electronics PLC. Any reference to trademarked product names used within this publication is owned by their respective companies. Deep Sea Electronics Plc reserves the right to change the contents of this document without prior notice. Amendments since last publication Amd. No. Comments 1 Added Maintenance Alarm 2 Added manual fuel pump and manual speed control (Issue 2.1) 3 Added more detail to many sections of the manual (Issue 2.1) including CTs, Earth Fault, Overcurrent, RS232,

Modem, RS485, external sounder, expansion modules (DSE2100 series), 4 Added changes to Dual Mutual, Fuel usage, dummy load control, load shedding, protections disabled, 2500

series display (for version 4 module additions) 5 Additions for V5 modules including modem diagnostics and updated front panel editor details including

scheduler editing. 6 Additions for V6 including Mains current alarms and alternative breaker control button operation. 7 Additions for V7 Electronic Engine features additional alarms. 8 Additions for V8 new and changed displays added and SMS module control. 9 Additions for V9 resetting maintenance alarms from facia and cooldown in stop mode. 10 Shutdown and electrical trip alarms for Positive KVr and Negative KVr 11 Changes to Tier 4 support

Clarification of notation used within this publication.

NOTE:

Highlights an essential element of a procedure to ensure correctness.

CAUTION!

Indicates a procedure or practice, which, if not strictly observed, could result in damage or destruction of equipment.

WARNING!

Indicates a procedure or practice, which could result in injury to personnel or loss of life if not followed correctly.


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TABLE OF CONTENTS Section Page

DEEP SEA ELECTRONICS ................................................................................... 1

1 BIBLIOGRAPHY .............................................................................................. 6

1.1 INSTALLATION INSTRUCTIONS ....................................................................................... 6

1.2 TRAINING GUIDES ............................................................................................................. 6

1.3 MANUALS ............................................................................................................................ 6

1.4 THIRD PARTY DOCUMENTS ............................................................................................. 6

2 INTRODUCTION .............................................................................................. 7

3 SPECIFICATIONS ............................................................................................ 8

3.1 PART NUMBERING ............................................................................................................ 8

3.2 MODEL NAMING ................................................................................................................. 8

3.3 SHORT NAMES ................................................................................................................... 9

3.4 TERMINAL SPECIFICATION .............................................................................................. 9

3.5 POWER SUPPLY REQUIREMENTS .................................................................................. 9

3.5.1 PLANT SUPPLY INSTRUMENTATION DISPLAY ....................................................... 9

3.6 GENERATOR AND MAINS VOLTAGE / FREQUENCY SENSING .................................. 10

3.7 CURRENT SENSING ......................................................................................................... 10

3.8 INPUTS .............................................................................................................................. 10

3.8.1 DIGITAL INPUTS ........................................................................................................ 10

3.8.2 ANALOGUE INPUTS .................................................................................................. 11

3.8.2.1 OIL PRESSURE ................................................................................................................................... 11

3.8.2.2 COOLANT TEMPERATURE ................................................................................................................ 11

3.8.2.3 FUEL LEVEL ........................................................................................................................................ 12

3.8.2.4 FLEXIBLE SENSOR ............................................................................................................................. 12

3.8.3 CHARGE FAIL INPUT ................................................................................................ 12

3.8.4 MAGNETIC PICKUP ................................................................................................... 13

3.9 OUTPUTS .......................................................................................................................... 13

3.9.1 OUTPUTS A & B ......................................................................................................... 13

3.9.2 OUTPUTS C & D ........................................................................................................ 13

3.9.3 OUTPUTS E,F,G & H ................................................................................................. 13

3.10 COMMUNICATION PORTS ........................................................................................... 14

3.11 COMMUNICATION PORT USAGE .............................................................................. 14

3.11.1 CAN INTERFACE ...................................................................................................... 14

3.11.2 USB CONNECTION ................................................................................................... 15

3.11.3 RS232 ......................................................................................................................... 16

3.11.4 RS485 ......................................................................................................................... 18

3.12 DSENET® FOR EXPANSION MODULES .................................................................... 19

3.12.1 DSENET® USED FOR MODBUS ENGINE CONNECTION ...................................... 19

3.13 SOUNDER ...................................................................................................................... 20

3.13.1 ADDING AN EXTERNAL SOUNDER TO THE APPLICATION .................................. 20

3.14 ACCUMULATED INSTRUMENTATION ........................................................................ 20

3.15 DIMENSIONS AND MOUNTING ................................................................................... 21

3.15.1 FIXING CLIPS ............................................................................................................. 22

3.15.2 CABLE TIE FIXING POINTS ...................................................................................... 23

3.15.3 SILICON SEALING GASKET...................................................................................... 23

3.16 APPLICABLE STANDARDS .......................................................................................... 24

3.16.1 ENCLOSURE CLASSIFICATIONS ............................................................................. 26

3.16.2 NEMA CLASSIFICATIONS ......................................................................................... 27

4 INSTALLATION .............................................................................................. 28

4.1 USER CONNECTIONS ...................................................................................................... 28

4.2 TERMINAL DESCRIPTION ............................................................................................... 29

4.2.1 DC SUPPLY, FUEL AND START OUTPUTS ............................................................. 29

4.2.2 ANALOGUE SENSORS .............................................................................................. 30


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4.2.3 MAGNETIC PICKUP, CAN AND EXPANSION ........................................................... 31

4.2.4 LOAD SWITCHING AND GENERATOR VOLTAGE SENSING ................................. 32

4.2.5 MAINS VOLTAGE SENSING ...................................................................................... 32

4.2.6 GENERATOR CURRENT TRANSFORMERS ............................................................ 33

4.2.7 CONFIGURABLE DIGITAL INPUTS ........................................................................... 35

4.2.8 PC CONFIGURATION INTERFACE CONNECTOR .................................................. 35

4.2.9 RS485 CONNECTOR ................................................................................................. 36

4.2.10 RS232 CONNECTOR ................................................................................................. 36

4.3 TYPICAL WIRING DIAGRAMS ......................................................................................... 37

4.3.1 7210 AUTOSTART CONTROLLER ............................................................................ 38

4.3.2 7220 AMF CONTROLLER .......................................................................................... 39

4.3.3 7310 AUTOSTART CONTROLLER ............................................................................ 40

4.3.4 7320 AMF CONTROLLER .......................................................................................... 41

4.3.5 DSENET® ................................................................................................................... 42

4.3.6 CONNECTIONS FOR DUAL MUTUAL STANDBY ..................................................... 43

4.3.7 EARTH SYSTEMS ...................................................................................................... 44

4.3.7.1 NEGATIVE EARTH .............................................................................................................................. 44

4.3.7.2 POSITIVE EARTH ............................................................................................................................... 44

4.3.7.3 FLOATING EARTH .............................................................................................................................. 44

4.4 ALTERNATIVE TOPOLOGIES .......................................................................................... 45

4.4.1 3 PHASE, 4 WIRE WITHOUT EARTH FAULT PROTECTION .................................. 45

4.4.2 SINGLE PHASE WITH RESTRICTED EARTH FAULT .............................................. 46

4.4.3 SINGLE PHASE WITHOUT EARTH FAULT .............................................................. 47

4.4.4 2 PHASE (L1 & L2) 3 WIRE WITH RESTRICTED EARTH FAULT ............................ 48

4.4.5 2 PHASE (L1 & L2) 3 WIRE WITHOUT EARTH FAULT ............................................ 49

4.4.6 2 PHASE (L1 & L3) 3 WIRE WITH RESTRICTED EARTH FAULT ............................ 50

4.4.7 2 PHASE (L1 & L3) 3 WIRE WITHOUT EARTH FAULT MEASURING ..................... 51

4.4.8 3 PHASE 4 WIRE WITH UNRESTRICTED EARTH FAULT MEASURING ............... 52

4.4.9 CT LOCATION ............................................................................................................ 53

4.5 TYPICAL ARRANGEMENT OF DSENET® ....................................................................... 54

5 DESCRIPTION OF CONTROLS .................................................................... 55

5.1 DSE7210 / DSE7310 AUTOSTART CONTROL MODULE ............................................... 55

5.2 DSE7220 / DSE7320 AMF CONTROL MODULE.............................................................. 57

5.3 QUICKSTART GUIDE ........................................................................................................ 59

5.3.1 STARTING THE ENGINE ........................................................................................... 59

5.3.2 STOPPING THE ENGINE ........................................................................................... 59

5.4 VIEWING THE INSTRUMENT PAGES .............................................................................. 60

5.4.1 STATUS ...................................................................................................................... 61

5.4.2 ENGINE ....................................................................................................................... 62

5.4.3 GENERATOR .............................................................................................................. 63

5.4.4 MAINS (DSE7220/DSE7320 ONLY) ........................................................................... 64

5.4.5 SERIAL PORT ............................................................................................................. 64

5.4.6 ABOUT ........................................................................................................................ 68

5.4.7 CAN ERROR MESSAGES .......................................................................................... 69

5.5 VIEWING THE EVENT LOG .............................................................................................. 70

5.6 USER CONFIGURABLE INDICATORS ............................................................................ 71

5.7 CONTROLS ....................................................................................................................... 72

5.7.1.1 TEST (DSE7220/DSE7320 ONLY) ...................................................................................................... 72

5.7.1.2 START ................................................................................................................................................. 72

6 OPERATION (STANDALONE) ...................................................................... 74

6.1 ALTERNATIVE CONFIGURATIONS ................................................................................. 74

6.2 DUMMY LOAD / LOAD SHEDDING CONTROL ............................................................... 75

6.2.1 DUMMY LOAD CONTROL ......................................................................................... 75

6.2.2 LOAD SHEDDING CONTROL .................................................................................... 76

6.3 SMS CONTROL ................................................................................................................. 77

6.4 STOP MODE ...................................................................................................................... 78

6.4.1 ECU OVERRIDE ......................................................................................................... 79

6.5 AUTOMATIC MODE .......................................................................................................... 80

6.5.1 WAITING IN AUTO MODE ......................................................................................... 80

6.5.2 STARTING SEQUENCE ............................................................................................. 80

6.5.3 ENGINE RUNNING ..................................................................................................... 81

6.5.4 STOPPING SEQUENCE ............................................................................................. 81


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6.6 MANUAL MODE ................................................................................................................ 82

6.6.1 WAITING IN MANUAL MODE .................................................................................... 82


6.6.3 ENGINE RUNNING..................................................................................................... 83

6.6.4 MANUAL FUEL PUMP CONTROL ............................................................................. 83

6.6.5 MANUAL SPEED CONTROL ..................................................................................... 83

6.6.6 STOPPING SEQUENCE ............................................................................................ 84

6.7 TEST MODE ...................................................................................................................... 85

6.7.1 WAITING IN TEST MODE .......................................................................................... 85


6.7.3 ENGINE RUNNING..................................................................................................... 86

7 OPERATION (DUAL MUTUAL STANDBY) ................................................... 87

8 PROTECTIONS .............................................................................................. 88

8.1 PROTECTIONS DISABLED .............................................................................................. 89

8.1.1 INDICATION / WARNING ALARMS ........................................................................... 89

8.1.2 SHUTDOWN / ELECTRICAL TRIP ALARMS ............................................................ 89

8.1.3 CAN ALARMS ............................................................................................................. 90

8.2 INDICATIONS .................................................................................................................... 91

8.3 WARNINGS........................................................................................................................ 92

8.4 HIGH CURRENT WARNING ALARM ............................................................................... 93

8.5 SHUTDOWNS .................................................................................................................... 94

8.6 ELECTRICAL TRIPS ......................................................................................................... 96

8.7 HIGH CURRENT SHUTDOWN / ELECTRICAL TRIP ALARM ........................................ 97

8.7.1 IMMEDIATE WARNING.............................................................................................. 97

8.7.2 IDMT ALARM .............................................................................................................. 97

8.8 EARTH FAULT SHUTDOWN / ELECTRICAL TRIP ALARM ......................................... 100

8.9 SHORT CIRCUIT ALARM ............................................................................................... 101

8.10 MAINTENANCE ALARM ............................................................................................. 102

8.11 SCHEDULER ............................................................................................................... 103

8.11.1 STOP MODE............................................................................................................. 103

8.11.2 MANUAL MODE ....................................................................................................... 103

8.11.3 AUTO MODE ............................................................................................................ 103

8.12 FRONT PANEL CONFIGURATION ............................................................................. 104

8.13 ACCESSING THE MAIN FRONT PANEL CONFIGURATION EDITOR ..................... 105

8.13.1 EDITING A PARAMETER ......................................................................................... 106

8.13.2 ADJUSTABLE PARAMETERS ................................................................................. 107

8.14 ACCESSING THE ‘RUNNING’ CONFIGURATION EDITOR ...................................... 109

8.14.1 EDITING A PARAMETER ......................................................................................... 109

8.14.2 ADJUSTABLE PARAMETERS (RUNNING EDITOR) .............................................. 109

9 COMMISSIONING ........................................................................................ 110

9.1.1 PRE-COMMISSIONING............................................................................................ 110

10 FAULT FINDING ....................................................................................... 111

11 MAINTENANCE, SPARES, REPAIR AND SERVICING ........................... 113

11.1 PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE ............................. 113

11.1.1 DSE7200 SERIES ..................................................................................................... 113

11.1.1.1 PACK OF PLUGS .......................................................................................................................... 113

11.1.1.2 INDIVIDUAL PLUGS ...................................................................................................................... 113

11.1.2 DSE7300 SERIES ..................................................................................................... 114

11.1.2.1 PACK OF PLUGS .......................................................................................................................... 114

11.1.2.2 INDIVIDUAL PLUGS ...................................................................................................................... 114

11.2 PURCHASING ADDITIONAL FIXING CLIPS FROM DSE .......................................... 114

11.3 PURCHASING ADDITIONAL SEALING GASKET FROM DSE .................................. 114

11.4 EXPANSION MODULES .............................................................................................. 115

11.5 ETHERNET (LAN) CONNECTION .............................................................................. 116

12 WARRANTY .............................................................................................. 117

13 DISPOSAL................................................................................................. 117

13.1 WEEE (WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT) ........................... 117

13.2 ROHS (RESTRICTION OF HAZARDOUS SUBSTANCES) ........................................ 117


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1 BIBLIOGRAPHY

This document refers to and is referred to by the following DSE publications which can be obtained from the DSE website www.deepseaplc.com

1.1 INSTALLATION INSTRUCTIONS

Installation instructions are supplied with the product in the box and are intended as a ‘quick start’ guide only.

DSE PART DESCRIPTION

053-026 DSE7210 Installation Instructions 053-027 DSE7220 Installation Instructions 053-028 DSE7310 Installation Instructions 053-029 DSE7320 Installation Instructions 053-032 DSE2548 LED Expansion Annunciator Installation Instructions 053-033 DSE2130 Input Expansion Installation Instructions 053-034 DSE2157 Output Expansion Installation Instructions 053-064 DSE2500 Series Display Expansion Installation Instructions

1.2 TRAINING GUIDES Training Guides are produced to give ‘handout’ sheets on specific subjects during training sessions


056-005 Using CTs With DSE Products 056-010 Overcurrent Protection 056-018 Negative Phase Sequence 056-019 Earth Fault Protection 056-020 Loss of Excitation 056-022 Breaker Control 056-024 GSM Modem 056-026 kW & kVAr 056-029 Smoke Limiting 056-030 Module PIN Codes

1.3 MANUALS


057-004 Electronic Engines And DSE Wiring Manual 057-077 DSE7000 Series Configuration Software Manual 057-082 DSE2130 Input Expansion Manual 057-083 DSE2157 Output Expansion Manual 057-084 DSE2548 Annunciator Expansion Manual 057-107 DSE2500 Series Display Operator Manual

1.4 THIRD PARTY DOCUMENTS The following third party documents are also referred to:

REFERENCE DESCRIPTION ISBN 1-55937-879-4 IEEE Std C37.2-1996 IEEE Standard Electrical Power System Device Function

Numbers and Contact Designations. Institute of Electrical and Electronics Engineers Inc ISBN 0-7506-1147-2 Diesel generator handbook. L.L.J.Mahon ISBN 0-9625949-3-8 On-Site Power Generation. EGSA Education Committee.


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2 INTRODUCTION

This document does not contain operating instructions for the DSE7500 series synchronising and load sharing controllers. This is contained within DSE publications - part numbers 057-088 (DSE7510), 057-089 (DSE7520) and 057-090 (DSE7560). This document details the installation and operation requirements of the DSE7200 and DSE7300 Series modules, part of the DSEControl® range of products. The manual forms part of the product and should be kept for the entire life of the product. If the product is passed or supplied to another party, ensure that this document is passed to them for reference purposes. This is not a controlled document. You will not be automatically informed of updates. Any future updates of this document will be included on the DSE website at www.deepseaplc.com

The DSE7000 series is designed to provide differing levels of functionality across a common platform. This allows the generator OEM greater flexibility in the choice of controller to use for a specific application.

The DSE7000 series module has been designed to allow the operator to start and stop the generator, and if required, transfer the load to the generator either manually (via fascia mounted push-buttons) or automatically. Additionally, the DSE7320 automatically starts and stops the generator set depending upon the status of the mains (utility) supply. The user also has the facility to view the system operating parameters via the LCD display.

The DSE7000 module monitors the engine, indicating the operational status and fault conditions, automatically shutting down the engine and giving a true first up fault condition of an engine failure by a COMMON AUDIBLE ALARM. The LCD display indicates the fault.

The powerful ARM microprocessor contained within the module allows for incorporation of a range of complex features:

• Text based LCD display (supporting multiple languages).

• True RMS Voltage, Current and Power monitoring.

• Engine parameter monitoring.

• Fully configurable inputs for use as alarms or a range of different functions.

• Engine ECU interface to electronic engines.

Using a PC and the Configuration Suite software allows alteration of selected operational sequences, timers and alarms.

Additionally, the module’s integral fascia configuration editor allows adjustment of a subset of this information. A robust plastic case designed for front panel mounting houses the module. Connections are via locking plug and sockets.


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3 SPECIFICATIONS

3.1 PART NUMBERING

7210 - 002 - 00 At the time of this document production, there are no variants of this product. This document does not contain operating instructions for the DSE7500 series synchronising and load sharing controllers. This is contained within DSE publications - part numbers 057-088 (DSE7510), 057-089 (DSE7520) and 057-090 (DSE7560).

3.2 MODEL NAMING

72 10

Product type

DSE 7210 Autostart Module

7210

Variant

Standard product

00

Hardware revision

Initial module release 001

DSE 7220 Automatic Mains Failure Module

7220

DSE 7310 Autostart Module

7310

DSE 7320 Automatic Mains Failure Module

7320

Series

DSE 7200 series 72

DSE 7300 series 73

Autostart (remote start) and manual start

10

Function

Autostart, manual start and start upon mains failure (AMF)

20

Changes to module outputs to ease production process

(no functional changes) 002

Changes to circuit for UL approval (no functional changes)

003

Changes to accommodate new LCD display

(no functional changes) 004

005 Changes for UL approved board Current revision for UL

Changes fuel and crank to relays (not for UL )

006


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3.3 SHORT NAMES Short name Description DSE7000 All modules in the DSE7000 Series DSE7x10 All Autostart modules in the DSE7000 Series DSE7x20 All AMF modules in the DSE7000 Series DSE72x0 All modules in the DSE7200 series DSE73x0 All modules in the DSE7300 series

3.4 TERMINAL SPECIFICATION Connection type Two part connector.

• Male part fitted to module

• Female part supplied in module packing case - Screw terminal, rising clamp, no internal spring.

Example showing cable entry and screw terminals of a 10 way connector Minimum cable size 0.5mm² (AWG 24)

Maximum cable size 2.5mm² (AWG 10)

NOTE : NOTE : NOTE : NOTE : For purchasing additional connector plugs from DSE, please see the section entitled For purchasing additional connector plugs from DSE, please see the section entitled For purchasing additional connector plugs from DSE, please see the section entitled For purchasing additional connector plugs from DSE, please see the section entitled Maintenance, Spares, Repair and Maintenance, Spares, Repair and Maintenance, Spares, Repair and Maintenance, Spares, Repair and Servicing Servicing Servicing Servicing elsewhere in this document.elsewhere in this document.elsewhere in this document.elsewhere in this document.

3.5 POWER SUPPLY REQUIREMENTS Minimum supply voltage 8V continuous Cranking dropouts Able to survive 0V for 50mS providing the supply was at least 10V before the

dropout and recovers to 5V afterwards. This is more than sufficient to allow the module to operate during engine cranking where the battery supply often falls as low as 4V (on a 12V system!) This is achieved without the need for internal batteries or other external requirements.

Maximum supply voltage 35V continuous (60V protection for surges) Reverse polarity protection -35V continuous

Maximum operating current DSE7200 / DSE7300 160mA at 24V 340mA at 12V

Maximum standby current DSE7200 / DSE7300 80mA at 24V 160mA at 12V

3.5.1 PLANT SUPPLY INSTRUMENTATION DISPLAY Range 0V-70V DC (note Maximum continuous operating voltage of 35V DC) Resolution 0.1V Accuracy ±1% full scale (±0.7V)


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3.6 GENERATOR AND MAINS VOLTAGE / FREQUENCY SENSING Measurement type True RMS conversion Sample Rate 5KHz or better Harmonics Up to 10

th or better

Input Impedance 300K Ω ph-N Phase to Neutral 15V (minimum required for sensing frequency) to 333V AC (absolute maximum)

Suitable for 110V to 277V nominal (±20% for under/overvoltage detection) Phase to Phase 26V (minimum required for sensing frequency) to 576V AC (absolute maximum)

Suitable for 190V ph-ph to 479V ph-ph nominal (±20% for under/overvoltage detection) Common mode offset from Earth 100V AC (max) Resolution 1V AC phase to neutral

2V AC phase to phase Accuracy ±1% of full scale phase to neutral (±3.33V ph-N)

±2% of full scale phase to phase (±11.52V ph-ph) Minimum frequency 3.5Hz Maximum frequency 75.0Hz Frequency resolution 0.1Hz Frequency accuracy ±0.2Hz

3.7 CURRENT SENSING Measurement type True RMS conversion Sample Rate 5KHz or better Harmonics Up to 10

th or better

Nominal CT secondary rating 1A or 5A (5A recommended) Maximum continuous current 5A Overload Measurement 3 x Nominal Range setting Absolute maximum overload 50A for 1 second Burden 0.5VA (0.02Ω current shunts) common mode offset ±2V peak plant ground to CT common terminal Resolution 0.5% of 5A Accuracy ±1% of Nominal (1A or 5A) (excluding CT error)

3.8 INPUTS

3.8.1 DIGITAL INPUTS

Number DSE7200 6 DSE7300 8

Arrangement Contact between terminal and ground Low level threshold 2.1V minimum High level threshold 6.6V maximum Maximum input voltage +50V DC with respect to plant supply negative Minimum input voltage -24V DC with respect to plant supply negative Contact wetting current 7mA typical Open circuit voltage 12V typical


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3.8.2 ANALOGUE INPUTS

3.8.2.1 OIL PRESSURE

Measurement type Resistance measurement by measuring voltage across sensor with a fixed current applied

Arrangement Differential resistance measurement input Measurement current 15mA Full scale 240Ω Over range / fail 270Ω Resolution 1-2 PSI / 0.1 Bar Accuracy ±2% of full scale resistance (±4.8Ω) excluding transducer error Max common mode voltage ±2V Display range 0-200 PSI / 13.7 bar subject to limits of the sensor

3.8.2.2 COOLANT TEMPERATURE


Arrangement Differential resistance measurement input Measurement current 10mA Full scale 480Ω Over range / fail 540Ω Resolution 1°C, 2°F Accuracy +/-2% of full scale resistance (±9.6Ω) excluding transducer error Max common mode voltage ±2V Display range 0°C -140°C, 32°F - 284°F Depending on sensor


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3.8.2.3 FUEL LEVEL


Arrangement Differential resistance measurement input Measurement current 10mA Full scale 480Ω Over range / fail 540Ω Resolution 1% Accuracy +/-2% of full scale resistance (±9.6Ω) excluding transducer error Max common mode voltage ±2V Display range 0-250%

3.8.2.4 FLEXIBLE SENSOR

NOTE : Flexible sensor is not available on DSE7200 series controllers


Arrangement Differential resistance measurement input Measurement current 10mA Full scale 480Ω Over range / fail 540Ω Resolution 1% Accuracy +/-2% of full scale resistance (±9.6Ω) excluding transducer error Max common mode voltage ±2V Display range 0-250%

3.8.3 CHARGE FAIL INPUT Minimum voltage 0V Maximum voltage 35V (plant supply) Resolution 0.2V Accuracy ± 1% of max measured voltage (±0.35V) Excitation Active circuit constant power output Output Power 2.5W Nominal @12V and 24V Current at 12V 210mA Current at 24V 104mA


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3.8.4 MAGNETIC PICKUP Type Differential input Minimum voltage 0.5V RMS Max common mode voltage ±2V Maximum voltage Clamped to ±70V by transient suppressers, dissipation not to exceed 1W. Maximum frequency 10,000Hz Resolution 6.25 RPM Accuracy ±25 RPM Flywheel teeth 10 to 500

NOTE : DSE can supply a suitable magnetic pickup device, available in two body thread lengths : DSE Part number 020-012 - Magnetic Pickup probe 5/8 UNF 2½” thread length DSE Part number 020-013 - Magnetic Pickup probe 5/8 UNF 4” thread length

Magnetic Pickup devices can often be ‘shared’ between two or more devices. For example, one device can often supply the signal to both the DSE7000 series module and the engine governor. The possibility of this depends upon the amount of current that the magnetic pickup can supply.

3.9 OUTPUTS

3.9.1 OUTPUTS A & B Type Normally used for Fuel / Start outputs. Fully configurable for other purposes if the module is configured to

control an electronic engine. Supplied from Emergency Stop terminal 3. Rating 15A resistive @ 35V

3.9.2 OUTPUTS C & D Type Voltage free relays, fully configurable, normally used for generator / mains load switch control. Rating 8A resistive @ 250 V AC

3.9.3 OUTPUTS E,F,G & H Type Fully configurable, supplied from DC supply terminal 2. Rating 3A resistive @ 35V


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3.10 COMMUNICATION PORTS USB Port USB2.0 Device for connection to PC running DSE configuration suite only

Max distance 6m (20 feet) Serial Communication (not available on DSE7200 series)

RS232 and RS485 are both fitted but do NOT provide independent operation

RS232 Serial port (not available on DSE7200 series)

Non – Isolated port Max Baud rate 115K baud subject to S/W TX, RX, RTS, CTS, DSR, DTR, DCD Male 9 way D type connector Max distance 15m (50 feet)

RS485 Serial port (not available on DSE7200 series)

Isolated Data connection 2 wire + common Half Duplex Data direction control for Transmit (by s/w protocol) Max Baud Rate 19200

External termination required (120Ω) Max common mode offset 70V (on board protection transorb) Max distance 1.2km (¾ mile)

CAN Port Engine CAN Port Standard implementation of ‘Slow mode’, up to 250K bits/s Non-Isolated.

Internal Termination provided (120Ω) Max distance 40m (133 feet)

3.11 COMMUNICATION PORT USAGE

3.11.1 CAN INTERFACE

Modules are fitted with the CAN interface as standard and are capable of receiving engine data from engine CAN controllers compliant with the CAN standard. CAN enabled engine controllers monitor the engine’s operating parameters such as engine speed, oil pressure, engine temperature (among others) in order to closely monitor and control the engine. The industry standard communications interface (CAN)

transports data gathered by the engine controller interface. This allows generator controllers such as the DSE7000 series to access these engine parameters with no physical connection to the sensor device.

NOTE: - For further details for connections to CAN enabled engines and the functions available with each engine type, refer to the manual Electronic Engines and DSE Wiring. Part No. 057-004


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3.11.2 USB CONNECTION The USB port is provided to give a simple means of connection between a PC and the DSE7000 series controller. Using the DSE Configuration Suite Software, the operator is then able to control the module, starting or stopping the generator, selecting operating modes, etc. Additionally, the various operating parameters (such as output volts, oil pressure, etc.) of the remote generator are available to be viewed or changed. To connect a DSE7000 series module to a PC by USB, the following items are required:

• DSE7200 or DSE73000 series module

• DSE 7000 series configuration software (Supplied on configuration suite software CD or available from www.deepseaplc.com).

• USB cable Type A to Type B. (This is the same cable as often used between a PC and a USB printer) DSE can supply this cable if required : PC Configuration interface lead (USB type A – type B) DSE Part No 016-125

NOTE: - The DC supply must be connected to the module for configuration by PC.

NOTE: - Refer to DSE7000 series Configuration Suite Manual for further details on configuring, monitoring and control.


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3.11.3 RS232 The RS232 port on the controller supports the Modbus RTU protocol. The Gencomm register table for the controller is available upon request from the DSE Technical Support Department. RS232 is for short distance communication (max 15m) and is typically used to connect the controller to a telephone or GSM modem for more remote communications. Many PCs are not fitted with an internal RS232 serial port. DSE DOES NOT recommend the use of USB to RS232 convertors but can recommend PC add-ons to provide the computer with an RS232 port. 3.11.3.1 RECOMMENDED PC RS232 SERIAL PORT ADD-ONS Remember to check these parts are suitable for your PC. Consult your PC supplier for further advice.

• Brainboxes PM143 PCMCIA RS232 card (for laptop PCs)

• Brainboxes VX-001 Express Card RS232 (for laptops and nettops PCs)

• Brainboxes UC246 PCI RS232 card (for desktop PCs)

• Brainboxes PX-246 PCI Express 1 Port RS232 1 x 9 Pin (for desktop PCs)

Supplier: Brainboxes Tel: +44 (0)151 220 2500 Web: http://www.brainboxes.com Email: Sales: [email protected] NB DSE Have no business tie to Brainboxes. Over many years, our own engineers have used these products and are happy to recommend them.


17

3.11.3.2 RECOMMENDED EXTERNAL MODEMS:

• Multitech Global Modem – MultiModem ZBA (PSTN) DSE Part Number 020-252 (Contact DSE Sales for details of localisation kits for these modems)

• Sierra Fastrak Xtend GSM modem kit (PSU, Antenna and modem)* DSE Part number 0830-001-01

NOTE: *For GSM modems a SIM card is required, supplied by your GSM network provider :

• For SMS only, a ‘normal’ voice SIM card is required. This enables the controller to send SMS messages to designated mobile phones upon status and alarm conditions.

• For a data connection to a PC running DSE Configuration Suite Software, a ‘special’ CSD (Circuit Switched Data) SIM card is required that will enable the modem to answer an incoming data call. Many ‘pay as you go’ services will not provide a CSD (Circuit Switched Data) SIM card.


18

3.11.4 RS485 The RS485 port on the series controller supports the Modbus RTU protocol. The DSE Gencomm register table for the controller is available upon request from the DSE Technical Support Department. RS485 is used for point-to-point cable connection of more than one device (maximum 32 devices) and allows for connection to PCs, PLCs and Building Management Systems (to name just a few devices). One advantage of the RS485 interface is the large distance specification (1.2km when using Belden 9841 (or equivalent) cable. This allows for a large distance between the module and a PC running the DSE Configuration Suite software. The operator is then able to control the module, starting or stopping the generator, selecting operating modes, etc. The various operating parameters (such as output volts, oil pressure, etc.) of the remote generator can be viewed or changed.

NOTE:- For a single module to PC connection and distances up to 6m (8yds) the USB connection method is more suitable and provides for a lower cost alternative to RS485 (which is more suited to longer distance connections).

3.11.4.1 RECOMMENDED PC RS485 SERIAL PORT ADD-ONS Remember to check these parts are suitable for your PC. Consult your PC supplier for further advice.

• Brainboxes PM154 PCMCIA RS485 card (for laptops PCs) Set to ‘Half Duplex, Autogating” with ‘CTS True’ set to ‘enabled’

• Brainboxes VX-023 ExpressCard 1 Port RS422/485 (for laptops and nettop PCs)

• Brainboxes UC320 PCI Velocity RS485 card (for desktop PCs) Set to ‘Half Duplex, Autogating” with ‘CTS True’ set to ‘enabled’

• Brainboxes PX-324 PCI Express 1 Port RS422/485 (for desktop PCs)

Supplier: Brainboxes Tel: +44 (0)151 220 2500 Web: http://www.brainboxes.com Email: Sales: [email protected] NB DSE have no business tie to Brainboxes. Over many years,our own engineers have used these products and are happy to recommend them.


19

3.12 DSENET® FOR EXPANSION MODULES DSENet® is the interconnection cable between the host controller and the expansion module(s) and must not be connect to any device other than DSE equipment designed for connection to the DSENet®

NOTE: DSENet® is not available on DSE7200 series controllers.

Cable type Two core screened twisted pair Cable characteristic impedance 120Ω Recommended cable Belden 9841

Belden 9271 Maximum cable length 1200m (¾ mile) when using Belden 9841 or direct equivalent.

600m (666 yds) when using Belden 9271 or direct equivalent. DSENet® topology “Daisy Chain” Bus with no stubs (spurs) DSENet® termination 120Ω. Fitted internally to host controller. Must be fitted externally to the ‘last’

expansion module by the customer. Maximum expansion modules Refer to host controller documentation.

NOTE : As a termination resistor is internally fitted to the host controller, the host controller must be the ‘first’ unit on the DSENet®. A termination resistor MUST be fitted to the ‘last’ unit on the DSENet®. For connection details, you are referred to the section entitled ‘typical wiring diagram’ elsewhere in this document.

3.12.1 DSENET® USED FOR MODBUS ENGINE CONNECTION

As DSENet® utilises an RS485 hardware interface, this port can be configured for connection to Cummins Modbus engines (Engines fitted with Cummins GCM (Generator Control Module)). This leaves the RS485 interface free for connection to remote monitoring equipment (i.e. Building Management System, PLC or PC RS485 port). While this is a very useful feature in some applications, the obvious drawback is that the DSENet® interface is no longer available for connection to expansion devices. Example of configuring the DSENet® for connection to Cummins QST GMC using the DSE Configuration Suite Software:


20

3.13 SOUNDER DSE7000 Series features an internal sounder to draw attention to warning, shutdown and electrical trip alarms. Sounder level 64db @ 1m

3.13.1 ADDING AN EXTERNAL SOUNDER TO THE APPLICATION Should an external alarm or indicator be required, this can be achieved by using the DSE Configuration Suite PC software to configure an auxiliary output for “Audible Alarm”, and by configuring an auxiliary input for “Alarm Mute” (if required). The audible alarm output activates and de-activates at the same time as the module’s internal sounder. The Alarm mute input and internal alarm mute button activate ‘in parallel’ with each other. Either signal will mute both the internal sounder and audible alarm output. Example of configuration to achieve external sounder with external alarm mute button:

3.14 ACCUMULATED INSTRUMENTATION

NOTE: When an accumulated instrumentation value exceeds the maximum number as listed below, it will reset and begin counting from zero again.

Engine hours run Maximum 99999 hrs 59 minutes (approximately 11yrs 4months) Number of starts 1,000,000 (1 million) The number of logged Engine Hours and Number of Starts can be set/reset using the DSE Configuration Suite PC software. Depending upon module configuration, this may have been PIN number locked by your generator supplier .


21

3.15 DIMENSIONS AND MOUNTING DIMENSIONS 240.0mm x 181.1mm x 41.7mm (9.4” x 7.1” x 1.6”)

PANEL CUTOUT 220mm x 160mm (8.7” x 6.3”)

WEIGHT 0.7kg (1.4lb)


22

3.15.1 FIXING CLIPS Supplied fixing clips hold the module into the panel fascia. Withdraw the fixing clip screw (turn anticlockwise) until only the pointed end is protruding from the clip.

• Insert the three ‘prongs’ of the fixing clip into the slots in the side of the 7000 series module case.

• Pull the fixing clip backwards (towards the back of the module) ensuring all three prongs of the clip are inside their allotted slots.

• Turn the fixing clip screws clockwise until they make contact with the panel fascia.

• Turn the screws a little more to secure the module into the panel fascia. Take care not to over tighten the fixing clip screws.

NOTE:- In conditions of excessive vibration, mount the module on suitable anti-vibration mountings.

Fixing clip fitted to module

Fixing clip


23

3.15.2 CABLE TIE FIXING POINTS Integral cable tie fixing points are included on the rear of the module’s case to aid wiring. This additionally provides strain relief to the cable loom by removing the weight of the loom from the screw connectors, thus reducing the chance of future connection failures. Care should be taken not to overtighten the cable tie (for instance with cable tie tools) to prevent the risk of damage to the module case.

Cable tie fixing point With cable and tie in place

3.15.3 SILICON SEALING GASKET The supplied silicon gasket provides improved sealing between the 7000 series module and the panel fascia. The gasket is fitted to the module before installation into the panel fascia. Take care to ensure the gasket is correctly fitted to the module to maintain the integrity of the seal.

Gasket fitted to module

Sealing gasket


24

3.16 APPLICABLE STANDARDS

BS 4884-1 This document conforms to BS4884-1 1992 Specification for presentation of essential information.

BS 4884-2 This document conforms to BS4884-2 1993 Guide to content

BS 4884-3 This document conforms to BS4884-3 1993 Guide to presentation

BS EN 60068-2-1 (Minimum temperature)

-30°C (-22°F)

BS EN 60068-2-2 (Maximum temperature)

+70°C (158°F)

BS EN 60950 Safety of information technology equipment, including electrical business equipment

BS EN 61000-6-2 EMC Generic Immunity Standard (Industrial)

BS EN 61000-6-4 EMC Generic Emission Standard (Industrial)

BS EN 60529 (Degrees of protection provided by enclosures) (see overleaf)

IP65 (front of module when installed into the control panel with the supplied sealing gasket) IP42 (front of module when installed into the control panel WITHOUT being sealed to the panel)

UL508 NEMA rating (Approximate) (see overleaf)

12 (Front of module when installed into the control panel with the supplied sealing gasket). 2 (Front of module when installed into the control panel WITHOUT being sealed to the panel)

IEEE C37.2 (Standard Electrical Power System Device Function Numbers and Contact Designations)

Under the scope of IEEE 37.2, function numbers can also be used to represent functions in microprocessor devices and software programs. The controller is device number 11L-8000 (Multifunction device protecting Line (generator) –module). As the module is configurable by the generator OEM, the functions covered by the module will vary. Under the module’s factory configuration, the device numbers included within the module are : 2 – Time delay starting or closing relay 3 – Checking or interlocking relay 5 – Stopping Device 6 – Starting circuit breaker 8 – Control power disconnecting device 10 – Unit sequence switch 11 – Multifunction device 12 – Overspeed device 14 – Underspeed device 23 – Temperature control device 26 – Apparatus thermal device 27AC – AC undervoltage relay 27DC – DC undervoltage relay 29 – Isolating contactor or switch 30 – Annunciator relay 31 – Separate Excitation Device 37 – Undercurrent or underpower relay (USING INTERNAL PLC EDITOR) 41 – Field circuit breaker 42 – Running circuit breaker 44 – Unit sequence relay 46 – Reverse-phase or phase-balance current relay 48 – Incomplete sequence relay 49 – Machine or transformer thermal relay

Continued overleaf.


25

IEEE C37.2 (Standard Electrical Power System Device Function Numbers and Contact Designations)

Continued… 50 – Instantaneous overcurrent relay 51 – AC time overcurrent relay 52 – AC circuit breaker 53 – Exciter or DC generator relay 54 – Turning gear engaging device 55 – Power factor relay (USING INTERNAL PLC EDITOR) 59AC – AC overvoltage relay 59DC – DC overvoltage relay 62 – Time delay stopping or opening relay 63 – Pressure switch 71 – Level switch 74 – Alarm relay 78 – Phase-angle measuring relay 79 – Reclosing relay (USING INTERNAL PLC EDITOR) 81 – Frequency relay 83 – Automatic selective control or transfer relay 86 – Lockout relay

In line with our policy of continual development, Deep Sea Electronics, reserve the right to change specification without notice.


26

3.16.1 ENCLOSURE CLASSIFICATIONS

IP CLASSIFICATIONS

7000 series specification under BS EN 60529 Degrees of protection provided by enclosures

IP65 (Front of module when module is installed into the control panel with the optional sealing gasket).

IP42 (front of module when module is installed into the control panel WITHOUT being sealed to the panel)

First Digit Second Digit

Protection against contact and ingress of solid objects Protection against ingress of water

0 No protection 0 No protection

1 Protected against ingress solid objects with a diameter of more than 50 mm. No protection against deliberate access, e.g. with a hand, but large surfaces of the body are prevented from approach.

1 Protection against dripping water falling vertically. No harmful effect must be produced (vertically falling drops).

2 Protected against penetration by solid objects with a diameter of more than 12 mm. Fingers or similar objects prevented from approach.

2 Protection against dripping water falling vertically. There must be no harmful effect when the equipment (enclosure) is tilted at an angle up to 15° from its normal position (drops falling at an angle).

3 Protected against ingress of solid objects with a diameter of more than 2.5 mm. Tools, wires etc. with a thickness of more than 2.5 mm are prevented from approach.

3 Protection against water falling at any angle up to 60° from the vertical. There must be no harmful effect (spray water).

4 Protected against ingress of solid objects with a diameter of more than 1 mm. Tools, wires etc. with a thickness of more than 1 mm are prevented from approach.

4 Protection against water splashed against the equipment (enclosure) from any direction. There must be no harmful effect (splashing water).

5 Protected against harmful dust deposits. Ingress of dust is not totally prevented but the dust must not enter in sufficient quantity to interface with satisfactory operation of the equipment. Complete protection against contact.

5 Protection against water projected from a nozzle against the equipment (enclosure) from any direction. There must be no harmful effect (water jet).

6 Protection against ingress of dust (dust tight). Complete protection against contact.

6 Protection against heavy seas or powerful water jets. Water must not enter the equipment (enclosure) in harmful quantities (splashing over).


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3.16.2 NEMA CLASSIFICATIONS 7000 series NEMA Rating (Approximate)

12 (Front of module when module is installed into the control panel with the optional sealing gasket).

2 (front of module when module is installed into the control panel WITHOUT being sealed to the panel)

NOTE: - There is no direct equivalence between IP / NEMA ratings. IP figures shown are approximate only.

1

IP30

Provides a degree of protection against contact with the enclosure equipment and against a limited amount of falling dirt.

2

IP31

Provides a degree of protection against limited amounts of falling water and dirt.

3

IP64

Provides a degree of protection against windblown dust, rain and sleet; undamaged by the formation of ice on the enclosure.

3R

IP32

Provides a degree of protection against rain and sleet:; undamaged by the formation of ice on the enclosure.

4 (X)

IP66

Provides a degree of protection against splashing water, windblown dust and rain, hose directed water; undamaged by the formation of ice on the enclosure. (Resist corrosion).

12/12K

IP65

Provides a degree of protection against dust, falling dirt and dripping non corrosive liquids.

13

IP65

Provides a degree of protection against dust and spraying of water, oil and non corrosive coolants.


28

4 INSTALLATION The DSE7000 Series module is designed to be mounted on the panel fascia. For dimension and mounting details, see the section entitled Specification, Dimension and mounting elsewhere in this document.

4.1 USER CONNECTIONS

To aid user connection, icons on the rear of the module ease Identification of terminal functions.

NOTE : Availability of some terminals depends upon module version. The section entitled Terminal Description elsewhere in this manual details this further.

RS485 connection

RS232 connection

Terminals 1-11 Terminals 15-19 Terminals 22-30

Terminals 39-46 Terminals 47-50 Terminals 51-55 Terminals 60-67

USB Connection


29

4.2 TERMINAL DESCRIPTION

4.2.1 DC SUPPLY, FUEL AND START OUTPUTS

Icon PIN No

DESCRIPTION CABLE SIZE

NOTES

1 DC Plant Supply Input (Negative)

2.5mm² AWG 13

2 DC Plant Supply Input (Positive)

2.5 mm² AWG 13

(Recommended Maximum Fuse 15A anti-surge) Supplies the module (2A anti-surge requirement) and Output relays E,F,G & H

3 Emergency Stop Input

2.5mm² AWG 13

Plant Supply Positive. Also supplies outputs 1 & 2. (Recommended Maximum Fuse 20A)

4 Output relay A (FUEL) 2.5mm² AWG 13

Plant Supply Positive from terminal 3. 15 Amp rated. Fixed as FUEL relay if electronic engine is not configured.

5 Output relay B (START) 2.5mm² AWG 13

Plant Supply Positive from terminal 3. 15 Amp rated. Fixed as START relay if electronic engine is not configured.

6 Charge fail / excite

2.5mm² AWG 13

Do not connect to ground (battery negative). If charge alternator is not fitted, leave this terminal disconnected.

7 Functional Earth

2.5mm² AWG 13

Connect to a good clean earth point.

8 Output relay E 1.0mm² AWG 18

Plant Supply Positive from terminal 2. 3 Amp rated.

9 Output relay F 1.0mm² AWG 18


10 Output relay G 1.0mm² AWG 18

Plant Supply Positive. from terminal 2. 3 Amp rated.

11 Output relay H 1.0mm² AWG 18


NOTE:- Terminals 12 to 14 are not fitted to the DSE7200/DSE7300 series controller.

NOTE:- When the module is configured for operation with an electronic engine, FUEL and START output requirements may be different. Refer to Electronic Engines and DSE Wiring for further information. DSE Part No. 057-004.


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4.2.2 ANALOGUE SENSORS

PIN No


NOTES

15 Sensor Common Return 0.5mm² AWG 20

Return feed for sensors

16 Oil Pressure Input 0.5mm² AWG 20

Connect to Oil pressure sensor

17 Coolant Temperature Input 0.5mm² AWG 20

Connect to Coolant Temperature sensor

18 Fuel Level input 0.5mm² AWG 20

Connect to Fuel Level sensor

19 Flexible sensor (not available on 7200 series controller)

0.5mm² AWG 20

Connect to additional sensor (user configurable)

NOTE:- Terminals 20 and 21 are not fitted to the 7200/7300 series controller.

NOTE:- . It is VERY important that terminal 15 (sensor common) is soundly connected to an earth point on the ENGINE BLOCK, not within the control panel, and must be a sound electrical connection to the sensor bodies. This connection MUST NOT be used to provide an earth connection for other terminals or devices. The simplest way to achieve this is to run a SEPERATE earth connection from the system earth star point, to terminal 15 directly, and not use this earth for other connections.

NOTE:- . If you use PTFE insulating tape on the sensor thread when using earth return sensors, ensure you do not insulate the entire thread, as this will prevent the sensor body from being earthed via the engine block.


31

4.2.3 MAGNETIC PICKUP, CAN AND EXPANSION

PIN No


NOTES

22 Magnetic pickup Positive 0.5mm² AWG 20

Connect to Magnetic Pickup device

23 Magnetic pickup Negative 0.5mm² AWG 20


24 Magnetic pickup screen Shield Connect to ground at one end only

25 CAN port H 0.5mm² AWG 20

Use only 120Ω CAN approved cable

26 CAN port L 0.5mm² AWG 20


27 CAN port Common 0.5mm² AWG 20


28 + 0.5mm² AWG 20

Use only 120Ω RS485 approved cable

29 - 0.5mm² AWG 20


30 SCR 0.5mm² AWG 20


NOTE:- Terminals 31 to 38 are not fitted to the 7200 / 7300 controller

NOTE:- Screened cable must be used for connecting the Magnetic Pickup, ensuring that the screen is earthed at one end ONLY.

NOTE:- Screened 120ΩΩΩΩ impedance cable specified for use with CAN must be used for the CAN link and the Multiset comms link.

DSE stock and supply Belden cable 9841 which is a high quality 120ΩΩΩΩ impedance cable suitable for CAN use (DSE part number 016-030)

NOTE:- When the module is configured for CAN operation, terminals 22, 23 & 24 should be left unconnected. Engine speed is transmitted to the 7000 series controller on the CAN link. Refer to Electronic Engines and DSE Wiring for further information. Part No. 057-004.


32

4.2.4 LOAD SWITCHING AND GENERATOR VOLTAGE SENSING

PIN No


NOTES

39 Output relay C 1.0mm

AWG 18 Normally configured to control mains contactor coil (Recommend 10A fuse)

40 Output relay C 1.0mm

AWG 18 Normally configured to control mains contactor coil

41 Output relay D 1.0mm

AWG 18 Normally configured to control generator contactor coil (Recommend 10A fuse)

42 Output relay D 1.0mm

AWG 18 Normally configured to control generator contactor coil

43 Generator L1 (U) voltage monitoring

1.0mm² AWG 18

Connect to generator L1 (U) output (AC) (Recommend 2A fuse)

44 Generator L2 (V) voltage monitoring input

1.0mm² AWG 18

Connect to generator L2 (V) output (AC) (Recommend 2A fuse)

45 Generator L3 (W) voltage monitoring input

1.0mm² AWG 18

Connect to generator L3 (W) output (AC) (Recommend 2A fuse)

46 Generator Neutral (N) input 1.0mm² AWG 18

Connect to generator Neutral terminal (AC)

NOTE:- The above table describes connections to a three phase, four wire alternator. For alternative wiring topologies, please see the ALTERNATIVE AC TOPOLOGIES section of this manual.

4.2.5 MAINS VOLTAGE SENSING

PIN No


NOTES

47 Mains L1 (R) voltage monitoring 1.0mm

AWG 18 Connect to Mains L1 (R) incoming supply (AC) (Recommend 2A fuse)

48 Mains L2 (S) voltage monitoring 1.0mm

AWG 18 Connect to Mains L1 (S) incoming supply (AC) (Recommend 2A fuse)

49 Mains L3 (T) voltage monitoring 1.0mm

AWG 18 Connect to Mains L1 (T) incoming supply (AC) (Recommend 2A fuse)

50 Mains Neutral (N) input 1.0mm

AWG 18 Connect to Mains N incoming supply (AC)

NOTE:- Terminals 47-50 are not fitted to the 7210 / 7310 controller.


33

4.2.6 GENERATOR CURRENT TRANSFORMERS

WARNING!:- Do not disconnect this plug when the CTs are carrying current. Disconnection will open circuit the secondary of the C.T.’s and dangerous voltages may then develop. Always ensure the CTs are not carrying current and the CTs are short circuit connected before making or breaking connections to the module.

NOTE:- The 7000 series module has a burden of 0.5VA on the CT. Ensure the CT is rated for the burden of the 7000 series controller, the cable length being used and any other equipment sharing the CT. If in doubt, consult your CT supplier.

NOTE:- Take care to ensure correct polarity of the CT primary as shown below. If in doubt, check with the CT supplier.

CT LABELLING

p1, k or K is the primary of the CT that ‘points’ towards the GENERATOR

p2, l or L is the primary of the CT that ‘points’ towards the LOAD

s1 is the secondary of the CT that connects to the DSE Module’s input for the CT measuring (I1,I2,I3)

s2 is the secondary of the CT that should be commoned with the s2 connections of all the other CTs and connected to the CT common terminal of the DSE7000 series modules.

CT labelled as

p1, k or K

CT labelled as

p2, l or L

To Supply

To Load


34

Connection of CT s1 terminal

PIN No


NOTES

51 CT Secondary for Gen L1 2.5mm² AWG 13

Connect to s1 secondary of L1 monitoring CT





Connection to terminals 54 & 55 (DSE7200 SERIES)

Pin No

Description CABLE SIZE

54 DO NOT CONNECT

55 Common for CTs connected to L1,L2,L3 (s2) 2.5mm² AWG 13

NOTE:- Terminals 56 to 59 are not fitted to the 7200 / 7300 series controller.

NOTE:- Take care to ensure correct polarity of the CT primary as shown overleaf. If in doubt, check with the CT supplier.

Connection to terminals 54 & 55 (DSE7300 SERIES) The function of terminals 54 and 55 CHANGES depending upon what kind of earth fault protection (if any) is being used:

Topology Pin No

Description CABLE SIZE

No earth fault measuring

54 DO NOT CONNECT

55 Connect to s2 of the CTs connected to L1,L2,L3,N

2.5mm² AWG 13

Restricted earth fault measuring

54 Connect to s2 of the CTs connected to L1,L2,L3,N

2.5mm² AWG 13

55 Connect to s1 of the CT on the neutral conductor

2.5mm² AWG 13

Un-restricted earth fault measuring (Earth fault CT is fitted in the neutral to earth link)

54 Connect to s1 of the CT on the neutral to earth conductor.

55

Connect to s2 of the CT on the neutral to earth link. Also connect to the s2 of CTs connected to L1, L2, L3.

2.5mm² AWG 13

NOTE:- Terminals 56 to 59 are not fitted to the 7200 / 7300 series controller.


35

4.2.7 CONFIGURABLE DIGITAL INPUTS

PIN No


NOTES

60 Configurable digital input A 0.5mm² AWG 20

Switch to negative

61 Configurable digital input B 0.5mm² AWG 20

Switch to negative

62 Configurable digital input C 0.5mm² AWG 20

Switch to negative

63 Configurable digital input D 0.5mm² AWG 20

Switch to negative

64 Configurable digital input E 0.5mm² AWG 20

Switch to negative

65 Configurable digital input F 0.5mm² AWG 20

Switch to negative

66 Configurable digital input G (not available on 7200 series)

0.5mm² AWG 20

Switch to negative

67 Configurable digital input H (not available on 7200 series)

0.5mm² AWG 20

Switch to negative

NOTE:- Terminals 66 to 69 are not fitted to the 7200 series controller.

NOTE:- Terminals 68 and 69 are not fitted to the 7300 series controller.

4.2.8 PC CONFIGURATION INTERFACE CONNECTOR


NOTES

Socket for connection to PC with 7xxx series PC software.

0.5mm² AWG 20

This is a standard USB type A to type B connector.

NOTE:- The USB connection cable between the PC and the 7000 series module must not be extended beyond 5m (5yds). For distances over 5m, it is possible to use a third party USB extender. Typically, they extend USB up to 50m (yds). The supply and support of this type of equipment is outside the scope of Deep Sea Electronics PLC.

CAUTION!: Care must be taken not to overload the PCs USB system by connecting more than the recommended number of USB devices to the PC. For further information, consult your PC supplier.

CAUTION!: This socket must not be used for any other purpose.

This configuration cable is the same as normally used between a PC and a USB printer!


36

4.2.9 RS485 CONNECTOR

NOTE:- RS485 connector is not fitted to the 7200 series controller.

PIN No NOTES

A Two core screened twisted pair cable.

120Ω impedance suitable for RS485 use. Recommended cable type - Belden 9841 Max distance 1000m (1km) when using Belden 9841 or direct equivalent.

B

SCR

4.2.10 RS232 CONNECTOR


PIN No NOTES

1 Received Line Signal Detector (Data Carrier Detect)

2 Received Data

3 Transmit Data

4 Data Terminal Ready

5 Signal Ground

6 Data Set Ready

7 Request To Send

8 Clear To Send

9 Ring Indicator

View looking into the male connector on the 7000 series module

Location of RS232 connector

Location of RS485 connector


37

4.3 TYPICAL WIRING DIAGRAMS As every system has different requirements, these diagrams show only a TYPICAL system and do not intend to show a complete system. Genset manufacturers and panel builders may use these diagrams as a starting point, however you are referred to the completed system diagram provided by your system manufacturer for complete wiring detail. Further wiring suggestions are available in the following DSE publications, available at www.deepseaplc.com to website members.


056-022 Breaker Control (Training guide) 057-004 Electronic Engines and DSE Wiring


38

4.3.1 7210 AUTOSTART CONTROLLER 3 phase, 4 wire


39

4.3.2 7220 AMF CONTROLLER 3 phase, 4 wire


40

4.3.3 7310 AUTOSTART CONTROLLER 3 phase, 4 wire with restricted earth fault protection

NOTE:- Earthing the neutral conductor ‘before’ the neutral CT allows the module to read earth faults ‘after’ the CT only (Restricted to load / downstream of the CT) Earthing the neutral conductor ‘after’ the neutral CT allows the module to read earth faults ‘before’ the CT only (Restricted to generator / upstream of the CT)


41

4.3.4 7320 AMF CONTROLLER 3 phase, 4 wire with restricted earth fault protection



42

4.3.5 DSENET®

NOTE: NOTE: NOTE: NOTE: ---- This feature is only available on DSE7300 Series modulesThis feature is only available on DSE7300 Series modulesThis feature is only available on DSE7300 Series modulesThis feature is only available on DSE7300 Series modules

DSENet® is the communication port between the host controller (DSE7300 series) and the expansion device as shown below. Further details are contained within the Specification section of this documents and within the operator manual for the specific expansion module you are connecting to.

NOTE: NOTE: NOTE: NOTE: ---- This feature is This feature is This feature is This feature is notnotnotnot availableavailableavailableavailable if the if the if the if the DSE7300 Series moduleDSE7300 Series moduleDSE7300 Series moduleDSE7300 Series module has been configured to use the DSENethas been configured to use the DSENethas been configured to use the DSENethas been configured to use the DSENet® port as the port as the port as the port as the

interface to Cummins Modbus Engine GCM.interface to Cummins Modbus Engine GCM.interface to Cummins Modbus Engine GCM.interface to Cummins Modbus Engine GCM.

NOTE:- Screened 120ΩΩΩΩ impedance cable specified for use with CAN must be used for the DSENet® (RS485) connection.

DSE stock and supply Belden cable 9841 which is a high quality 120ΩΩΩΩ impedance cable suitable for DSENet® use (DSE part number 016-030)


43

4.3.6 CONNECTIONS FOR DUAL MUTUAL STANDBY

DUAL MUTUAL STANDBY

NOTE: NOTE: NOTE: NOTE: ---- This feature is available only on DSE7000 Series modules, V2.0.0 anThis feature is available only on DSE7000 Series modules, V2.0.0 anThis feature is available only on DSE7000 Series modules, V2.0.0 anThis feature is available only on DSE7000 Series modules, V2.0.0 and above.d above.d above.d above.

The output controls are failsafe. In the event of a module being out of service (battery removed) the output de-energises, giving the ok to run signal to the other set.

Screen capture from DSE Configuration Suite PC Software showing the configuration of the Master and Slave controllers.

In case of set 1 failure, the output activates and energises the external relay RLY1 to call for the second set to start.

RLY1 contact closes a battery negative signal onto the input, instructing the set to start.


44

4.3.7 EARTH SYSTEMS

4.3.7.1 NEGATIVE EARTH The typical wiring diagrams located within this document are designed and show connections for a negative earth system (the battery negative is connected to Earth)

4.3.7.2 POSITIVE EARTH When using a DSE module with a Positive Earth System (the battery positive is connected to Earth), the following points need to be followed :

• Follow the typical wiring diagram as normal for all sections EXCEPT the earthing points

• All points shown as Earth on the typical wiring diagram should connect to BATTERY NEGATIVE (not earth).

4.3.7.3 FLOATING EARTH Where neither the battery positive nor battery negative terminals are connected to earth the following points need to be followed

• Follow the typical wiring diagram as normal for all sections EXCEPT the earthing points

• All points shown as Earth on the typical wiring diagram should connect to BATTERY NEGATIVE (not earth).


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4.4 ALTERNATIVE TOPOLOGIES The 7000 controller is factory configured to connect to a 3 phase, 4 wire Star connected alternator. This section details connections for alternative AC topologies. Ensure to configure the 7000 series controller to suit the required topology.

NOTE:- Further details of module configuration are contained within the DSE7000 Series configuration software manual (DSE part number 057-077)

4.4.1 3 PHASE, 4 WIRE WITHOUT EARTH FAULT PROTECTION

NOTE:- Mains sensing (Terminals 47-50) is not fitted to DSE7210/ DSE7310 autostart controllers.


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4.4.2 SINGLE PHASE WITH RESTRICTED EARTH FAULT

NOTE:- Earth fault measuring not available on 7200 series controllers.

NOTE:- Earth fault protection alarm only available on 7300 series V2.0 and above controllers. 7300 series V1.x.x modules have Earth fault measuring only (no protection alarms).




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4.4.3 SINGLE PHASE WITHOUT EARTH FAULT



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4.4.4 2 PHASE (L1 & L2) 3 WIRE WITH RESTRICTED EARTH FAULT





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4.4.5 2 PHASE (L1 & L2) 3 WIRE WITHOUT EARTH FAULT



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4.4.6 2 PHASE (L1 & L3) 3 WIRE WITH RESTRICTED EARTH FAULT





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4.4.7 2 PHASE (L1 & L3) 3 WIRE WITHOUT EARTH FAULT MEASURING



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4.4.8 3 PHASE 4 WIRE WITH UNRESTRICTED EARTH FAULT MEASURING




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4.4.9 CT LOCATION

NOTE:- CT Location is not applicable to the DSE7210 / DSE7310 autostart controllers.

There are two possible locations for the current transformers in the system:

1) Generator : The CTs are used to measure and display generator current only. The typical wiring diagrams in the preceding section all show the CT measuring the generator load. For clarity, an example is shown below.

2) Load : The CTs are used to measure and display generator current when the generator is on load and mains current when the mains is on load. The module display automatically changes to display the current in the relevant instrumentation page. This example shows the CTs in the ‘load’ for a three phase delta system but the same philosophy is applicable to the other topologies.


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4.5 TYPICAL ARRANGEMENT OF DSENET® A total of twenty (20) devices can be connected to the DSENet®, made up of the following devices :

Device Max number supported DSE2130 Input Expansion 4 DSE2157 Output Expansion 10 DSE2548 LED Expansion 10 DSE2510 Display for DSE7310 3 DSE2520 Display for DSE7320 3


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5 DESCRIPTION OF CONTROLS The following section details the function and meaning of the various controls on the module.

5.1 DSE7210 / DSE7310 AUTOSTART CONTROL MODULE

Menu navigation buttons

Four configurable LEDs

Select Stop mode

Select Manual mode

Select Auto mode

Mute alarm / Lamp test

Start engine (when in manual mode)

Close generator (manual mode only)

Open generator (manual mode only)

Main status and instrumentation display


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NOTE:- “Generator on load” LED has two modes of operation depending upon the configuration of the controllers digital inputs. 1) Digital input configured for “Generator closed auxiliary” – The LED illuminates when the generator

closed auxiliary input is active – The LED shows the state of the auxiliary contact. 2) There is NO input configured for “Generator closed auxiliary” (factory default setting) – The LED

illuminates when the 7x20 gives the loading signal to the generator – The LED shows the state of the 7x20’s loading request.

Close Generator LED. On When The Generator Is Required To Be On Load.

Generator Available LED. On when the generator is within limits and able to take load.


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5.2 DSE7220 / DSE7320 AMF CONTROL MODULE

Continued overleaf….

Menu navigation buttons

Four configurable LEDs

Select Stop mode

Select Manual mode

Select Auto mode

Mute alarm / Lamp test

Start engine (when in manual mode)

Transfer to generator (manual mode only)

Transfer to mains (manual mode only)

Main status and instrumentation display

Select Test on load mode


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NOTE:- “Generator on load” LED has two modes of operation depending upon the configuration of the controllers digital inputs. 3) Digital input configured for “Generator closed auxiliary” – The LED illuminates when the generator

closed auxiliary input is active – The LED shows the state of the auxiliary contact. 4) There is NO input configured for “Generator closed auxiliary” (factory default setting) – The LED

illuminates when the 7x20 gives the loading signal to the generator – The LED shows the state of the 7x20’s loading request.

NOTE:- “Mains on load” LED has two modes of operation depending upon the configuration of the controllers digital inputs. 5) Digital input configured for “Mains closed auxiliary” – The LED illuminates when the mains closed

auxiliary input is active – The LED shows the state of the auxiliary contact. 6) There is NO input configured for “Mains closed auxiliary” (factory default setting) – The LED illuminates

when the 7x20 gives the loading signal to the mains – The LED shows the state of the 7x20’s loading request.

Close Generator LED. On When The Generator Is Required To Be On Load.

Generator Available LED. On when the generator is within limits and able to take load.

Mains Available LED. On when the mains is within limits and able to take load.

Close Mains LED. On When The Generator Is Required To Be On Load.


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5.3 QUICKSTART GUIDE This section provides a quick start guide to the module’s operation.

5.3.1 STARTING THE ENGINE

NOTE:- For further details, see the section entitled ‘OPERATION’ elsewhere in this manual.

5.3.2 STOPPING THE ENGINE

NOTE:- For further details, see the section entitled ‘OPERATION’ elsewhere in this manual.

First, select manual mode…

…then press the Start button to crank the engine.

Select Stop/Reset mode. The generator is stopped.


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5.4 VIEWING THE INSTRUMENT PAGES It is possible to scroll to display the different pages of information by repeatedly operating the next / previous page

buttons .

ExampleExampleExampleExample

Status

Engine

Generator

And so on until the last page is reached. A Further press of the scroll right button, returns the display to the Status page.

The complete order and contents of each information page are given in the following sections

Once selected the page will remain on the LCD display until the user selects a different page, or after an extended period of inactivity (LCD Page Timer), the module will revert to the status display. If no buttons are pressed upon entering an instrumentation page, the instruments will be displayed automatically subject to the setting of the LCD Scroll Timer. The LCD Page and LCD Scroll timers are configurable using the DSE Configuration Suite Software or by using the Front Panel Editor.

The screenshot shows the factory settings for the timers, taken from the DSE Configuration Suite Software.

Alternatively, to scroll manually through all instruments on the currently selected page, press the scroll buttons. The ‘autoscroll’ is disabled.

To re-enable ‘autoscroll’ press the scroll buttons to scroll to the ‘title’ of the instrumentation page (ie Engine). A short time later (the duration of the LCD Scroll Timer) the instrumentation display will begin to autoscroll. When scrolling manually, the display will automatically return to the Status page if no buttons are pressed for the duration of the configurable LCD Page Timer.

If an alarm becomes active while viewing the status page, the display shows the Alarms page to draw the operator’s attention to the alarm condition.

If you want to view one of the instruments towards the end of the list, it may be quicker to scroll up through the instruments rather than down!

If you want to view one of the instrument pages towards the end of the list, it may be quicker to scroll left through the pages rather than right!


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5.4.1 STATUS

This is the ‘home’ page, the page that is displayed when no other page has been selected, and the page that is automatically displayed after a period of inactivity (LCD Page Timer) of the module control buttons. This page is configurable using the DSE Configuration Suite Software.

Factory setting of Status screen showing engine stopped... ...and engine running

The contents of this display may vary depending upon configuration by the generator manufacturer / supplier. The display above was achieved with the factory settings, shown below in the DSE Configuration suite software:

NOTE:- The following sections detail instrumentation pages, accessible using the scroll left and right buttons, regardless of what pages are configured to be displayed on the ‘status’ screen.

‘Stop Mode’ etc is displayed on the Home Page

With a summary of the instrumentation shown when the engine is running.

Other pages can be configured to be shown, automatically scrolling when the set is running.


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5.4.2 ENGINE Contains instrumentation gathered about the engine itself, some of which may be obtained using the CAN or other electronic engine link.

• Engine Speed

• Oil Pressure

• Coolant Temperature

• Engine Battery Volts

• Run Time

• Oil Temperature*

• Coolant Pressure*

• Inlet Temperature*

• Exhaust Temperature*

• Fuel Temperature*

• Turbo Pressure

• Fuel Pressure*

• Fuel Consumption*

• Fuel Used*

• Fuel Level*

• Auxiliary Sensors (If fitted and configured)

• Engine Maintenance Due (If configured)

• Engine ECU Link* *When connected to suitably configured and compatible engine ECU. For details of supported engines see ‘Electronic Engines and DSE wiring’ (DSE Part number 057-004).

Depending upon configuration and instrument function, some of the instrumentation items may include a tick icon beside them. This denotes a further function is available, detailed in the ‘operation’ section of this document. Example:

The tick icon denotes that manual fuel pump control is enabled in this system. Press and hold to start the fuel transfer pump, release to stop the pump. This is further detailed in the section entitled ‘operation’ elsewhere in this document.


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5.4.3 GENERATOR

Contains electrical values of the generator (alternator), measured or derived from the module’s voltage and current inputs.

• Generator Voltage (ph-N)

• Generator Voltage (ph-ph)

• Generator Frequency

• Generator Current

• Generator Earth Current

• Generator Load (kW)

• Generator Load (kVA)

• Generator Power Factor

• Generator Load (kVAr)

• Generator Load (kWh, kVAh, kVArh)

• Generator Phase Sequence

• Dual Mutual Status

Available : The set is running and available Inhibited : The set is prevented from running by the ‘other‘ controller

Master : The master set will call for the slave when the timer (hrs:mins) expires. Slave : The master will call for the slave until the timer (hrs:mins) expires.


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5.4.4 MAINS (DSE7220/DSE7320 ONLY) Contains electrical values of the mains (utility) supply, measured or derived from the module’s mains voltage and current (where applicable) inputs.

• Mains Voltage (ph-N)

• Mains Voltage (ph-ph)

• Mains Current (if the CT location is in the ‘load’ and the mains is ‘on load’)

• Mains Frequency

5.4.5 SERIAL PORT

This section is included to give information about the currently selected serial port and external modem (if connected). The items displayed on this page will change depending upon configuration of the module. You are referred to your system supplier for further details.

NOTE:- Factory Default settings are for the RS232 port to be enabled (no modem connected), operating at 19200 baud, modbus slave address 10.

Example 1 – Module connected to a RS232 telephone modem. When the DSE7300 series module is power up, it will send ‘initialisation strings’ to the connected modem. It is important therefore that the modem is already powered, or is powered up at the same time as the DSE7300 series module. At regular intervals after powerup, the modem is reset, and reinitialised, to ensure the modem does not ‘hang up’. If the DSE7300 series module does not correctly communicate with the modem, “Modem initialising’ will appear on the Serial Port instrument screen as shown overleaf. If the module is set for “incoming calls” or for “incoming and outgoing calls”, then if the modem is dialled, it will answer after two rings (using the factory setting ‘initialisation strings’. Once the call is established, all data is passed from the dialling PC and the DSE7300 series module. If the module is set for “outgoing calls” or for “incoming and outgoing calls”, then the module will dial out whenever an alarm is generated. Note that not all alarms will generate a dial out, this is dependant upon module configuration of the event log. Any item configured to appear in the event log will cause a dialout.

Press down to view the modem status....

Indicates that a modem is configured. Shows ‘RS232’ if no modem is configured or ‘RS485’ if the RS485 port is selected.


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Example 1 continued – Modem diagnostics

NOTE:- Modem diagnostic screens are available on 73xx module versions 5 and above only. The modem screens appear only when the module has been configured for use with a modem.

Modem diagnostic screens are included; press when viewing the Serial Port instrument to cycle the available screens. If you are experiencing modem communication problems, this information will aid troubleshooting.

Line Description

RTS Request To Send Flow control

CTS Clear To Send Flow control

DSR Data Set Ready Ready to communicate

DTR Data Terminal Ready Ready to communicate

DCD Data Carrier Detect Modem is connected

Shows the state of the modem communication lines. These can help diagnose connection problems. Example : RTS A dark background shows the line is active. RTS a grey background shows that the line is toggling high and low. RTS No background indicates that the line is inactive

Shows the last command sent to the modem and the result of the command.


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Modem Setup Sequence

1)

If the Modem and DSE7000 series communicate successfully:

2) In case of communication failure between the modem and DSE7000 series module, the modem is automatically reset and initialisation is attempted once more:

3) In the case of a module that is unable to communicate with the modem, the display will continuously cycle between ‘Modem Reset’ and ‘Modem Initialising’ as the module resets the modem and attempts to communicate with it again, this will continue until correct communication is established with the modem. In this instance, you should check connections and verify the modem operation.

Example 2 – Module connected to a modem. Example 3 – Modem status of a GSM modem Many GSM modems are fitted with a status LED to show operator cell status and ringing indicator. These can be a useful troubleshooting tool. In the case of GSM connection problems, try calling the DATA number of the SIMCARD with an ordinary telephone. There should be two rings, followed by the modem answering the call and then ‘squealing’. If this does not happen, you should check all modem connections and double check with the SIM provider that it is a DATA SIM and can operate as a data modem. DATA is NOT the same as FAX or GPRS and is often called Circuit Switched Data (CSD) by the SIM provider.

NOTE:NOTE:NOTE:NOTE: In the case of GSM modems, it is important In the case of GSM modems, it is important In the case of GSM modems, it is important In the case of GSM modems, it is important that a DATA ENABLED SIM is used. This is often a different number than that a DATA ENABLED SIM is used. This is often a different number than that a DATA ENABLED SIM is used. This is often a different number than that a DATA ENABLED SIM is used. This is often a different number than

the ‘voice number’the ‘voice number’the ‘voice number’the ‘voice number’ and is often called Circuit Switched Data (CSD) by the SIM providerand is often called Circuit Switched Data (CSD) by the SIM providerand is often called Circuit Switched Data (CSD) by the SIM providerand is often called Circuit Switched Data (CSD) by the SIM provider....

If the GSM modem is not purchased from DSE, ensure that it has been correctly set to operate at 9600 baud. You may need to install a terminal program on your PC and consult your modem supplier to do this. GSM modems purchased from DSE are already configured to work with the DSE7300 series module.

Currently connected GSM operator and signal strength.


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Example 4 - Module RS485 port configured for connection to a modbus master.

DSE7300 series modules operate as a modbus RTU slave device. In a modbus system there can be only one Master, typically a PLC, HMI system or PC SCADA system. This master requests for information from the modbus slave (DSE7300 series module) and may (in control systems) also send request to change operating modes etc. Unless the Master makes a request, the slave is ‘quiet’ on the datalink. The factory settings are for the module to communicate at 19200 baud, modbus slave address 10. To use the RS485 port, ensure that ‘port usage’ is correctly set using the DSE Configuration Suite Software. Required settings are shown below.

‘Master inactivity timeout’ should be set to at least twice the value of the system scan time. For example if a modbus master PLC requests data from the DSE7300 modbus slave once per second, the timeout should be set to at least 2 seconds. The DSE Modbus Gencomm document containing register mappings inside the DSE module is available upon request from [email protected]. Email your request along with the serial number of your DSE module to ensure the correct information is sent to you. Typical requests (using Pseudo code) BatteryVoltage=ReadRegister(10,0405,1) : reads register (hex) 0405 as a single register (battery volts) from slave address 10. WriteRegister(10,1008,2,35701, 65535-35701) : Puts the module into AUTO mode by writing to (hex) register 1008, the values 35701 (auto mode) and register 1009 the value 65535-35701 (the bitwise opposite of auto mode) Shutdown=(ReadRegister(10,0306,1) >> 12) & 1) : reads (hex) 0306 and looks at bit 13 (shutdown alarm present) Warning=(ReadRegister(10,0306,1) >> 11) & 1) : reads (hex) 0306 and looks at bit 12 (Warning alarm present) ElectricalTrip=(ReadRegister(10,0306,1) >> 10) & 1) : reads (hex) 0306 and looks at bit 11 (Electrical Trip alarm present) ControlMode=ReadRegister(10,0304,2); reads (hex) register 0304 (control mode).


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5.4.6 ABOUT Contains important information about the module and the firmware versions. This information may be asked for when contacting DSE Technical Support Department for advice.

About

Variant 7320 Application V8.0.7 USB ID BC614E

Press to access more information about the module.

About

Bootloader V1.3.4

Analogue V2.0.0

Press to access more information about the module.

About

Engine Type Volvo EMS2b

Version V1.18

• Variant (ie 7210, 7220, 7310, 7320)

• Application Version – The version of the module’s main firmware file (Updatable using the Firmware Update Wizard in the DSE Configuration Suite Software).

• USB ID – Unique identifier for PC USB connection

• Bootloader - Firmware Update bootloader software version

• Analogue – Analogue measurements software version

• Engine Type – The type of engine or ECU file which is configured within the module.

• Version – Engine type file version.


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5.4.7 CAN ERROR MESSAGES When connected to a suitable CAN engine the 7000 series controller displays alarm status messages from the ECU.

Alarm

ECU Warning Warning

Press to access the list of current active Engine DTCs (Diagnostic Trouble Codes).

Engine DTCs The code interpreted by the module shows on the display as a text message. Additionally, the manufacturer’s code is shown. Water Level

Low Xxx,xxx,xxx

NOTE:- For details on these code meanings, refer to the ECU instructions provided by the engine manufacturer, or contact the engine manufacturer for further assistance.

NOTE:- For further details on connection to electronic engines please refer to Electronic engines and DSE wiring. Part No. 057-004

Type of alarm as reported by the ECU

Type of alarm that is triggered in the DSE module (ie Warning or Shutdown)


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5.5 VIEWING THE EVENT LOG The DSE7000 series modules maintain a log of past alarms and/or selected status changes. The log size has been increased in the module over past module updates and is always subject to change. At the time of writing, the 7300 series log is capable of storing the last 250 log entries. Under default factory settings, the event log only includes shutdown and electrical trip alarms logged (The event log does not contain Warning alarms), however this is configurable by the system designer using the DSE Configuration Suite software.

Once the log is full, any subsequent shutdown alarms will overwrite the oldest entry in the log. Hence, the log will always contain the most recent shutdown alarms. The module logs the alarm, along with the date and time of the event (or engine running hours if configured to do so). If the module is configured and connected to send SMS text

To view the event log, repeatedly press the next page button until the LCD screen displays the Event log :

Event log 1

Oil Pressure Low Shutdown 12 Sep 2007, 08:25:46

Press down to view the next most recent shutdown alarm:

Continuing to press down cycles through the past alarms after which the display shows the most recent alarm and the cycle begins again.

To exit the event log and return to viewing the instruments, press the next page button to select the next instrumentation page.

Example showing the possible configuration of the DSE7000 series event log (DSE Configuration Suite Software) This also shows the factory settings of the module (Only shutdown alarms and the mains status are logged).

This is event 1.


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5.6 USER CONFIGURABLE INDICATORS

These LEDs can be configured by the user to indicate any one of 100+ different functions based around the following:-

• Indications - Monitoring of a digital input and indicating associated functioning user’s equipment - Such as Battery Charger On or Louver’s Open, etc.

• WARNINGS and SHUTDOWNS - Specific indication of a particular warning or shutdown condition, backed up by LCD indication - Such as Low Oil Pressure Shutdown, Low Coolant level, etc.

• Status Indications - Indication of specific functions or sequences derived from the modules operating state - Such as Safety On, Pre-heating, Panel Locked, Generator Available, etc.

User configurable LEDs


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5.7 CONTROLS

Stop / Reset This button places the module into its Stop/Reset mode. This will clear any alarm conditions for which the triggering criteria have been removed. If the engine is running and the module is in Stop mode, the module will automatically instruct the changeover device to unload the generator (‘Close Generator’ becomes inactive (if used)). The fuel supply de-energises and the engine comes to a standstill. Should a remote start signal be present while operating in this mode, a remote start will not occur.

Manual This mode allows manual control of the generator functions. Once in Manual mode the module will

respond to the start button, start the engine, and run off load. If the engine is running off-load in the Manual mode and a remote start signal becomes present, the module will automatically instruct the changeover device to place the generator on load (‘Close Generator’ becomes active (if used)). Upon removal of the remote start signal, the generator remains on load until either selection of the ‘STOP/RESET’ or ‘AUTO’ modes. For further details, please see the more detailed description of ‘Manual operation’ elsewhere in this manual.

Auto This button places the module into its ‘Automatic’ mode. This mode allows the module to control the function of the generator automatically. The module will monitor the remote start input and mains supply status and once a start request is made, the set will be automatically started and placed on load. Upon removal of the starting signal, the module will automatically transfer the load from the generator and shut the set down observing the stop delay timer and cooling timer as necessary. The module will then await the next start event. For further details, please see the more detailed description of ‘Auto operation’ elsewhere in this manual.

5.7.1.1 TEST (DSE7220/DSE7320 ONLY) This button places the module into its ‘Test’ mode. This allows an on load test of the generator.

Once in Test mode the module will respond to the start button, start the engine, and run on load. For further details, please see the more detailed description of ‘Test operation’ elsewhere in this manual.

5.7.1.2 START

This button is only active in STOP/RESET or MANUAL mode. Pressing this button in manual or test mode will start the engine and run off load (manual) or on load (test). Pressing this button in STOP/RESET mode will turn on the CAN engine ECU (when correctly configured and fitted to a compatible engine ECU)

Mute / Lamp Test This button silences the audible alarm if it is sounding and illuminates all of the LEDs as a lamp test feature/ When correctly configured and fitted to a compatible engine ECU, pressing this button in

STOP/RESET mode after pressing the START button (to power the ECU) will cancel any “passive” alarms on the engine ECU.


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Transfer to generator Operative in Manual Mode only ‘Normal’ breaker button control

• Allows the operator to transfer the load to the generator ‘Alternative’ breaker button control (7320 V6+ only)

• If mains is on load, transfers the load to the generator.

• If generator is on load, opens the generator breaker

• If generator and mains are off load, closes the generator breaker.

Open generator (DSE7210/DSE7310 only) Allows the operator to open the generator (when in Manual mode only)

Transfer to mains Operative in Manual Mode only ‘Normal’ breaker button control

• Allows the operator to transfer the load to the mains ‘Alternative’ breaker button control (7320 V6+ only)

• If generator is on load, transfers the load to the mains.

• If mains is on load, opens the mains breaker

• If generator and mains are off load, closes the mains breaker.

Menu navigation Used for navigating the instrumentation, event log and configuration screens. For further details, please see the more detailed description of these items elsewhere in this manual.


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6 OPERATION (STANDALONE) The following description details the sequences followed by a module containing the standard ‘factory configuration’. Remember that if you have purchased a completed generator set or control panel from your supplier, the module’s configuration will probably have been changed by them to suit their particular requirements. Always refer to your configuration source for the exact sequences and timers observed by any particular module in the field.

6.1 ALTERNATIVE CONFIGURATIONS Depending upon the configuration of your system by the generator supplier, the system may have selectable configurations (for example to select between 50Hz and 60Hz running). If this has been enabled your generator supplier will advise how this selection can be made (usually by externally operated selector switch or by selecting the required configuration file in the DSE7000 series front panel configuration editor).


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6.2 DUMMY LOAD / LOAD SHEDDING CONTROL

NOTE:NOTE:NOTE:NOTE:---- Dummy Load / Load Shedding Control is only available on DSE7300 series controllerDummy Load / Load Shedding Control is only available on DSE7300 series controllerDummy Load / Load Shedding Control is only available on DSE7300 series controllerDummy Load / Load Shedding Control is only available on DSE7300 series controllers V4 or above. This feature is not s V4 or above. This feature is not s V4 or above. This feature is not s V4 or above. This feature is not

available on DSE7200 series.available on DSE7200 series.available on DSE7200 series.available on DSE7200 series.

This feature may be enabled by the system designer to ensure the loading on the generator is kept to a nominal amount. If the load is low, ‘dummy loads’ (typically static load banks) can be introduced to ensure the engine is not too lightly loaded. Conversely as the load increases towards the maximum rating of the set, non-essential loads can be shed to prevent overload of the generator.

6.2.1 DUMMY LOAD CONTROL The dummy load control feature (if enabled) allows for a maximum of five dummy load steps. When the set is first started, all configured Dummy Load Control outputs are de-energised. Once the generator is placed onto load, the generator loading is monitored by the Dummy Load Control scheme. If the generator loading falls below the Dummy Load Control Trip setting (kW), the Dummy Load Control Trip Delay is displayed on the module display. If the generator loading remains at this low level for the duration of the timer, the first Dummy Load Control output is energised. This is used to energise external circuits to switch in (for instance) a static load bank. The generator loading has now been increased by the first dummy load. Again the generator loading is monitored. This continues until all configured Dummy Load Control outputs are energised. Should the generator loading rise above the Dummy Load Return level, the Dummy Load Return Delay begins. If the loading remains at these levels after the completion of the timer, the ‘highest’ active Dummy Load Control output is de-energised. This continues until all Dummy Load Control outputs have been de-energised.

Example screen shot of Dummy Load Control setup in the DSE Configuration Suite


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6.2.2 LOAD SHEDDING CONTROL The Load Shedding Control feature (if enabled) allows for a maximum of five load shedding steps. When the generator is about to take load, the configured number of Load Shedding Control Outputs at Startup will energise. This configurable setting allows (for instance) certain loads to be removed from the generator prior to the set’s load switch being closed. This can be used to ensure the initial loading of the set is kept to a minimum, below the Load Acceptance specification of the generating set. The generator is then placed on load. The Load Shedding Control scheme begins. When the load reaches the Load Shedding Trip level the Trip Delay timer will start. If the generator loading is still high when the timer expires, the first Load shedding Control output will energise. When the load has been above the trip level for the duration of the timer the ‘next’ Load shedding Control output will energise and so on until all Load Shedding Control outputs are energised. If at any time the load falls back below the Load Shedding Return level, the Return Time will start. If the load remains below the return level when the timer has expired the ‘highest’ Load Shedding Control output that has been energised will be de-energised. This process will continue until all outputs have been de-energised. When the set enters a stopping sequence for any reason the Load Shedding control’ outputs will de-energise at the same time as the generator load switch is signalled to open.

Example screen shot of Load Shedding Control setup in the DSE Configuration Suite


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6.3 SMS CONTROL

NOTE:- Only available in version DSE73xx version 8+ modules with a suitable GSM modem connected to the RS232 port and configured to receive the control commands.

The SMS Control feature (if enabled) allows the user to send control commands to a DSE73xx via SMS message. There are five control commands that the user can send to the module, these control commands are in the table below.

NOTE:- Multiple SMS Control Commands CANNOT be sent in a single SMS message.

Control Command Number

Module Action

1 Start the generator off load if in the ‘Auto’ position.

2 Start the generator on load if in the ‘Auto’ position..

3 Cancel an SMS start request.

4 Put the module into the ‘STOP’ position.

5 Put the module into the ‘AUTO’ position.

To send an SMS command, the user will need (if configured) the SMS Control Pin Number and the Control Command Number. Only these numbers must be included in the SMS, the module will not respond to any SMS with extra characters or missing PIN number (if configured). Below is an example how to start and run the generator on load by SMS message.

NOTE:- There must be a space between the SMS PIN Number and the Control Command Number

SMS Message 1 This SMS message will place the module into the AUTO position.

0123 5

SMS Message 2 This SMS message will start and run the generator on load..

0123 2

SMS Message3 This SMS message will remove the start and run command given by the previous SMS message and leave the module in the AUTO position 0123 3

SMS Message 4

This SMS message will place the module into the STOP position. 0123 4

Example screen shot of SMS Control setup in the DSE Configuration Suite

Pin Number

Control Command Number


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6.4 STOP MODE

STOP mode is activated by pressing the button. In STOP mode, the module will remove the generator from load (if necessary) before stopping the engine if it is already running. If the engine does not stop when requested, the FAIL TO STOP alarm is activated (subject to the setting of the Fail to Stop timer). To detect the engine at rest the following must occur :

• Engine speed is zero as detected by the Magnetic Pickup or CANbus ECU (depending upon module variant).

• Generator frequency must be zero.

• Oil pressure switch must be closed to indicate low oil pressure (MPU version only) When the engine has stopped, it is possible to send configuration files to the module from DSE Configuration Suite PC software and to enter the Front Panel Editor to change parameters. Any latched alarms that have been cleared will be reset when STOP mode is entered. The engine will not be started when in STOP mode. If remote start signals are given, the input is ignored until AUTO mode is entered. When configured to do so, if the generator has been on load, pressing the stop button will open the generator breaker and force it to do a cooling run. If the stop button is activated again during the cooling run, the generator will stop instantly. When configured to do so, When left in STOP mode for five minutes with no presses of the fascia buttons, the

module enters low power mode. To ‘wake’ the module, press the button or any other fascia control button.

Sleep mode configuration in the DSE Configuration Suite Software

Cool down in stop mode configuration in the DSE Configuration Suite Software


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6.4.1 ECU OVERRIDE

NOTE:- ECU Override function is only applicable when the controller is configured for a CAN engine.

NOTE:- Depending upon system design, the ECU may be powered or unpowered when the module is in STOP mode. ECU override is only applicable if the ECU is unpowered when in STOP mode.

When the ECU powered down (as is normal when in STOP mode), it is not possible to read the diagnostic trouble codes or instrumentation. Additionally, it is not possible to use the engine manufacturers’ configuration tools. As the ECU is usually unpowered when the engine is not running, it must be turned on manually as follows :

• Select STOP mode on the DSE controller.

• Press and hold the START button to power the ECU. As the controller is in STOP mode, the engine will not be started.

.

• The ECU will remain powered 2 minutes after the START button is released. This is also useful if the engine manufacturer’s tools need to be connected to the engine, for instance to configure the engine as the ECU needs to be powered up to perform this operation.


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6.5 AUTOMATIC MODE

NOTE:- If a digital input configured to panel lock is active, changing module modes will not be possible. Viewing the instruments and event logs is NOT affected by panel lock.

Activate auto mode be pressing the pushbutton. An LED indicator beside the button confirms this action. Auto mode will allow the generator to operate fully automatically, starting and stopping as required with no user intervention.

6.5.1 WAITING IN AUTO MODE If a starting request is made, the starting sequence will begin. Starting requests can be from the following sources:

• Mains supply out of limits (DSE7220/7320 only)

• Activation of an auxiliary input that has been configured to remote start on load or remote start off load.

• Activation of the inbuilt exercise scheduler.

• Instruction from external remote telemetry devices using the RS232 or RS485 interface (DSE7310/DSE7320 only).

6.5.2 STARTING SEQUENCE To allow for ‘false’ start requests such as mains brownouts, the start delay timer begins. There are individual start delay timers for each of the different start request types. Should all start requests be removed during the start delay timer, the unit will return to a stand-by state. If a start request is still present at the end of the start delay timer, the fuel relay is energised and the engine will be cranked.

NOTE:- If the unit has been configured for CAN, compatible ECU’s will receive the start command via CAN.

If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the crank rest duration after which the next start attempt begins. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and the display shows Fail to Start. The starter motor is disengaged when the engine fires. Speed detection is factory configured to be derived from the main alternator output frequency, but can additionally be measured from a Magnetic Pickup mounted on the flywheel (Selected by PC using the 7000 series configuration software). Additionally, rising oil pressure can be used to disconnect the starter motor (but cannot detect underspeed or overspeed).

NOTE:- If the unit has been configured for CAN, speed sensing is via CAN.

After the starter motor has disengaged, the Safety On timer activates, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault.


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6.5.3 ENGINE RUNNING Once the engine is running, the Warm Up timer, if selected, begins, allowing the engine to stabilise before accepting the load. DSE7210/DSE7310 - The generator will be placed on load. DSE7220/DSE7320 - Load will be transferred from the mains supply to the generator

NOTE:-The load transfer signal remains inactive until the Oil Pressure has risen. This prevents excessive wear on the engine.

As the load increases and decreases, the DSE7300 series module (not available on DSE7200 series) may (depending upon configuration) add dummy loads or remove non-essential loads. This is configured as part of the Load Shedding and Dummy Load control settings in the DSE Configuration Suite Software. See section entitled Dummy Load / Load Shedding elsewhere in this document for further details. If all start requests are removed, the stopping sequence will begin.

6.5.4 STOPPING SEQUENCE The return delay timer operates to ensure that the starting request has been permanently removed and isn’t just a short term removal. Should another start request be made during the cooling down period, the set will return on load. If there are no starting requests at the end of the return delay timer, the load is transferred back from the generator to the mains supply and the cooling timer is initiated. The cooling timer allows the set to run off load and cool sufficiently before being stopped. This is particularly important where turbo chargers are fitted to the engine. After the cooling timer has expired, the set is stopped.


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6.6 MANUAL MODE


Activate Manual mode be pressing the pushbutton. An LED indicator beside the button confirms this action. Manual mode allows the operator to start and stop the set manually, and if required change the state of the load switching devices.

6.6.1 WAITING IN MANUAL MODE When in manual mode, the set will not start automatically.

To begin the starting sequence, press the button.

6.6.2 STARTING SEQUENCE

NOTE:- There is no start delay in this mode of operation.

The fuel relay is energised and the engine is cranked.


If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the crank rest duration after which the next start attempt is made. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and the display shows Fail to Start. When the engine fires, the starter motor is disengaged. Speed detection is factory configured to be derived from the main alternator output frequency but can additionally be measured from a Magnetic Pickup mounted on the flywheel (Selected by PC using the 7000 series configuration software). Additionally, rising oil pressure can be used disconnect the starter motor (but cannot detect underspeed or overspeed).




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6.6.3 ENGINE RUNNING In manual mode, the load is not transferred to the generator unless a ‘loading request’ is made. A loading request can come from a number of sources.

• Pressing the transfer to generator button

• Mains supply out of limits (DSE7220/DSE7320 only)

• Activation of an auxiliary input that has been configured to remote start on load

• Activation of the inbuilt exercise scheduler if configured for ‘on load’ runs.


Once the load has been transferred to the generator, it will not be automatically transferred back to the mains supply. To manually transfer the load back to the mains either:

• Press the transfer to mains button (DSE7220/DSE7320 only)

• Press the Open Generator button (DSE7210/DSE7310 only)

• Press the auto mode button to return to automatic mode. For further details of breaker control, see the section entitled “controls and indications” elsewhere in this manual.

6.6.4 MANUAL FUEL PUMP CONTROL

NOTE:-Manual Fuel Pump Control is only available on suitably configured systems with V3 or higher control modules. Consult your set supplier for further advice.

• Navigate to the instruments page using the buttons and locate FUEL LEVEL. is shown on the module display to indicate that this feature is available.

• Press and hold the button to energise the transfer pump. The pump starts two seconds after the button is pressed.

• Release the button to de-energise the transfer pump.

6.6.5 MANUAL SPEED CONTROL

NOTE:-Manual Speed Control is only available on suitably configured systems with V3 or higher control modules. Consult your set supplier for further advice.

• Navigate to the instruments page using the buttons and locate ENGINE SPEED. is shown on the module display to indicate that this feature is available.

• Press the button to enter edit mode

• Press (up or down) to change the engine speed.

• Press the button again to exit the editor and leave the engine running at the newly selected speed.


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6.6.6 STOPPING SEQUENCE In manual mode the set will continue to run until either :

• The stop button is pressed – The set will stop immediately or after off load cooling run depending upon configuration.

• The auto button is pressed. The set will observe all auto mode start requests and stopping timers before beginning the Auto mode stopping sequence.


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6.7 TEST MODE

NOTE:- Test Mode is only applicable to DSE7220/DSE7320 controllers.


Activate test mode be pressing the pushbutton. An LED indicator beside the button confirms this action. Test mode will start the set and transfer the load to the generator to provide a Test on load function.

6.7.1 WAITING IN TEST MODE When in test mode, the set will not start automatically.

To begin the starting sequence, press the button.

6.7.2 STARTING SEQUENCE The set begins to crank.


If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the crank rest duration after which the next start attempt is made. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and the display shows Fail to Start. When the engine fires, the starter motor is disengaged. Speed detection is factory configured to be derived from the main alternator output frequency but can additionally be measured from a Magnetic Pickup mounted on the flywheel (Selected by PC using the 7000 series configuration software). Additionally, rising oil pressure can be used disconnect the starter motor (but cannot detect underspeed or overspeed).




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6.7.3 ENGINE RUNNING Once the engine is running, the Warm Up timer, if selected, begins, allowing the engine to stabilise before accepting the load. Load will be automatically transferred from the mains supply to the generator.


In test mode, the set will continue to run on load until either:

• The stop button is pressed – The set will stop immediately or after off load cooling run depending upon configuration.

• The auto button is pressed. The set will observe all auto mode start requests and stopping timers before beginning the Auto mode stopping sequence.


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7 OPERATION (DUAL MUTUAL STANDBY)

NOTE:- Dual Mutual Standby is only available in DSE7210 and DSE7310 series V2.0 or above. Load Balancing is only available in DSE7000 series V4 or above.

The following description details the sequences followed by a module containing the standard ‘factory configuration’ modified to allow two controllers to operate in Dual Mutual Standby. The operating modes are as per Standalone operation with the dual mutual functions detailed below. Remember that if you have purchased a completed generator set or control panel from your supplier, the module’s configuration will probably have been changed by them to suit their particular requirements. Always refer to your configuration source for the exact sequences and timers observed by any particular module in the field.

Screen shot from DSE Configuration Suite PC Software showing the configuration of the Master and Slave controllers.

Dual Mutual Standby will allow the generators to operate fully automatically, starting and stopping as required with no user intervention, with the master backed up by the slave. It is also possible to configure the master to change duty based upon a scheduler, to allow for ‘load balancing’ (V4 or above only)

If a starting request is made, the starting sequence will begin. Starting requests can be from the following sources:

• Activation of an auxiliary input that has been configured to remote start o It is usual that one remote start signal controls both modules In this instance, the Master will start

its generator. Should the Master fail, it instructs the Slave to start and take the load. o If the Master running and the remote start signal is given to the Slave, the Slave will not start its

generator until the Master generator fails.

• Activation of the inbuilt exercise scheduler. o In dual mutual standby operation the scheduler operates totally independently to the Master/Slave

scheme. Both generators could start, but only one will be allowed to close its load switch to power the load.

NOTE:- In all operating modes, only one module will be permitted to close its load switching device.


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8 PROTECTIONS When an alarm is present, the Audible Alarm will sound and the Common alarm LED if configured will illuminate.

The audible alarm can be silenced by pressing the Mute button The LCD display will jump from the ‘Information page’ to display the Alarm Page

Alarm 1/2

Warning Low oil pressure

The LCD will display multiple alarms E.g. “High Engine Temperature shutdown”, “Emergency Stop” and “Low Coolant Warning”. These will automatically scroll in the order that they occurred. In the event of a warning alarm, the LCD will display the appropriate text. If a shutdown then occurs, the module will again display the appropriate text. Example:-

Alarm 1/2

Warning Oil pressure Low

Alarm 2/2

Shutdown Coolant Temperature High

The type of alarm. E.g. Shutdown or warning

The nature of alarm, eg Low oil pressure

Number of present alarms. This is alarm 1 of a total of 2 present alarms


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8.1 PROTECTIONS DISABLED

NOTE:- This feature is available in module versions 4 and above.

User configuration is possible to prevent Shutdown / Electrical Trip alarms from stopping the engine. Under such conditions, Protections Disabled will appear on the module display to inform the operator of this status. This feature is provided to assist the system designer in meeting specifications for “Warning only”, “Protections Disabled”, “Run to Destruction”, “War mode” or other similar wording. When configuring this feature in the PC software, the system designer chooses to make the feature either permanently active, or only active upon operation of an external switch. The system designer provides this switch (not DSE) so its location will vary depending upon manufacturer, however it normally takes the form of a key operated switch to prevent inadvertent activation. Depending upon configuration, a warning alarm may be generated when the switch is operated. The feature is configurable in the PC configuration software for the module. Writing a configuration to the controller that has “Protections Disabled” configured, results in a warning message appearing on the PC screen for the user to acknowledge before the controller’s configuration is changed. This prevents inadvertent activation of the feature.

8.1.1 INDICATION / WARNING ALARMS Under Indication or Warning alarms :

• The module operation is unaffected by the Protections Disabled feature. See sections entitled Indications and Warnings elsewhere in this document.

8.1.2 SHUTDOWN / ELECTRICAL TRIP ALARMS

NOTE:- The EMERGENCY STOP input and shutdown alarm continues to operate even when Protections Disabled has been activated.

Under Shutdown or Electrical Trip alarm conditions (excluding Emergency Stop) :

• The alarm is displayed on the screen as detailed in the section entitled Shutdown alarms elsewhere in this document.

• The set continues to run.

• The load switch maintains its current position (it is not opened if already closed)

• Shutdown Blocked also appears on the LCD screen to inform the operator that the Protections Disabled feature has blocked the shutdown of the engine under the normally critical fault.

• The ‘shutdown’ alarm is logged by the controllers Event Log (if configured to log shutdown alarms) and also logs that the Shutdown was prevented.


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8.1.3 CAN ALARMS

NOTE:- Please refer to the engine manufacturer’s documentation for Can error message information.

CAN alarms are messages sent from the CAN ECU to the DSE controller and displayed as follows in the below tables.

Display Reason

CAN ECU WARNING The engine ECU has detected a warning alarm and has informed the DSE module of this situation. The exact error is also indicated on the module’s display and action taken depending upon the setting for the DM1 signals

ECU SHUTDOWN The engine ECU has detected a shutdown alarm and has informed the DSE module of this situation. The exact error is also indicated on the module’s display.

ECU DATA FAIL The module is configured for CAN operation and does not detect data on the engine CAN datalink, the engine shuts down.

DM1 Signals. Messages from the CAN ECU that are configurable within the DSE module for:-

Warning, Electrical Trip, shutdown or None

Display Reason

Amber Warning The CAN ECU has detected a Amber warning.

Red Shutdown The CAN ECU has detected a Red Shutdown.

Malfunction The CAN ECU has detected a Malfunction message.

Protect The CAN ECU has detected a Protect message

Advanced CAN alarms Allows configuration of additional can messages from the engine ECU.

Display Reason

Water in Fuel The ECU has detected water in the fuel action taken is set by settings in advanced.

After Treatment The ECU has detected “After Treatment alarm” consult engine manufacturer for details” action taken by DSE controller is set by settings in advanced

NOTE:- For CAN ECU error code meanings, refer to the ECU documentation provided by the engine manufacturer, or contact the engine manufacturer for further assistance.


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8.2 INDICATIONS Indications are non-critical and often status conditions. They do not appear on the LCD of the module as a text message. However an output or LED indicator can be configured to draw the operators attention to the event. Example

• Input configured for indication.

• The LCD text will not appear on the module display but can be added in the configuration to remind the system designer what the input is used for.

• As the input is configured to Indication there is no alarm generated.

• LED Indicator to make LED1 illuminate when Digital Input A is active.

• The Insert Card Text allows the system designer to print an insert card detailing the LED function.

• Sample showing operation of the LED.


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8.3 WARNINGS Warnings are non-critical alarm conditions and do not affect the operation of the generator system, they serve to draw the operators attention to an undesirable condition. Example

Alarm 1/1

Charge Failure Warning

In the event of an alarm the LCD will jump to the alarms page, and scroll through all active warnings and shutdowns. By default, warning alarms are self-resetting when the fault condition is removed. However enabling ‘all warnings are latched’ will cause warning alarms to latch until reset manually. This is enabled using the 7000 series configuration suite in conjunction with a compatible PC.

Display Reason

CHARGE FAILURE The auxiliary charge alternator voltage is low as measured from the W/L terminal.

BATTERY UNDER VOLTAGE

The DC supply has fallen below the low volts setting level for the duration of the low battery volts timer

BATTERY OVER VOLTAGE The DC supply has risen above the high volts setting level for the duration of the high battery volts timer

FAIL TO STOP The module has detected a condition that indicates that the engine is running when it has been instructed to stop.

NOTE:NOTE:NOTE:NOTE:---- ‘Fail to Stop’ could indicate a faulty oil pressure sen‘Fail to Stop’ could indicate a faulty oil pressure sen‘Fail to Stop’ could indicate a faulty oil pressure sen‘Fail to Stop’ could indicate a faulty oil pressure sensosososor r r r or switch or switch or switch or switch ---- If If If If the the the the engine is engine is engine is engine is

at rest check oil senat rest check oil senat rest check oil senat rest check oil sensosososor wiringr wiringr wiringr wiring and configuration.and configuration.and configuration.and configuration.

FUEL USAGE Indicates the amount of fuel measured by the fuel level sensor is in excess of the Fuel Usage alarm settings. This often indicates a fuel leak or potential fuel theft.

AUXILIARY INPUTS Auxiliary inputs can be user configured and will display the message as written by the user.

LOW FUEL LEVEL The level detected by the fuel level sensor is below the low fuel level setting.

kW OVERLOAD The measured Total kW is above the setting of the kW overload warning alarm

EARTH FAULT (DSE7300 series V2.0 or above only)

The measured Earth Fault Current has been in excess of the earth fault trip and has surpassed the IDMT curve of the Earth Fault alarm.

NEGATIVE PHASE SEQUENCE (DSE7000 series V2.0 or above only)

Indicates ‘out of balance’ current loading of the generator. Sometimes also called Negative Sequence Current or Symmetry Fault

MAINTENANCE DUE (DSE7000 series V2.1 or above only)

Indicates that the maintenance alarm has triggered. A visit is required by the Generator service company.

LOADING VOLTAGE NOT REACHED

Indicates that the generator voltage is not above the configured loading voltage. The generator will not take load when the alarm is present after the safety timer.

LOADING FREQUENCY NOT REACHED

Indicates that the generator frequency is not above the configured loading frequency. The generator will not take load when the alarm is present after the safety timer.


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PROTECTIONS DISABLED Shutdown and electrical trip alarms can be disabled by user configuration. In this case, Protections Disabled will appear on the module display; The alarm text will be displayed but the engine will continue to run. This is ‘logged’ by the module to allow DSE Technical Staff to check if the protections have been disabled on the module at any time. This feature is available from V4 onwards.

LOW OIL PRESSURE The module detects that the engine oil pressure has fallen below the low oil pressure pre-alarm setting level after the Safety On timer has expired.

ENGINE HIGH TEMPERATURE The module detects that the engine coolant temperature has exceeded the high engine temperature pre-alarm setting level after the Safety On timer has expired.

ENGINE LOW TEMPERATURE The module detects that the engine coolant temperature has fallen below the high engine temperature pre-alarm setting level.

OVERSPEED The engine speed has risen above the overspeed pre alarm setting

UNDERSPEED The engine speed has fallen below the underspeed pre alarm setting

GENERATOR OVER FREQUENCY

The generator output frequency has risen above the pre-set pre-alarm setting.

GENERATOR UNDER FREQUENCY

The generator output frequency has fallen below the pre-set pre-alarm setting after the Safety On timer has expired.

GENERATOR OVER VOLTAGE

The generator output voltage has risen above the pre-set pre-alarm setting.

GENERATOR UNDER VOLTAGE

The generator output voltage has fallen below the pre-set pre-alarm setting after the Safety On timer has expired.

ECU WARNING The engine ECU has detected a warning alarm and has informed the DSE module of this situation. The exact error is also indicated on the module’s display.

If the module is configured for CAN and receives an “error” message from the engine control unit, ‘Can ECU Warning” is shown on the module’s display and a warning alarm is generated.

8.4 HIGH CURRENT WARNING ALARM GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the pre-set trip a warning alarm initiates. The module shows Alarm Warning High Current. If this high current condition continues for an excess period, then the alarm escalates to a shutdown condition. For further details of the high current alarm, please see High Current Shutdown Alarm. By default, High Current Warning Alarm is self-resetting when the overcurrent condition is removed. However enabling ‘all warnings are latched’ will cause the alarm to latch until reset manually. This is enabled using the 7000 series configuration suite in conjunction with a compatible PC.


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8.5 SHUTDOWNS

NOTE:- Shutdown and Electrical Trip alarms can be disabled by user configuration. See the section entitled Protections Disabled elsewhere in this document.

Shutdowns are latching alarms and stop the Generator. Clear the alarm and remove the fault then press Stop/Reset

to reset the module. Example

Alarm 1/1

Oil Pressure Low Shutdown

NOTE:- The alarm condition must be rectified before a reset will take place. If the alarm condition remains, it will not be possible to reset the unit (The exception to this is the Low Oil Pressure alarm and similar ‘active from safety on’ alarms, as the oil pressure will be low with the engine at rest).

Display Reason


The measured Earth Fault Current has been in excess of the earth fault trip and has surpassed the IDMT curve of the Earth Fault alarm.

FAIL TO START The engine has not fired after the preset number of start attempts

EMERGENCY STOP The emergency stop button has been depressed. This a failsafe (normally closed to battery positive) input and will immediately stop the set should the signal be removed. Removal of the battery positive supply from the emergency stop input will also remove DC supply from the Fuel and Start outputs of the controller.

NOTE:- The Emergency Stop Positive signal must be present otherwise the unit will shutdown.

LOW OIL PRESSURE The engine oil pressure has fallen below the low oil pressure trip setting level after the Safety On timer has expired.

ENGINE HIGH TEMPERATURE The engine coolant temperature has exceeded the high engine temperature trip setting level after the Safety On timer has expired.

FUEL USAGE Indicates the amount of fuel measured by the fuel level sensor is in excess of the Fuel Usage alarm settings. This often indicates a fuel leak or potential fuel theft.

PHASE ROTATION (DSE7000 series V2.0 or above only)

The phase rotation is measured as being different to the configured direction.

OVERSPEED The engine speed has exceeded the pre-set trip

NOTE:-During the start-up sequence, the overspeed trip logic can be configured to allow an extra trip level margin. This is used to prevent nuisance tripping on start-up - Refer to the 7000 series configuration software manual under heading ‘Overspeed Overshoot’ for details.

UNDERSPEED The engine speed has fallen below the pre-set trip after the Safety On timer has expired.


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Display Reason

GENERATOR OVER FREQUENCY The generator output frequency has risen above the preset level

GENERATOR UNDER FREQUENCY The generator output frequency has fallen below the preset level

GENERATOR OVER VOLTAGE The generator output voltage has risen above the preset level

GENERATOR UNDER VOLTAGE The generator output voltage has fallen below the preset level

OIL PRESSURE SENSOR OPEN CIRCUIT

The oil pressure sensor is detected as not being present (open circuit)

AUXILIARY INPUTS An active auxiliary input configured as a shutdown will cause the engine to shut down. The display shows the text as configured by the user.

LOSS OF SPEED SIGNAL The speed signal from the magnetic pickup is not being received by the DSE controller.

ECU DATA FAIL The module is configured for CAN operation and does not detect data on the engine Can datalink, the engine shuts down.

ECU SHUTDOWN The engine ECU has detected a shutdown alarm and has informed the DSE module of this situation. The exact error is also indicated on the module’s display.

kW OVERLOAD The measured Total kW is above the setting of the kW overload shutdown alarm



MAINTENANCE DUE (DSE7000 series V2.1 or above only)

Indicates that the maintenance alarm has triggered. A visit is required by the Generator service company.

GENERATOR HIGH CURRENT A High Current condition has continued for an excess period, then the alarm escalates to either a shutdown or electrical trip condition (depending upon module configuration). For further details of the high current alarm, please see High Current Shutdown / Electrical Trip Alarm.


Indicates that the generator voltage is not above the configured loading voltage after the safety timer. The generator will shutdown.


Indicates that the generator frequency is not above the configured loading frequency after the safety timer. The generator will shutdown.


POSITIVE VAr Positive VArs has exceeded the trip settings.

NEGATIVE VAr Negative VArs has exceeded the trip settings.


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8.6 ELECTRICAL TRIPS

NOTE:- Shutdown and Electrical Trip alarms can be disabled by user configuration. See the section entitled Protections Disabled elsewhere in this document.

Electrical trips are latching and stop the Generator but in a controlled manner. On initiation of the electrical trip condition the module will de-energise the ‘Close Generator’ Output to remove the load from the generator. Once this has occurred the module will start the Cooling timer and allow the engine to cool off-load before shutting down the engine. The alarm must be accepted and cleared, and the fault removed to reset the module. Example

Alarm 1/1

Generator Current High Electrical Trip

Electrical trips are latching alarms and stop the Generator. Remove the fault then press Stop/Reset to reset the module.

Display Reason

GENERATOR HIGH CURRENT If a generator output in excess of the high current alarm point, a warning alarm occurs. If this high current condition continues for an excess period, then the alarm escalates to either a shutdown or electrical trip condition (depending upon module configuration). For further details of the high current alarm, please see High Current Shutdown / Electrical Trip Alarm.

AUXILIARY INPUTS If an auxiliary input configured as an electrical trip is active, the appropriate message will be displayed as configured by the user.

kW OVERLOAD The measured Total kW is above the setting of the kW overload Electrical Trip alarm


The measured Earth Current is above the setting of the Earth fault alarm.



FUEL USAGE Indicates the amount of fuel used is in excess of the Fuel Usage alarm settings. This often indicates a fuel leak or potential fuel theft.


Indicates that the generator voltage is not above the configured loading voltage after the safety timer. The generator will shutdown.


Indicates that the generator frequency is not above the configured loading frequency after the safety timer. The generator will shutdown.


GENERATOR UNDER FREQUENCY

The generator output frequency has fallen below the preset level

GENERATOR UNDER VOLTAGE The generator output voltage has fallen below the preset level

UNDERSPEED The engine speed has fallen below the underspeed setting

POSITIVE VAr Positive VArs has exceeded the trip settings.

NEGATIVE VAr Negative VArs has exceeded the trip settings.


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8.7 HIGH CURRENT SHUTDOWN / ELECTRICAL TRIP ALARM The overcurrent alarm combines a simple warning trip level with a fully functioning IDMT curve for thermal protection.

8.7.1 IMMEDIATE WARNING If the Immediate Warning is enabled, the controller generates a warning alarm as soon as the Trip level is reached. The alarm automatically resets once the generator loading current falls below the Trip level (unless All Warnings are latched is enabled). For further advice, consult your generator supplier.

8.7.2 IDMT ALARM

If the IDMT Alarm is enabled, the controller begins following the IDMT ‘curve’ when the trip level is passed.

If the Trip is surpassed for an excess amount of time the IDMT Alarm triggers (Shutdown or Electric trip as selected in Action). High current shutdown is a latching alarm and stops the Generator.

Remove the fault then press Stop/Reset to reset the module. High current electrical trip is a latching alarm and removes the generator from the load, before stopping the Generator after the off load cooling timer.

Remove the fault then press Stop/Reset to reset the module.

The higher the overload, the faster the trip. The speed of the trip is dependent upon the fixed formula:

T = t / ((IA / I T) – 1) 2

Where: T is the tripping time in seconds

IA is the actual current of the most highly loaded line (L1 or L2 or L3)

IT is the delayed over-current trip point

t is the time multiplier setting and also represents the tripping time in seconds at twice full load (when IA / IT = 2).


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Factory settings for the IDMT Alarm when used on a brushless alternator are as follows (screen capture from the DSE Configuration Suite PC software :

These settings provide for normal running of the generator up to 100% full load. If full load is surpassed, the Immediate Warning alarm is triggered, the set continues to run. The effect of an overload on the generator is that the alternator windings begin to overheat; the aim of the IDMT alarm is to prevent the windings being overload (heated) too much. The amount of time that the set can be safely overloaded is governed by how high the overload condition is. With typical settings as above, the tripping curve is followed as shown below. This allows for overload of the set to the limits of the Typical Brushless Alternator whereby 110% overload is permitted for 1 hour. If the set load reduces, the controller then follows a cooling curve. This means that a second overload condition may trip much sooner than the first as the controller knows if the windings have not cooled sufficiently. For further details on the Thermal damage curve of your alternator, you are referred to your alternator manufacturer and generator supplier.

IT (Trip setting value)

t (time multiplier)


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8.8 EARTH FAULT SHUTDOWN / ELECTRICAL TRIP ALARM When the module is suitably connected using the ‘Earth Fault CT’. The module measures Earth Fault and can optionally be configured to generate an alarm condition (shutdown or electrical trip) when a specified level is surpassed.

If the Earth Fault alarm is enabled, the controller begins following the IDMT ‘curve’. If the Trip is surpassed for an excess amount of time the Alarm triggers (Shutdown or Electric trip as selected in Action).

The higher the Earth Fault, the faster the trip. The speed of the trip is dependent upon the fixed formula :

T = K x 0.14 / ((I / Is) 0.02

-1)

Where: T is the tripping time in seconds (accurate to +/- 5% or +/- 50ms (whichever is the greater)

K is the time multiplier setting

I is the actual earth current measured

Is is the trip setting value The settings shown in the example above are a screen capture of the DSE factory settings, taken from the DSE Configuration Suite software.

IS (Trip setting

value)

K (time multiplier setting)


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8.9 SHORT CIRCUIT ALARM

If the Short Circuit alarm is enabled, the controller begins following the IDMT ‘curve’. If the Trip is surpassed for an excess amount of time the Alarm triggers (Shutdown or Electrical trip as selected in Action).

The higher the Short Circuit, the faster the trip. The speed of the trip is dependent upon the fixed formula :

T = K x 0.14 / ((I / Is) 0.02

-1)

Where: T is the tripping time in seconds (accurate to +/- 5% or +/- 50ms (whichever is the greater)

K is the time multiplier setting

I is the actual current measured

Is is the trip setting value

The settings shown in the example above are a screen capture of the DSE factory settings, taken from the DSE Configuration Suite software.

IS (Trip setting

value)

K (time multiplier setting)


102

8.10 MAINTENANCE ALARM Depending upon module configuration one or more levels of maintenance alarm may occur based upon a configurable schedule. There are three maintenance alarms in the DSE7200/DSE7300 series V3 and above, and one level of maintenance alarm in prior versions. Example 1

Screen capture from DSE Configuration Suite Software showing the configuration of Maintenance Alarm 1 and Maintenance Alarm 2. When activated, the maintenance alarm can be either a warning (set continues to run) or shutdown (running the set is not possible). Resetting the maintenance alarm is normally actioned by the site service engineer after performing the required maintenance. The method of reset is either by:

• Activating a input that has been configured to maintenance x reset, where x is the number of the maintenance alarm (1 to 3).

• Pressing the maintenance reset button in the DSE Configuration Suite, Maintenance section.

• Pressing and holding the stop button when the module’s display is on the maintenance alarm section. (V9.x.x and above)

Example 2 Screen capture from DSE Configuration Suite Software showing the configuration of a digital input for Reset Maintenance Alarm 1. Example 3 Screen capture from DSE Configuration Suite Software showing the Maintenance Alarm Reset ‘button’ in the DSE Configuration Suite SCADA | MAINTENANCE section.

Example 4 Screen capture from DSE Configuration Suite Software showing the configuration holding stop button to reset the maintenance alarm.


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8.11 SCHEDULER DSE7000 Series contains an inbuilt exercise run scheduler, capable of automatically starting and stopping the set. Up to 16 scheduled start/stop sequences can be configured to repeat on a 7-day or 28-day cycle. Scheduled runs may be on load or off load depending upon module configuration. Example Screen capture from DSE Configuration Suite Software showing the configuration of the Exercise Scheduler. In this example the set will start at 09:00 on Monday and run for 5 hours, then start at 13:30 on Tuesday and run for 30 minutes.

8.11.1 STOP MODE

• Scheduled runs will not occur when the module is in STOP/RESET mode.

8.11.2 MANUAL MODE

• Scheduled runs will not occur when the module is in MANUAL mode.

• Activation of a Scheduled Run ‘On Load’ when the module is operating OFF LOAD in Manual mode will have no effect, the set continues to run OFF LOAD

8.11.3 AUTO MODE

• Scheduled runs will operate ONLY if the module is in AUTO mode with no Shutdown or Electrical Trip alarm present.

• If the module is in STOP or MANUAL mode when a scheduled run begins, the engine will not be started. However, if the module is moved into AUTO mode during a scheduled run, the engine will be called to start.

• Depending upon configuration by the system designer, an external input can be used to inhibit a scheduled run.

• If the engine is running OFF LOAD in AUTO mode and a scheduled run configured to ‘On Load’ begins, the set is placed ON LOAD for the duration of the Schedule.


104

8.12 FRONT PANEL CONFIGURATION

This configuration mode allows the operator limited customising of the way the module operates.

Use the module’s navigation buttons to traverse the menu and make value changes to the parameters:

Accept

Next page

Previous page

Increase value / next item

Decrease value / next item


105

8.13 ACCESSING THE MAIN FRONT PANEL CONFIGURATION EDITOR

Ensure the engine is at rest and the module is in STOP mode by pressing the Stop/Reset button.

Press the Stop/Reset and Info buttons simultaneously. If a module security PIN has been set, the PIN number request is then shown :

Press , the first ‘#’ changes to ‘0’. Press (up or down) to adjust it to the correct value.

Press (right) when the first digit is correctly entered. The digit you have just entered will now show ‘#’ for security.

Repeat this process for the other digits of the PIN number. You can press (left) if you need to move back to adjust one of the previous digits.

When is pressed after editing the final PIN digit, the PIN is checked for validity. If the number is not correct, you must re-enter the PIN. If the PIN has been successfully entered (or the module PIN has not been enabled), the editor is displayed :

NOTE: NOTE: NOTE: NOTE: The PIN number is not set by DSE when the module leaves the factory. If the module has a PIN code set, this has been The PIN number is not set by DSE when the module leaves the factory. If the module has a PIN code set, this has been The PIN number is not set by DSE when the module leaves the factory. If the module has a PIN code set, this has been The PIN number is not set by DSE when the module leaves the factory. If the module has a PIN code set, this has been

affectedaffectedaffectedaffected by your generator supplier whoby your generator supplier whoby your generator supplier whoby your generator supplier who should be contacted if you require the code. If the code has been ‘lost’ or ‘forgotten’, the should be contacted if you require the code. If the code has been ‘lost’ or ‘forgotten’, the should be contacted if you require the code. If the code has been ‘lost’ or ‘forgotten’, the should be contacted if you require the code. If the code has been ‘lost’ or ‘forgotten’, the

module must be returned to the DSE factory module must be returned to the DSE factory module must be returned to the DSE factory module must be returned to the DSE factory to have the module’s code removed. A charge will be made for this procedure. to have the module’s code removed. A charge will be made for this procedure. to have the module’s code removed. A charge will be made for this procedure. to have the module’s code removed. A charge will be made for this procedure.

NB NB NB NB ---- This procedure cannot be performed This procedure cannot be performed This procedure cannot be performed This procedure cannot be performed away from the DSE factory.away from the DSE factory.away from the DSE factory.away from the DSE factory.


106

8.13.1 EDITING A PARAMETER Enter the editor as described above.

Press the (left) or (right) buttons to cycle to the section you wish to view/change.

Press the (up or down) buttons to select the parameter you wish to view/change within the currently selected section.

To edit the parameter, press to enter edit mode. The parameter begins to flash to indicate that you are editing the value.

Press the (up or down) buttons to change the parameter to the required value.

Press to save the value. The parameter ceases flashing to indicate that it has been saved.

To exit the editor at any time, press and hold the button.

NOTE: - The editor automatically exits after 5 minutes of inactivity to ensure security.

NOTE: - The PIN number is automatically reset when the editor is exited (manually or automatically) to ensure security.

NOTE: - More comprehensive module configuration is possible using the 7xxx series PC configuration software. Please contact us for further details.


107

8.13.2 ADJUSTABLE PARAMETERS

Front Panel Configuration Editor

= Only available on DSE7220 / DSE7320 AMF Modules

Section Parameter as shown on display Factory Settings DISPLAY Contrast 53%

Language English

LCD Page Timer 5m

Auto Scroll Delay 2s

Current Date and time hh:mm

EDITOR Alt Config Default Config

ENGINE Oil Pressure Low Shutdown 1.03bar

Oil Pressure Low Pre Alarm 1.17bar

Coolant Temperature Low Warning 70ºC

Coolant Temperature High Pre Alarm 90ºC

Coolant Temperature High Shutdown 95ºC

Remote Start Delay Off Load 5s

Remote Start Delay On Load 5s

Mains Fail Start Delay 5s

Telemetry Start Delay 5s

Start Delay Timer 5s

Pre Heat Timer 0s

Crank Duration Timer 10s

Crank Rest Timer 10s

Safety On Delay 10s

Smoke Limiting 0s

Smoke Limiting Off 0s

Warm Up Timer 0s

Cool Down Timer 1m

Engine Under Speed Shutdown Inactive

Engine Under Speed Shutdown 1200RPM

Engine Under Speed Warning Inactive

Engine Under Speed Warning 1350RPM

Engine Over Speed Warning Inactive

Engine Over Speed Warning 1650RPM

Engine Over Speed Shutdown 1710RPM

Engine Speed Overshoot Delay 2s

Engine Speed Overshoot 0s

Fail To Stop Delay 30s

Battery Under Voltage Warning Active

Battery Under voltage Warning Delay 1m

Battery Under Voltage 10V

Battery Over Voltage Warning Active

Battery Over Voltage Warning Delay 1m

Battery Over Voltage Warning 30V

Charge Alternator Failure Warning Active

Charge Alternator Failure Warning 6V Charge Alternator Warning Delay 5s Charge Alternator Failure Shutdown Active Charge Alternator Failure Shutdown 4.0V Charge Alternator Shutdown Delay 5s Droop control Inactive

Droop control 4% (Compatible engine ECUs only)

DPTC Auto Regeneration Inhibit Active

Fuel Usage Alarm (Running Rate) 0%-100%

Fuel Usage Alarm (Stopped Rate) 0%-100%

GENERATOR Generator Under Voltage Shutdown 184V

Generator Under Voltage Pre Alarm 196V

Generator Voltage Nominal 230V

Generator Over Voltage Pre Alarm 265V

Generator Over Voltage Shutdown 277V

Generator Under Frequency Shutdown 40Hz

Generator Under Frequency Pre Alarm 42Hz

Generator Frequency Nominal 50Hz

Generator Over Frequency Pre Alarm 55Hz

Generator Over Frequency Shutdown 57Hz

Full Load Rating 500A

Kw Overload Trip 100%

Delayed Over Current Active

Delayed Over Current 100%

AC System 3 Phase, 4 Wire

CT Primary 600A

CT Secondary 5A

Earth CT Primary 500A

Earth Fault Trip Inactive

Earth Fault Trip 10%

Generator transient delay 0s


108

Front Panel Configuration Editor (continued)

Section Parameter as shown on display Factory Settings

MAINS Mains Under Voltage Trip 184V

Mains Over Voltage Trip 276V

Mains Under Frequency Trip 45Hz

Mains Over Frequency Trip 55Hz

Mains Transient Delay 2s

Return Delay 30s

Mains Transfer Time 0.7s

TIMERS LCD Page Timer 5m

Auto Scroll Delay 3s

Pre Heat Timer 0s

Crank Duration Timer 0s

Crank Rest Timer 10s

Safety On Delay 10s

Smoke Limiting 10s

Smoke Limiting Off 0s

Warm Up Timer 0s

Cool Down Timer 0s

Speed Overshoot Delay 1m

Fail To Stop Delay 2s

Battery voltage Low Warning Delay 30s

Battery Voltage High Warning Delay 1m

Return Delay 1m

Generator Transient Delay 30s

Mains Transient Delay 0s

Mains Transfer Time 2s

Schedule 0.7s

SCHEDULE Schedule On Load Active

Schedule Period Active (only available when Scheduler is active)

Schedule time and Date Selection (1-16) Press to begin editing then or to select the different parameters in the scheduler.


109

8.14 ACCESSING THE ‘RUNNING’ CONFIGURATION EDITOR The ‘running’ editor can be entered while the engine is running. All protections remain active if the engine is running while the running editor is entered.

Press and hold the button to enter the running editor.

8.14.1 EDITING A PARAMETER Enter the editor as described above.

Press the (left) or (right) buttons to cycle to the section you wish to view/change.

Press the (up or down) buttons to select the parameter you wish to view/change within the currently selected section.

To edit the parameter, press to enter edit mode. The parameter begins to flash to indicate that you are editing the value.

Press the (up or down) buttons to change the parameter to the required value.

Press to save the value. The parameter ceases flashing to indicate that it has been saved.

To exit the editor at any time, press and hold the button.

8.14.2 ADJUSTABLE PARAMETERS (RUNNING EDITOR) Running Editor (Factory default settings are shown in bold italicised text)

Section Parameter as shown on display Factory Setting

DISPLAY Contrast 50%

Language English

Engine Engine Speed (If ‘manual speed control’ is enabled) 0.0Hz

DPTC Auto Regen Inhibit Active (only available when DPF Regeneration Control is selected)

DPTC Manual Regen Inactive (only available when DPF Regeneration Control is selected)


110

9 COMMISSIONING

9.1.1 PRE-COMMISSIONING Before the system is started, it is recommended that the following checks are made:-

10.1. The unit is adequately cooled and all the wiring to the module is of a standard and rating compatible with the system. Check all mechanical parts are fitted correctly and that all electrical connections (including earths) are sound.

10.2. The unit DC supply is fused and connected to the battery and that it is of the correct polarity.

10.3. The Emergency Stop input is wired to an external normally closed switch connected to DC positive.

NOTE:- If Emergency Stop feature is not required, link this input to the DC Positive. The module will not operate unless either the Emergency Stop is fitted correctly OR terminal 3 is connected to DC positive.

10.4. To check the start cycle operation, take appropriate measures to prevent the engine from starting (disable the operation of the fuel solenoid). After a visual inspection to ensure it is safe to proceed, connect the battery supply. Select “MANUAL” and then press “START” the unit start sequence will commence.

10.5. The starter will engage and operate for the pre-set crank period. After the starter motor has attempted to start the engine for the pre-set number of attempts, the LCD will display ‘Failed to start. Select the STOP/RESET position to reset the unit.

10.6. Restore the engine to operational status (reconnect the fuel solenoid). Select “MANUAL” and then press “START”. This time the engine should start and the starter motor should disengage automatically. If not then check that the engine is fully operational (fuel available, etc.) and that the fuel solenoid is operating. The engine should now run up to operating speed. If not, and an alarm is present, check the alarm condition for validity, then check input wiring. The engine should continue to run for an indefinite period. It will be possible at this time to view the engine and alternator parameters - refer to the ‘Description of Controls’ section of this manual.

10.7. Select “AUTO” on the front panel, the engine will run for the pre-set cooling down period, then stop. The generator should stay in the standby mode. If not check that there is not a signal present on the Remote start input.

10.8. Initiate an automatic start by supplying the remote start signal (if configured). The start sequence will commence and the engine will run up to operational speed. Once the generator is available a load transfer will take place (if configured), the Generator will accept the load. If not, check the wiring to the Generator Contactor Coil (if used). Check the Warming timer has timed out.

10.9. Remove the remote start signal. The return sequence will begin. After the pre-set time, the generator is

unloaded. The generator will then run for the pre-set cooling down period, then shutdown into its standby mode.

10.10. Set the modules internal clock/calendar to ensure correct operation of the scheduler and event logging functions. For details of this procedure see section entitled Front Panel Configuration – Editing the date and time.

10.11. If, despite repeated checking of the connections between the 7000 series controller and the customer’s system, satisfactory operation cannot be achieved, then the customer is requested to contact the factory for further advice on:-

INTERNATIONAL TEL: +44 (0) 1723 890099 INTERNATIONAL FAX: +44 (0) 1723 893303

E-mail: [email protected] Website : www.deepseaplc.com


111

10 FAULT FINDING

SYMPTOM POSSIBLE REMEDY Unit is inoperative Read/Write configuration does not operate

Check the battery and wiring to the unit. Check the DC supply. Check the DC fuse.

Unit shuts down Check DC supply voltage is not above 35 Volts or below 9 Volts Check the operating temperature is not above 70°C. Check the DC fuse.

Unit locks out on Emergency Stop If no Emergency Stop Switch is fitted, ensure that a DC positive signal is connected to the Emergency Stop input. Check emergency stop switch is functioning correctly. Check Wiring is not open circuit.

Intermittent Magnetic Pick-up sensor fault

Ensure that Magnetic pick-up screen only connects to earth at one end, if connected at both ends, this enables the screen to act as an aerial and will pick up random voltages. Check pickup is correct distance from the flywheel teeth.

Low oil Pressure fault operates after engine has fired

Check engine oil pressure. Check oil pressure switch/sensor and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sensor is compatible with the 73x0 Module and is correctly configured.

High engine temperature fault operates after engine has fired.

Check engine temperature. Check switch/sensor and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sensor is compatible with the 7000 series module.

Shutdown fault operates Check relevant switch and wiring of fault indicated on LCD display. Check configuration of input.

Warning fault operates Check relevant switch and wiring of fault indicated on LCD display. Check configuration of input.

Fail to Start is activated after pre-set number of attempts to start

Check wiring of fuel solenoid. Check fuel. Check battery supply. Check battery supply is present on the Fuel output of the module. Check the speed-sensing signal is present on the 7000 series module’s inputs. Refer to engine manual.

Continuous starting of generator when in AUTO

Check that there is no signal present on the “Remote Start” input. Check configured polarity is correct. Check the mains supply is available and within configured limits (DSE7220/DSE7320 only)

Generator fails to start on receipt of Remote Start signal.

Check Start Delay timer has timed out. Check signal is on “Remote Start” input. Confirm correct configuration of input is configured to be used as “Remote Start”. Check that the oil pressure switch or sensor is indicating low oil pressure to the controller. Depending upon configuration, then set will not start if oil pressure is not low.

Pre-heat inoperative Check wiring to engine heater plugs. Check battery supply. Check battery supply is present on the Pre-heat output of module. Check pre-heat configuration is correct.

Starter motor inoperative Check wiring to starter solenoid. Check battery supply. Check battery supply is present on the Starter output of module. Ensure that the Emergency Stop input is at Positive. Ensure oil pressure switch or sensor is indicating the “low oil pressure” state to the 7300 series controller.

Engine runs but generator will not take load

Check Warm up timer has timed out. Ensure generator load inhibit signal is not present on the module inputs. Check connections to the switching device. Note that the set will not take load in manual mode unless there is an active remote start on load signal.


112

SYMPTOM POSSIBLE REMEDY Incorrect reading on Engine gauges Fail to stop alarm when engine is at rest

Check engine is operating correctly. Check sensor and wiring paying particular attention to the wiring to terminal 47 (refer to appendix). Check that sensor is compatible with the 7000 series module and that the module configuration is suited to the sensor.

Module appears to ‘revert’ to an earlier configuration

When editing a configuration using the PC software it is vital that the configuration is first ‘read’ from the controller before editing it. This edited configuration must then be “written” back to the controller for the changes to take effect. When editing a configuration using the fascia editor, be sure to press the

Accept button to save the change before moving to another item or exiting the fascia editor

Set will not take load Ensure the generator available LED is lit Check that the output configuration is correct to drive the load switch device and that all connections are correct. Remember that the set will not take load in manual mode unless a remote start on load input is present or the close generator button is pressed.

Inaccurate generator measurements on controller display

Check that the CT primary, CT secondary and VT ratio settings are correct for the application. Check that the CTs are wired correctly with regards to the direction of current flow (p1,p2 and s1,s2) and additionally ensure that CTs are connected to the correct phase (errors will occur if CT1 is connected to phase 2). Remember to consider the power factor. Ie (kW = kVA x powerfactor) The 7000 series controller is true RMS measuring so gives more accurate display when compared with an ‘averaging’ meter such as an analogue panel meter or some lower specified digital multimeters. Accuracy of the controller is better than 1% of full scale. Ie Gen volts full scale is 333V ph-n so accuracy is ±3.33V (1% of 333V).

NOTE:- The above fault finding is provided as a guide check-list only. As the module can be configured to provide a wide range of different features, always refer to the source of your module configuration if in doubt.


113

11 MAINTENANCE, SPARES, REPAIR AND SERVICING The DSE7000 Series controller is designed to be Fit and Forget. As such, there are no user serviceable parts within the controller. In the case of malfunction, you should contact your original equipment supplier (OEM).

11.1 PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE

11.1.1 DSE7200 SERIES If you require additional plugs from DSE, please contact our Sales department using the part numbers below.

11.1.1.1 PACK OF PLUGS

Module type Plug Pack Part Number

DSE7210 057-511

DSE7220 007-512

11.1.1.2 INDIVIDUAL PLUGS

7000 series terminal designation Plug description Part No.

1-11

11 way 5.08mm 007-451

15-18

4 way 5.08mm 007-100

22-30

9 way 5.08mm 007-167

39-46

8 way 7.62mm 007-454

47-50

4 way 7.62mm (Not fitted to DSE7210) 007-171

51-56

6 way 5.08mm 007-446

60-65 6 way 5.08mm (DSE7200 series only) 007-379

60-67 8 way 5.08mm (DSE7300 series only) 007-164

PC Configuration interface lead (USB type A – type B)

016-125

NOTE:- Terminal 19 is not fitted to DSE72000 series controllers.

NOTE:- Mains sensing (Terminals 47-50) is not fitted on DSE7210 autostart controller.



114

11.1.2 DSE7300 SERIES If you require additional plugs from DSE, please contact our Sales department using the part numbers below.

11.1.2.1 PACK OF PLUGS

Module type Plug Pack Part Number

DSE7310 057-513

DSE7320 007-514

11.1.2.2 INDIVIDUAL PLUGS

7000 series terminal designation Plug description Part No.

1-11

11 way 5.08mm 007-451

15-19

5 way 5.08mm 007-445

22-30

9 way 5.08mm 007-167

39-46

8 way 7.62mm 007-454

47-50

4 way 7.62mm (Not fitted to DSE7310) 007-171

51-56

6 way 5.08mm 007-446

60-67 8 way 5.08mm 007-164

RS485 3 way 5.08mm 007-174

PC Configuration interface lead (USB type A – type B)

016-125

NOTE:- Mains sensing (Terminals 47-50) is not fitted on DSE7310 autostart controller.

11.2 PURCHASING ADDITIONAL FIXING CLIPS FROM DSE

Item Description Part No.

7000 series fixing clips (packet of 4) 020-294

11.3 PURCHASING ADDITIONAL SEALING GASKET FROM DSE

Item Description Part No.

7000 series silicon sealing gasket 020-507


115

11.4 EXPANSION MODULES

NOTE:- Expansion modules are not compatible with the DSE7200 series controllers.

NOTE:- A maximum of twenty (20) expansion modules can be connected to the DSENet®.

NOTE:- DSENet® utilises an RS485 connection. Using Belden 9841 (or equivalent) cable allows for the expansion cable to be extended to a maximum of 1.2km. DSE Stock and supply Belden 9841 cable. DSE Part Number 016-030.

Item

Description

DSE Part numbers

Max No. supported

Model order number

Sales literature

Operator manual

Installation Instructions

4 Model DSE2130 expansion input module provides additional analogue and digital inputs for use with the 73x0 controller.

2130-001-00 055-060 057-082 053-033

10 Model DSE2157 expansion relay module provides eight additional voltage free relays for use with the 73x0 controller

2157-001-00 055-061 057-083 053-034

10

Model DSE2548 expansion LED module provides additional LED indications, internal sounder and remote lamp test/alarm mute for use with the 73x0 controller.

2548-001-00 055-062 057-084 053-032

3

Model DSE2500 Series Expansion Display module provides remote control / display capability for the 7300 series controller. DSE2510 is suitable for DSE7310 controllers DSE2520 is suitable for DSE7320 controllers

2510-001-00 2520-001-00

055-074 057-107 053-064


116

11.5 ETHERNET (LAN) CONNECTION

NOTE:- DSE860 and DSE865 cannot be used with the DSE7210 or DSE7220 control modules.

Item Description Model order

number Sales

literature Operator manual

Installation Instructions

Model DSE860 RS232 to Ethernet Adaptor. Enables connection of the DSE7300 series to an Ethernet for monitoring / control / configuration using the DSE Configuration Suite Software.

0860-001-00 055-071 057-099 053-062

Model DSE865 RS485 to Ethernet Adaptor. Enables connection of the DSE7300 series to an Ethernet for monitoring / control / configuration using the DSE Configuration Suite Software.

0865-001-00 055-071 057-099 053-062


117

12 WARRANTY DSE provides limited warranty to the equipment purchaser at the point of sale. For full details of any applicable warranty, you are referred to your original equipment supplier (OEM).

13 DISPOSAL

13.1 WEEE (WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT) Directive 2002/96/EC If you use electrical and electronic equipment you must store, collect, treat, recycle and dispose of WEEE separately from your other waste.

13.2 ROHS (RESTRICTION OF HAZARDOUS SUBSTANCES) Directive 2002/95/EC:2006 To remove specified hazardous substances (Lead, Mercury, Hexavalent Chromium, Cadmium, PBB & PBDE´s) Exemption Note: Category 9. (Monitoring & Control Instruments) as defined in Annex 1B of the WEEE directive will be exempt from the RoHS legislation. This was confirmed in the August 2005 UK´s Department of Trade and Industry RoHS REGULATIONS Guide (Para 11). Despite this exemption, DSE has been carefully removing all non RoHS compliant components from our supply chain and products. When this is completed a Lead Free & RoHS compatible manufacturing process will be phased into DSE production. This is a process that is almost complete and is being phased through different product groups.

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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

057-011 5210 OPERATING MANUAL ISSUE 5.1 18/06/2007 AM 1

COMPLEX SOLUTIONS MADE SIMPLE.

DEEP SEA ELECTRONICS PLC

DSE5210 AUTOSTART CONTROL MODULE

OPERATING MANUAL


2 057-011 5210 OPERATING MANUAL ISSUE 5.1 18/06/2007 AM

Deep Sea Electronics Plc Highfield House Hunmanby North Yorkshire YO14 0PH ENGLAND Sales Tel: +44 (0) 1723 890099 Sales Fax: +44 (0) 1723 893303 E-mail: [email protected] Website: www.deepseaplc.com

DSE Model 5210 Control and Instrumentation System Operators Manual © Deep Sea Electronics Plc All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means or other) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988. Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to Deep Sea Electronics Plc at the address above. Any reference to trademarked product names used within this publication is owned by their respective companies. Deep Sea Electronics Plc reserves the right to change the contents of this document without prior notice.



TABLE OF CONTENTS Section Page 1 INTRODUCTION .............................................................................................. 5

2 CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION. ........ 5

3 OPERATION .................................................................................................... 6 3.1 AUTOMATIC MODE OF OPERATION ............................................................................... 6 3.2 MANUAL OPERATION ....................................................................................................... 8

4 PROTECTIONS ................................................................................................ 9 4.1 WARNINGS ....................................................................................................................... 10 4.2 ANALOGUE PRE-ALARMS .............................................................................................. 10 4.3 HIGH CURRENT WARNING ALARM ............................................................................... 11 4.4 SHUTDOWNS .................................................................................................................... 12 4.5 HIGH CURRENT SHUTDOWN ALARM ........................................................................... 14 4.6 ELECTRICAL TRIPS ......................................................................................................... 14

5 LCD INDICATORS AND LOGO INSERT ....................................................... 15

6 DESCRIPTION OF CONTROLS .................................................................... 16 6.1 TYPICAL LCD DISPLAY SCREENS ................................................................................ 17 6.2 LCD DISPLAY AREAS ...................................................................................................... 18 6.3 VIEWING THE INSTRUMENTS ........................................................................................ 19 6.4 VIEWING THE EVENT LOG .............................................................................................. 20 6.5 INDICATORS ..................................................................................................................... 21 6.6 CONTROLS ....................................................................................................................... 21

7 FRONT PANEL CONFIGURATION ............................................................... 22 7.1 ACCESSING THE FRONT PANEL CONFIGURATION EDITOR ..................................... 22

7.1.1 ENTERING THE CONFIGURATION EDITOR PIN NUMBER ................................... 22 7.2 EDITING AN ANALOGUE VALUE.................................................................................... 23

7.2.1 EDITING THE CURRENT DATE/TIME ...................................................................... 25 8 INSTALLATION INSTRUCTIONS .................................................................. 26

8.1 PANEL CUT-OUT .............................................................................................................. 26 8.2 COOLING ........................................................................................................................... 26 8.3 UNIT DIMENSIONS ........................................................................................................... 26 8.4 FRONT PANEL LAYOUT .................................................................................................. 27 8.5 REAR PANEL LAYOUT .................................................................................................... 27

9 ELECTRICAL CONNECTIONS ...................................................................... 28 9.1 CONNECTION DETAILS ................................................................................................... 28

9.1.1 PLUG “A” 8 WAY ........................................................................................................ 28 9.1.2 PLUG “B” 11 WAY ...................................................................................................... 28 9.1.3 PLUG “D” 4 WAY (OPTIONAL) .................................................................................. 29 9.1.4 PLUG “F” 4 WAY ........................................................................................................ 29 9.1.5 PLUG “G” 5 WAY ........................................................................................................ 29 9.1.6 PLUG “H” 4 WAY ........................................................................................................ 29 9.1.7 PC CONFIGURATION INTERFACE CONNECTOR .................................................. 29 9.1.8 EXPANSION OUTPUT CONNECTOR ....................................................................... 29

9.2 CONNECTOR FUNCTION DETAILS ................................................................................ 30 9.2.1 PLUG “A” 8 WAY ........................................................................................................ 30 9.2.2 PLUG “B” 11 WAY ...................................................................................................... 30 9.2.3 PLUG “D” 4 WAY (OPTIONAL, FITTED TO RS485 CONTROLERS ONLY) ............ 31 9.2.4 PLUG “F” 4 WAY ........................................................................................................ 31 9.2.5 PLUG “G” 5 WAY ........................................................................................................ 31 9.2.6 PLUG “H” 4 WAY ........................................................................................................ 31 9.2.7 PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE ............................ 31

10 SPECIFICATION ......................................................................................... 32

11 COMMISSIONING ....................................................................................... 34



11.1.1 PRE-COMMISSIONING .............................................................................................. 34 12 FAULT FINDING ..........................................................................................35

13 TYPICAL WIRING DIAGRAM ......................................................................36

14 FACTORY DEFAULT CONFIGURATION ...................................................37

15 ICONS AND LCD IDENTIFICATION ...........................................................40 15.1 PUSH BUTTONS ............................................................................................................ 40 15.2 STATUS / MEASUREMENT UNITS .............................................................................. 40 15.3 ALARM INDICATIONS .................................................................................................. 40

16 APPENDIX ...................................................................................................41 16.1 ALTERNATIVE WIRING TOPOLOGIES ....................................................................... 41

16.1.1 3 PHASE, 3 WIRE ....................................................................................................... 41 16.1.2 1 PHASE, 2 WIRE ....................................................................................................... 41 16.1.3 2 PHASE, 3 WIRE ( 2 PHASE CENTRE TAP NEUTRAL) ......................................... 42

16.2 5210 IDMT TRIPPING CURVES (TYPICAL) ................................................................. 43 16.3 SENDER WIRING RECOMMENDATIONS .................................................................... 44

16.3.1 EARTH RETURN SENDERS ...................................................................................... 44 16.3.2 INSULATED RETURN SENDERS .............................................................................. 44 16.3.3 FUEL LEVEL SENDERS ............................................................................................ 45

16.4 5200 SERIES CONFIGURATION SOFTWARE AND P810 INTERFACE MODULE .... 46 16.5 OUTPUT EXPANSION ................................................................................................... 46

16.5.1 RELAY OUTPUT EXPANSION (157) ......................................................................... 46 16.5.2 LED OUTPUT EXPANSION (548) .............................................................................. 46

16.6 INPUT EXPANSION ....................................................................................................... 46 16.7 STANDBY GENERATING SET? ................................................................................... 46 16.8 FULLY INTEGRATED AUTO MAINS FAILURE ........................................................... 46 16.9 ENCLOSURE CLASSIFICATIONS ................................................................................ 47



1 INTRODUCTION The DSE 5210 autostart module has been designed to allow the OEM to meet most of the industry’s complex specifications. It has been primarily designed to allow the user to start and stop the generator, and if required, transfer the load to the generator either manually (via external push-buttons) or automatically. The user also has facility to view all the system operating parameters via the LCD display. The DSE 5210 module monitors the engine, indicating the operational status and fault conditions; automatically shutting down the engine and giving a true first up fault condition of an engine failure by a flashing COMMON ALARM LED. Exact failure mode information is indicated by the LCD display on the front panel. The powerful Microprocessor contained within the module allows for a range of complex features to be incorporated as standard; • Graphical Icon based LCD display (excluding the need for translations and languages). • Voltage, Current and Power monitoring. • Engine parameter monitoring. • Fully configurable inputs for use as alarms or a range of different functions. • Extensive range output functions using built in relay outputs or relay expansion available. Selective operational sequences, timers and alarm trips can be altered by the customer via a PC using the 5200 series configuration software and P810 interface. Access to critical operational sequences and timers for use by qualified engineers, are barred by a security code. The module is housed in a robust plastic case for front panel mounting. Connections to the module are via locking plug and sockets. 2 CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION.

NOTE: Highlights an essential element of a procedure to ensure correctness.

CAUTION! Indicates a procedure or practice which, if not strictly observed, could result in damage or destruction of equipment.

WARNING! Indicates a procedure or practice, which could result in injury to personnel or loss of life if not followed correctly.

© Deep Sea Electronics Plc owns the copyright to this manual, which cannot be copied, reproduced or disclosed to a third party without prior written permission.

Compliant with BS EN 60950 Low Voltage Directive Compliant with BS EN 50081-2 EMC Directive Compliant with BS EN 50082-2 EMC Directive

Year 2000 Compliant



3 OPERATION The following description details the sequences followed by a module containing the standard ‘factory configuration’. Always refer to your configuration source for the exact sequences and timers observed by any particular module in the field.

3.1 AUTOMATIC MODE OF OPERATION

NOTE:- If a digital input configured to panel lock is active, the LCD will display the

icon. When in panel lock, changing module modes will not be possible. Viewing the instruments and event logs

is NOT affected by panel lock.

This mode is activated by pressing the pushbutton. An LED indicator beside the button confirms this action. When a Remote Start signal is applied to the remote start input, the following sequence is initiated:- The Remote Start Active indicator illuminates (if configured). To allow for false signals the Start Delay timer is initiated. After this delay, if the pre-heat output option is selected then the pre-heat timer is initiated, and the corresponding auxiliary output (if configured) will energise.

NOTE:- If the Remote Start signal is removed during the Start Delay timer, the unit will return to a stand-by state. After the above delays, the Fuel Solenoid is energised, and then one second later, the Starter Motor is engaged. The engine is cranked for a pre-set time period. If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and

Fail to Start fault will be displayed accompanied by a flashing shutdown symbol.



When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from the Alternator output. Alternatively, a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is selected by PC using the 5200 series configuration software). Rising oil pressure can also be used to disconnect the starter motor; however, it cannot be used for underspeed or overspeed detection. After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault. Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to stabilise before accepting the load. If an auxiliary output has been selected to give a load transfer signal, this would then activate.

NOTE:-A load transfer will not be initiated until the Oil Pressure has risen. Thus preventing excessive wear on the engine. On removal of the Remote Start signal, the Stop delay timer is initiated, once it has timed out, the load Transfer signal is de-energised, removing the load. The Cooling timer is then initiated, allowing the engine a cooling down period off load before shutting down. Once the Cooling timer expires, the Fuel Solenoid is de-energised, bringing the generator to a stop. Should the Remote Start signal be re-activated during the cooling down period, the generating set will return to an on load condition.



3.2 MANUAL OPERATION

NOTE:- If a digital input configured to panel lock is active, the LCD will display the

icon. When in panel lock, changing module modes will not be possible. Viewing the instruments and event logs

is NOT affected by panel lock.

To initiate a start sequence in MANUAL, press the pushbutton. When the controller is in the manual mode (indicated by an LED indicator beside the button), pressing the START (I) button will initiate the start sequence.

NOTE:- There is no Start Delay in this mode of operation. If the pre-heat output option is selected this timer is then initiated, and the auxiliary output selected is energised. The Fuel Solenoid is energised, and then the Starter Motor is engaged. The engine is cranked for a pre-set time period. If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and

Fail to Start fault will be displayed accompanied by a flashing shutdown indicator. When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from the Alternator output. Alternatively, a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is selected by PC using the 5200 series configuration software). Rising oil pressure can also be used to disconnect the starter motor; however, it cannot be used for underspeed or overspeed detection. After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault. Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to stabilise before it can be loaded. The generator will run off load, unless a Remote Start signal is applied, and if Load Transfer has been selected as a control source, the appropriate auxiliary output selected will activate. If the Remote Start signal is removed, the generator will continue to run On load until the Auto mode is selected. The Remote Stop Delay Timer will time out, the load is then disconnected. The generator will then run off load allowing the engine a cooling down period. Selecting STOP (O) de-energises the FUEL SOLENOID, bringing the generator to a stop.



4 PROTECTIONS The module will indicate that an alarm has occurred in several ways; The LCD display will indicate a ‘common alarm’ either :

(warning) or (shutdown) If appropriate, the LCD display or LED indicators will display the appropriate alarm icon i.e. for battery charging failure :

NOTE:- Alarm icons in the LED display area are ‘hid until lit’. This means that the display area appears totally clear, and ‘free from clutter’. The advantage of this is that when an alarm does occur, the respective LED icon will illuminate on the otherwise blank fascia. This makes alarm identification much clearer.

If no alarms are present the LCD will extinguish any alarm icons.

In the event of a warning alarm, the LCD will display the appropriate icon. If a shutdown then occurs, the module will display the appropriate icon. The original warning alarm icon will remain displayed. Example:-

Low battery volts warning (all symbols steady)

Followed by….

Low battery volts warning indicator still present, common alarm indicator has changed to a shutdown symbol and is now flashing. Also present is the flashing underspeed LED.

Underspeed and Shutdown alarm Icons are displayed flashing. The original warning will remain displayed as long at the triggering conditions remain. Any subsequent warnings or shutdowns that occur will be displayed steady, therefore only the first-up shutdown will appear flashing.



4.1 WARNINGS Warnings are non-critical alarm conditions and do not affect the operation of the generator system, they serve to draw the operators attention to an undesirable condition. In the event of a warning alarm, the LCD will display:-

BATTERY CHARGE FAILURE, if the module does not detect a voltage from the warning light terminal on the auxiliary charge alternator the icon will illuminate. BATTERY LOW VOLTAGE, if the module detects that the plant DC supply has fallen below the low volts setting level, the module will display:-

V The Battery Low Voltage alarm is delayed by the Low DC Volts Delay timer. BATTERY HIGH VOLTAGE, if the module detects that the plant DC supply has risen above the high volts setting level, the module will display:-

V FAIL TO STOP, If the module detects the engine is still running when the ‘Fail to stop timer’ expires, then the module will display:-

NOTE:- ‘Fail to Stop’ could indicate a faulty oil pressure sender - If engine is at rest check oil sender wiring and configuration. AUXILIARY INPUTS, if an auxiliary input has been configured as a warning the appropriate LCD segment will be displayed:- !

LOW FUEL LEVEL. If the fuel level detected by the fuel level sender falls below the low fuel level setting, a warning will occur.

The icon will illuminate. 4.2 ANALOGUE PRE-ALARMS The following alarms are termed ‘pre-alarms’ as they pre warn the operator of a potentially more serious alarm condition. For instance, if the engine temperature rises past the pre alarm level, a warning condition will occur to notify the operator. If the temperature falls below the level, then the alarm ceases, and the set will continue to run as normal. However if the temperature continues to rise until the coolant temperature trip point is reached, the warning is escalated and a high coolant temperature shutdown is initiated.

During a pre-alarm condition, the warning symbol is displayed on the LCD display, along with the appropriate icon: LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low oil pressure pre-alarm setting level after the Safety On timer has expired, a warning will occur. The icon will illuminate.



HIGH ENGINE TEMPERATURE if the module detects that the engine coolant temperature has exceeded the high engine temperature pre-alarm setting level after the Safety On timer has expired, a warning will occur.

The icon will illuminate. OVERSPEED, if the engine speed exceeds the pre-alarm trip a warning is initiated. The icon will illuminate. Overspeed is not delayed, it is an immediate warning. UNDERSPEED, if the engine speed falls below the pre-set pre-alarm after the Safety On timer has expired, a warning is initiated.

The icon will illuminate. GENERATOR HIGH FREQUENCY if the module detects a generator output frequency in excess of the pre-set pre-alarm, a warning is initiated.

The icon will illuminate. Generator High Frequency is not delayed, it is an immediate warning. GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the pre-set pre-alarm after the Safety On timer has expired, a warning is initiated.

The icon will illuminate. GENERATOR HIGH VOLTAGE if the module detects a generator output voltage in excess of the pre-set trip a shutdown is initiated.

The V icon will illuminate. High voltage is not delayed, it is an immediate shutdown. GENERATOR LOW VOLTAGE if the module detects a generator output voltage below the below the pre-set pre-alarm after the Safety On timer has expired, a warning is initiated.

The V icon will illuminate. 4.3 HIGH CURRENT WARNING ALARM GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the pre-set trip a warning is initiated.

The A icon will illuminate. If this high current condition continues for an excess period of time, then the alarm is escalated to a shutdown condition. For further details of the high current alarm, please see High Current Shutdown Alarm.



4.4 SHUTDOWNS Shutdowns are latching and stop the Generator. The alarm must be cleared, and the fault removed to reset the module. In the event of a shutdown alarm, the LCD will display:-

(flashing). The appropriate icon will also be displayed flashing

NOTE:- The alarm condition must be rectified before a reset will take place. If the alarm condition remains, it will not be possible to reset the unit (The exception to this is the Low Oil Pressure alarm and similar ‘delayed alarms’, as the oil pressure will be low with the engine at rest). Any subsequent warnings or shutdowns that occur will be displayed steady, therefore only the first-up shutdown will appear flashing. FAIL TO START, if the engine does not fire after the pre-set number of attempts has been made a shutdown will be initiated. The icon will illuminate. EMERGENCY STOP, removal of the positive DC Supply from the Emergency Stop input initiates the following sequence, firstly it will initiate a controlled shutdown of the Generator and prevent any attempt to restart the Generator until the Emergency Stop push-button has been reset. Secondly, it removes the positive DC supply from both the Fuel Solenoid and Starter Solenoid.

The icon will illuminate.

NOTE:- The Emergency Stop positive signal must be present otherwise the unit will shutdown.

LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low oil pressure trip setting level after the Safety On timer has expired, a shutdown will occur. The icon will illuminate. HIGH ENGINE TEMPERATURE if the module detects that the engine coolant temperature has exceeded the high engine temperature trip setting level after the Safety On timer has expired, a shutdown will occur.

The icon will illuminate. OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated. The icon will illuminate. Overspeed is not delayed, it is an immediate shutdown.

NOTE:-However, during the start-up sequence the overspeed trip logic can be configured to allow an extra trip level margin, this is used to prevent nuisance tripping on start-up - Refer to the 5200 series configuration software manual under heading ‘Overspeed Overshoot’ for details.

UNDERSPEED, if the engine speed falls below the pre-set trip after the Safety On timer has expired, a shutdown is initiated.

The icon will illuminate.



GENERATOR HIGH FREQUENCY if the module detects a generator output frequency in excess of the pre-set trip a shutdown is initiated.

The icon will illuminate. Generator High Frequency is not delayed, it is an immediate shutdown. GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the pre-set trip after the Safety On timer has expired, a shutdown is initiated.

The icon will illuminate. GENERATOR HIGH VOLTAGE if the module detects a generator output voltage in excess of the pre-set trip a shutdown is initiated.

The V icon will illuminate. High voltage is not delayed, it is an immediate shutdown. GENERATOR LOW VOLTAGE if the module detects a generator output voltage below the below the pre-set trip after the Safety On timer has expired, a shutdown is initiated.

The V icon will illuminate. OIL PRESSURE SENDER OPEN CIRCUIT, if the module detects a loss of signal from the oil pressure sender (open circuit) a shutdown is initiated. The LCD will indicate:-

(Steady) (In addition ‘-----‘on the engine oil pressure instrument). Sender failure is not delayed, it is an immediate shutdown. AUXILIARY INPUTS, if an auxiliary input has been configured as a shutdown the appropriate LCD segment will be displayed:- !

LOSS OF SPEED SIGNAL, if the speed sensing signal is lost during cranking, a shutdown is initiated. The icon will illuminate. (Steady) (In addition ‘-----‘on the engine RPM instrument).

NOTE:- This will only occur if the speed sensing signal is lost during cranking or during the safety on timer. If the signal is lost during normal operation, the Generator will shutdown with an Under-speed alarm.



4.5 HIGH CURRENT SHUTDOWN ALARM GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the pre-set trip a warning is initiated. This warning will continue for a period of time depending upon the level of overload that the generator is subjected to, and the configuration setting for Generator High Current in the 5200 series configuration software. For instance, the factory default settings for Generator High Current allow for a loading of the generator to 110% for one hour. That is to say if the generator load level exceeds the trip point by 10%, a warning alarm will occur while the overload condition exists. If the load level does not drop to normal levels within one hour, the set is stopped, the 5210 module displaying either shutdown alarm or electrical trip alarm depending upon module configuration.

Additionally, the A icon will illuminate.

NOTE:- Higher overload levels will result in a faster acting shutdown condition. For instance with the factory default configuration, an overload level twice that of the trip level ( typically 200%) will result in a Generator High Current shutdown condition after 36 seconds. For details of the relationship between the overload and the shutdown time, please see the Appendix section of this manual. 4.6 ELECTRICAL TRIPS Electrical trips are latching and stop the Generator but in a controlled manner. On initiation of the electrical trip condition the module will de-energise the ‘Load Transfer’ Output to remove the load from the generator. Once this has occurred, the module will start the Cooling timer and allow the engine to cool, off-load before shutting down the engine. The alarm must be accepted and cleared, and the fault removed to reset the module.

In the event of an electrical trip alarm, the icon will illuminate.

Additionally, During the cooling timer the warning symbol is displayed followed by the flashing shutdown

symbol when the cooling timer has expired. AUXILIARY INPUTS, if an auxiliary input has been configured as an electrical trip the appropriate LCD segment will be displayed:- !

GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the pre-set trip a warning is initiated.

The A icon will illuminate. If this high current condition continues for an excess period of time, then the alarm is escalated to either a shutdown or electrical trip condition (depending upon module configuration). For further details of the high current alarm, please see High Current Shutdown Alarm.



5 LCD INDICATORS AND LOGO INSERT USER CONFIGURABLE LCD indicators These indicators can be configured by the user to indicate any one of 100+ different functions based around the following:-

• INDICATIONS - Monitoring of a digital input and indicating associated functioning user’s equipment - Such as Battery Charger On or Louvre Open, etc.

• WARNINGS and SHUTDOWNS - Specific indication of a particular warning or shutdown condition, backed up by LCD indication - Such as Low Oil Pressure Shutdown, Low Coolant level, etc.

• STATUS INDICATIONS - Indication of specific functions or sequences derived from the modules operating state - Such as Safety On, Pre-heating, Panel Locked, Generator Available, etc.

These indicators are annunciated using a removable insert card. Additionally the module’s logo can be changed to suit generator manufacturer’s requirements. This can be used for instance to give custom branding to the module, or even include the service telephone number. DSE have produced the ‘insert card creator’ software, shipped with the DSE Software CD to ease the production of text and logo insert cards to suit your application.

Removal and insertion of the text insert card

Removal and insertion of the Logo insert card



6.1 TYPICAL LCD DISPLAY SCREENS INSTRUMENTS

The LCD displays the various engine parameters such as ‘ENGINE SPEED’, ‘OIL PRESSURE’, ‘HOURS RUN’, etc. Each instrument is displayed with the appropriate units of measure.

In this example, the values being displayed are Generator phase to neutral L1-N, AC voltages V.

STATUS ICONS

The LCD also displays the status of the controller by showing (for example) an hourglass symbol when a timer is in progress or by displaying a common alarm symbol. This display is indicating that the timer is in progress and a warning alarm is present. See the ‘Protections’ section of this manual for details of the alarms. In this example the values being displayed are the three factory

AC currents A USER DEFINED INDICATIONS

The LCD displays the user-defined indications when configured and active. The icons will illuminate and point to the appropriate text insert label. These indications can be used to indicate the operation of external equipment (i.e. ‘Battery Charger On’, ‘Breaker Closed’ etc) or to indicate internal states (i.e. Engine Running, Safety On, etc).

USER DEFINED ALARMS

The LCD displays the user-defined alarms when configured and active. The icons will illuminate and point to the appropriate text insert label. These alarms can be used to indicate the operation of external alarms (i.e. ‘Low Fuel Level’, ‘Low Coolant level’ etc) or to indicate internal alarms (i.e. Fail to Stop, MPU fault, etc).

HOURS RUN COUNTER

The LCD displays the generator hours run time while both the generator symbol and the clock symbol are present. In this example the hours run time would read 21 hours and 35 minutes.

HOURS RUN (100 hrs +)

The hours run up to and including 99 are displayed on the third line of the display. Minutes run are displayed after the decimal point. All hours above 99, (i.e. the hundreds, thousands and tens of thousands units) are displayed on the second line of the display. In this example the hours run time would read 221 hours and 35 minutes.

HOURS RUN (1000 hrs +)

All hours above 99, (i.e. the hundreds, thousands and tens of thousands units) are displayed on the second line of the display. In this example the hours run time would read 3221 hours and 35 minutes.



6.2 LCD DISPLAY AREAS

Instrument values

Display information & units of measure

Alarm icons

Status icons

User configurable display icons



6.3 VIEWING THE INSTRUMENTS It is possible to scroll to display the different instruments by repeatedly operating the scroll button. Once selected the instrument will remain on the LCD display until the user selects a different instrument or after a period of inactivity, the module will revert to the initial display (Hz/RPM). Instrument Page Order:- • Generator RPM / Frequency (Hz) • AC Voltage Line-Neutral • AC Voltage Line-Line • Oil Pressure • Coolant temperature • Fuel level (%) • Engine Hours Run • DC Battery Voltage • AC Line Current • AC Line power (kW) • AC Line power (kVA) • AC phase angle (cos ∅) Manually Selecting an Instrument Initial display (Hz/RPM)

Pressing the DOWN button the LCD will then show (Generator L-N voltages)

Pressing the DOWN button the LCD will then show (Generator L-L voltages)

Pressing the button again will scroll through each individual instrument eventually returning to the original instrument displayed.

NOTE:-Once selected the instrument will remain on the LCD display until the user selects a different instrument or after a period of inactivity, the module will revert to the initial display.



6.4 VIEWING THE EVENT LOG The model 5210 remote start module maintains a log of the last 15 shutdown alarms to enable the operator or engineer to view the past alarms history. Only shutdown and electrical trip alarms are logged; warning alarms are not logged. Once the log is full (15 shutdown alarms), any subsequent shutdown alarms will overwrite the oldest entry in the log. Hence, the log will always contain the 15 most recent shutdown alarms. The alarm is logged, along with the date and time of the event in the format shown in this example.

To view the event log, press the log button . The LCD display will flash the log symbol to confirm that the event log has been entered.

In this example, the oil can symbol represents an oil pressure shutdown, backed up by the flashing shutdown symbol in the LCD display. The value displayed means that the oil pressure shutdown occurred on November 1st 2002 at 8:17.

Press down to view the next most recent shutdown alarm :

In this example, the fuel pump symbol represents a fuel level shutdown, backed up by the flashing shutdown symbol in the LCD display. The value displayed means that the oil pressure shutdown occurred on November 1st 2002 at 11:50.

Continuing to press down will cycle through the past alarms until all 15 logged alarms have been viewed, after which the most recent alarm will again be showed and the cycle will begin again.

To exit the event log and return to viewing the instruments, press the log button.



6.5 INDICATORS COMMON ALARM LCD indicators These indicate when an alarm condition is present. The Alarm icons or LEDs will detail the exact nature of the alarm. (warning) or

(shutdown) USER CONFIGURABLE LCD INDICATORS These LCD’s can be configured by the user to indicate any on of the different functions based around the following:- • INDICATIONS - Monitoring of a digital input and indicating

associated functioning user’s equipment - Such as Battery Charger On or Louvres Open, etc.

• WARNINGS and SHUTDOWNS - Specific indication of a particular warning or shutdown condition, backed up by LCD indication (!)- Such as Low Oil Pressure Shutdown, Low Coolant level, etc.

• STATUS INDICATIONS - Indication of specific functions or sequences derived from the modules operating state - Such as Safety On, Pre-heating, Generator Available, etc.

6.6 CONTROLS STOP/RESET This button places the module into its Stop/reset mode. This will clear any alarm conditions for which the triggering criteria have been removed. If the engine is running and this position is selected, the module will automatically instruct the changeover device to un-load the generator (‘Load transfer’ becomes inactive (if used)). The fuel supply will be removed and engine will be brought to a standstill. Should a remote start signal be present while operating in this mode, a remote start will not occur.

MANUAL This mode is used to allow manual control of the generator functions. Once in Manual mode the module will respond to the start (I) button and start the engine and run off load. If the engine is running off-load in the Manual mode and a remote start signal becomes present, the module will automatically instruct the changeover device to place the generator on load (‘Load transfer’ becomes active (if used)). Should the remote start signal then be removed the generator will remain on load until either the ‘STOP/RESET’ or ‘AUTO’ positions is selected.

AUTO This button places the module into its ‘Automatic’ mode. This mode allows the module to control the function of the generator automatically. The module will monitor the remote start input and once a start condition is signalled the set will be automatically started and placed on load (‘Load transfer’ becomes active (if used)). If the starting signal is removed the module will automatically transfer the load from the generator and shut the set down observing the stop delay timer and cooling timer as necessary. The module will then await the next start event. For further details, please see the more detailed description of ‘Auto Operation’ earlier in this manual.

START

This button is only active in MANUAL mode. Pressing this button in manual mode will start the engine and run off load. If the engine is running off-load in the Manual mode and a remote start signal becomes present, the module will automatically instruct the changeover device to place the generator on load (‘Load transfer’ becomes active (if used)). Should the remote start signal then be removed the generator will remain on load until either the ‘STOP/RESET’ or ‘AUTO’ positions is selected.

I



7 FRONT PANEL CONFIGURATION Although full configuration of the module is possible using the 5200 series configuration software, selected parameters that may require adjustment in the field are able to be adjusted via the module’s fascia. 7.1 ACCESSING THE FRONT PANEL CONFIGURATION EDITOR This configuration mode allows the operator limited customising of the way the module operates.

Operation Detail To enter the ‘configuration mode’ press both the CONFIGURE/LOG and STOP buttons together. + 7.1.1 ENTERING THE CONFIGURATION EDITOR PIN NUMBER If the module PIN number has been set, the PIN number request is then shown. The configuration cannot be viewed or changed until the PIN number is correctly entered. If no PIN has been set, then skip to the next section.

Pin The first - is flashing.

----

Pin Press + or – buttons to adjust it to the correct value for the first digit of the PIN number. Press when the first digit is correctly entered. The value you have entered will ‘disappear’ to maintain security. 1---

Pin The second - is now flashing. Press + or – buttons to adjust it to the correct value for the second digit of the PIN number. Press when the second digit is correctly entered. ----

Pin The third - is now flashing. Press + or – buttons to adjust it to the correct value for the third digit of the PIN number. Press when the third digit is correctly entered. ----

Pin The fourth - is now flashing. Press + or – buttons to adjust it to the correct value for the fourth digit of the PIN number. Press when the fourth digit is correctly entered. ----

NOTE: - When is pressed after editing the final PIN digit, the PIN is checked for validity. If the number is not correct, the editor is automatically exited. To retry you must re-enter the editor as described above. If the PIN is entered correctly, The first configurable parameter is then displayed :

The parameter being displayed in this example is the Low Oil Pressure prealarm, being indicated by the illuminated oil can.

The warning symbol is indicating that it is the warning (pre-alarm) parameter that is being displayed.

NOTE:- To exit the front panel configuration editor at any time, press the Stop/Reset button.

Ensure you have saved any changes you have made by pressing the button first.



7.2 EDITING AN ANALOGUE VALUE Press the button to enter edit mode. This is indicated by the flashing parameter. In this example, entering edit mode will cause the 1.2 value to flash.

When in edit mode, pressing the + or – buttons will adjust the parameter to the desired value. Press the button to ‘save’ the value. The value will stop flashing to confirm that it has been saved.

To select another value to edit, press the + button :

The next parameter being displayed in this example is the Low Oil Pressure shutdown, being indicated by the illuminated oil can.

The shutdown symbol is indicating that it is the shutdown (trip) parameter that is being displayed.

Continuing to press the + or – buttons will cycle through the adjustable parameters in the following order : Config’ Section Parameter Type Icons displayed Analogue senders Low Pressure Pre Alarm Low Pressure Trip High Temperature Pre Alarm High Temperature Trip Fuel Level Pre Alarm Calendar Date/time Date/time Timers Start delay Timer 2 Preheat Timer 3 Crank attempt Timer 4 Crank rest Timer 5 Safety delay Timer 6 Overspeed overshoot Timer 7 Warming up Timer 8 Return delay Timer 10 Cooling run Timer 11 E.T.S.(Energise to stop) solenoid hold Timer 12 Generator output Generator Under Voltage L1-N Trip V Generator Under Voltage L1-N Pre Alarm V Generator Over Voltage Pre Alarm V Generator Over Voltage Trip V Generator Under Frequency Trip Generator Under Frequency Pre Alarm Generator Over Frequency Pre Alarm Generator Over Frequency Trip Delayed Overcurrent % Trip AEngine speed Under Speed (RPM) Trip Under Speed (RPM) Pre Alarm Over Speed (RPM) Pre Alarm Over Speed (RPM) Trip DC Voltages Low DC Voltage Warning V High DC Voltage Warning V Charge Alternator Failure Warning



NOTE: - The timers are numbered to enable them to be identified when in configuration mode. Some numbers are reserved so do not appear in the list. In the following example timer number 2 (‘Start delay’ from the above list) is currently set to 5.0 seconds.

Ie the ‘hour glass’ indicates that it is a timer being displayed. The ‘2’ indicates that it is timer number 2 (Start delay). The current setting is 5.0 (seconds).



7.2.1 EDITING THE CURRENT DATE/TIME The date/time should be initially set using the 5200 series configuration software. However, there may be certain circumstances where a minor change to the module’s time is required. One such instance is correction for daylight saving.

NOTE:- The 5210 controller maintains the current date/time so long as it connected to a DC supply within the operating range. Disconnection of the supply will result in the date/time being frozen until the module’s power is reapplied. When this occurs, the date/time will resume operation from the time the power was disconnected. If this occurs, you can use the front panel editor to correct the date/time or reset it using the 5200 series configuration software.

NOTE: - The calendar is used by the 5210’s run scheduler and the event log.

Press the configure/log and Stop/Reset buttons simultaneously. The LCD configure indicator will

flash to indicate that the module is in ‘configuration mode’. Release the Stop/Reset button then release the

configure/log button. Press the + button until the calendar is shown :

This display is showing a time of 4:30 on 21st October 2002.

To edit the time, press the button. The time, 4.30 in this example, will begin flashing. Press the + or – buttons

to adjust the time in one minute steps until the desired time is shown. Press the button to save the change. The time stops flashing to confirm that is has been successfully stored.



8 INSTALLATION INSTRUCTIONS The model DSE 5210 Module has been designed for front panel mounting. Fixing is by 4 clips for easy assembly. 8.1 PANEL CUT-OUT

220.00mm (8.7”)

Maximum panel thickness – 8mm (0.3”) In conditions of excessive vibration the module should be mounted on suitable anti-vibration mountings. 8.2 COOLING The module has been designed to operate over a wide temperature range -30 to +70º C. Allowances should be made for the temperature rise within the control panel enclosure. Care should be taken NOT to mount possible heat sources near the module unless adequate ventilation is provided. The relative humidity inside the control panel enclosure should not exceed 95%. 8.3 UNIT DIMENSIONS

Panel cut-out 220mm x 160mm ( 8.7” x 6.3”)

160.00mm (6.3”)



8.4 FRONT PANEL LAYOUT

8.5 REAR PANEL LAYOUT



9 ELECTRICAL CONNECTIONS Connections to the Module are via plug and sockets. 9.1 CONNECTION DETAILS The following describes the connections and recommended cable sizes to the 7 plugs and sockets on the rear of the Module. See rear panel layout FIG 6. 9.1.1 PLUG “A” 8 WAY PIN No


NOTES

1 DC Plant Supply Input (negative)

2.5mm

2 DC Plant Supply Input (positive)

2.5mm (Recommended Maximum Fuse 21A)

3 Emergency Stop Input 2.5mm Plant Supply positive. In addition, supplies fuel & start outputs. (Recommended Maximum Fuse 32A)

4 Fuel relay Output 2.5mm Plant Supply positive from pin 3. 16 Amp rated. 5 Start relay Output 2.5mm Plant Supply positive from pin 3. 16 Amp rated. 6 Auxiliary Output relay 1 1.0mm Plant Supply positive. 5 Amp rated. 7 Auxiliary Output relay 2 1.0mm Plant Supply positive. 5 Amp rated. 8 Auxiliary Output relay 3 1.0mm Plant Supply positive. 5 Amp rated.

9.1.2 PLUG “B” 11 WAY PIN No


NOTES

9 Charge fail / excite 2.5mm Do not connect to ground (battery –ve) 10 Auxiliary input 1 0.5mm Switch to negative 11 Auxiliary input 2 0.5mm Switch to negative 12 Auxiliary input 3 0.5mm Switch to negative 13 Auxiliary input 4 0.5mm Switch to negative 14 Auxiliary input 5 0.5mm Switch to negative 15 Auxiliary input 6 0.5mm Switch to negative 16 Functional Earth 2.5mm Connect to a good clean earth point 17 Magnetic pickup positive 0.5mm Connect to Magnetic Pickup device 18 Magnetic pickup negative 0.5mm Connect to Magnetic Pickup device 19 Not connected -

NOTE:- Ensure magnetic pickup screen is connected to ground at one end only.

NOTE:- Connector C is not fitted to the 5210 remote start module.



9.1.3 PLUG “D” 4 WAY (OPTIONAL) PIN No


NOTES

23 RS485 port Common 0.5mm Use only 120Ω RS485 approved cable 24 RS485 port B 0.5mm Use only 120Ω RS485 approved cable 25 RS485 port A 0.5mm Use only 120Ω RS485 approved cable 26 Not connected -

NOTE:- Connector E is not fitted to the 5210 remote start module. 9.1.4 PLUG “F” 4 WAY PIN No


NOTES

35 Generator L1 voltage monitoring input

1.0mm Connect to generator L1 output (AC) (Recommend 2A fuse)





38 Generator Neutral input 1.0mm Connect to generator Neutral terminal (AC) 9.1.5 PLUG “G” 5 WAY PIN No


NOTES

39 CT Secondary for L1 2.5mm Connect to secondary of L1 monitoring CT 40 CT Secondary for L2 2.5mm Connect to secondary of L2 monitoring CT 41 CT Secondary for L3 2.5mm Connect to secondary of L3 monitoring CT 42 CT secondary common 2.5mm Connect to secondary of all monitoring CT’s 43 Not connected -

9.1.6 PLUG “H” 4 WAY PIN No


NOTES

44 Oil Pressure Input 0.5mm Connect to Oil pressure sender 45 Coolant Temperature

Input 0.5mm Connect to Coolant Temperature sender

46 Fuel Level input 0.5mm Connect to Fuel Level sender 47 Sender Common Return 0.5mm Return feed for senders*.

NOTE*:- If using single terminal senders refer to connection diagram. If using earth return type senders connect return terminals to pin 47 and also connect pin 47 to earth. This is detailed in the Appendix section entitled “Sender wiring recommendations” elsewhere in this manual. 9.1.7 PC CONFIGURATION INTERFACE CONNECTOR

8-way connector allows connection to PC via the 810 configuration interface. Module can then be re-configured utilising the 5200 series configuration software.

9.1.8 EXPANSION OUTPUT CONNECTOR

The expansion connector allows connection to the 157 relay expansion module or to the 548 LED Remote annunciator module.



9.2 CONNECTOR FUNCTION DETAILS The following describes the functions of the 3 connectors on the rear of the module. See rear panel layout FIG 5. 9.2.1 PLUG “A” 8 WAY PIN No

DESCRIPTION

1 DC Supply negative. System DC negative input. (Battery Negative). 2 DC Supply positive. System DC positive input. (Battery Positive). 3 Emergency Stop input. Internally linked to Starter and Fuel outputs. If this input is not connected to

positive the module will be locked out, and if the engine is running it will shutdown immediately. The Positive Supply is also removed from Starter and Fuel outputs, therefore only a single pole Emergency Shutdown button is required.

4 Fuel Relay output. Plant Supply positive from pin 3. Used to control the fuel solenoid or engine fuel control system.

5 Starter Relay output. Plant Supply positive from pin 3. Used to control the Starter Motor. 6 Auxiliary Relay output 1. Plant Supply positive. Configurable output, see Calibration Manual for

options available. 7 Auxiliary Relay output 2. Plant Supply positive. Configurable output, see Calibration Manual for

options available. 8 Auxiliary Relay output 3. Plant Supply positive. Configurable output, see Calibration Manual for

options available. 9.2.2 PLUG “B” 11 WAY PIN No

DESCRIPTION

9 Charge Fail input / Excitation output. Supplies excitation to the Plant Battery Charging Alternator, also an input for the Charge Fail detection circuitry.

10 Auxiliary input 1. This is a negative switched configurable input, see Calibration Manual for options available. It is possible to configure the input to be a normally closed signal or a normally open signal.






16 Functional Earth - Ensure connection to a good clean earth point. 17 Magnetic Input positive. An AC signal from the magnetic pickup positive for speed sensing. 18 Magnetic Input negative. An AC signal from the magnetic pickup negative for speed sensing. 19 Not connected


NOTE:- Connector C is not fitted to the 5210 remote start module.



9.2.3 PLUG “D” 4 WAY (OPTIONAL, FITTED TO RS485 CONTROLERS ONLY) PIN No

DESCRIPTION

23 RS485 port Common 24 RS485 port B. Use only screened 120Ω cable approved specifically for use in RS485 applications. 25 RS485 port A. Use only screened 120Ω cable approved specifically for use in RS485 applications. 26 Not used. Do not connect to this terminal.

NOTE:- Connector E is not fitted to the 5210 remote start module.

9.2.4 PLUG “F” 4 WAY PIN No

DESCRIPTION

35 Generator L1 sensing input. Connect to alternator L1 output. 36 Generator L2 sensing input. Connect to alternator L2 output. If using single phase only do not

connect this terminal. 37 Generator L3 sensing input. Connect to alternator L3 output. If using single phase only do not

connect this terminal. 38 Generator N sensing input. Connect to alternator N output.

9.2.5 PLUG “G” 5 WAY PIN No

DESCRIPTION

39 Generator L1 current transformer connection. 40 Generator L2 current transformer connection. If single phase is used do not connect this pin. 41 Generator L3 current transformer connection. If single phase is used do not connect this pin. 42 Generator current transformer common connection and CT earth connection. 43 Not used. Do not connect to this terminal.


DESCRIPTION

44 Oil Pressure sensing input. Connect to resistive type oil pressure sender. Refer to connection diagram for details.

45 Coolant Temperature sensing input. Connect to resistive type coolant temperature sender. Refer to connection diagram for details.

46 Fuel Level sensing input. Connect to resistive type fuel level sender. Refer to connection diagram for details.

47 Sender Common connection. Return feed from sender units - refer to connection diagram for details.

9.2.7 PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE If you require additional plugs from DSE, please contact our Sales department using the part numbers below. 5210 Terminal Connector Plug description DSE Part number

1-8 A BL08 8way 5.08mm spacing connector plug 007-125 9-19 B BL11 11way 5.08mm spacing connector plug 007-135 23-26 D BL04 4way 3.81mm spacing connector plug 007-408 35-38 F BL04 4way 10.16mm spacing connector plug 007-003 39-43 G BL05 5way 5.08mm spacing connector plug 007-329 44-47 H BL04 4way 5.08mm spacing connector plug 007-100

NOTE:- Connectors C and E are not fitted to the 5210 remote start module.



10 SPECIFICATION

DC Supply Continuous voltage rating : 8V to 35V Cranking dip protection : Able to survive 0V for 50mS, providing supply was at least 10V before dropout and supply recovers to 5V. This is achieved without the need for internal batteries Charge Fail/ Excitation: 0V to 35V fixed power source 25W Max. Standby Current: 250mA at 12V. 125mA at 24V. Max. Operating Current: 425mA at 12V. 215mA at 24V

Alternator Input Range: 15V - 277(ph-N) (+20%) 50Hz - 60Hz 30V - 480(ph-ph) (+20%) 50Hz - 60Hz Accuracy: 1% of full scale Average sensing Supported topologies: 3 Phase 4wire Single phase 2 wire 3 phase 3 wire 2 Phase 3 wire L1 & L2 2 Phase 3 wire L1 & L3

CT’s Burden: 0.5VA Primary rating: 1A - 6000A (user selectable) Secondary rating: 5A secondary Accuracy of measurement: 1% of full load rating (when using 0.5% or better CTs) Lower class CTs will reduce the overall accuracy of the reading. Recommendations: Class 1 required for instrumentation Protection class required if using for protection.

Magnetic Pickup Voltage range : +/- 0.5V minimum (during cranking) to 70V Peak Frequency range: 10,000 Hz (max)

Relay outputs Fuel: 16 Amp DC at supply voltage Start: 16 Amp DC at supply voltage Auxiliary outputs 1,2,3: 5 Amp DC at supply voltage

Dimensions Overall: 240mm x 172 mm x 57mm (9 ½“ x 6 ¾” x 2 ¼”) Panel cut-out: 220mm x 160mm ( 8.7” x 6.3”) Max panel thickness 8mm ( 0.3”)



Electrical Safety /Electromagnetic Compatibility

BS EN 60950 Safety of information technology equipment, including electrical business equipment BS EN 61000-6-2 EMC Generic Emission Standard (Industrial) BS EN 61000-6-4 EMC Generic Emission Standard (Industrial)

Environmental BS EN 60068-2-1 Cold Temperature -30°C BS EN 60068-2-2 Hot Temperature +70°C BS2011-2-1 Humidity 93% RH@40°C for 48 Hours BS EN 60068-2-6 Vibration 10 sweeps at 1 octave/minute in each of 3 major axes 5Hz to 8Hz @ +/-7.5mm constant displacement 8Hz to 500Hz @ 2gn constant acceleration BS EN 60068-2-27 Shock 3 Half sine shocks in each of 3 major axes 15gn amplitude, 11mS durationBS EN 60529 Degrees of protection provided by enclosures: IP55 (Front of module when module is installed into the control panel with the optional sealing gasket). IP42 (front of module when module is installed into the control panel WITHOUT being sealed to the panel)NEMA Rating (Approximate) 12 (Front of module when module is installed into the control panel with the optional sealing gasket). 2 (front of module when module is installed into the control panel WITHOUT being sealed to the panel)

Product Certification

C US

European CE approved. UL approved C-UL / CSA approved.

Russia and other CIS countries approved

BS EN 2002/95/EC Restriction of Hazardous

Substances (RoHS)

BS EN 2002/96/EC Waste Electrical and

Electronic Equipment (WEEE)

Relevant Company Certification

BS EN ISO 9001:2000 Applicable to Design,

marketing, assembly, service and repair of electronic control

modules




11 COMMISSIONING 11.1.1 PRE-COMMISSIONING Before the system is started, it is recommended that the following checks are made:- 7.1. The unit is adequately cooled and all the wiring to the module is of a standard and rating compatible with the

system. 7.2. The unit DC supply is fused and connected to the battery and that it is of the correct polarity. 7.3. The Emergency Stop input is wired to an external normally closed switch connected to DC positive.

NOTE:- If Emergency Stop feature is not required link this input to the DC Positive. The module will not operate unless either the Emergency Stop is fitted correctly OR Pin 3 is connected to DC positive (positive)

7.4. To check the start cycle operation, take appropriate measures to prevent the engine from starting (disable the

operation of the fuel solenoid). After a visual inspection to ensure it is safe to proceed, connect the battery supply. Select “MANUAL”, the unit start sequence will commence.

7.5. The starter will engage and operate for the pre-set crank period. After the starter motor has attempted to start

the engine for the pre-set number of attempts the LCD will display its icon indicating; ‘Failed to start’ . Select the STOP/RESET position to reset the unit.

7.6. Restore the engine to operational status (reconnect the fuel solenoid), again select “MANUAL”, this time the

engine should start and the starter motor should disengage automatically. If not then check the engine is fully operational (fuel available, etc.) and that the fuel solenoid is operating. The engine should now run up to operating speed. If not, and an alarm is present, check the alarm condition for validity, then check input wiring. The engine should continue to run for an indefinite period. It will be possible at this time to view the engine and alternator parameters - refer to the ‘Description of Controls’ section of this manual.

7.7. Select “AUTO” on the front panel, the engine will run for the pre-set cooling down period, then stop. The

generator should stay in the standby mode. If not check that there is not a signal present on the Remote start input.

7.8. Initiate an automatic start by supplying the remote start signal. The start sequence will commence and the

engine will run up to operational speed. Once the generator is available a load transfer will take place, the Generator will accept the load. If not, check the wiring to the Generator Contactor Coil (if used). Check the Warming timer has timed out.

7.9. Remove the remote start signal, the return sequence will start. After the pre-set time period, the load will be

removed from the generator. The generator will then run for the pre-set cooling down period, then shutdown into it’s standby mode.

7.10. Set the modules internal clock/calendar to ensure correct operation of the scheduler and event logging

functions. For details of this procedure see section entitled Front Panel Configuration – Editing the date/time. 7.11. If despite repeated checking of the connections between the 5210 and the customer’s system, satisfactory

operation cannot be achieved, then the customer is requested to contact the factory for further advice on:-





12 FAULT FINDING

SYMPTOM POSSIBLE REMEDY Unit is inoperative Check the battery and wiring to the unit. Check the DC supply. Check the DC

fuse. Unit shuts down Check DC supply voltage is not above 35 Volts or below 9 Volts

Check the operating temperature is not above 70 °C. Check the DC fuse. Unit locks out on Emergency Stop

If an Emergency Stop Switch is not fitted, ensure that a positive is connected to the Emergency Stop input. Check emergency stop switch is functioning correctly. Check Wiring is not open circuit.


Ensure that Magnetic pick-up screen is only connected at one end, if connected at both ends, this enables the screen to act as an aerial and will pick up random voltages.


Check engine oil pressure. Check oil pressure switch/sender and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sender is compatible with the 5210 Module and is correctly configured.


Check engine temperature. Check switch/sender and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sender is compatible with the 5210 Module.




Check wiring of fuel solenoid. Check fuel. Check battery supply. Check battery supply is present on the Fuel output of the module. Check the speed sensing signal is present on the 5210 inputs. Refer to engine manual.


Check that there is no signal present on the “Remote Start” input. Check configured polarity is correct.


Check Start Delay timer has timed out. If remote start fault, check signal is on “Remote Start” input. Confirm input is configured to be used as “Remote Start”.

Pre-heat inoperative Check wiring to engine heater plugs. Check battery supply. Check battery supply is present on the Pre-heat output of module. Check pre-heat has been selected in your configuration.

Starter motor inoperative Check wiring to starter solenoid. Check battery supply. Check battery supply is present on the Starter output of module. Ensure that the Emergency Stop input is at positive.


Check Warm up timer has timed out. Ensure generator load inhibit signal is not present on the module inputs.

Incorrect reading on Engine gauges

Check engine is operating correctly. Check sender and wiring paying particular attention to the wiring to terminal 47 (refer to appendix). Check that sender is compatible with the 5210 Module and is correctly configured.

NOTE: - The above fault finding is provided as a guide check-list only. As it is possible for the module to be configured to provide a wide range of different features, always refer to the source of your module configuration if in doubt.



13 TYPICAL WIRING DIAGRAM



14 FACTORY DEFAULT CONFIGURATION In the tables below, the icon indicates an item that can be adjusted from the module’s front panel editor. Absence of the icon beside an item means that adjustment of this parameter is only possible using the 5200 series configuration software in conjunction with the P810 interface. For further details on adjustment from the front panel editor, see the section entitled “Front panel configuration” elsewhere within this manual. Module settings Value Base module 5210 remote start module Miscellaneous settings Value Alternator fitted Yes Poles 4 Magnetic pickup fitted No AC System 3 phase, 4 wire Enable fast loading feature No Number of start attempts 3 Input settings - Analogue Value Low oil pressure input type VDO 10 bar High coolant temp input type VDO 120 degrees C Trip Return Low oil pressure pre-alarm 1.17 Bar 17.0 PSI 1.24 Bar 18.0 PSI Low oil pressure shutdown 1.03 Bar 14.9 PSI N/A High coolant temp pre-alarm 115°C 239°F 110°C 230°F High coolant temp shutdown 120°C 248°F N/A Fuel level input type VDO Ohm Range Fuel pump control No Low fuel level 10% Input settings - Digital Value 1 Remote start Close to activate 2 User configured Close to activate, Indication Always active 3 User configured Close to activate, Warning Active from safety on 4 User configured Close to activate, Shutdown Always active 5 User configured Close to activate, Shutdown Active from safety on 6 User configured Close to activate, Electrical trip Always active LCD indicator settings Value 1 Lit Remote start present 2 Lit Digital input 2 active 3 Lit System in auto mode 4 Lit Common alarm Output settings – Relay Value 1 Energise Preheat (during pre-heat timer) 2 Energise Common alarm 3 Energise Close generator



Output settings – Expansion A Value 1 Energise Output not used 2 Energise Output not used 3 Energise Output not used 4 Energise Output not used 5 Energise Output not used 6 Energise Output not used 7 Energise Output not used 8 Energise Output not used Timer settings Value Start delay 5s Pre-heat 0s Sensor fail delay 2.0s Cranking time 10s Crank rest time 10s Smoke limit 0s Smoke limit off 0s Safety on delay 10s Overspeed overshoot 0s Warming up time 0s Transfer time 0.7s Breaker close pulse 0.0s Breaker trip pulse 0.0s Return delay 30s Cooling time 30s ETS solenoid hold 0s Fail to stop delay 30s Generator transient delay

1s

Battery low volts delay 1m Battery high volts delay 1m LCD page timer 5m Generator settings – Voltage/frequency Trip Return Under volts trip 184V AC N/A Under volts pre-alarm 196V AC 207V AC Over volts pre-alarm 265V AC 253V AC Over volts trip 276V AC N/A Under frequency trip 40.0 Hz N/A Under frequency pre-alarm 42.0 Hz 45.0 Hz Over frequency pre-alarm 55.0 Hz 52.0 Hz Over frequency trip 57.0 Hz N/A Generator settings – Current/power Value Generator CT primary 500 A Generator full load rating 500 A Delayed overcurrent 100% ( 500 A ) Trip Curve 36



Engine settings – Crank disconnect Value Crank disconnect on generator frequency 21.0 Hz Crank disconnect oil pressure <Disabled> Check oil pressure prior to starting Yes Engine settings – speed Value Underspeed trip 1250 RPM Underspeed prealarm 1350 RPM Overspeed prealarm 1650 RPM Overspeed trip 1750 RPM Overspeed overshoot 0% Plant battery settings Trip Return Under volts warning 8.0 V DC 9.0 V DC Over volts warning 33.0 V DC 32.0 V DC Charge alternator warning 8.0 V DC N/A Exercise scheduler settings Value Enable exercise scheduler No



15 ICONS AND LCD IDENTIFICATION 15.1 PUSH BUTTONS Display Description Display Description Display Description

Stop/Reset Auto mode Manual mode

Configure / log I Start (when in manual mode) Scroll

15.2 STATUS / MEASUREMENT UNITS Display Description Display Description Display Description

L1 Phase L2 Phase L3 Phase

L1- N Phase - Neutral L2- N Phase - Neutral L3- N Phase -Neutral

L1- L2 Phase - Phase L2- L3 Phase - Phase L3- L1 Phase - Phase

BAR Pressure KPa KPa Oil Pressure Units PSI Pressure

V Voltage oF Temperature Hz Frequency

A Amperes oC Temperature RPM Speed

kW KiloWatts kVA Apparent power KW divided by kVA

Hours Run AC Generator

Timer in progress DC Factory (load) Configuration

mode active Fuel level Event log

Panel locked by configurable input

15.3 ALARM INDICATIONS Display Description Display Description Display Description

Warning Alarm Shutdown Alarm Electrical Trip

Fuel Low Oil Pressure A High Current Warning

Charge Fail High Coolant Temperature V Over Voltage (AC)

Emergency Stop Fail to start (Over-

crank) V Under Voltage (AC)

V Over Voltage (DC) Over-speed Over frequency

V Under Voltage

(DC) Under-speed Under frequency

Auxiliary Indication !

Auxiliary Alarm (Warning or Shutdown)



16 APPENDIX 16.1 ALTERNATIVE WIRING TOPOLOGIES The 5200 series controllers can support many different wiring topologies (AC systems) to suit the many systems in use world-wide. The ‘Typical connection diagram’ details how to connect the module when used in a 3 phase, 4 wire system (3 phase star connected alternators). Changes to this typical wiring diagram for other AC systems are detailed below.

NOTE:- The factory default configuration for the 5210 module is for use with the 3 phase, 4 wire AC system. If another system is to be used, the controller must be reconfigured using the 5200 series configuration software. 16.1.1 3 PHASE, 3 WIRE The alternator is 3 phase delta connected. Phases are separated by 120°

16.1.2 1 PHASE, 2 WIRE Single phase alternator with neutral conductor.



16.1.3 2 PHASE, 3 WIRE ( 2 PHASE CENTRE TAP NEUTRAL) The alternator is 2 phase star connected. The live phases are separated by 180°



16.2 5210 IDMT TRIPPING CURVES (TYPICAL)

5210 Delayed over-current protection

1

10

100

1000

10000

100000

1000000

1 2 3

Current as a multiple of the trip-point setting (tripping curve = 36)

Trip

ping

tim

e in

sec

onds



16.3 SENDER WIRING RECOMMENDATIONS 16.3.1 EARTH RETURN SENDERS

Connection Name Terminal Number

Oil pressure Sender 44

Coolant temperature sender 45

Fuel level sender 46

Sender common 47

NOTE:- . It is important that terminal 47 ( sender common ) is soundly connected to an earth point on the ENGINE BLOCK, not within the control panel, and must be a sound electrical connection to the sender bodies.

NOTE:- . If you use PTFE insulating tape on the sender thread when using earth return senders, ensure you do not insulate the entire thread as this will prevent the sender body from being earthed via the engine block. 16.3.2 INSULATED RETURN SENDERS





Sender common 47

NOTE:- . It is important that terminal 47 ( sender common ) is soundly connected to an earth point on the ENGINE BLOCK, not within the control panel .



16.3.3 FUEL LEVEL SENDERS The resistive fuel level senders supported by the 5200 series controllers are devices that translate fuel level into resistance. A change in fuel level translates directly to a change in the resistance of the sender. In the case of a parallel sided fuel tank, an accurate measure of the fuel level can easily be made, however as shown in the example below, this is not the case with non-parallel sided fuel tanks. Therefore it is recommended that only parallel sided fuel tanks are used to ensure correct fuel level detection.

The fuel sender measures the distance between the top of the tank and the fuel level. Typically, they use a ball float. In this example, the distance between the top of the tank and the level of the fuel is 50% of the height of the tank. The fuel level sender will report the tank correctly as being 50% full. For a parallel-sided tank like this one, 50% distance between the top of the tank and the level of the fuel will occur when the tank is 50% full of fuel. In this example, the distance between the top of the tank and the level of the fuel is again 50% of the height of the tank, the fuel level sender will report the tank as being 50% full. However, as the bottom of the tank is curved, the actual amount of fuel in the tank is only about 40%. The fuel sender is incorrectly reporting the amount of remaining fuel.



16.4 5200 SERIES CONFIGURATION SOFTWARE AND P810 INTERFACE MODULE

The 5210 module can be configured using PC with Interface Module 810 and 52xx series PC configuration software. The 5200 series configuration software kit comprises the following:-

• 810 Interface Module • 25 to 9 way adapter • RJ45 (8 Pin) Connecting Lead • DSE SoftwareCD with configuration software

16.5 OUTPUT EXPANSION There are several methods of output expansion available for the 5210 module:- 16.5.1 RELAY OUTPUT EXPANSION (157) An expansion module is available, which connects to the configuration socket, and enables the 5210 to use eight additional relays, providing Volt-free contacts for customer connection. Refer to technical data sheet on the 157 relay module for further details. 16.5.2 LED OUTPUT EXPANSION (548) An expansion module is available, which connects to the configuration socket, and enables the 5210 to use eight additional LED’s, providing remote LED indication up to 50 metres away. Refer to technical data sheet on the 548 LED module for further details. It is possible to use a mix of 157 and 548 modules to give both relay and LED expansion of the same 8 items if required (Please refer to our Technical Support department for details.). 16.6 INPUT EXPANSION It is possible to increase the number of monitored inputs available by utilising a DSE 540/541 Protection Expansion/Annunciator. Please refer to our Technical department for details.

16.7 STANDBY GENERATING SET? The 5210 needs to be given a remote start signal to initiate an engine start. This can be supplied by a Mains/Utility monitoring module to make the generating set start up automatically should the mains/utility supply fail. The 5210 module may be used in conjunction with DSE Automatic transfer switch controllers such as the model 500 (pictured) , 705 or 530. These not only monitor the mains and issue a start command to the 5210; they also provide control of the contactors or other changeover devices. Please refer to our Technical Support department for details.

16.8 FULLY INTEGRATED AUTO MAINS FAILURE The 5210 module can easily be upgraded with a 5220 controller. It has exactly the same mounting details and uses exactly the same rear connectors. Upgrading takes seconds and instantly provides integral mains (utility) monitoring and changeover functions in the same controller. Please refer to our website for details (http://www.deepseaplc.com)



16.9 ENCLOSURE CLASSIFICATIONS IP CLASSIFICATIONS BS EN 60529 Degrees of protection provided by enclosures

First Digit Second digit

















NEMA CLASSIFICATIONS


1

IP30


2

IP31


3

IP64


3R

IP32


4 (X)

IP66


12/12K

IP65


13

IP65




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DSE5310 AUTOSTART CONTROL MODULE

OPERATING MANUAL

DSE Model 5310 Automatic Mains Failure & Instrumentation System Operators Manual

2 Part No. 057-013 5310 OPERATING MANUAL ISSUE 7.1 18/06/2007 ADM

Deep Sea Electronics Plc Highfield House Hunmanby North Yorkshire YO14 0PH ENGLAND Sales Tel: +44 (0) 1723 890099 Sales Fax: +44 (0) 1723 893303 E-mail: [email protected] Website: www.deepseaplc.com

DSE Model 5310 Control and Instrumentation System Operators Manual © Deep Sea Electronics Plc All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means or other) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988. Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to Deep Sea Electronics Plc at the address above. Any reference to trademarked product names used within this publication is owned by their respective companies. Deep Sea Electronics Plc reserves the right to change the contents of this document without prior notice.


Part No. 057-013 5310 OPERATING MANUAL ISSUE 7.1 18/06/2007 ADM 3

TABLE OF CONTENTS Section Page 1 INTRODUCTION .............................................................................................. 5 2 CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION. ........ 5 3 OPERATION .................................................................................................... 6

3.1 AUTOMATIC MODE OF OPERATION ............................................................................... 7 3.2 MANUAL OPERATION ....................................................................................................... 9

4 PROTECTIONS .............................................................................................. 10 4.1 WARNINGS ....................................................................................................................... 11 4.2 ANALOGUE PRE-ALARMS ............................................................................................. 13 4.3 HIGH CURRENT WARNING ALARM ............................................................................... 14 4.4 SHUTDOWNS .................................................................................................................... 15 4.5 HIGH CURRENT SHUTDOWN ALARM ........................................................................... 19 4.6 ELECTRICAL TRIPS ......................................................................................................... 19

5 DESCRIPTION OF CONTROLS .................................................................... 20 5.1 TYPICAL LCD DISPLAY SCREENS ................................................................................ 22

5.1.1 TYPICAL STATUS DISPLAY...................................................................................... 22 5.1.2 TYPICAL INSTRUMENT DISPLAY ............................................................................ 22 5.1.3 TYPICAL ALARM DISPLAY ....................................................................................... 22 5.1.4 TYPICAL EVENT DISPLAY ........................................................................................ 23

5.2 VIEWING THE INSTRUMENTS ........................................................................................ 23 5.2.1 INSTRUMENT PAGE CONTENT ............................................................................... 24 5.2.2 MANUALLY SELECTING AN INSTRUMENT ............................................................ 24 5.2.3 MODEM STATUS ....................................................................................................... 25 5.2.4 CAN ERROR MESSAGES ......................................................................................... 26

5.3 VIEWING THE EVENT LOG .............................................................................................. 26 5.4 USER CONFIGURABLE INDICATORS ........................................................................... 27 5.5 CONTROLS ....................................................................................................................... 27

6 FRONT PANEL CONFIGURATION ............................................................... 28 6.1.1 ENTERING THE CONFIGURATION EDITOR PIN NUMBER ................................... 28

6.2 EDITING A VALUE ............................................................................................................ 30 6.2.1 LIST OF ADJUSTABLE PARAMETERS IN ‘MAIN CONFIGURATION EDITOR’ ...... 31 6.2.2 LIST OF ADJUSTABLE PARAMETERS IN ‘APPLICATION EDITOR’ ...................... 32 6.2.3 EDITING THE CURRENT DATE AND TIME ............................................................. 33

7 INSTALLATION INSTRUCTIONS .................................................................. 35 7.1 PANEL CUT-OUT .............................................................................................................. 35 7.2 COOLING........................................................................................................................... 35 7.3 UNIT DIMENSIONS ........................................................................................................... 35 7.4 FRONT PANEL LAYOUT .................................................................................................. 36 7.5 REAR PANEL LAYOUT .................................................................................................... 36

8 ELECTRICAL CONNECTIONS ...................................................................... 37 8.1 CONNECTION DETAILS................................................................................................... 37

8.1.1 PLUG “A” 8 WAY ........................................................................................................ 37 8.1.2 PLUG “B” 11 WAY ...................................................................................................... 38 8.1.3 PLUG “C” 3 WAY ........................................................................................................ 38 8.1.4 PLUG “D” 4 WAY (OPTIONAL) .................................................................................. 39 8.1.5 PLUG “F” 4 WAY ........................................................................................................ 39 8.1.6 PLUG “G” 5 WAY ........................................................................................................ 39 8.1.7 PLUG “H” 4 WAY ........................................................................................................ 40 8.1.8 PC CONFIGURATION INTERFACE CONNECTOR .................................................. 40 8.1.9 EXPANSION OUTPUT CONNECTOR ....................................................................... 40

8.2 CONNECTOR FUNCTION DETAILS ................................................................................ 41 8.2.1 PLUG “A” 8 WAY ........................................................................................................ 41 8.2.2 PLUG “B” 11 WAY ...................................................................................................... 41



8.2.3 PLUG “C” 3 WAY ........................................................................................................ 42 8.2.4 PLUG “D” 4 WAY (OPTIONAL) .................................................................................. 42 8.2.5 PLUG “F” 4 WAY ......................................................................................................... 42 8.2.6 PLUG “G” 5 WAY ........................................................................................................ 43 8.2.7 PLUG “H” 4 WAY ........................................................................................................ 43 8.2.8 PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE ............................ 43

9 SPECIFICATION .............................................................................................44 10 COMMISSIONING .......................................................................................46

10.1.1 PRE-COMMISSIONING .............................................................................................. 46

11 FAULT FINDING ..........................................................................................47 12 FACTORY DEFAULT CONFIGURATION ...................................................48 13 TYPICAL WIRING DIAGRAM ......................................................................52 14 APPENDIX ...................................................................................................53

14.1 ALTERNATIVE WIRING TOPOLOGIES ....................................................................... 53 14.1.1 3 PHASE, 3 WIRE ....................................................................................................... 53 14.1.2 1 PHASE, 2 WIRE ....................................................................................................... 54 14.1.3 2 PHASE, 3 WIRE ( 2 PHASE CENTRE TAP NEUTRAL) ......................................... 54

14.2 ICONS AND LCD IDENTIFICATION ............................................................................. 55 14.2.1 PUSH BUTTONS ........................................................................................................ 55 14.2.2 STATUS / MEASUREMENT UNITS ........................................................................... 55 14.2.3 LED INDICATION ....................................................................................................... 55

14.3 5310 IDMT TRIPPING CURVES (TYPICAL) ................................................................. 56 14.4 SENDER WIRING RECOMMENDATIONS .................................................................... 57

14.4.1 EARTH RETURN SENDERS ..................................................................................... 57 14.4.2 INSULATED RETURN SENDERS ............................................................................. 57 14.4.3 FUEL LEVEL SENDERS ............................................................................................ 57

14.5 CAN INTERFACE ......................................................................................................... 59 14.6 OUTPUT EXPANSION ................................................................................................... 59

14.6.1 RELAY OUTPUT EXPANSION (157) ......................................................................... 59 14.6.2 LED OUTPUT EXPANSION (548) .............................................................................. 59

14.7 INPUT EXPANSION ....................................................................................................... 59 14.8 COMMUNICATIONS OPTION CONNECTIONS ........................................................... 60

14.8.1 DESCRIPTION ............................................................................................................ 60 14.8.2 PC TO CONTROLLER (DIRECT) CONNECTION ..................................................... 60 14.8.3 MODEM TO CONTROLLER CONNECTION ............................................................. 60 14.8.4 RS485 LINK TO CONTROLLER ................................................................................ 61 14.8.5 MODBUS™ ................................................................................................................. 62

14.9 ENCLOSURE CLASSIFICATIONS ............................................................................... 63



1 INTRODUCTION The DSE 5310 autostart module has been designed to allow the user to start and stop the generator, and if required, transfer the load to the generator either manually (via external push-buttons) or automatically. The user also has facility to view all the system operating parameters via the LCD display. The DSE 5310 module monitors the engine, indicating the operational status and fault conditions; automatically shutting down the engine and giving a true first up fault condition of an engine failure by a COMMON AUDIBLE ALARM. The exact failure mode is indicated by text messages on the LCD display on the front panel. The powerful microprocessor contained within the module allows for a range of complex features to be incorporated as standard: • Text based LCD display (supporting multiple languages). • Voltage, Current and Power monitoring. • Engine parameter monitoring. • Fully configurable inputs for use as alarms or a range of different functions. • Extensive range of output functions using built in relay outputs or relay expansion modules available. Selective operational sequences, timers and alarm trips can be altered by the customer via a PC using the 52/53xx series configuration software and P810 interface. Additionally, a subset of this information can be adjusted from the module’s front panel configuration editor. The module is housed in a robust plastic case for front panel mounting. Connections to the module are via locking plug and sockets. 2 CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION.

NOTE:

Highlights an essential element of a procedure to ensure correctness.

CAUTION!

Indicates a procedure or practice which, if not strictly observed, could result in damage or destruction of equipment.

WARNING!

Indicates a procedure or practice, which could result in injury to personnel or loss of life if not followed correctly.

Compliant with BS EN 60950 Low Voltage Directive Compliant with BS EN 50081-2 EMC Directive Compliant with BS EN 50082-2 EMC Directive

Indicates a function only applicable when the controller is configured for connection to a CAN engine controller



3 OPERATION The following description details the sequences followed by a module containing the standard ‘factory configuration’. Always refer to your configuration source for the exact sequences and timers observed by any particular module in the field.

FIG 1



3.1 AUTOMATIC MODE OF OPERATION

NOTE:- If a digital input configured to panel lock is active, changing module modes will not be

possible. Viewing the instruments and i is NOT affected by panel lock. If panel lock is active the Panel lock indicator (if configured) illuminates.

This mode is activated by pressing the pushbutton. An LED indicator beside the button confirms this action. If the Remote Start input (if configured) is activated the relevant indicator (if configured) illuminates. To allow for false remote start signals, the Start Delay timer is initiated. After this delay, if the pre-heat output option is selected then the pre-heat timer is initiated, and the corresponding auxiliary output (if configured) will energise.

NOTE:- If the Remote Start signal is removed during the Start Delay timer, the unit will return to a stand-by state.

After the above delays the Fuel Solenoid (or enable ECU output if configured) is energised, then one second later, the Starter Motor is engaged.


The engine is cranked for a pre-set time. If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and Fail to Start fault will be displayed.

Alarm Shutdown Failed to start When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from the Alternator output. Alternatively, a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is selected by PC using the 5xxx series configuration software). Rising oil pressure can also be used to disconnect the starter motor; however, it cannot be used for underspeed or overspeed detection.




After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault. Once the engine is running, the Warm Up timer, if selected, is initiated, allowing the engine to stabilise before accepting the load. If an auxiliary output has been selected to give a load transfer signal, this then activates.

NOTE:-A load transfer will not be initiated until the Oil Pressure has risen. Thus preventing excessive wear on the engine.

On removal of the Remote Start signal, the Stop delay timer is initiated, once it has timed out, the load Transfer signal is de-energised, removing the load. The Cooling timer is then initiated, allowing the engine a cooling down period off load before shutting down. Once the Cooling timer expires the Fuel Solenoid is de-energised, bringing the generator to a stop. Should the Remote Start signal be re-activated during the cooling down period, the set will return on load.



3.2 MANUAL OPERATION

NOTE:- If a digital input configured to panel lock is active, changing module modes will not be

possible. Viewing the instruments and event logs i is NOT affected by panel lock. If panel lock is active the Panel lock indicator (if configured) illuminates.

To initiate a start sequence in MANUAL, press the pushbutton. When the controller is in the manual mode (indicated by an LED indicator beside the button), pressing the START (I) button will initiate the start sequence.

NOTE:- There is no Start Delay in this mode of operation.

If the pre-heat output option is selected this timer is then initiated, and the auxiliary output selected is energised. After the above delay, the Fuel Solenoid (or ECU output if configured) is energised, then one second later, the Starter Motor is engaged.


The engine is cranked for a pre-set time period. If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and Fail to Start will be displayed. When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from the Alternator output. Alternatively, a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is selected by PC using the 52/53xx series configuration software). Rising oil pressure can also be used to disconnect the starter motor; however, it cannot be used for underspeed or overspeed detection.


After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault. Once the engine is running, the Warm Up timer, if selected, is initiated, allowing the engine to stabilise before it can be loaded. The generator will run off load, unless the Remote Start on load signal is applied or, if Close generator has been selected as a control source, the appropriate auxiliary output will then activate. The generator will continue to run On load, until the Auto mode is selected. If Auto mode is selected, and the remote start on load signal is not active, then the Stop Delay Timer begins, after which, the load is disconnected. The generator will then run off load allowing the engine a cooling down period. Selecting STOP (O) de-energises the FUEL SOLENOID, bringing the generator to a stop.



4 PROTECTIONS When an alarm is present, the Audible Alarm will sound and the Common alarm LED if configured will illuminate.

The audible alarm can be silenced by pressing the ‘Mute’ button

The LCD display will jump from the ‘Information page’ to display the Alarm Page

Alarm Warning Low oil pressure

The type of alarm. E.g. Shutdown or warning

The nature of alarm, eg Low oil pressure.

The LCD will display multiple alarms E.g. “High Engine Temperature shutdown”, “Emergency Stop” and “Low Coolant Warning” alarms have been triggered. These will automatically scroll round in the order that they occurred;

Running in auto If no alarms are present the LCD will display this default page.

Generator on load L-N 230V 240A 50Hz L-L 400V 133kW In the event of a warning alarm, the LCD will display the appropriate text. If a shutdown then occurs, the module will again display the appropriate text. Example:-

Alarm Shutdown High engine temperature

Followed by….

Alarm Shutdown Emergency stop

Followed by….

Alarm

Warning Low coolant level

The unit will scroll through all active alarms in a continuous loop.

Alarm Shutdown High engine temperature



4.1 WARNINGS Warnings are non-critical alarm conditions and do not affect the operation of the generator system, they serve to draw the operators attention to an undesirable condition. In the event of an alarm the LCD will jump to the alarms page, and scroll through all active warnings and shutdowns. BATTERY CHARGE FAILURE, will be displayed if the module does not detect a voltage from the warning light terminal on the auxiliary charge alternator.

Alarm Warning Charge fail

BATTERY LOW VOLTAGE, will be displayed if the module detects that the plant DC supply has fallen below the low volts setting level. The Battery Low Voltage alarm is delayed by the Low DC Volts Delay timer.

Alarm Warning Low battery volts

BATTERY HIGH VOLTAGE, will be displayed if the module detects that the plant DC supply has risen above the high volts setting level. The Battery High Voltage alarm is delayed by the High DC Volts Delay timer.

Alarm Warning High battery volts

MAINTENANCE ALARM, will be displayed if the maintenance period is exceeded (engine running hours or date interval whichever is configured).

Alarm Warning Maintenance alarm

FAIL TO STOP, will be displayed if the module detects the engine is still running when the ‘Fail to stop timer’ expires.

Alarm Fail to stop

NOTE:- ‘Fail to Stop’ could indicate a faulty oil pressure sender - If engine is at rest check oil sender wiring and configuration.



AUXILIARY INPUTS, auxiliary inputs can be user configured and will display the message as written by the user. Example

Alarm Warning Bearing temp high

LOW FUEL LEVEL will be displayed if the fuel level detected by the fuel level sender falls below the low fuel level setting.

Alarm Warning Low fuel level

CAN ECU ERROR If the module is configured for CAN instruments and receives an “error” message from the engine control unit, ‘Can ECU error” is shown on the module’s display and a warning alarm is

generated. Example

Alarm The display will alternate between the text display and the manufacturers error codes

Alarm Can ECU error Exhaust high temperature

Can ECU error SPNnnnnnnn FMInnnnnnn



4.2 ANALOGUE PRE-ALARMS The following alarms are termed ‘pre-alarms’ as they pre warn the operator of a potentially more serious alarm condition. For instance, if the engine temperature rises past the pre alarm level, a warning condition will occur to notify the operator. If the temperature falls below this level, then the alarm ceases, and the set will continue to run as normal. However if the temperature continues to rise until the coolant temperature trip point is reached, the warning is escalated and a high coolant temperature shutdown is initiated. LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low oil pressure pre-alarm setting level after the Safety On timer has expired, a warning will occur. Alarm Warning Low Oil Pressure will be displayed.

Alarm Warning Low oil pressure

HIGH ENGINE TEMPERATURE if the module detects that the engine coolant temperature has exceeded the high engine temperature pre-alarm setting level after the Safety On timer has expired, a warning will occur. Alarm Warning High Coolant Temperature will be displayed.

Alarm Warning High temperature

LOW ENGINE TEMPERATURE if the module detects that the engine coolant temperature has fallen below the low engine temperature pre-alarm setting level after the Safety On timer has expired, a warning will occur. Alarm Warning Low Coolant Temp will be displayed.

Alarm Warning Low Coolant Temp

OVERSPEED, if the engine speed exceeds the pre-alarm trip a warning is initiated. Alarm Warning Overspeed will be displayed. It is an immediate warning.

Alarm Warning Overspeed

UNDERSPEED, if the engine speed falls below the pre-set pre-alarm after the Safety On timer has expired, a warning is initiated. Alarm Warning Underspeed will be displayed.

Alarm Warning Underspeed



GENERATOR HIGH FREQUENCY if the module detects a generator output frequency in excess of the pre-set pre-alarm, a warning is initiated. Alarm Warning High frequency will be displayed, it is an immediate warning.

Alarm Warning Over frequency

GENERATOR LOW FREQUENCY if the module detects a generator output frequency below the pre-set pre-alarm after the Safety On timer has expired, a warning is initiated. Alarm Warning Low Frequency will be displayed

Alarm Warning Under frequency

GENERATOR HIGH VOLTAGE if the module detects a generator output voltage in excess of the pre-set pre-alarm, a warning is initiated. Alarm Warning High voltage will be displayed, it is an immediate warning.

Alarm Warning AC Overvolts

GENERATOR LOW VOLTAGE if the module detects a generator output voltage below the pre-set pre-alarm after the Safety On timer has expired, a warning is initiated. Alarm Warning Low Voltage will be displayed.

Alarm Warning AC Undervolts

CAN ECU ERROR If the module is configured for CAN instruments and receives an “error” message from the engine control unit, ‘Can ECU error” is shown on the module’s display and a warning alarm is

generated. Example


Alarm Can ECU error Exhaust high temperature

Can ECU error SPNnnnnnnn FMInnnnnnn

4.3 HIGH CURRENT WARNING ALARM GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the pre-set trip a warning is initiated. Alarm Warning High Current will be displayed. If this high current condition continues for an excess period of time, then the alarm is escalated to a shutdown condition. For further details of the high current alarm, please see High Current Shutdown Alarm.

Alarm Warning High current



4.4 SHUTDOWNS Shutdowns are latching and stop the Generator. The alarm must be cleared, and the fault removed to reset the module.

NOTE:- The alarm condition must be rectified before a reset will take place. If the alarm condition remains it will not be possible to reset the unit (The exception to this is the Low Oil Pressure alarm and similar ‘delayed alarms’, as the oil pressure will be low with the engine at rest).

FAIL TO START, if the engine does not fire after the pre-set number of attempts has been made a shutdown will be initiated. Alarm Shutdown Fail To Start will be displayed.

Alarm Shutdown Failed to start EMERGENCY STOP, removal of the Positive DC Supply from the Emergency Stop input initiates the following sequence. Firstly it will initiate a controlled shutdown of the Generator and prevent any attempt to restart the Generator until the Emergency Stop push-button has been reset. Secondly it removes the Positive DC supply from both the Fuel Solenoid and Starter Solenoid. Alarm Shutdown Emergency Stop will be displayed.

Alarm Shutdown Emergency stop

NOTE:- The Emergency Stop Positive signal must be present otherwise the unit will shutdown.

LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low oil pressure trip setting level after the Safety On timer has expired, a shutdown will occur. Alarm Shutdown Low Oil Pressure will be displayed.

Alarm Shutdown Low oil pressure HIGH ENGINE TEMPERATURE if the module detects that the engine coolant temperature has exceeded the high engine temperature trip setting level after the Safety On timer has expired, a shutdown will occur. Alarm Shutdown High Engine Temperature will be displayed.

Alarm Shutdown High temperature



OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated. Alarm Shutdown Overspeed will be displayed. Overspeed is not delayed, it is an immediate shutdown.

Alarm Shutdown Overspeed

NOTE:-During the start-up sequence the overspeed trip logic can be configured to allow an extra trip level margin. This is used to prevent nuisance tripping on start-up - Refer to the 53xx series configuration software manual under heading ‘Overspeed Overshoot’ for details.

UNDERSPEED, if the engine speed falls below the pre-set trip after the Safety On timer has expired, a shutdown is initiated. Alarm Shutdown Underspeed will be displayed.

Alarm Shutdown Underspeed GENERATOR HIGH FREQUENCY if the module detects a generator output frequency in excess of the pre-set trip a shutdown is initiated. Alarm Shutdown High Frequency will be displayed, it is an immediate shutdown.

Alarm Shutdown Over frequency GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the pre-set trip after the Safety On timer has expired, a shutdown is initiated. Alarm Shutdown Low Frequency will be displayed.

Alarm Shutdown Under frequency GENERATOR HIGH VOLTAGE if the module detects a generator output voltage in excess of the pre-set trip a shutdown is initiated. Alarm Shutdown High Volts will be displayed, it is an immediate shutdown.

Alarm Shutdown AC Overvolts GENERATOR LOW VOLTAGE if the module detects a generator output voltage below the below the pre-set trip after the Safety On timer has expired, a shutdown is initiated. Alarm Shutdown Low Volts will be displayed.

Alarm Shutdown AC Undervolts



OIL PRESSURE SENDER OPEN CIRCUIT, if the module detects a loss of signal from the oil pressure sender (open circuit) a shutdown is initiated. Alarm Shutdown Sender Fault will be displayed. Sender failure is not delayed, it is an immediate shutdown.

Alarm Shutdown Oil pressure sender fault AUXILIARY INPUTS, if an auxiliary input has been configured as a shutdown the appropriate message will be displayed as configured by the user.

Alarm Shutdown Bearing temp high MAINTENANCE ALARM, will be displayed if the maintenance period is exceeded (engine running hours or date interval whichever is configured). The engine is shutdown (if configured to do so)

Alarm Shutdown Maintenance alarm

LOSS OF SPEED SIGNAL, if the speed sensing signal is lost during cranking, a shutdown is initiated. Alarm Shutdown Loss Of Speed Signal will be displayed.

Alarm Shutdown Loss of speed signal

NOTE:- This will only occur if the speed sensing signal is lost during cranking or during the safety on timer. If the signal is lost during normal operation the Generator will shutdown with an Under-speed alarm.

CAN DATA FAIL If the module is configured for CAN operation and does not detect data on the engine Can datalink, a shutdown will occur and ‘Can data fail’ is shown on the module’s display.

Alarm

Shutdown Can data fail

CAN ECU FAIL If the module is configured for CAN instruments and receives a “fail” message from the engine control unit, the engine is shutdown and ‘Can ECU fail” is shown on the module’s display.

Example


Alarm Can ECU fail Fuel pressure low

Can ECU fail SPNnnnnnnn FMInnnnnnn

NOTE:- If the CAN message is a manufacturers specific code, it may not be displayed as text. If this is the case the display will show the generic manufacturers code, which must be cross-referenced with the engine manufacturers literature. . Please contact the engine manufacturer for further assistance.



Example

Alarm Can ECU fail SPNnnnnn FMInnnn



4.5 HIGH CURRENT SHUTDOWN ALARM GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the pre-set trip a warning is initiated. This warning will continue for a period of time depending upon the level of overload that the generator is subjected to, and the configuration setting for Generator High Current in the 5xxx series configuration software.

Alarm Shutdown High current trip For instance the factory default settings for Generator High Current allow for a loading of the generator to 110% for one hour. That is to say if the generator load level exceeds the trip point by 10%, a warning alarm will occur while the overload condition exists. If the load level does not drop to normal levels within one hour, the set is stopped, the 5310 module displaying either shutdown alarm or electrical trip alarm depending upon module configuration.

NOTE:- Higher overload levels will result in a faster acting shutdown condition. For instance with the factory default configuration, an overload level twice that of the trip level ( typically 200%) will result in a Generator High Current shutdown condition after 36 seconds. For details of the relationship between the overload and the shutdown time, please see the Appendix section of this manual.

4.6 ELECTRICAL TRIPS Electrical trips are latching and stop the Generator but in a controlled manner. On initiation of the electrical trip condition the module will de-energise the ‘Close Generator’ Output to remove the load from the generator. Once this has occurred the module will start the Cooling timer and allow the engine to cool off-load before shutting down the engine. The alarm must be accepted and cleared, and the fault removed to reset the module. AUXILIARY INPUTS, if an auxiliary input has been configured as an electrical trip the appropriate message will be displayed as configured by the user. Example

Alarm Electrical trip Phase rotation

GENERATOR HIGH CURRENT. If the module detects a generator output current in excess of the pre-set trip a warning is initiated. If this high current condition continues for an excess period of time, then the alarm is escalated to either a shutdown or electrical trip condition (depending upon module configuration). For further details of the high current alarm, please see High Current Shutdown Alarm.

Alarm Electrical trip High current




Scroll Down Next page Configurable LEDs

Stop Manual Auto Mute/Lamp Test

Start



Close Generator Output LED. On When

The Generator Is Required To Be On

Load

Generator available LED. On When The

Generator Is Available For Loading.

NOTE:- “Generator on load” LED has two modes of operation depending upon the configuration of the controllers digital inputs. 1) Digital input configured for “Generator closed auxiliary” – The LED will be lit when the generator

closed auxiliary input is active – The LED shows the state of the auxiliary contact. 2) There is NO input configured for “Generator closed auxiliary” (factory default setting) – The LED will

be lit when the 5310 gives the loading signal to the generator – The LED shows the state of the 5310’s loading request.



5.1 TYPICAL LCD DISPLAY SCREENS 5.1.1 TYPICAL STATUS DISPLAY

Waiting in auto Indicates that the module is in Automatic. The unit will respond to an active remote start.

Starting remote Indicates that the module is in automatic and that a start sequence

has been initiated, with an active remote start. The module is attempting to crank the generator.

Cranking attempt 1

Running in auto Indicates that the module is in Automatic, and that the generator is running on load. This default screen also indicates the average line to neutral voltage, highest of the 3 phase currents, generator frequency, average line to line voltage and total kilowatts.

Generator on load L-N 230V 240A 50Hz L-L 400V 133kW 5.1.2 TYPICAL INSTRUMENT DISPLAY

Coolant temperature The display of coolant temperature in both degrees centigrade and Fahrenheit.

60 ºC 140 ºF

Oil pressure The display of engine oil pressure in Bar, Pounds Per Square Inch

and kilo Pascal. 6 Bar 87 PSI 600 kPa

Generator Amps The display of all three generator line currents. L1 L2 L3 238 241 241 5.1.3 TYPICAL ALARM DISPLAY

Alarm The module is warning that the engine oil pressure has fallen below a pre-set level. The generator is not shut down. Warning

Low oil pressure

Alarm The oil pressure has fallen below a second pre-set value and has shut down the generator. Shutdown

Low oil pressure

Alarm The module is warning that the battery volts is below a pre-set value. Warning

Low battery Volts



5.1.4 TYPICAL EVENT DISPLAY Event log 21:15:00 On the 10th September 2005 at 21:15 the unit detected that the oil

pressure was below the pre-set trip level, and has shut down the generator.

10th September 2005 Low oil pressure Shutdown Event log 20:10:00 On the 8th September 2005 at 20:10. The emergency stop button

was pressed and the generator was shut down. 8th September 2005 Emergency stop Shutdown Event log 08:46:00 On the 7th September 2005 at 08:46 the unit detected that the

generator out put volts exceeded pre-set trip level, and has shut down the generator.

7th September 2005 Over Volts Shutdown 5.2 VIEWING THE INSTRUMENTS It is possible to manually scroll to display the different pages of information by repeatedly operating the next page

i button. Page order:- • Status display • Instrument display • Alarms display • Event log It is possible to manually scroll to display the different instruments by repeatedly operating the next page

button . Once selected the instrument will remain on the LCD display until the user selects a different instrument or after a period of inactivity for the duration of the configurable Page Timer, the module will revert to the default display.

Alternatively, to autoscroll through all instruments on the currently selected page, press and hold the scroll button.

To disable autoscroll, press and hold the scroll button, or select another page with the page select i button.

When autoscroll is disabled, the display will automatically return to the Status/Alarms page if no buttons are pressed for the duration of the configurable Page Timer.

If an alarm becomes active while viewing instruments, the Status/Alarms page will be automatically displayed to draw the operator’s attention to the alarm condition.



5.2.1 INSTRUMENT PAGE CONTENT • Engine speed • Oil Pressure • Coolant temperature • Fuel level (%) • Engine Hours Run • DC Battery Voltage • Charge alternator volts • Modem Status (GSM only) • Generator AC RMS Voltage Line-Neutral • Generator AC RMS Voltage Line-Line • AC RMS Line Current • Generator Output • Number of starts If enhanced instrumentation is selected, the following instrumentation will become available, if supported by the engine manufacturer. • Engine oil temperature • Inlet manifold temperature

• Coolant pressure

• Fuel pressure

• Fuel consumption

• Total fuel used

• Turbo pressure 5.2.2 MANUALLY SELECTING AN INSTRUMENT Default display Running in auto

Generator on load L-N 230V 240A 50Hz L-L 400V 133kW

Pressing the DOWN button the LCD will then show Engine speed.

Engine speed

1500 RPM 50 Hz

Pressing the DOWN button the LCD will then show Oil pressure.

Oil pressure

6 Bar 87 PSI 600 Kpa

Pressing the button again will scroll through each individual instrument eventually returning to the original instrument displayed.

NOTE:-Once selected the instrument will remain on the LCD display until the user selects a different instrument or after a period of inactivity for the duration of the configurable Page Timer, the module will revert to the initial display.



5.2.3 MODEM STATUS When configured and connected to a GSM Modem for cellular network communications, the GSM MODEM STATUS screen shows the following information. Modem Status The modem is reset by the 5300 series controller. Resetting modem

Modem Status Modem initialising strings are sent to the modem (as set in the Edit Config | Comms

tab of the configuration software. Initialising modem…

Modem Status The modem has been initialised and is ready to answer.

Ready to answer

If the module does not detect that the modem is operating correctly, this procedure begins again from Resetting modem and will continue to repeat until the modem operation is detected correctly. GSM STATUS If the DSE controller detects that the modem connected is a GSM modem, the following additional status is shown: Modem Status The modem has been initialised and is ready to answer. OK shows the SIM card is

inserted but there is no signal Ready to answer OK

Modem Status The modem has been initialised and is ready to answer.

The SIM card is inserted, the signal is received full strength and the operator name is shown.

NOTE:- Operator name is not available in all GSM areas.

Ready to answer OK ORANGE UK Modem Status The modem has been initialised and is ready to answer.

The SIM card is inserted, the signal is received but is low and the operator name is shown.

NOTE:- Operator name is not available in all GSM areas.

Ready to answer OK ORANGE UK



5.2.4 CAN ERROR MESSAGES

Where 53xx controllers are connected to a suitable Can ECU, alarm status messages are transmitted to the 53xx controller and displayed on the alarms page.

Alarm Here the ECU code is interpreted by the module, which

displays the warning as text. An error is like a warning, and does not shutdown the generator. The display will alternate between the text display and the manufacturers error codes

Alarm CAN ECU error Exhaust hi temp

CAN ECU error SPNnnnnn FMInnnnn

Alarm A CAN ECU fail is a shutdown and the module stops the

generator. The display will alternate between the text display and the manufacturers error codes

Alarm CAN ECU fail Fuel pressure low

CAN ECU fail SPNnnnnn FMInnnnn

Alarm Where the module does not recognise the ECU error / fail

code the SPN and FMI codes are displayed. These codes then have to be cross referenced with engine manufactures literature to determine the exact problem.

CAN ECU error SPNnnnnn FMInnnnn

NOTE:- For details on these code meanings, refer to the ECU instructions provided by the engine manufacturer, or contact the engine manufacturer for further assistance.

NOTE:- For further details on connection to electronic engines please refer to the CAN and DSE wiring manual.

5.3 VIEWING THE EVENT LOG The 53xx modules maintains a log of the last 30 shutdown alarms to enable the operator or engineer to view the past alarms history. Only shutdown and electrical trip alarms are logged; warning alarms are not logged. Once the log is full (30 events, any subsequent shutdown alarms will overwrite the oldest entry in the log. Hence the log will always contain the 30 most recent shutdown alarms. The alarm is logged, along with the date and time of the event in the format shown in this example.

Event log 21:15:00

10th September 2005 Low oil pressure Shutdown

To view the event log, repeatedly press the next page button i the LCD screen displays Event log.

Press down to view the next most recent shutdown alarm:

Continuing to press down will cycle through the past alarms until all 30 logged alarms have been viewed, after which the most recent alarm will again be showed and the cycle will begin again.

To exit the event log and return to viewing the instruments, press the next page i button.



5.4 USER CONFIGURABLE INDICATORS

These LEDs can be configured by the user to indicate any one of 100+ different functions based around the following:- • Indications - Monitoring of a digital input and indicating associated functioning user’s

equipment - Such as Battery Charger On or Louver’s Open, etc. • WARNINGS And SHUTDOWNS - Specific indication of a particular warning or

shutdown condition, backed up by LCD indication - Such as Low Oil Pressure Shutdown, Low Coolant level, etc.

• Status Indications - Indication of specific functions or sequences derived from the modules operating state - Such as Safety On, Pre-heating, Panel Locked, Generator Available, etc.

5.5 CONTROLS

Stop / Reset This button places the module into its Stop/reset mode. This will clear any alarm conditions for which the triggering criteria have been removed. If the engine is running and this position is selected, the module will automatically instruct the changeover device to unload the generator (‘Close Generator’ becomes inactive (if used)). The fuel supply will be removed and engine will be brought to a standstill. Should a remote start signal be present while operating in this mode, a remote start will not occur. If configured, the 5310 controller will enter sleep mode after 60 seconds of inactivity as a power saving feature.

Manual This mode is used to allow manual control of the generator functions. Once in Manual mode the module will respond to the start (I) button and start the engine and run off load. If the engine is running off-load in the Manual mode and a remote start signal becomes present, the module will automatically instruct the changeover device to place the generator on load (‘Close Generator’ becomes active (if used)). Should the remote start signal then be removed the generator will remain on load until either the ‘STOP/RESET’ or ‘AUTO’ positions is selected.

Auto This button places the module into its ‘Automatic’ mode. This mode allows the module to control the function of the generator automatically. The module will monitor the remote start input and once a start condition is signalled the set will be automatically started and placed on load (‘Close Generator’ becomes active (if used)). If the starting signal is removed the module will automatically transfer the load from the generator and shut the set down observing the stop delay timer and cooling timer as necessary. The module will then await the next start event. For further details please see the more detailed description of ‘Auto Operation’ earlier in this manual.Test This button places the module into its ‘Test’ mode. This mode allows the operator to perform an ‘on load’ test of the system. Once in Test mode the module will respond to the start I button and start the engine, and run on load (‘Close Generator’ becomes active (if used)). The generator will continue to run on load until Auto mode is selected. Then, If the starting signal is removed, the module will automatically transfer the load from the generator and shut the set down observing the stop delay timer and cooling timer as necessary. The module will then await the next start event. For further details please see the more detailed description of ‘Test Operation’ earlier in this manual.

Start This button is only active in STOP/RESET , MANUAL or TEST mode. Pressing this button in manual or test mode will start the engine and run off load (manual) or on load (test). Pressing this button in STOP/RESET mode will turn on the CAN engine ECU (when correctly configured and fitted to a compatible engine ECU)

I Mute / Lamp Test This button silences the audible alarm if it is sounding and illuminates all of the LEDs. If there is no audible alarm this button will only illuminate all the LEDs. When correctly configured and fitted to a compatible engine ECU, pressing this button in STOP/RESET mode after pressing the START I button (to power the ECU) will cancel any “passive” alarms on the engine ECU.



6 FRONT PANEL CONFIGURATION This configuration mode allows the operator limited customising of the way the module operates.

Operation Detail To enter the ‘configuration mode’ press both the INFO and STOP buttons together.

+ 6.1.1 ENTERING THE CONFIGURATION EDITOR PIN NUMBER The configuration editor contains two sections.

• Main configuration editor (for ‘site adjustable’ or ‘commissioning’ parameters) • Application editor (to allow installation engineers to make application changes).

The ‘Application Editor’ is designed to allow the module to be configured for different applications without needing to re-configure the module settings. This makes it particularly suitable for applications where the generator would be used in a number of different roles, specifically in Rental or mobile type applications.

If the module PIN number has been set, the PIN number request is then shown. The configuration cannot be viewed or changed until the PIN number is correctly entered. Enter either the ‘main’ PIN or the application PIN. If no PIN has been set, then skip to the next section.

NOTE:- The ‘Application Editor’ must be enabled first in order to make it accessible from the module’s fascia. This is done by setting a PIN (number) for the module’s main front panel editor, using the 5xxx for Windows™ PC configuration software.

- button + button button The configuration editor contains two sections.

• Main configuration editor (for ‘site adjustable’ or ‘commissioning’ parameters) • Application editor (to allow installation engineers to make application changes).

The ‘Application Editor’ is designed to allow the module to be configured for different applications without needing to re-configure the module settings. This makes it particularly suitable for applications where the generator would be used in a number of different roles, specifically in Rental or mobile type applications.



If the module PIN number has been set, the PIN number request is then shown. The configuration cannot be viewed or changed until the PIN number is correctly entered. Enter either the ‘main’ PIN or the application PIN. If no PIN has been set, then skip to the next section.

NOTE:- The ‘Application Editor’ must be enabled first in order to make it accessible from the module’s fascia. This is done by setting a PIN (number) for the module’s main front panel editor, using the 5xxx for Windows™ PC configuration software.

Enter pin The first * is flashing. Press + or – buttons to adjust it to the correct value for the first digit of the PIN number. Press when the first digit is correctly entered. The entered digit will turn back to a * to maintain security.

****

Enter pin The second * is now flashing. Press + or – buttons to adjust it to the correct value for the second digit of the PIN number. Press when the second digit is correctly entered. The entered digit will turn back to a * to maintain security.

****

Enter pin The third * is now flashing. Press + or – buttons to adjust it to the correct value for the third

digit of the PIN number. Press when the third digit is correctly entered. The entered digit will turn back to a * to maintain security.

****

Enter pin The fourth * is now flashing. Press + or – buttons to adjust it to the correct value for the fourth digit of the PIN number. Press when the fourth digit is correctly entered. ****

NOTE:- When is pressed after editing the final PIN digit, the PIN is checked for validity. If the number is not correct, the editor is automatically exited. To retry you must re-enter the editor as described above.

Oil pressure pre-alarm If the Configuration PIN has been entered successfully (or the PIN

number has not been set in the module) the first configurable parameter is displayed :

2 Bar 30 PSI 200 kPa

NOTE:- To exit the front panel configuration editor at any time, press the Stop/Reset button. Ensure you have saved any changes you have made by pressing the button first.

NOTE:- When the editor is visible, it is automatically exited after 5 minutes of inactivity to ensure security.

NOTE:- If the Application Menu PIN is entered, then only the Application Menu is displayed. If the Full Configuration PIN is entered, the entire configuration menu is displayed including the Application Menu.

NOTE:- The PIN number is automatically reset when the editor is exited (manually or automatically) to ensure security.



6.2 EDITING A VALUE

Oil pressure pre-alarm Press the Stop/Reset and Info i buttons simultaneously. If the module PIN number has been set, the PIN number request is then shown. The configuration cannot be viewed or changed until the PIN number is correctly entered. (see the section ACCESSING THE FRONT PANEL CONFIGURATION EDITOR) Press the + button until the desired page is shown. EG oil pressure pre-alarm.


Oil pressure pre-alarm To edit the oil pressure pre-alarm, press the button, the

pressure will start to flash. Pressing the + or – buttons will adjust the parameter to the desired value. In this example, the 30 PSI will be adjusted, and the bar/kPA units will automatically show their respective values.


Oil pressure pre-alarm Press the button to ‘save’ the value. The value will stop flashing to confirm that it has been saved. 3 Bar 45 PSI

300 kPa

Oil pressure shutdown To select another value to edit, press the + button. 1 Bar 15 PSI

100 kPa


Continuing to press the + or – buttons will cycle through the adjustable parameters in the order shown overleaf:



6.2.1 LIST OF ADJUSTABLE PARAMETERS IN ‘MAIN CONFIGURATION EDITOR’

Section Parameter Display shows Values Input settings Low Oil Pressure warning Oil pressure pre-alarm 0-4bar (1.17bar) Low Oil Pressure shutdown Oil pressure shutdown 0-4bar (1.03bar) High Temperature warning Coolant temp pre-alarm 80-140°C (110°C) High Temperature shutdown Coolant temp shutdown 80-140°C (120°C) Low Coolant Temperature Low Coolant Temperature 65-136°C (65°C) Timers Generator transient delay Gen transient delay 0 -10s (0s)

Start delay Start delay 0 -60m (5s)

Return delay Return delay 0 -60m (30s)

Preheat Preheat 0 -60m (5s)

Crank attempt Cranking time 0 -60s (10s)

Crank rest Crank rest 0-60s (10s)

Safety delay Safety on delay 0-30s (10s)

Overspeed overshoot Overspeed overshoot 0-10s (0s)

Warming up Warm up 0-60m (0s)

Cooling run Cooling 0-60m (60s)

Fail to stop delay Fail to stop 0-30s (30s)

Low battery volts delay Battery low delay 0-10m (1m)

High battery volts delay Battery high delay 0-10m (1m)

Generator Generator Under voltage shutdown Gen low voltage shutdown 50-360V ph-N (184V) Generator Under voltage prealarm Gen low voltage pre-alarm 50-360V ph-N (196V)

Generator Over voltage prealarm Gen high voltage pre-alarm 50-360V ph-N (253V)

Generator Over voltage shutdown Gen high voltage shutdown 50-360V ph-N (265V)

Generator Under frequency shutdown Gen low frequency shutdown 0 -75Hz (40Hz)

Generator Under frequency prealarm Gen low frequency pre-alarm 0 -75Hz (42Hz)

Generator Over frequency prealarm Gen high frequency pre-alarm 0 -75Hz (55Hz)

Generator Over frequency shutdown Gen high frequency shutdown 0 -75Hz (57Hz)

Generator delayed overcurrent Delayed high current 100-200% (100%)

Engine Underspeed (RPM) shutdown Underspeed shutdown 0-6000RPM (1270)

Underspeed (RPM) warning Underspeed pre-alarm 0-6000RPM (1350)

Overspeed (RPM) warning Overspeed pre-alarm 0-6000RPM (1650)

Overspeed (RPM) shutdown Overspeed shutdown 0-6000RPM (1710)

Overspeed overshoot % Overspeed overshoot percent 0-10 (0%)

Low DC Voltage Battery low warning 0-24V (8V)

High DC Voltage Battery high warning 0-24V (33V)

Charge Alternator Failure Charge fail warning 0-24V (6V)

Display Language Language ENGLISH, OTHER (see note below)

Application Engine speed selection Alternative Frequency Disable, Enable

Volts selection Alternative Voltage Disable, Enable

Wiring topography AC System 3 phase 4 wire Single phase, 2 wire 3 phase, 3 wire 2 phase 3 wire (L1 & L2) 2 phase 3 wire (L1 & L3)

Full load current rating Generator Full Load 5A - 6000A (500A) Droop Disable, Enable

Droop % 0% - 5%

LCD Contrast Contrast

Date/Time Date and Time dd mmm yyyy hh:mm

NOTE:- Display language selection via the modules front panel configuration editor is between English and a PC configurable language. This ‘other’ language is configurable using the 5xxx PC configuration software in conjunction with the P810 interface.

NOTE:- Droop percent is only applicable to CAN controlled engines when CAN is enabled in the 5300 series controller.



6.2.2 LIST OF ADJUSTABLE PARAMETERS IN ‘APPLICATION EDITOR’ Section Parameter Display shows Values Application Engine speed selection Alternative Frequency Disable, Enable

Volts selection Alternative Voltage Disable, Enable

Wiring topography AC System 3 phase 4 wire Single phase, 2 wire 3 phase, 3 wire 2 phase 3 wire (L1 & L2) 2 phase 3 wire (L1 & L3)

Full load current rating Generator Full Load 5A - 6000A (500A) Droop Disable, Enable

Droop % 0% - 5%

LCD Contrast Contrast

Date/Time Date and Time dd mmm yyyy hh:mm



6.2.3 EDITING THE CURRENT DATE AND TIME The date and time can be set either using the 5xxx series configuration software or the front panel configuration editer.

NOTE:- The 5320 controller maintains the current date and time so long as it is connected to a DC supply within the operating range. Disconnection of the supply will result in the date and time being frozen until the module’s power is reapplied. When this occurs, the date and time will resume operation from the time the power was disconnected. If this occurs you can use the front panel configuration editor to correct the date and time or reset it using the 5xxx series configuration software.

NOTE:- The calendar is used by the 5310’s run scheduler and the event log.

Date and time Press the Stop/Reset and Info i buttons simultaneously.

If the module PIN number has been set, the PIN number request is then shown. The configuration cannot be viewed or changed until the PIN number is correctly entered. (see the section ACCESSING THE FRONT PANEL CONFIGURATION EDITOR) Press the + button until the desired page is shown. Date and time

19 Sep 2005 10:00

Date and time To edit the Date and time, press the button, the minutes will

start to flash. Pressing the + or – buttons will adjust the minutes to the desired value.

19 Sep 2005 10:00

Date and time Press the button to ‘save’ the value, and select the hours for adjustment. The hours will start to flash.

Pressing the + or – buttons will adjust the hours to the desired value.

19 Sep 2005 10:00

Date and time Press the button to ‘save’ the value, and select the day for adjustment. The day will start to flash.

Pressing the + or – buttons will adjust the day to the desired value.

19 Sep 2005 10:00



Date and time Press the button to ‘save’ the value, and select the month for adjustment. The month will start to flash.

Pressing the + or – buttons will adjust the month to the desired value.

19 Sep 2005 10:00

Date and time Press the button to ‘save’ the value, and select the year for adjustment. The year will start to flash.

Pressing the + or – buttons will adjust the year to the desired value.

19 Sep 2005 10:00

Date and time Press the button to ‘save’ the values. 19 Sep 2005 10:00


Continuing to press the + or – buttons will cycle through the adjustable parameters in the order shown overleaf:



7 INSTALLATION INSTRUCTIONS The model DSE 5310 Module has been designed for front panel mounting. Fixing is by 4 clips for easy assembly. 7.1 PANEL CUT-OUT

220.00mm (8.7”)

FIG 3

Maximum panel thickness – 8mm (0.3”) In conditions of excessive vibration the module should be mounted on suitable anti-vibration mountings. 7.2 COOLING The module has been designed to operate over a wide temperature range -30 to +70º C. Allowances should be made for the temperature rise within the control panel enclosure. Care should be taken NOT to mount possible heat sources near the module unless adequate ventilation is provided. The relative humidity inside the control panel enclosure should not exceed 95%. 7.3 UNIT DIMENSIONS

Panel cutout 220mm x 160mm ( 8.7” x 6.3”) FIG 4

160.00mm (6.3”)



7.4 FRONT PANEL LAYOUT

FIG 5 7.5 REAR PANEL LAYOUT

FIG 6



8 ELECTRICAL CONNECTIONS Connections to the Module are via plug and sockets. 8.1 CONNECTION DETAILS The following describes the connections and recommended cable sizes to the 7 plugs and sockets on the rear of the Module. See rear panel layout FIG 6. 8.1.1 PLUG “A” 8 WAY PIN No


NOTES

1 DC Plant Supply Input (Negative)

2.5mm² AWG 13

2 DC Plant Supply Input (Positive)

2.5 mm² AWG 13

(Recommended Maximum Fuse 21A)

3 Emergency Stop Input 2.5mm² AWG 13

Plant Supply Positive. Also supplies fuel & start outputs. (Recommended Maximum Fuse 32A)

4 Fuel relay Output 2.5mm² AWG 13

Plant Supply Positive from pin 3. 16 Amp rated.

5 Start relay Output 2.5mm² AWG 13

Plant Supply Positive from pin 3. 16 Amp rated.

6 Auxiliary Output relay 1 1.0mm² AWG 18

Plant Supply Positive. 5 Amp rated.





NOTE:- When the module is configured for CAN operation, FUEL, START and AUXILIARY output requirements may be different. Refer to CAN and DSE Wiring for further information.





NOTES

9 Charge fail / excite 2.5mm² AWG 13

Do not connect to ground (battery Negative)

10 Auxiliary input 1 0.5mm² AWG 20

Switch to Negative


Switch to Negative


Switch to Negative


Switch to Negative


Switch to Negative


Switch to Negative

16 Functional Earth 2.5mm² AWG 13

Connect to a good clean earth point

17 Magnetic pickup Positive 0.5mm² AWG 20


18 Magnetic pickup Negative 0.5mm² AWG 20


19 Not connected -


NOTE:- When the module is configured for CAN operation, terminals 17 & 18 should be left unconnected. Engine speed is transmitted to the 53xx controller on the CAN link. Refer to CAN and DSE Wiring for further information.

8.1.3 PLUG “C” 3 WAY PIN No


NOTES

20 CAN port Common 0.5mm² AWG 20


21 CAN port H 0.5mm² AWG 20


22 CAN port L 0.5mm² AWG 20


NOTE:- Screened 120Ω impedance cable specified for use with CANBUS must be used. DSE stock and supply Belden cable 9841 which is a high quality 120Ω impedance cable suitable for CANbus use (DSE part number 016-030) Refer to CAN and DSE Wiring for further information.



8.1.4 PLUG “D” 4 WAY (OPTIONAL) PIN No


NOTES

23 RS485 port Common 0.5mm² AWG 20


24 RS485 port B 0.5mm² AWG 20


25 RS485 port A 0.5mm² AWG 20


26 Not connected -

NOTE: - Screened 120Ω impedance cable specified for use with RS485 must be used. DSE stock and supply Belden cable 9841 which is a high quality 120Ω impedance cable suitable for RS485 use (DSE part number 016-030)

NOTE: - Connector E is not fitted to the 5310 remote start module.

8.1.5 PLUG “F” 4 WAY PIN No

DESCRIPTION CABLE SIZE NOTES


1.0mm² AWG 18

Connect to generator L1 output (AC) (Recommend 2A fuse)


1.0mm² AWG 18



1.0mm² AWG 18


38 Generator Neutral input 1.0mm² AWG 18

Connect to generator Neutral terminal (AC)

8.1.6 PLUG “G” 5 WAY PIN No


NOTES

39 CT Secondary for L1 2.5mm² AWG 13

Connect to secondary of L1 monitoring CT





42 CT secondary common 2.5mm² AWG 13

Connect to secondary of all monitoring CT’s

43 Not connected -

WARNING! - Do not disconnect this plug when the generator set is running. Disconnection will open circuit the secondary of the CT’s and dangerous voltages may then develop. Always ensure the generating set is at rest before making or breaking connections to the module.





NOTES

44 Oil Pressure Input 0.5mm² AWG 20

Connect to Oil pressure sender

45 Coolant Temperature Input

0.5mm² AWG 20

Connect to Coolant Temperature sender

46 Fuel Level input 0.5mm² AWG 20

Connect to Fuel Level sender

47 Sender Common Return 0.5mm² AWG 20

Return feed for senders*.

NOTE*:- If using single terminal senders refer to connection diagram. If using earth return type senders connect return terminals to pin 47 and also connect pin 47 to earth. This is detailed in the Appendix section entitled “Sender wiring recommendations” elsewhere in this manual.

NOTE:- When the module is configured for CAN operation, terminals 44 & 45 should be left unconnected. Engine oil pressure and coolant temperature is transmitted to the 53xx controller on the CAN link.

8.1.8 PC CONFIGURATION INTERFACE CONNECTOR

8-way connector allows connection to PC via the 810 configuration interface. Module can then be re-configured utilising the 5xxx series configuration software.

8.1.9 EXPANSION OUTPUT CONNECTOR

The expansion connector allows connection to the 157 relay expansion module or to the 548 LED Remote annunciator module.



8.2 CONNECTOR FUNCTION DETAILS The following describes the functions of the 7 connectors on the rear of the module. See rear panel layout FIG 5. 8.2.1 PLUG “A” 8 WAY PIN No

DESCRIPTION

1 DC Supply Negative input. (Battery Negative). 2 DC Supply Positive input. (Battery Positive). 3 Emergency Stop input. Internally linked to Starter and Fuel outputs. If this input is

not connected to positive the module will be locked out, and if the engine is running it will shutdown immediately. The Positive Supply is also removed from Starter and Fuel outputs, therefore only a single pole Emergency Shutdown button is required.

4 Fuel Relay output. Plant Supply Positive from pin 3. Used to control the fuel solenoid or engine fuel control system.

5 Starter Relay output. Plant Supply Positive from pin 3. Used to control the Starter Motor.

6 Auxiliary Relay output 1. Plant Supply Positive. Configurable output, see Calibration Manual for options available.




DESCRIPTION

9 Charge Fail input / Excitation output. Supplies excitation to the Plant Battery Charging Alternator, also an input for the Charge Fail detection circuitry.







16 Functional Earth - Ensure connection to a good clean earth point. 17 Magnetic Input Positive. An AC signal from the magnetic pickup Positive for speed

sensing. 18 Magnetic Input Negative. An AC signal from the magnetic pickup Negative for

speed sensing. 19 Not connected

NOTE: - Ensure magnetic pickup screen is connected to ground at one end only.



NOTE: - When the module is configured for CAN operation, terminals 17 & 18 should be left unconnected. Engine speed is transmitted to the 53xx controller on the CAN link.

8.2.3 PLUG “C” 3 WAY

PIN No

DESCRIPTION

20 CAN port Common. Do not connect this terminal to earth. Use only screened 120Ω cable approved specifically for use in CAN applications.

21 CAN port H. Use only screened 120Ω cable approved specifically for use in CAN applications. 22 CAN port L. Use only screened 120Ω cable approved specifically for use in CAN applications.

NOTE:- Screened 120Ω impedance cable specified for use with CANBUS must be used. DSE stock and supply Belden cable 9841 which is a high quality 120Ω impedance cable suitable for CANbus use (DSE part number 016-030)

8.2.4 PLUG “D” 4 WAY (OPTIONAL)

PIN No

DESCRIPTION

23 RS485 port Common 24 RS485 port B. Use only screened 120Ω cable approved specifically for use in RS485 applications. 25 RS485 port A. Use only screened 120Ω cable approved specifically for use in RS485 applications. 26 Not used. Do not connect to this terminal.

NOTE:- Screened 120Ω impedance cable specified for use with RS485 must be used. DSE stock and supply Belden cable 9841 which is a high quality 120Ω impedance cable suitable for RS485 use (DSE part number 016-030)

NOTE: - Connector E is not fitted to the 5310 remote start module.

8.2.5 PLUG “F” 4 WAY

PIN No

DESCRIPTION

35 Generator L1 sensing input. Connect to alternator L1 output. 36 Generator L2 sensing input. Connect to alternator L2 output. If using single phase only do not

connect this terminal. 37 Generator L3 sensing input. Connect to alternator L3 output. If using single phase only do not

connect this terminal. 38 Generator N sensing input. Connect to alternator N output.



8.2.6 PLUG “G” 5 WAY PIN No DESCRIPTION

39 Generator L1 current transformer connection. 40 Generator L2 current transformer connection. If single phase is used do not connect this pin. 41 Generator L3 current transformer connection. If single phase is used do not connect this pin. 42 Generator current transformer common connection and CT earth connection. 43 Not used. Do not connect to this terminal.

WARNING! - Do not disconnect this plug when the generator set is running. Disconnection will open circuit the secondary of the CT’s and dangerous voltages may then develop. Always ensure the generating set is at rest before making or breaking connections to the module.

8.2.7 PLUG “H” 4 WAY

PIN No

DESCRIPTION

44 Oil Pressure sensing input. Connect to resistive type oil pressure sender. Refer to connection diagram for details.

45 Coolant Temperature sensing input. Connect to resistive type coolant temperature sender. Refer to connection diagram for details.

46 Fuel Level sensing input. Connect to resistive type fuel level sender. Refer to connection diagram for details.

47 Sender Common connection. Return feed from sender units - refer to connection diagram for details.

NOTE:- When the module is configured for CAN operation, terminals 44 & 45 should be left unconnected. Engine oil pressure and coolant temperature is transmitted to the 53xx controller on the CAN link.

8.2.8 PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE If you require additional plugs from DSE, please contact our Sales department using the part numbers below. 5310 Terminal Connector Plug description DSE Part number

1-8 A BL08 8way 5.08mm spacing connector plug 007-125 9-19 B BL11 11way 5.08mm spacing connector plug 007-135

20-22 C BL03 3way 3.81mm spacing connector plug 007-409 23-26 D BL04 4way 3.81mm spacing connector plug 007-408 35-38 F BL04 4way 10.16mm spacing connector plug 007-003 39-43 G BL05 5way 5.08mm spacing connector plug 007-329 44-47 H BL04 4way 5.08mm spacing connector plug 007-100

NOTE:- Plug E is not fitted to this module.



9 SPECIFICATION

DC Supply Continuous voltage rating : 8V to 35V Cranking dip protection : Able to survive 0V for 50mS, providing supply was at least 10V before dropout and supply recovers to 5V. This is achieved without the need for internal batteries Charge Fail/ Excitation: 0V to 35V fixed power source 25W Max. Standby Current: 250mA at 12V. 125mA at 24V. Max. Sleep Mode Current: 75mA at 12V. 45mA at 24V Max. Operating Current: 425mA at 12V. 215mA at 24V

Alternator Input Range: 15V - 277(ph-N) (+20%) 50Hz - 60Hz (Minimum 15V AC Ph-N) Accuracy: 1% of full scale Average sensing Supported topologies: 3 Phase 4 wire 3 phase 3 wire Single phase 2 wire 2 Phase 3 wire L1 & L2 2 Phase 3 wire L1 & L3

Bus Input Range: 15V - 277(ph-N) (+20%) 50Hz - 60 Hz Accuracy: 1% of full scale Average sensing Supported topologies: 3 Phase 4 wire 3 phase 3 wire Single phase 2 wire 2 Phase 3 wire L1 & L2 2 Phase 3 wire L1 & L3

CT’s Burden: 0.5VA Primary rating: 1A - 6000A (user selectable) Secondary rating: 1A or 5A secondary (user selectable) Accuracy of measurement: 1% of full load rating (when using 0.5% or better CTs with 5A secondary winding) Lower class CTs will reduce the overall accuracy of the reading. Recommendations: Class 1 required for instrumentation Protection class required if using for protection.

Magnetic Pickup Voltage range : +/- 0.5V minimum (during cranking) to 70V Peak Frequency range: 10,000 Hz (max)

Relay outputs Fuel: 16 Amp DC at supply voltage Start: 16 Amp DC at supply voltage Auxiliary outputs 1,2,3: 5 Amp DC at supply voltage Output 4 (Generator loading relay) Voltage free, normally open, 8 Amp 250V AC RMS rated Output 5 (spare) Voltage free, normally closed, 8 Amp 250V AC RMS rated



Dimensions Overall:

240mm x 172 mm x 57mm (9 ½“ x 6 ¾” x 2 ¼”) Panel cut-out: 220mm x 160mm ( 8.7” x 6.3”) Max panel thickness 8mm ( 0.3”)

Electrical Safety /Electromagnetic Compatibility

BS EN 60950 Safety of information technology equipment, including electrical business equipment BS EN 61000-6-2 EMC Generic Emission Standard (Industrial) BS EN 61000-6-4 EMC Generic Emission Standard (Industrial)

Environmental BS EN 60068-2-1 Cold Temperature -30°C BS EN 60068-2-2 Hot Temperature +70°C BS2011-2-1 Humidity 93% RH@40°C for 48 Hours BS EN 60068-2-6 Vibration 10 sweeps at 1 octave/minute in each of 3 major axes 5Hz to 8Hz @ +/-7.5mm constant displacement 8Hz to 500Hz @ 2gn constant acceleration BS EN 60068-2-27 Shock 3 Half sine shocks in each of 3 major axes 15gn amplitude, 11mS durationBS EN 60529 Degrees of protection provided by enclosures: IP55 (Front of module when module is installed into the control panel with the optional sealing gasket). IP42 (front of module when module is installed into the control panel WITHOUT being sealed to the panel)NEMA Rating (Approximate) 12 (Front of module when module is installed into the control panel with the optional sealing gasket). 2 (front of module when module is installed into the control panel WITHOUT being sealed to the panel)

Product Certification

C US

European CE approved. UL approved C-UL / CSA approved.

Russia and other CIS countries approved

BS EN 2002/95/EC Restriction of Hazardous

Substances (RoHS)

BS EN 2002/96/EC Waste Electrical and

Electronic Equipment (WEEE)

CAN interface certified by MTU for use with MDEC

engines

Relevant Company Certification

BS EN ISO 9001:2000 Applicable to Design,

marketing, assembly, service and repair of electronic control

modules




10 COMMISSIONING 10.1.1 PRE-COMMISSIONING Before the system is started, it is recommended that the following checks are made:- 10.1. The unit is adequately cooled and all the wiring to the module is of a standard and rating compatible with the

system. 10.2. The unit DC supply is fused and connected to the battery and that it is of the correct polarity. 10.3. The Emergency Stop input is wired to an external normally closed switch connected to DC positive.

NOTE:- If Emergency Stop feature is not required, link this input to the DC Positive. The module will not operate unless either the Emergency Stop is fitted correctly OR Pin 3 is connected to DC positive.

10.4. To check the start cycle operation take appropriate measures to prevent the engine from starting (disable the

operation of the fuel solenoid). After a visual inspection to ensure it is safe to proceed, connect the battery supply. Select “MANUAL”, the unit start sequence will commence.

10.5. The starter will engage and operate for the pre-set crank period. After the starter motor has attempted to

start the engine for the pre-set number of attempts the LCD will display ‘Failed to start. Select the STOP/RESET position to reset the unit.

10.6. Restore the engine to operational status (reconnect the fuel solenoid), again select “MANUAL”, this time the

engine should start and the starter motor should disengage automatically. If not then check that the engine is fully operational (fuel available, etc.) and that the fuel solenoid is operating. The engine should now run up to operating speed. If not, and an alarm is present, check the alarm condition for validity, then check input wiring. The engine should continue to run for an indefinite period. It will be possible at this time to view the engine and alternator parameters - refer to the ‘Description of Controls’ section of this manual.

10.7. Select “AUTO” on the front panel, the engine will run for the pre-set cooling down period, then stop. The

generator should stay in the standby mode. If not check that there is not a signal present on the Remote start input.

10.8. Initiate an automatic start by supplying the remote start signal. The start sequence will commence and the

engine will run up to operational speed. Once the generator is available a load transfer will take place, the Generator will accept the load. If not, check the wiring to the Generator Contactor Coil (if used). Check the Warming timer has timed out.

10.9. Remove the remote start signal, the return sequence will start. After the pre-set time period, the load will be

removed from the generator. The generator will then run for the pre-set cooling down period, then shutdown into it’s standby mode.

10.10. Set the modules internal clock/calendar to ensure correct operation of the scheduler and event logging

functions. For details of this procedure see section entitled Front Panel Configuration – Editing the date and time.

10.11. If, despite repeated checking of the connections between the 5310 and the customer’s system, satisfactory

operation cannot be achieved, then the customer is requested to contact the factory for further advice on:-





11 FAULT FINDING

SYMPTOM POSSIBLE REMEDY Unit is inoperative Check the battery and wiring to the unit. Check the DC supply. Check the DC

fuse. Unit shuts down Check DC supply voltage is not above 35 Volts or below 9 Volts

Check the operating temperature is not above 70 °C. Check the DC fuse. Unit locks out on Emergency Stop If an Emergency Stop Switch is not fitted, ensure that a positive is connected

to the Emergency Stop input. Check emergency stop switch is functioning correctly. Check Wiring is not open circuit.


Ensure that Magnetic pick-up screen is only connected at one end, if connected at both ends, this enables the screen to act as an aerial and will pick up random voltages.


Check engine oil pressure. Check oil pressure switch/sender and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sender is compatible with the 5310 Module and is correctly configured.


Check engine temperature. Check switch/sender and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sender is compatible with the 5310 Module.




Check wiring of fuel solenoid. Check fuel. Check battery supply. Check battery supply is present on the Fuel output of the module. Check the speed sensing signal is present on the 5310 inputs. Refer to engine manual.


Check that there is no signal present on the “Remote Start” input. Check configured polarity is correct.


Check Start Delay timer has timed out. If remote start fault, check signal is on “Remote Start” input. Confirm input is configured to be used as “Remote Start”.

Pre-heat inoperative Check wiring to engine heater plugs. Check battery supply. Check battery supply is present on the Pre-heat output of module. Check pre-heat has been selected in your configuration.

Starter motor inoperative Check wiring to starter solenoid. Check battery supply. Check battery supply is present on the Starter output of module. Ensure that the Emergency Stop input is at Positive.


Check Warm up timer has timed out. Ensure generator load inhibit signal is not present on the module inputs. Check connections to the switching device.

Incorrect reading on Engine gauges

Check engine is operating correctly. Check sender and wiring paying particular attention to the wiring to terminal 47 (refer to appendix). Check that sender is compatible with the 5310 Module and is correctly configured.

NOTE:- The above fault finding is provided as a guide check-list only. As it is possible for the module to be configured to provide a wide range of different features always refer to the source of your module configuration if in doubt.



12 FACTORY DEFAULT CONFIGURATION In the tables below, the icon indicates an item that can be adjusted from the module’s front panel editor. Absence of the icon beside an item means that adjustment of this parameter is only possible using the 5300 series configuration software in conjunction with the P810 interface. For further details on adjustment from the front panel editor, see the section entitled “Front panel configuration” elsewhere within this manual. 5300 series configuration software. Configuration for 5310 module. Filename – 5310a.XCF Printed on 25/10/05 Module settings Value Base module 5310 Remote start module Miscellaneous settings Value Two lines of text (Configuration description) Blank

Alternator fitted Yes Poles 4 Magnetic pickup fitted No CAN enabled No AC System 3 phase, 4 wire VT Ratio Disabled Number of start attempts 3 Enable fast loading feature No Audible alarm prior to starting No Sleep when in stop mode No All warnings are latched No Input settings – Analogue | Oil pressure Value Low oil pressure input type VDO 10 bar Trip Return Low oil pressure pre-alarm 1.17 Bar 17.0 PSI 1.24 Bar 18.0 PSI Low oil pressure shutdown 1.03 Bar 14.9 PSI N/A Input settings – Analogue | Coolant temp

Value

High coolant temp input type VDO 120 degrees C Trip Return High coolant temp pre-alarm 115°C 239°F 110°C 230°F High coolant temp shutdown 120°C 248°F N/A Low coolant temp pre-alarm Disabled Disabled Input settings – Analogue | Fuel level Value Fuel level input type Disabled



Input settings - Digital Value 1 Remote start on load Close to activate 2 Lamp test Close to activate 3 User configured Close to activate, Warning Active from safety on 4 User configured Close to activate, Shutdown Always active 5 User configured Close to activate, Shutdown Active from safety on 6 User configured Close to activate, Electrical trip Always active

NOTE:- Inputs set to ‘User configured’ have an extra text box to allow the user to type in a description. Output settings – Relay Value 1 Energise Preheat (during pre-heat timer) 2 Energise Common alarm 3 Energise Close generator Output settings – Expansion A

Value

1 Energise System in auto mode 2 Energise Fail to start 3 Energise Generator available 4 Energise Delayed alarms armed 5 Energise Combined under / over freq. shutdown 6 Energise Combined under / over voltage shutdown 7 Energise Cooling timer in progress 8 Energise Mains failure Output settings – Expansion B

Value

1 Energise Output not used 2 Energise Output not used 3 Energise Output not used 4 Energise Output not used 5 Energise Output not used 6 Energise Output not used 7 Energise Output not used 8 Energise Output not used LED indicator settings Value 1 Lit Digital input 1 active 2 Lit Digital input 2 active 3 Lit System in auto mode 4 Lit Common alarm



Timer settings Value Start delay 5s Pre-heat 0s Cranking time 10s Crank rest time 10s Smoke limit 0s Smoke limit off 0s Safety on delay 10s Overspeed overshoot 2s Warming up time 0s Breaker close pulse 0.5s Breaker trip pulse 0.5s Return delay 30s Cooling time 1m ETS solenoid hold 0s Fail to stop delay 30s Generator transient delay 0s Battery low volts delay 1m Battery high volts delay 1m LCD page timer 5m Generator settings – Voltage/frequency Trip Return Under volts trip 184V AC N/A Under volts pre-alarm 196V AC 207V AC Over volts pre-alarm 265V AC 253V AC Over volts trip 276V AC N/A Under frequency trip 40.0Hz N/A Under frequency pre-alarm 42.0Hz 45.0Hz Over frequency pre-alarm 55.0Hz 52.0Hz Over frequency trip 57.0Hz N/A Droop Disabled N/A Droop % 0.0% N/A Loading Voltage 207V Ph-N Loading Frequency 45.0 Hz Alternative voltage 230v norm / 115v alt Disabled on module Alternative Frequency 50Hz norm / 60Hz alt Disabled on module Generator settings – Current/power Value Generator CT primary 600A Generator CT secondary 5A CT location Generator only Generator full load rating 500 A Delayed overcurrent 100% ( 500A ) Trip Curve 36 Engine settings – Crank disconnect Value Crank disconnect on generator frequency 21.0Hz Crank disconnect oil pressure <Disabled> Check oil pressure prior to starting Yes Engine settings – speed Value Underspeed trip 1250 RPM Disabled Underspeed prealarm 1350 RPM Disabled Overspeed prealarm 1650 RPM Disabled Overspeed trip 1750 RPM Disabled Overspeed overshoot 0% Disabled



Plant battery settings Trip Return Under volts warning 8.0V DC 9.0V DC Over volts warning 33.0 V DC 32.0V DC Charge alternator warning 6.0V DC N/A Exercise scheduler settings Value Enable exercise scheduler No Comms Value Site identity Genset ID Modem mode No modem Modem init (not auto answer) E0S7=60S0=0&S0&C1&D3 Modem init (auto answer) E0S7=60S0=2&S0&C1&D3 Modem Hang H0 Master inactivity timeout 0 Slave ID 10 (Default) Baud Rate 19200 (Default) Languages Value Fixed Languages English (UK) User configured languages Not used



13 TYPICAL WIRING DIAGRAM



14 APPENDIX 14.1 ALTERNATIVE WIRING TOPOLOGIES The 53xx series controllers can support many different wiring topologies (AC systems) to suit the many systems in use worldwide. The ‘Typical connection diagram’ details how to connect the module when used in a 3 phase, 4 wire system (3 phase star connected alternators). Changes to this typical wiring diagram for other AC systems are detailed below.

NOTE:- The factory default configuration for the 5310 module is for use with the 3 phase, 4 wire AC system. If another system is to be used, the controller must be reconfigured using the 5xxx series configuration software.

14.1.1 3 PHASE, 3 WIRE



14.1.2 1 PHASE, 2 WIRE Single phase alternator with neutral conductor.

14.1.3 2 PHASE, 3 WIRE ( 2 PHASE CENTRE TAP NEUTRAL) The alternator is 2 phase star connected. The live phases are separated by 180°



14.2 ICONS AND LCD IDENTIFICATION 14.2.1 PUSH BUTTONS

Display Description Display Description Display Description

Stop/Reset i Page scroll Auto mode

Scroll Manual mode

I Start (when in Manual or Test

mode) Mute

14.2.2 STATUS / MEASUREMENT UNITS

Display Description Display Description Display Description

L1 Phase L2 Phase L3 Phase

L1- N Phase - Neutral L2- N Phase - Neutral L3- N Phase -Neutral

L1- L2 Phase - Phase L2- L3 Phase - Phase L3- L1 Phase - Phase

BAR Pressure KPa KPa Oil Pressure Units PSI Pressure

V Voltage oF Temperature Hz Frequency

A Amperes oC Temperature RPM Speed

kW KiloWatts kVA Apparent power KW divided by

kVA 14.2.3 LED INDICATION Display Description

Generator available



14.3 5310 IDMT TRIPPING CURVES (TYPICAL)

5310 Delayed over-current protection

1

10

100

1000

10000

100000

1000000

1 2 3

Current as a multiple of the trip-point setting (tripping curve = 36)

Trip

ping

tim

e in

sec

onds



14.4 SENDER WIRING RECOMMENDATIONS 14.4.1 EARTH RETURN SENDERS





Sender common 47

NOTE:- . It is important that terminal 47 ( sender common ) is soundly connected to an earth point on the ENGINE BLOCK, not within the control panel, and must be a sound electrical connection to the sender bodies.

NOTE:- . If you use PTFE insulating tape on the sender thread when using earth return senders, ensure you do not insulate the entire thread as this will prevent the sender body from being earthed via the engine block.

14.4.2 INSULATED RETURN SENDERS





Sender common 47

NOTE:- . It is important that terminal 47 ( sender common ) is soundly connected to an earth point on the ENGINE BLOCK, not within the control panel .

14.4.3 FUEL LEVEL SENDERS

53xx

53xx



The resistive fuel level senders supported by the 5300 series controllers are devices that translate fuel level into resistance. A change in fuel level translates directly to a change in the resistance of the sender. In the case of a parallel sided fuel tank, an accurate measure of the fuel level can easily be made, however as shown in the example below, this is not the case with non-parallel sided fuel tanks. Therefore it is recommended that only parallel sided fuel tanks are used to ensure correct fuel level detection.

The fuel sender measures the distance between the top of the tank and the fuel level. Typically, they use a ball float. In this example, the distance between the top of the tank and the level of the fuel is 50% of the height of the tank. The fuel level sender will report the tank correctly as being 50% full. For a parallel-sided tank like this one, 50% distance between the top of the tank and the level of the fuel will occur when the tank is 50% full of fuel. In this example, the distance between the top of the tank and the level of the fuel is again 50% of the height of the tank, the fuel level sender will report the tank as being 50% full. However, as the bottom of the tank is curved, the actual amount of fuel in the tank is only about 40%. The fuel sender is incorrectly reporting the amount of remaining fuel.



14.5 CAN INTERFACE

Modules are fitted with the CAN interface as standard and are capable of receiving engine data from engine CAN controllers compliant with the CAN standard. CAN enabled engine controllers monitor the engines operating parameters such as engine speed, oil

pressure, engine temperature (among others) in order to closely monitor and control the engine. The data that is gathered by the engine controller is then transmitted on an industry standard communications interface (CAN). This allows generator controllers such as the DSE 53xx range to access these engine parameters with no physical connection to the sensor device.

NOTE:- For further details for connections to CAN enabled engines refer to the manual CAN and DSE Wiring Part No. 057-004

14.6 OUTPUT EXPANSION There are several methods of output expansion available for the 5xxx module:- 14.6.1 RELAY OUTPUT EXPANSION (157) An expansion module is available, which connects to the configuration socket and enables the 53xx to use eight additional relays on the 157 relay module, providing Volt-free contacts for customer connection. A maximum of 2 off 157 relay modules can be connected, there are identified as ‘A’ and ‘B’ and give a total of 16 extra relay outputs. Refer to technical data sheet on the 157 relay module for further details. 14.6.2 LED OUTPUT EXPANSION (548) An expansion module is available, which connects to the configuration socket, and enables the 53xx to use eight additional LED’s on the 548 module, providing remote LED’s indication up to 50 metres away. A maximum of 2 off 548 LED modules can be connected, there are identified as ‘A’ and ‘B’ and give a total of 16 extra LED outputs. It is possible to use a mix of 157 and 548 modules to give both relay and LED expansion if required (Please refer to our Technical Support department for details.). 14.7 INPUT EXPANSION It is possible to increase the number of monitored inputs available by utilising either :

DSE P130 input expansion 54x Protection Expansion/Annunciator.

Please refer to the relevant product documentation for further details.



14.8 COMMUNICATIONS OPTION CONNECTIONS

14.8.1 DESCRIPTION

The 5xxx series configuration software allows the 5310 controller to communicate with a PC. The computer can be connected to the module either directly (P810 shown to the right), via a modem (RS232)* or via an RS485 link**. The operator is then able to remotely control the module, starting or stopping the generator, selecting operating modes, etc. The various operating parameters (such as output volts, oil pressure, etc.) on the remote generator can also be viewed. The information contained in this manual should be read in conjunction with the appropriate module documentation. This manual only details the operation of the communications software and how it should be used. The operation of the module is detailed in its own relevant manual.

NOTE: - *If modem communications is a requirement, then it is important to order the correct 5310 module with the RS232 communications board fitted. This provides a 9-way D-type connector suitable for connection to the modem. Please refer to the comms section of this manual for details of how the system should be configured. **If RS485 communications is required, then it is important to order the correct 5310 module with the RS485 communications board fitted. This provides a 3-way terminal block for connection of the RS485 link.

14.8.2 PC TO CONTROLLER (DIRECT) CONNECTION To connect a 5310 to a modem the following items are required: -

• Any 5310 Module (RS232 or RS485) • 5xxx series configuration software (Supplied on DSE software

CD). • P810 interface (USB or RS232 as required)

14.8.3 MODEM TO CONTROLLER CONNECTION

To connect a 5310 to a modem the following items are required: -

• 5310 Module with RS232 Communications Interface • Compatible RS232 Modem (PSTN or GSM) • Suitable connection leads • Power supply for the modem • 5xxx series configuration software (Supplied on DSE software CD). • Access to a PSTN Line or GSM network.

CAUTION! - The modem must be powered from a suitably stabilised supply, preferably supplied with the modem (see below). Failure to ensure continuity of supply will result in communication difficulties at such times as Mains failure or during cranking. An uninterruptible power supply arrangement is recommended (AC or DC depending on modem power requirement).



14.8.4 RS485 LINK TO CONTROLLER The RS485 enabled 5310 modules are able to communicate with a PC or other RS485 enabled device over a standard RS485 connection. Typical uses of RS485 are: • Direct connection to a remote PC running the 5xxx series configuration software. RS485 is capable of

communication over a distance of 1.2km where suitable 120Ω RS485 cable is installed. • Connection to a building management to allow mains, generator and engine parameters/alarm conditions to be

displayed along with information from other devices (air conditioning, fire alarm system etc).

NOTE: - The RS485 system will comprise of one MODBUS master (typically a PC) and up to 31 MODBUS slaves. The 5310 modules are always MODBUS slave devices. To ensure correct operation a suitable 120Ω terminal resistor must be fitted to each end of the RS485 connection bus.

Caution! - The A and B lines of the 485 network should be terminated at each end with a 120Ω resistor. Some RS485 devices (PC cards in particular) are already fitted with a terminating resistor. However if they are not installed as an ‘end of line’ device then such terminating resistors must be removed. Other RS485 devices may be fitted with a ‘switchable’ resistor, again this must be switched out if the device is not installed as an ‘end of line’ device.

Typical connections of RS485 PC system (master) to RS485 DSE controller (slave)



TYPICAL BUILDING MANAGEMENT SCHEME USING RS485 MONITORING

CAUTION! -. RS485 cabling must be 120Ω impedance cable, specified for use with RS485. 120Ω terminating resistors must be fitted to the first and last devices on the bus. Some PC RS485 cards are already fitted with this resistor, and in this case should not be fitted externally. If in doubt, consult the supplier of your PC RS485 card. If the 5310 controller is the ‘last’ device on the bus, then it’s RS485 connection must be suitably terminated with a 120Ω resistor as detailed in the specification laid out in the RS485 standard. Recommended cable BELDEN 9841 120Ω RS485 cable. DSE part number 016-030.

NOTE: - The RS485 output uses ‘MODBUS’ protocol. It is possible to use third party software to monitor and control the 5310 module via this protocol. Please refer to Deep Sea Electronics Plc for details.

14.8.5 MODBUS™ The RS485 output uses Modbus™ communications protocol. This uses a master-slave technique to communicate. Only the Master can initiate a packet transaction, called a ‘query’. When appropriate the slave (5310 Module) responds to the query and provides the information requested by the master. All supported data can be read and written as specified in the register table (documentation is available from Deep Sea Electronics Plc.). When the 5310 Module receives a query it will respond by either supplying the requested register data or performing the requested action. A slave device (the 5310 module) will never initiate communications on the Modbus™ link. The 5310 can only be configured as a slave device. The Master can only query individual slaves. Refer to the Modbus™ protocol document for more details.



14.9 ENCLOSURE CLASSIFICATIONS IP CLASSIFICATIONS BS EN 60529 Degrees of protection provided by enclosures

First Digit Second digit

















NEMA CLASSIFICATIONS


1

IP30


2

IP31


3

IP64


3R

IP32


4 (X)

IP66


12/12K

IP65


13

IP65




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dse72/7300 series operators manual

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