DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
TABLE OF CONTENTS Section
Page
INTRODUCTION ................................................. .......................................................................................................... ...............................................................................5 ......................5 CLARIFICATION OF NOTATION NOTATION USED WITHIN THIS PUBLICATION........................................6 1.
OPERATION................................................................................................................................7 1.1 CONTROL ...................................................... .................................................................................................................... ......................................................................7 ........7 FIG 1............................................................................................................. 1.....................................................................................................................................7 ........................7 1.2 NORMAL MANUAL OPERATION OPERATION ...................................................................... ........................................................................................7 ..................7 1.3 AUTOMATIC (REMOTE) OPERATION OPERATION ..................................................................... ...............................................................................9 ..........9
2.
PROTECTIONS.........................................................................................................................12 VIEWING ALARMS........................................................................................... ALARMS................................................................................................................13 .....................13 2.1 WARNINGS........................................................................................................................14 2.2 SHUTDOWNS....................................................................................................................15 2.3 ELECTRICAL TRIPS..................................................................................... TRIPS..........................................................................................................17 .....................17 2.4 PRE-ALARMS AND OPTIONS ............................................................... ..........................................................................................17 ...........................17
3.
DESCRIPTION OF CONTROLS............................................................. CONTROLS ...............................................................................................19 ..................................19 3.1 LCD DISPLAY .......................................................... ................................................................................................................ ..........................................................19 ....19 VIEWING THE INSTRUMENT AND EVENT LOG PAGES ..........................................................20 SYNCHROSCOPE OPERATION (IF FITTED)..........................................................................21 FITTED)..........................................................................21 OPERATOR CONFIGURATION CONFIGURATION MODE ............................................................. .......................................................................................22 ..........................22 POWER UP LCD DISPLAY .................................................... ..........................................................................................................2 ......................................................24 4 3.2 LED INDICATORS ......................................................... ............................................................................................................. .........................................................26 .....26 3.3 CONTROL PUSH-BUTTONS ..................................................................... .................................................................................................27 ............................27
3.
INSTALLATION INSTALLATION INSTRUCTIONS INSTRUCTIONS ........................................................................ .............................................................................................28 .....................28 3.1 PANEL CUT-OUT................................. CUT-OUT............................................................................................... ..............................................................................28 ................28 FIG 3............................................................................................................ 3...................................................................................................................................28 .......................28 3.2 COOLING ...................................................... ............................................................................................................... .....................................................................28 ............28 3.3 UNIT DIMENSIONS ......................................................... ...........................................................................................................2 ..................................................28 8 FIG 4............................................................................................................ 4...................................................................................................................................28 .......................28 3.4 FRONT PANEL LAYOUT...................................................................................................29 LAYOUT...................................................................................................29 FIG 5............................................................................................................ 5...................................................................................................................................29 .......................29 3.5 REAR PANEL LAYOUT ............................................................... .....................................................................................................2 ......................................29 9 FIG 6............................................................................................................. 6...................................................................................................................................29 ......................29
4.
ELECTRICAL CONNECTIONS..................................................................................... CONNECTIONS.................................................................................................30 ............30 4.1 CONNECTION DETAILS ............................................................. ...................................................................................................30 ......................................30 PLUG “A” 13 WAY ......................................................... ................................................................................................................ ............................................................30 .....30 PLUG “B” 17 WAY ......................................................... ................................................................................................................ ............................................................30 .....30 PLUG “C” 4 WAY .............................................................. ................................................................................................................. .........................................................31 ......31 PLUG “D” 11 WAY (ONLY (ONLY FITTED IF SYNCHRONISING OPTION IS REQUESTED)...........31 REQUESTED)...........31 PC CONFIGURATION CONFIGURATION INTERFACE CONNECTOR.................................................................32 CONNECTOR.................................................................32 EXPANSION INTERFACE CONNECTOR ........................................................................ ................................................................................32 ........32 4.2 CONNECTOR FUNCTION DETAILS.................................................................................3 DETAILS.................................................................................33 3 PLUG “A” 13 WAY ......................................................... ................................................................................................................ ............................................................33 .....33 PLUG “B” 17 WAY ......................................................... ................................................................................................................ ............................................................34 .....34 PLUG “C” 4 WAY .................................................... ................................................................................................................. ...................................................................34 ......34 PLUG “D” 11 WAY (ONLY (ONLY FITTED IF SYNCHRONISING OPTION IS REQUESTED)...........35 REQUESTED)...........35
5.
SPECIFICATION .......................................................... ............................................................................................................... .............................................................36 ........36
6.
COMMISSIONING.....................................................................................................................37 6.1 PRE-COMMISSIONING PRE-COMMISSIONING .......................................................... ......................................................................................................37 ............................................37
7.
FAULT FINDING................................................................. FINDING............................................................................................................... .......................................................38 .........38
8.
TYPICAL WIRING DIAGRAMS ............................................................... .................................................................................................39 ..................................39
9 FACTORY DEFAULT CONFIGURATION CONFIGURATION ........................................................... .....................................................................................41 ..........................41 10. 3
ICONS AND AND LED INDENTIFIC INDENTIFICATIO ATION.......... N............... ........... ........... ........... ........... ........... ............ ........... ........... ........... ........... ........... ........... .......46 .46
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
10.1 ICON DESCRIPTIONS.................................................................................... DESCRIPTIONS......................................................................................................... ..................... 46 10.2 LED IDENTIFICATION DIAGRAM ...................................................................... ....................................................................................... ................. 47 10.3 SENDER WIRING RECOMMENDATIONS.......................................................................... RECOMMENDATIONS.......................................................................... 47 11.
NAVIGATION CHART ........................................................ ...........................................................................................................49 ...................................................49
12.APPENDIX 12.APPENDIX .......................................................... .................................................................................................................... ........................................................................ .............. 50 12.1 55X IDMT IDMT TRIPPING CURVES CURVES (TYPICAL) .......................................................... ..................................................................... ........... 50 12.2 55X SHORT SHORT CIRCUIT CIRCUIT TRIPPING TRIPPING CURVES CURVES (TYPICAL (TYPICAL)) ............ ................. ........... ............ ............ ............ ............51 ......51 12.4 55X DEAD BUS OPERATION OPERATION ..................................................................... .......................................................................................... ..................... 52 12.3 USING THE THE 55X MODULE MODULE WITH ACB’S ............................................................................54 12.4 OUTPUT EXPANSION EXPANSION ....................................................... ......................................................................................................... .................................................. 55 12.4.1 RELAY OUTPUT EXPANSION EXPANSION (157) ......................................................... ............................................................................ ................... 55 12.4.2 LED OUTPUT OUTPUT EXPANSION (548)................................................................................. 55 12.5 INPUT EXPANSION EXPANSION ............................................................ ........................................................................................................... ................................................. .. 55 12. SYNCHRONISING NOTES.................................................................................... NOTES................................................................................................... ............... 56 13.1 CHECK SYNC VERSIONS................................................................................................... VERSIONS................................................................................................... 56 13.2 AUTO SYNC VERSIONS.................................................................................................. VERSIONS.................................................................................................. 56 13.3 LOAD LOAD SHARE SHARE VERSIONS VERSIONS ............................................................................ ............................................................................................... ................... 56
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DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
INTRODUCTION The DSE 550 Module, 550 Module, has been designed to allow the OEM to meet most of the industry’s complex specifications. 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 or automatically. automaticall y. The user also has facility to view all the syst em operating parameters parameters via the LCD display. The DSE 550 module 550 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 32-Bit Micro-processor contained within the module allows for a range of complex features to be incorporated as standard;
Full Multi-lingual LCD display (including non-western character fonts). Up to eight different languages held on-board the module. True RMS voltage monitoring. Optional Power measurement facility. Optional Communications capability (RS485 or RS232 including GSM/SMS functions) Optional Check Sync capability Optional Automatic Sync capability Optional Automatic Load Share capability Optional Multi-set communications 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 operational sequences, timers and alarm trips can be altered by the customer via a PC using the P810 For Windows ™ software and 810 interface Access to critical operational operational sequences sequences and and timers for use by qualified engineers, are are barred barred by a security security code. code. Module Module access access is barred barred by PIN code. code. Limited Limited operator operator selection selections, s, such as display language, can be changed from the module front panel. The module is housed in a robust plastic case for the front panel mounting. Connections to the module are via locking plug and sockets.
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DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION.
Highlights an essential element of a procedure to ensure correctness. Indicates a procedure or practice which, if not strictly observed, could result in damage or destruction of equipment. Indicates a procedure or practice which could result in injury to personnel or loss of life if not followed correctly. Indicates facility is only available available on V2.00 or later modules. If in doubt check ‘V’ number on power up display. Indicates facility is only available available on V3.00 or later modules. If in doubt check ‘V’ number on power up display. Indicates facility is only available available on V4.00 or later modules. If in doubt check ‘V’ number on power up display. 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.
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DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
1.
OPERATION
1.1
CONTROL
Control of the DSE 550 module 550 module is via push-buttons on the front of the module with STOP/RESET, MANUAL, START, AUTO and AUTO and ALARM MUTE functions. MUTE functions. For normal operation these are the only controls which need to be operated. The smaller push-buttons are used to access further information such as engine instruments. instruments . Details of their operation is detailed later in this document. The following descriptions detail the sequences followed by a module containing the standard ‘factory configuration’. configuration’. Always refer to your configuration configurat ion source for the exact sequences and timers observed by any particular module in the field.
Deep Sea Elec Electr tr oni nics cs plc Model 550
i O
I
AUTO
FIG 1 1.2
NORMAL MA MANUAL OP OPERATION
Operation To initiate a start sequence press the ‘Manual’ the ‘Manual’ push pushbutton.
The LED above the button will illuminate and the LCD display will briefly indicate:
7
Detail
MANUAL MODE
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
Operation The LED above the button will illuminate and the LCD display will then indicate:
Detail
GENERATOR AT REST
Then, press and hold the START push-button, once the module has commenced the start sequence the button may then be released. (However, it is possible to configure the module such the start-button must be held pressed to maintain engine cranking until disconnect speed is reached Refer to your configuration Source)
The LED above the button will illuminate and the LCD display will briefly indicate:
START
If the pre-heat output option is configured, the Pre-heat timer is then initiated, and the auxiliary output selected is energised. After the pre-heat timer has expired the module will deenergise the pre-heat output and commence engine starting; the following sequence occurs. The Fuel Solenoid is energised, then after a 1 second delay the Starter Motor is engaged
PRE-HEATING
The engine is cranked for the duration of the crank timer
CRANKING attempt.1 00:08
00:09 PRE-HEATING 00:00 FUEL ON
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 terminating cranking, along with options of Charge alternator voltage and oil pressure. If a Magnetic Pick-up is utilised it is also possible to configure the module so that if the starter motor fails to engage on the first attempt, the starter relay will be de-energised and the a second attempt to engage will be made. For further details on this function please refer to the 810 configuration manual. Operation Should the engine not fire on the first attempt and the crank timer expires, the module will rest the starter for the duration of the crank rest timer. Once this has expired the module will once again attempt to start the engine.
Detail
CRANK REST.
1
00:04 CRANKING attempt2 00:07
This will be repeated until either the engine fires or the pre-set number of attempts to start have been completed… Operation In this instance the module will indicate a ‘Fail to start’ alarm.
Detail
SHUTDOWN FAILED TO START
O
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DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
If the engine start is successful, the following sequence occurs:Operation After the starter motor has disengaged, the Safety On timer is activated.
Detail
WAITING FOR SAFETY ON 00:08
This timer allows Oil Pressure, High Engine Temperature, Underspeed, Undervolts, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault. Operation Once the engine is running and the Safety on timer has expired, full fault protection is made available.
Detail
GENERATOR AVAILABLE
Pressing the STOP/RESET PUSHBUTTON will deenergise the Fuel Solenoid and bring the engine to rest.
O
While the engine runs down the module will start it’s ‘Fail to stop’ timer.
STOP/RESET
While the engine runs down the module will start it’s ‘Fail to stop’ timer.
STOPPING
If the engine is still running when the ‘Fail to stop’ Timer expires the module will alarm.
SHUTDOWN FAIL TO STOP GENERATOR AT REST
Should the engine come to rest within the time allowed by the fail to stop timer the screen will revert to …
1.3
00:24
AUTOMATIC (REMOTE) OPERATION
Operation If the module is placed in ‘AUTO’ mode by pressing the ‘AUTO’ PUSHBUTTON, it will monitor the auxiliary inputs for a ‘REMOTE START’ signal.
Detail
AUTO
The LCD display will briefly indicate
AUTO MODE
The LCD display will then indicate
GENERATOR AT REST
Should the ‘REMOTE START’ signal be detected, the following sequence will occur… The module will start its ‘Start Delay’ timer, this is used START DELAY to ensure that the start event is really required and not 00:09 just a momentary transient signal. Once this timer has expired the module will continue with its normal start sequence as detailed below. Should the remote start signal be removed during either the start delay timer or pre-heat timer, the module will terminate its start sequence and return to its standby ‘AUTO‘ state until such time as a start is signalled again. 9
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
Operation If the pre-heat output option is configured, the pre-heat timer is then initiated, and the auxiliary output selected is energised. After the pre-heat timer has expired the module will deenergise the pre-heat output and commence engine starting; the following sequence occurs. The Fuel Solenoid is energised, then after a 1 second delay the Starter Motor is engaged The engine is cranked for the duration of the crank timer
Detail
PRE-HEATING 00:09 PRE-HEATING
00:00
FUEL ON CRANKING attempt.1 00:06
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 terminating cranking, along with options of Charge alternator voltage and oil pressure. If a Magnetic Pick-up is utilised it is also possible to configure the module so that if the starter motor fails to engage on the first attempt, the starter relay will be de-energised and the a second attempt to engage will be made. For further details on this function please refer to the 810 configuration manual. Operation Should the engine not fire on the first attempt and the crank timer expires, the module will rest the starter for the duration of the crank rest timer. Once this has expired the module will once again attempt to start the engine.
Detail
CRANK REST.
1
00:04 CRANKING attempt2 00:07
This will be repeated until either the engine fires or the pre-set number of attempts to start have been completed… Operation In this instance the module will indicate a ‘Fail to start’ alarm.
Detail
SHUTDOWN FAIL TO START
O
If the engine start is successful, the following sequence occurs:Operation After the starter motor has disengaged, the Safety On timer is activated.
Detail
WAITING FOR SAFETY ON 00:09
This timer allows Oil Pressure, High Engine Temperature, Underspeed, Undervolts, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault. Once the engine is running and the safety on timer has expired, full fault protection is made available. Operation Once the generator is running at the correct speed and up to voltage the Warm-up timer is then initiated 10
Detail
WARMING UP
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DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
00:08 Should the remote start signal be removed during either of the cranking or warm-up timers, the module will terminate its normal auto start sequence will initialise its ‘Cooling Timer’ and eventually return to its standby ‘AUTO‘ state until such time as a start is signalled again. Operation After the warm-up timer has expired the module will energise it’s Load Transfer Output.
Detail
GENERATOR AVAILABLE
The generator in now up and running and is selected to supply the load. Operation Should the remote start signal be removed the module will first initiate a return timer to ensure that it is safe to stop the generator.
Detail
GENERATOR AVAILABLE 00:06
Should the remote start input become active again within this time the module will continue to run the generator on load and ignore the fluctuating remote start signal until such time as it remains in-active for the duration of the stop delay timer. Once the return timer has expired, the module will de-energise the Load Transfer output. Operation The module will then commence its cooling timer, this allows the engine to run off load to ensure that it has adequately cooled before being brought to a standstill. Once the cooling timer has expired the module will deenergise the fuel solenoid and the engine will be brought to rest. If the engine is still running when the ‘Fail to stop’ Timer expires the module will alarm. Should the engine come to rest within the time allow by the fail to stop timer the screen will revert to
11
Detail
COOLING DOWN 2:34 STOPPING 00:27 SHUTDOWN FAIL TO STOP GENERATOR AT REST
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
2.
PROTECTIONS
The module will indicate that an alarm has occurred in several ways; The Audible Alarm will sound. This can be silenced by pressing the ‘Mute’ button
The “Common alarm” LED will illuminate( Warning = Steady , Shutdown = Flashing [steady when Muted]) The LCD display will jump from the ‘Information page’ to display the Alarm Page and the LED above the page icon will illuminate The LCD will the display
ALARM
Followed by the appropriate alarm text
SHUTDOWN LOW OIL PRESSURE
If no alarms are present the LCD will display the following message and will then return to the ‘Information Display’ page;
NO ALARM PRESENT
i 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;
ALARM SHUTDOWN HIGH ENGINE TEMP SHUTDOWN EMERGENCY STOP WARNING LOW COOLANT LEVEL
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DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
It is also possible to manually scroll to display the different alarms; Initial display
>>>>>>>
Pressing the DOWN button the LCD will then show… Pressing the DOWN button again the LCD will then show… Pressing the DOWN button again the LCD will then show… Pressing the DOWN button again the LCD will then show… Pressing the UP button the LCD will then show… etc, etc, etc.
ALARM SHUTDOWN HIGH ENGINE TEMP SHUTDOWN EMERGENCY STOP WARNING LOW COOLANT LEVEL ALARM WARNING LOW COOLANT LEVEL
VIEWING ALARMS If the module is operating in the normal ‘ INFORMATION PAGE’ display any alarm condition will automatically be displayed. Jumps to >>>
i If the user is viewing instrumentation, e.g. Then the alarm page will not automatically be displayed and must be viewed by the operator. To view an alarm operate the page button to move to the ‘Alarm’ page.
To clear an alarm the original triggering conditions must be removed before the alarm can be reset. Alarms are reset by pressing the ‘Stop/Reset’ pushbutton.
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DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
2.1
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. BATTERY CHARGE FAILURE, if the module does not detect a voltage from the warning light terminal on the auxiliary charge alternator, the module will display ‘ WARNING CHARGE ALT FAILURE’ on the LCD. The COMMON ALARM LED will also 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 ‘WARNING LOW BATTERY VOLTAGE’ on the LCD. The COMMON ALARM LED will also illuminate. BATTERY HIGH VOLTAGE, if the module detects that the plant DC supply has risen above the high volts setting level , the module will display ‘WARNING HIGH BATTERY VOLTAGE’ on the LCD. The COMMON ALARM LED will also illuminate. OIL PRESSURE SENDER/SWITCH, the module can be configured to only attempt to crank the engine if the Oil Pressure is initially low, (engine at rest, not running). The module will display ‘ FAIL TO STOP’ on the LCD. The COMMON ALARM LED will also illuminate. LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low oil pressure pre-alarm level after the Safety On timer has expired, a warning alarm will occur. The LCD will indicate ‘WARNING LOW OIL PRESSURE’ and the COMMON ALARM LED will illuminate. HIGH ENGINE TEMPERATURE, if the module detects that the engine coolant temperature has exceeded the high engine temperature pre-alarm level after the Safety On timer has expired, a warning alarm will occur. The LCD will indicate ‘ WARNING HI COOLANT TEMP.’ and the COMMON ALARM LED will illuminate. OVERSPEED, if the engine speed exceeds the pre-alarm level a warning is initiated. The LCD will indicate ‘WARNING OVERSPEED’ and the COMMON ALARM LED will illuminate. UNDERSPEED, if the engine speed falls below the pre-alarm level after the Safety On timer has expired, a warning alarm is initiated. The LCD will indicate ‘ WARNING UNDERSPEED’ and the COMMON ALARM LED will illuminate. GENERATOR HIGH FREQUENCY, if the module detects a generator output frequency in excess of the pre-alarm level a warning is initiated. The LCD will indicate ‘WARNING GEN HIGH FREQUENCY’ and the COMMON ALARM LED will illuminate. GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the pre-alarm level after the Safety On timer has expired, a warning is initiated. The LCD will indicate ‘WARNING GEN LOW FREQUENCY’ and the COMMON ALARM LED will illuminate. GENERATOR HIGH VOLTAGE, if the module detects a generator output voltage in excess of the pre-alarm level a warning is initiated. The LCD will indicate ‘WARNING GEN HIGH VOLTAGE WARNING’ and the COMMON ALARM LED will illuminate. GENERATOR LOW VOLTAGE, if the module detects a generator output voltage below the prealarm level after the Safety On timer has expired, a warning is initiated. The LCD will indicate ‘WARNING GEN LOW VOLTAGE WARNING’ and the COMMON ALARM LED will illuminate.
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MAINTENANCE DUE ALARM, if the engine exceed the allowed running hours or time between periodic maintenance a warning is initiated. The LCD will indicate ‘MAINTENANCE NOW DUE’ and the COMMON ALARM LED will illuminate. To clear the alarm a ‘MAINTENANCE RESET’ must be performed (refer to config source or P810 for Windows software manual for more detail) AUXILIARY INPUTS, if an auxiliary input has been configured as a warning the appropriate LCD message will be displayed and the COMMON ALARM LED will illuminate.
2.2
SHUTDOWNS
Shutdowns are latching and stop the Generator. The alarm must be accepted and cleared, and the fault removed to reset the module.
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 LCD will indicate ‘ SHUTDOWN FAIL TO START’ and the COMMON ALARM and LED will flash. EMERGENCY STOP, removal of the +ve 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 +ve DC supply from both the Fuel Solenoid and Starter Solenoid. The LCD will indicate ‘SHUTDOWN EMERGENCY STOP’ and the COMMON ALARM LED will flash.
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 LCD will indicate ‘SHUTDOWN LOW OIL PRESSURE’ and the COMMON ALARM LED will flash. 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 LCD will indicate ‘SHUTDOWN HIGH COOLANT TEMP’ and the COMMON ALARM LED will flash. OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated. The LCD will indicate ‘SHUTDOWN OVERSPEED’ and the COMMON ALARM LED will flash. Overspeed is not delayed, it is an immediate shutdown.
UNDERSPEED, if the engine speed falls below the pre-set trip after the Safety On timer has expired, a shutdown is initiated. The LCD will indicate ‘ SHUTDOWN UNDERSPEED’ and the COMMON ALARM LED will flash.
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DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
GENERATOR HIGH FREQUENCY, if the module detects a generator output frequency in excess of the pre-set trip a shutdown is initiated. The LCD will indicate ‘SHUTDOWN GEN HIGH FREQUENCY’ and the COMMON ALARM LED will flash. 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 LCD will indicate ‘GEN LOW FREQUENCY’ and the COMMON ALARM LED will flash. GENERATOR HIGH VOLTAGE, if the module detects a generator output voltage in excess of the pre-set trip a shutdown is initiated. The LCD will indicate ‘GEN HIGH VOLTAGE’ and the COMMON ALARM LED will flash. High voltage is not delayed, it is an immediate shutdown. GENERATOR LOW VOLTAGE, if the module detects a generator output voltage below the preset trip after the Safety On timer has expired, a shutdown is initiated. The LCD will indicate ‘GEN LOW VOLTAGE’ and the COMMON ALARM LED will flash. 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 ‘OIL PRESS SENDER FAULT’ and the COMMON ALARM LED will flash. Sender failure is not delayed, it is an immediate shutdown. GENERATOR EARTH FAULT , if the module detects a generator earth fault current in excess of the pre-set trip a shutdown is initiated. The LCD will indicate ‘GEN EARTH FAULT’ and the COMMON ALARM LED will flash. GENERATOR PHASE SEQUENCE WRONG , if the module detects a generator phase rotation error a shutdown is initiated. The LCD will indicate ‘GEN PHASE SEQ WRONG’ and the COMMON ALARM LED will flash. AUXILIARY INPUTS, if an auxiliary input has been configured as a Shutdown the appropriate LCD message will be displayed and the COMMON ALARM LED will flash.
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DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
2.3
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. GENERATOR REVERSE POWER , if the module detects a generator reverse power current in excess of the pre-set trip a shutdown is initiated. The LCD will indicate ‘GEN REVERSE POWER’ and the COMMON ALARM LED will flash. GENERATOR OVER CURRENT, if the module detects a generator output current in excess of the pre-set trip a shutdown is initiated. The LCD will indicate ‘GEN OVER CURRENT’ and the COMMON ALARM LED will flash. GENERATOR SHORT CIRCUIT, if the module detects a generator fault current in excess of the pre-set trip a shutdown is initiated. The LCD will indicate ‘GEN SHORT CIRCUIT’ and the COMMON ALARM LED will flash. AUXILIARY INPUTS, if an auxiliary input has been configured as an Electrical Trip the appropriate LCD message will be displayed and the COMMON ALARM LED will illuminate.
2.4
PRE-ALARMS AND OPTIONS
During module configuration it is possible to select pre-alarm levels for all of the above shutdowns and electrical trips to give a warning that the trip value is being approached. This allows the operator to take steps to prevent the shutdown from ultimately occurring by rectifying the triggering condition. If the module is fitted with the optional RS232 communication board, then the following alarm is available:MODEM POWER FAULT, if the module detects a modem supply current in excess of 350mA warning is initiated. The LCD will indicate ‘MODEM POWER FAULT’ and the COMMON ALARM LED will illuminate. The power supply to the modem will be removed until the alarm is reset.
If the module is fitted with the option of Check Sync
, then the following alarms are available:-
FAILED TO SYNCHRONISE, if the module cannot synchronise within the timer allowed by the Synchronising timer a warning is initiated. The LCD will indicate ‘FAILED TO SYNC’ and the COMMON ALARM LED will illuminate. BUS PHASE SEQUENCE WRONG, if the module detects a bus phase rotation error a warning is initiated. The LCD will indicate ‘BUS PHASE SEQ WRONG’ and the COMMON ALARM LED will illuminate. If the module is fitted with the option of Load Sharing available:-
, then the following alarms are
MSC FAILURE, if the module cannot ‘talk’ to the correct number of modules on the MSC link then the failure alarm is initiated. The LCD will indicate ‘MSC FAILURE’ and the COMMON ALARM LED will illuminate. MSC DATA ERROR, the data being transmitted to the modules on the MSC link is being corrupted – ensure correct specification cable is used and transmission lengths are not exceeded. The LCD will indicate ‘MSC DATA ERROR’ and the COMMON ALARM LED will illuminate. 17
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
MSC ID ERROR, each module must be configured with a unique MSC ID number. Should a module detect another module on the MSC network with the same number it will alarm. The LCD will indicate ‘MSC ID ERROR’ and the COMMON ALARM LED will illuminate.
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3.
DESCRIPTION OF CONTROLS
The following section details the function and meaning of the various controls on the module. LCD Display
User Configurable LED's with insert pocket
Deep Sea Electronics plc Model 550
Up and Down Scroll Buttons
Common Alarm Indicator
Information Page Indicator Event Log Page Indicator
i
Operator Configuration Mode Indicator Page Select Button
O
I
Alarm Mute Button
AUTO
Stop/Reset Button Generator Instruments Page Indicator
Auto Mode Button Start Button Engine Instruments Page Indicator Manual Mode Button Alarm Page Indicator
3.1 LCD DISPLAY
i
INFORMATION PAGE The LCD display normally indicates the status of the generator such as ‘GENERATOR AT REST’, ‘PRE-HEATING’,‘GENERATOR AVAILABLE’, etc. This is the default display and is always automatically returned to after a pre-set period of operator inactivity. ALARM PAGE The LCD also displays the exact nature of any alarm condition which have occurred such as ‘SHUTDOWN LOW OIL PRESSURE’. This allows very specific alarm conditions to be brought to the operators’ attention. Refer to the ‘Protections’ section of this manual for details of how to interact with the alarm page. ENGINE INSTRUMENTS PAGE The LCD displays the various engine parameters such as ‘ENGINE SPEED’, ‘OIL PRESSURE’, ‘HOURS RUN’, etc.
GENERATOR INSTRUMENT PAGE The LCD displays the various generator output values such as ‘GENERATOR VOLTAGE’, ‘GENERATOR CURRENT’, etc. If the enhanced instrumentation option is fitted the LCD will also display the values of ‘GENERATOR KW’, ‘GENERATOR pF’, ‘GENERATOR KVAr’, etc. EVENT LOG PAGE In the event of a shutdown alarm occurring the triggering alarm will be recorded in the Event Log Memory. The Memory will record the last 25 such shutdowns. Subsequent alarms will then over-write the oldest previous alarm. This feature allows service engineers arriving on site a detailed look at the recent history of the gen-set or plant.
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DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
VIEWING THE INSTRUMENT AND EVENT LOG PAGES To view a particular instrument operate the “ Page” button to move to the required page. Each press of the button will move the page indicator LED along. The LCD will also indicate the page title. i.e. To view the Engine Coolant temperature move to the ‘ Engine Instruments Page’. The LCD will display the page title and then will automatically commence scrolling down the various instrument . These will automatically scroll round, on reaching the last instrument the LCD display will then jump back to the page title and resume scrolling down the page. This sequence will be repeated until either the user moves off the page or after a period of inactivity the module will revert to the ‘Information Page’
ENGINE INSTRUMENTATION ENGINE SPEED 1503 RPM ENG OIL PRESSURE 2.5Bar 56psi COOLANT TEMP 78deg C 105deg f BATTERY VOLTAGE 24.5 V CHARGE ALT VOLTAGE 27.5 V ENGINE RUN TIME 50H 36M NUMBER OF STARTS 65 NEXT MAINTENANCE 123 Hours It is also possible to manually scroll to display the different instruments, once selected the instrument will remain on the LCD display until the user selects a different instrument or page, or after a period of inactivity the module will revert to the ‘Information Page’.
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Manually Selecting an Instrument Initial display
>>>>>>>
Pressing the DOWN button the LCD will then show… Pressing the DOWN button again the LCD will then show… Pressing the DOWN button again the LCD will then show… Pressing the DOWN button again the LCD will then show… Pressing the DOWN button again the LCD will then show… Pressing the UP button the LCD will then show… etc, etc, etc.
ENGINE INSTRUMENTS ENGINE SPEED 1503 RPM ENG OIL PRESSURE 2.5Bar 56psi COOLANT TEMP 78deg C 105deg f BATTERY VOLTAGE 24.5 V CHARGE ALT VOLTAGE 27.5 V BATTERY VOLTAGE 24.5 V
If the DOWN button is pressed while the LCD display is showing ‘NEXT MAINTENANCE DUE IN’ then the display will jump round to the top of the page and display the page title; ‘ ENGINE INSTRUMENTS’. Pressing the DOWN button again will then display; ‘ENGINE SPEED’
SYNCHROSCOPE OPERATION (IF FITTED) Display
Hz +2.9
V +0.2
Hz +0.9
V +0.2
Hz -0.2
V +0.2
Hz -0.2
21
V +0.2
Detail Initial stage of Synchronising display will only show the difference between the Bus Supply and the Generator Output. Here the display is showing a frequency mis-match of +2.9Hz - The gen-set frequency is too high and should be reduced (indicated by the arrow). The voltage is +0.2 volts high, but is within the limits set for synchronising. Once the difference between the Bus supply and the Generator output has been reduced the ‘Synchroscope’ display will become active. The moving bar will roll from left to right or right to left depending on the mis-match between the bus supply and the generator output. The area in the centre of the scope indicates the set limits for synchronising to occur. Synchronising will only occur when both the Frequency and the voltage differences are within acceptable limits - Indicated by ‘Tick’ marks on the top of the display. Then the moving bar display will show the phase difference. The engine speed should be adjusted until the moving bar enters the centre of the scope. Once the bus and the generator are synchronised the moving bar will be in the centre of the scope and the bar will be ‘locked’ into the synchronising window. While the bar is ‘locked’ the module will initiate a breaker close to load the generator onto the bus. Should synchronism be broken the moving bar will pass out of the synchronising window and the ‘locked’ indication will clear.
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
OPERATOR CONFIGURATION MODE This configuration mode allows the operator limited customising of the way the module operates. Operation To enter the ‘Operator configuration mode’ press both the UP and DOWN scroll buttons together.
Detail
+
The module will enter ‘Operator Configuration mode’ and the ‘Operator configuration mode indicator’ will illuminate above the PAGE button. The LCD will then display:
CONFIGURATION
To view the different configuration functions press the PAGE button.
The LCD will then display:
LANGUAGE ENGLISH
Pressing the UP or DOWN Button will then change the selected language. The LCD will then display the new language: Repeat until the required language is displayed.
or LANGUAGE French LANGUAGE GERMAN
To view the next function press the PAGE button.
The LCD will then display:
CONTRAST
Pressing the UP or DOWN Button will move the sliding bar UP (Darker) or DOWN (Lighter) - set this to the desired position. When correct, to view the next function press the PAGE button.
The LCD will then display:
or
AUTO SCROLL TIME 3.0 Seconds
This is the duration each instrument will be displayed for during the automatic scrolling. Use the UP and DOWN buttons to set this to the required value. When correct, to view the next function press the PAGE button.
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Operation The LCD will then display: Digital inputs configured as indications can be viewed on the LCD by pressing the UP or DOWN button when the ‘Information Page’ is active. To disable this function set to ‘NO’ by pressing the UP or DOWN button. When correct, to view the next function press the PAGE button.
The LCD will then display: If the set is part of a multi-set load sharing scheme this setting will appear. Changing this setting will allow the gen-sets duty priority to be changed to balance engine hours for example.
Detail
INDICATIONS ON LCD YES or
GEN SET RUN PRIORITY or
When correct, to view the next function press the PAGE button.
The LCD will then display: To exit the ‘Operator configuration mode’ with-out storing any changes made press the UP or DOWN button. If you wish to save the changes you have made to the configuration press the PAGE button.
The LCD will then display: To exit the ‘Operator configuration mode’ and store the changes you have made press the UP or DOWN button.
ABANDON CHANGES AND EXIT or
SAVE CHANGES AND EXIT or
The module will then return to the ‘ Information Page’ display and the ‘Operator Configuration Mode Indicator’ will extinguish.
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DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
POWER UP LCD DISPLAY On application of the DC supply the module LCD will display information about the module.
M550 NS 4W S01 C01 V2.00
M S Code Letter M
Meaning Module Type
C Options 550 NS 4W 550 CS 4W 550 AS 4W 550 NS 3W 550 CS 3W 550 AS 3W 555 NS 4W 555 CS 4W 555 AS 4W 555 NS 3W 555 CS 3W 555 AS 3W
S
System Options
C
Custom Options
00 01 00 01 02 09 10 13 14
24
V Detail Auto-start Module Variant with no Sync option, 4 wire (3ph+N) connection. Auto-start Module Variant with Check Sync option, 4 wire (3ph+N) connection. Auto-start Module Variant with Auto Sync option, 4 wire (3ph+N) connection. Auto-start Module Variant with out Sync option, 3 wire (3ph) connection. Auto-start Module Variant with Check Sync option, 3 wire (3ph) connection. Auto-start Module Variant with Auto Sync option, 3 wire (3ph) connection. Automatic Mains Failure Module Variant with no Sync option, 4 wire (3ph+N) connection. Automatic Mains Failure Module Variant with Check Sync option, 4 wire (3ph+N) connection. Automatic Mains Failure Module Variant with check Sync option, 4 wire (3ph+N) connection. Automatic Mains Failure Module Variant with no Sync option, 3 wire (3ph) connection. Automatic Mains Failure Module Variant with check Sync option, 3 wire (3ph) connection. Automatic Mains Failure Module Variant with Auto Sync option, 3 wire (3ph) connection. Basic Metering Version Enhanced Metering Version No options fitted RS232 Comms Board Fitted RS485 Comms Board Fitted RS232 Comms Board + Load Share (MSC-net) Fitted RS485 Comms Board + Load Share (MSC-net) Fitted RS232 Comms Board + Load Share (MSC/ CANbus) Fitted RS485 Comms Board + Load Share(MSC/ CANbus) Fitted
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Code Letter V
25
Meaning Software Version
Options X.XX
Detail Details internal firmware revision (FLASH Version)
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
3.2 LED INDICATORS COMMON ALARM LED This LED indicates when an alarm condition is present. The Alarms Page on the LCD will detail the exact nature of the alarm. ‘OFF ’ - no alarm active. ‘FLASHING’ - A shutdown alarm is present, but has not been muted. ‘STEADY ’ - A warning alarm is present or a shutdown alarm which has been muted is present. USER CONFIGURABLE LED’s These LED 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.
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3.3 CONTROL PUSH-BUTTONS STOP/RESET This push-button places the module into it’s Stop/reset mode. This will clear any alarm conditions for which the triggering criteria have been removed. If the engine is running and this push-button is operated, the module will automatically instruct the change-over device to un-load the generator (‘ Load transfer ’ becomes in-active (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 the mode, a remote start will not occur.
O
MANUAL This push-button is used to allow manual control of the generator functions. Entering this mode from any other mode will initially not cause any change of operating state, but allows further push-buttons to be used to control the generator operation. For example once in Manual mode it is possible to manually start the engine by using the ‘START’ pushbutton. If the engine is running off-load in the Manual mode and a remote start signal becomes present, the module will automatically instruct the change-over 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’ push-buttons are operated. START This push-button is used to manually start the engine. The module must first be placed in the ‘MANUAL’ mode of operation. The ‘START’ button should then be operated. The engine will then automatically attempt to start. Should it fail on the first attempt it will re-try until either the engine fires or the pre-set number of attempts have been made. To stop the engine the ‘STOP/RESET’ button should be operated. It is also possible to configure the modules such that the start push-button must be held to maintain engine cranking.
AUTO This push-button places the module into it’s ‘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. ALARM MUTE This push-button is used to silence the internal alarm sounder and also any external sounder devices fed from the audible alarm output. Any further alarm conditions will re-active the sounder. Once the alarm has been muted and investigated it may then be cleared. Refer to the ‘Protections’ section of this manual for details. When the Alarm Mute is operated a Lamp test function will also will be implemented and all LED indicators will be illuminated.
27
AUTO
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
3.
INSTALLATION INSTRUCTIONS
The model DSE 550 Module has been designed for front panel mounting. Fixing is by 4 spring loaded clips for easy assembly.
3.1
PANEL CUT-OUT
138.00mm
185.00mm
FIG 3 In conditions of excessive vibration the module should be mounted on suitable anti-vibration mountings.
3.2
COOLING
The module has been designed to operate over a wide temperature range -30 to +70º C. However 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 93% .
3.3
UNIT DIMENSIONS
All dimensions in mm.
144.0mm
137mm
157 808
CE
185.0mm
110.0mm
192.0mm 7.5mm
FIG 4
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3.4
FRONT PANEL LAYOUT
Deep Sea Electr onics plc Model 550
i O
I
AUTO
FIG 5 3.5
REAR PANEL LAYOUT
157 808
CE
FIG 6
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DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
4.
ELECTRICAL CONNECTIONS
Connections to the Module are via plug and sockets.
4.1
CONNECTION DETAILS
The following describes the connections and recommended cable sizes to the plugs and sockets on the rear of the Module. See rear panel layout FIG 5.
PLUG “A” 13 WAY PIN No 1 2 3 4 5 6 7 8 9 10 11 12 13
DESCRIPTION
CABLE SIZE
DC Plant Supply Input (-ve) DC Plant Supply Input (+ve) Emergency Stop Input
2.5mm
Fuel relay Output Start relay Output Auxiliary Output relay 1 Auxiliary Output relay 2 Charge Fail Input/ Excitation Output Auxiliary Input 1 Auxiliary Input 2 Auxiliary Input 3 Auxiliary Input 4 Auxiliary Input 5
NOTES
2.5mm
(Recommended Fuse Max. 21A)
2.5mm 2.5mm 2.5mm 1.0mm 1.0mm 1.0mm
Plant Supply +ve. Also supplies fuel & start outputs. (Recommended Fuse Max. 32A) Plant Supply +ve from pin 3. 16 Amp rated. Plant Supply +ve from pin 3. 16 Amp rated. Plant Supply +ve. 5 Amp rated. Plant Supply +ve. 5 Amp rated. Must NOT be connected to plant supply -ve.
0.5mm 0.5mm 0.5mm 0.5mm 0.5mm
Switch to -ve Switch to -ve Switch to -ve Switch to -ve Switch to -ve
PLUG “B” 17 WAY PIN No
DESCRIPTION
CABLE SIZE
14 15 16 17 18 19 20
Auxiliary Input 6 Auxiliary Input 7 Auxiliary Input 8 Auxiliary Input 9 Auxiliary Output relay 3 Auxiliary Output relay 4 Magnetic Pickup Input (+ve)
0.5mm 0.5mm 0.5mm 0.5mm 1.0mm 1.0mm 0.5mm
21
Magnetic Pickup Input (-ve) Oil Pressure Input Coolant Temperature Input Sender Common Return CT secondary for L1 CT secondary for L2 CT secondary for L3 CT secondary common Neutral CT secondary Functional Earth
0.5mm
22 23 24 25 26 27 28* 29* 30
30
0.5mm 0.5mm 0.5mm 2.5mm 2.5mm 2.5mm 2.5mm 2.5mm 2.5mm
NOTES Switch to -ve Switch to -ve Switch to -ve Switch to -ve Plant Supply +ve. 5 Amp rated. Plant Supply +ve. 5 Amp rated. Connect to Magnetic Pickup device using screened cable - See Note. Connect to Magnetic Pickup device using screened cable - See Note Connect to Oil pressure sender Connect to Coolant Temperature sender Return feed for senders**. Connect to secondary of L1 monitoring CT Connect to secondary of L2 monitoring CT Connect to secondary of L3 monitoring CT Connect to secondary of all monitoring CT’s Connect to Neutral CT secondary and Earth Connect to a good clean earth point
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PLUG “C” 4 WAY PIN No 31 32 33 34
DESCRIPTION Generator L1 Voltage Monitoring Input Generator L2 Voltage Monitoring Input Generator L3 Voltage Monitoring Input Generator Neutral Input
CABLE SIZE 1.0mm 1.0mm 1.0mm 1.0mm
NOTES Connect to generator L1 output (AC) (Recommend 2A Fuse Max.) Connect to generator L2 output (AC) (Recommend 2A Fuse Max.) Connect to generator L3 output (AC) (Recommend 2A Fuse Max.) Connect to generator Neutral output (AC)
PLUG “D” 11 WAY (ONLY FITTED IF SYNCHRONISING OPTION IS REQUESTED) PIN No 35 36 37 38 39 40 41 42 43 44 45
31
DESCRIPTION Generator Loading Relay Contact (Aux Relay 5) Generator Loading Relay Contact (Aux Relay 5) NOT USED Auxiliary Relay 6 Normally Closed Contact Auxiliary Relay 6 Changeover contact Auxiliary Relay 6 Normally Open contact NOT USED Bus L1 Voltage Monitoring Input Bus L2 Voltage Monitoring Input Bus L3 Voltage Monitoring Input Bus Neutral Input
CABLE SIZE
NOTES
2.5mm
Connect to generator contactor coil.
2.5mm
Connect to generator contactor coil feed supply.
2.5mm
Do not connect. Voltage Free, AC Rated
2.5mm
Voltage Free, AC Rated
2.5mm
Voltage Free, AC Rated
1.0mm 1.0mm 1.0mm 1.0mm
Do not connect. Connect to Bus L1 supply (AC) (Recommend 2A Fuse Max.) Connect to Bus L2 supply (AC) (Recommend 2A Fuse Max.) Connect to Bus L3 supply (AC) (Recommend 2A Fuse Max.) Connect to Bus Neutral supply (AC)
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
PC CONFIGURATION INTERFACE CONNECTOR 8-way connector allows connection to PC via 810 configuration interface. Module can then be re-configured utilising the P810 for Windows software.
EXPANSION INTERFACE CONNECTOR 157 808
4-way connector allows connection to the 157 relay expansion module or the 548 LED annunciator module. A maximum of 2 relay expansion modules may be connected in series to this port.
Auto-sync versions of the 55x can also control the P122 digital resistance module via this port. These can be fitted in addition the any 157 relay modules required. See caution note below.
When used in conjunction with the P122 Digital Resistance Modules, only P157 Relay Expansion modules with Part Number 81xxxxx MUST be used. When used in conjunction with the P122 Digital Resistance Modules, only P548 Relay Expansion modules with Part Number 81xxxxx MUST be used. Some versions of the module have the option of remote communications via RS232 or RS485. The details of these connections are covered in the Link500plus softw are manual Some versions of the module have the option of Load sharing. The details of these connections are covered in the Guide to Sync and load sharing manual.
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4.2
CONNECTOR FUNCTION DETAILS
The following describes the functions of the connectors on the rear of the module. See rear panel layout FIG 5.
PLUG “A” 13 WAY PIN No
DESCRIPTION
1 2 3
DC Supply -ve. System DC negative input. (Battery Negative). DC Supply +ve. System DC positive input. (Battery Positive). 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. Positive Supply is also removed from Starter and Fuel therefore only a single pole Emergency Shutdown button is required. Fuel Relay output. Plant Supply +ve from pin 3. Used to control the fuel solenoid or engine fuel control system. Starter Relay output. Plant Supply +ve from pin 3. Used to control the Starter Motor. Auxiliary Relay output 1. Plant Supply +ve. Configurable output, see Calibration Manual for options available. Auxiliary Relay output 2. Plant Supply +ve. Configurable output, see Calibration Manual for options available. Charge Fail input / Excitation output. Supplies excitation to the Plant Battery Charging Alternator, also an input for the Charge Fail detection circuitry. 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. Auxiliary input 2. 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. Auxiliary input 3. 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. Auxiliary input 4. 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. Auxiliary input 5. 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.
4 5 6 7 8 9
10
11
12
13
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DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
PLUG “B” 17 WAY PIN No
DESCRIPTION
14
Auxiliary input 6. 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. Auxiliary input 7. 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. Auxiliary input 8. 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. Auxiliary input 9. 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. Auxiliary Relay output 3. Plant Supply +ve. Configurable output, see Calibration Manual for options available. Auxiliary Relay output 4. Plant Supply +ve. Configurable output, see Calibration Manual for options available. Magnetic Input +ve. An AC signal from the magnetic pickup +ve for speed sensing. Magnetic Input -ve. An AC signal from the magnetic pickup -ve for speed sensing. Oil Pressure sensing input. Connect to resistive type oil pressure sender. Refer to connection diagram for details. Coolant Temperature sensing input. Connect to resistive type coolant temperature sender. Refer to connection diagram for details. Sender Common connection. Return feed from sender units - refer to connection diagram for details. Generator L1 current transformer connection. Generator L2 current transformer connection. If single phase is used do not connect this pin. Generator L3 current transformer connection. If single phase is used do not connect this pin. Generator current transformer common connection. Generator current transformer Neutral connection and CT earth connection. Functional Earth - Ensure connection to a good clean earth point.
15
16
17
18 19 20 21 22 23 24 25 26 27 28* 29* 30
PLUG “C” 4 WAY PIN No
DESCRIPTION
31 32
Generator L1 sensing input. Connect to alternator L1 output. Generator L2 sensing input. Connect to alternator L2 output. If using single phase only do not connect this terminal. Generator L3 sensing input. Connect to alternator L3 output. If using single phase only do not connect this terminal. Generator N sensing input. Connect to alternator N output.
33 34
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PLUG “D” 11 WAY (ONLY FITTED IF SYNCHRONISING OPTION IS REQUESTED) PIN No
DESCRIPTION
35
Generator Loading Relay (Aux Relay 5), Normally open, Volts free contacts to 36. Used to connect to Generator contactor or circuit breaker. Generator Loading Relay (Aux Relay 5) , Normally open, Volts free contacts to 35. Used to connect to Generator contactor or circuit breaker. DO NOT USE Generator Close Request Relay (Aux Relay 6), Normally Closed Change-over, Volts free contacts to 39 Generator Close Request Relay (Aux Relay 6), Change-over, Volts free contacts to 38 and 40. Generator Close Request Relay (Aux Relay 6), Normally open Change-over, Volts free contacts to 39. DO NOT USE Bus L1 sensing input. Connect to Bus L1 supply. Bus L2 sensing input. Connect to Bus L2 supply. If using single phase only do not connect this terminal. Bus L3 sensing input. Connect to Bus L3 supply. If using single phase only do not connect this terminal. Bus N sensing input. Connect to Bus N supply.
36 37 38 39 40 41 42 43 44 45
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DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
5.
SPECIFICATION
DC Supply Cranking Dropouts
Max. Operating Current Max. Standby Current Typical Standby Current Alternator Input Range Alternator Input Frequency Magnetic Input Range (if fitted) Magnetic Input Frequency Start Relay Output Fuel Relay Output Auxiliary Relay Outputs Dimensions Charge Fail / Excitation Range Operating Temperature Range CT Burden CT Secondary CT Class Electromagnetic Compatibility Electrical Safety Cold Temperature Hot Temperature Humidity Vibration
Shock
Synchronising option:Bus Input Voltage Range Bus Input Frequency Additional Sync Relays
36
9.0 to 35 V Continuous. Able to survive 0 V for 50 mS, providing supply was at least 10 V before dropout and supply recovers to 5V .This is achieved without the need for internal batteries. 513mA at 12 V. 263 mA at 24 V. 370 mA at 12 V. 210 mA at 24 V 363mA at 12 V. 190 mA at 24 V. 15V - 277 (ph-N) 3 Phase 4wire AC (+20%) 50 - 60 Hz at rated engine speed (Minimum 15V AC Ph-N) +/- 0.5 V to 70 V Peak 10,000 Hz (max). 16 Amp DC at supply voltage. 16 Amp DC at supply voltage. 5 Amp DC at supply voltage. 192 X 144 X 138 0 V to 35 V -30 to +70°C 2.5VA 5A Class 1 Protection Recommended (Basic Instrumentation) Class 1 Protection Required (Enhanced Instrumentation) BS EN 50081-2 EMC Generic Emission Standard (Industrial) BS EN 50082-2 EMC Generic Emission Standard (Industrial) BS EN 60950 BS EN 60068-2-1 to -30 oC BS EN 60068-2-2 to +70 oC BS2011-2-1 to 93% RH@40 oC for 48 Hours BS EN60068-2-6 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 3 Half sine shocks in each of 3 major axes 15gn amplitude, 11mS duration 15V - 277(ph-N) 3 Phase 4wire AC (+20%) 50 - 60 Hz (Minimum 15V AC Ph-N) 8 Amp AC RMS rated
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6.
COMMISSIONING
6.1 PRE-COMMISSIONING Before the system is started, it is recommended that the following checks are made:6.1. The unit is adequately cooled and all the wiring to the module is of a standard and rating compatible with the system. 6.2. The unit DC supply is fused and connected to the battery and that it is of the correct polarity. 6.3. The Emergency Stop input is wired to an external normally closed switch connected to DC positive.
6.1. 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. Press the “MANUAL” pushbutton, then press the ‘START’ pushbutton for a short time. The unit start sequence will commence. 6.2. 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 ‘Shutdown Failed to start ’. Press the STOP/RESET pushbutton to reset the unit. 6.3. Restore the engine to operational status (reconnect the fuel solenoid), again select “MANUAL” and operate the ‘START’ pushbutton, 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. 6.4. 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. 6.5. 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. 6.6. 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. 6.7. If despite repeated checking of the connections between the 550 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]
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DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
7.
FAULT FINDING SYMPTOM
Unit is inoperative
POSSIBLE REMEDY
Engine runs but generator will not take load
Check the battery and wiring to the unit. Check the DC supply. Check the DC fuse. 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. 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 550 Module. 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 550 Module. Check relevant switch and wiring of fault indicated on LCD display. Check configuration of input. Check relevant switch and wiring of fault indicated on LCD display. Check configuration of input. 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 550 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”. 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. 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 +Ve. Check Warm up timer has timed out. Ensure generator load inhibit signal is not present on the module inputs.
38
550 OPERATING MANUAL ISSUE 6 29/07/2003 MR
Unit shuts down
Unit locks out on Emergency Stop
Intermittent Magnetic Pick-up sensor fault Low oil Pressure fault operates after engine has fired
High engine temperature fault operates after engine has fired.
Shutdown fault operates Warning fault operates Fail to Start is activated after pre-set number of attempts to start
Continuous starting of generator when in AUTO Generator fails to start on receipt of Remote Start signal or under mains failure conditions. Pre-heat inoperative
Starter motor inoperative
l a u n a M s r o t a r e p O m e t s y S n o i t a t n e m u r t s n I d n a t n e m e g a n a M e n i g n E t r a t S c i t a m o t u A 0 5 5 l e d o M E S D
y a t l e p s s - i n d a e c i o G t / t s o d l e e t n n c a g a e P i e n d d l n e e b o t l a m e i i : c l - a p t E n l T e m a v h o e a O s i W c R N
n o i t t c o e d n e n t o c h t C e n r a n h E t r o y c a t e E e f b y t a t S e s f e a u h S M t
0 3 4
8 1
N
y a W 4 8 6 C C F
3 D L
A O 2 ) L L
d e t t i f T C l a r t u e N o N h t i W (
1 L
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F
S M A R G A I D G N I R I W L A C I P Y T . 8
F
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7
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n o i t a 0 r 1 u g i 8 f n o C
s t u p n i
9 1
9 3 0 4 g y a n l i e d R a t o s L e r u o q t a e r R e n e g n G i d a o L r 5 o 3 t a r y 6 e l 3 n a e e R G 1 3
6
9
7 1 6 1 5 1 4 1 3 1 2 1 1 1 0 1 9
8 7 6 5
r e p d m n e e T S
3 2 4 2 2 2
r e l i d O n e S
U P M
1 2 0 2
t e n o n b i o t t t t e c s s c s d i u u e u n v e n m u d m m n d o 4 o n r r c . 2 g e o n i l s l h t a c a e a a t k c e c i n e o i r d i i n d y o t l m n o c r v n b e o o a e l b c e r r o p t n e e T d i o o n d d t n g n t u n n o i e e t o e u r d r o s i c e e s e w s e G h h t a s e u n t h i e n h n e o T o b t b c T o
8
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l a u n a M s r o t a r e p O m e t s y S n o i t a t n e m u r t s n I d n a t n e m e g a n a M e n i g n E t r a t S c i t a m o t u A 0 5 5 l e d o M E S D
y a t l e p s s - i n d a e c i o G t / t s o d l e e t n n c a g a e P i e n d d l n e e b o t l a m e i i : c l E n p t l a v T e m h o a e a O s i W c R N
n o i t t c o e d n e n t o c h t C e n r a n h E t r o y a c t e E e f a y b t t e s S f e a u h S M t
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6
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5
t e n o n b i o t t t t e c s s c s d i u u e u n v e n m m n m u d d o 4 o r r n c . 2 g e o n i l s l h t a c a e a a t k i c e n e o i c r d i i n d y o t l m n o c r v n b e o o a e l b c e r r o p t n e e T d i o o n d d t n g t n n u n o i e e o r d t r e u o s i c e s e w e e G s h h e u n t a s t i n h e h n e o b o b t T c T o
R M 3 0 0 2 / 7 0 / 9 2 6 E U S S I L A U N A M G N I T A R E P O 0 5 5
F
3 F
2 1
0 4
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
9 FACTORY DEFAULT CONFIGURATION P810 for Windows. Configuration for 550 module. Page 1 of 4 Configuration description 1 Default Factory Settings 2 Check Sync fitted 3 09/10/00 4 Miles Revell Filename - 550cs.XCF Printed on 27/11/00 16:25:56 Module settings Base module 550 remote start module Check sync option fitted Yes Miscellaneous settings Alternator fitted Yes poles : 4 Magnetic pickup fitted No AC System 3 phase, 4 wire Enable generator sequence alarm Yes Enable bus sequence alarm Yes Phase sequence L1 L2 L3 Display indications on LCD display No Display load switching state machine No Enable fast loading feature Yes All warnings are latched No Start button must be held down to crank No Audible alarm prior to starting No Number of start attempts 3 Input settings Low oil pressure input type VDO 10 bar High coolang 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 High coolant temp pre-alarm 115°C 239°F 110°C 230°F High coolant temp shutdown 120°C 248°F Digital inputs 1 Remote start Close to activate 2 Generator closed auxiliary Close to activate 3 User configured Close to activate Warning Active from safety on Active text : Digital input 3 4 User configured Close to activate Shutdown Always active Active text : Digital input 4 5 User configured Close to activate Shutdown Active from safety on Active text : Auxiliary Input 5 6 User configured Close to activate Electrical trip Always active Active text : Auxiliary Input 6 7 User configured Close to activate Electrical trip Active from safety on Active text : Auxiliary Input 7 8 User configured Close to activate Indication Always active Active text : Auxiliary Input 8 9 Panel lock Close to activate LED settings 1 Lit Remote start present 2 Lit Panel locked by digital input 41
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
3 Lit Delayed alarms armed 4 Lit Check sync P810 for Windows. Configuration for 550 module. Page 2 of 4 Configuration description 1 Default Factory Settings 2 Check Sync fitted 3 09/10/00 4 Miles Revell Filename - 550cs.XCF Printed on 27/11/00 16:25:57 Output settings Module relays 1 Energise Preheat (during pre-heat timer) 2 Energise Common alarm 3 Energise Close generator 4 Energise System in auto mode 5 Energise Close generator 6 Energise Generator close request Expansion A 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 Expansion B 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
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550 OPERATING MANUAL ISSUE 6 29/07/2003 MR
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
Timer settings Starting timers Start delay 5s Pre-heat 0s Pre-heat bypass 0m 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 Load timers Warming up time 0s Transfer time 0.7s Breaker close pulse 0.0s Breaker trip pulse 0.0s Digital input 2 is assigned to generator auxiliary contact Gen close timer 1.3s Gen open timer 5s No digital input is assigned to mains auxiliary contact Stopping timers Return delay 30s Cooling time 30s ETS solenoid hold 0s Fail to stop delay 30s Other timers Battery low volts delay 1m Battery high volts delay 1m LCD auto scroll timer 2s LCD page timer 5m Reverse power alarm 0.0s
43
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
P810 for Windows. Configuration for 550 module. Page 3 of 4 Configuration description 1 Default Factory Settings 2 Check Sync fitted 3 09/10/00 4 Miles Revell Filename - 550cs.XCF Printed on 27/11/00 16:25:58 Generator settings Voltage and frequency settings Trip Return Under volts trip 184V AC Under volts pre-alarm 196V AC 207V AC Over volts pre-alarm 265V AC 253V AC Over volts trip 276V AC Under frequency trip 40.0 Hz 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 Power settings Generator CT primary 500 A Generator full load rating 500 A Earth fault CT primary rating 500 A Trip Curve/Multiplier Action Delayed overcurrent 100% ( 500 A ) 36 Electrical trip Short circuit 300% ( 1500 A ) 6 Electrical trip Earth fault 10% ( 50 A ) 1000 Shutdown Reverse power 0.3 KW Electrical trip Synchronising ( check sync ) settings Enable synchronising Yes Check sync phase angle 10° Check sync frequency 0.2 Hz Check sync RMS voltage 5.0VAC Sync advance time 0 mS Sync hold time 100 mS Fail to sync time 30.0s Engine settings Crank disconnect Trip Crank disconnect on generator frequency 21.0 Hz Crank disconnect on generator voltage Crank disconnect on charge alternator Crank disconnect on oil pressure Check oil pressure prior to starting Yes
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550 OPERATING MANUAL ISSUE 6 29/07/2003 MR
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
Speed settings 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 Maintenance alarm settings Enable maintenance alarm No P810 for Windows. Configuration for 550 module. Page 4 of 4 Configuration description 1 Default Factory Settings 2 Check Sync fitted 3 09/10/00 4 Miles Revell Filename - 550cs.XCF Printed on 27/11/00 16:25:58 Exercise scheduler settings Enable exercise scheduler No Language settings Default language English (UK) User defined language 1 Chinese (PRC) User defined language 2 Not used User defined language 3 Not used User defined language 4 Not used
45
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
10. ICONS AND LED INDENTIFICATION 10.1 ICON DESCRIPTIONS Symbol
I
Meaning Stop/Reset
Description Stop the generator and reset any alarm conditions. Refer to Section 1 of this Manual. Start the generator (if in an appropriate mode). Refer to Section 1 of this Manual.
Start Auto
Mains Failure Simulation (Test)
The controller will automatically start the generator when given a remote start command. The controller will start the generator under manual control. (Separate Start command may be necessary) An alarm condition has been detected. (Warning = Steady, Shutdown = Flashing ) On AMF modules this is used to simulate a mains failure event. (On load test)
Alarm Mute
Silences the audible warning device.
Lamp Test
Causes all indicating LED’s to illuminate to test for correct operation Instruments page for engine details such as Oil pressure, Engine temperature.
Manual
Common Alarm
Engine Instruments
46
Generator Instruments
Instruments page for generator details such as frequency and voltage
Event Log
Details recorded history of generator operation.
550 OPERATING MANUAL ISSUE 6 29/07/2003 MR
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
10.2 LED IDENTIFICATION DIAGRAM LED1
Deep Sea Electronics plc Model 550
LED2 LED3 LED4
i O
I
AUTO
10.3 SENDER WIRING RECOMMENDATIONS Using Earth return (single wire) senders
Connection name Oil pressure Coolant temperature Sender common
47
Terminal 22 23 24
22 24 55x / 560 module
23
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
Using insulated return (two wire) senders
Connection name Oil pressure Coolant temperature Sender common
48
Terminal 22 23 24
22 24 55x / 560 module
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550 OPERATING MANUAL ISSUE 6 29/07/2003 MR
g o L t n e v E
l a u n a M s r o t a r e p O m e t s y S n o i t a t n e m u r t s n I d n a t n e m e g a n a M e n i g n E t r a t S c i t a m o t u A 0 5 5 l e d o M E S D
1 t n e v E d e g g o L
2 t n e v E d e g g o L
3 t n e v E d e g g o L
4 t n e v E d e g g c o t L e
3
N
e c
y t i
2 . 0
+ n r - 4 1 n 3 - 5 . o V 3 3 3 3 3 3 3 8 3 3 e i 3 3 1 4 0 r L L L L L o 4 4 u L 4 i t l q P t N 2 L 4 u e d e 2 8 a - 6 3 4 2 2 8 2 8 2 8 t a 8 g 7 S 2 n 3 1 4 . L L L L L 6 r n L 2 2 4 4 F 4 a . l l l 5 5 e a 2 0 r L 4 0 o e a a a 6 h s t t e t t 4 4 4 m t z 4 6 N 2 2 8 5 r 1 5 o 7 1 5 o 7 1 2 v 8 1 o 7 7 a 1 e H a 2 . 1 5 a 0 h L D r m 1 4 1 2 A . L 4 T . L 4 T L 4 T L 8 9 1 L 4 E 0 . 0 e u L 3 L 1 h P 2 4 r r r h r 2 n t n n 5 n n n n n A n A n 0 n n A n A n h n A n A n L d a e s n e e e e e e e e e e e e e e e z V w w V V f f V W V e V e 3 o n G V G V G H G A G A G k G I G k G k G k G p G p G K G k G k G k G k G L L 3
n o i t a t n e m u r t s n I e n i g n E
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H C N O I T A e g a G I P V n o A i t N a r . m o 1 f n 1 I
F g s e c s e t e e l t r n I d m a a i d o t t p 5 g n e e S a V S 0 l t t e n e r P m f t 1 o l u p M u 6 e n o 5 t V A R M i S P s a s r t C y e 4 r e n e R e e a a g r V g V n 3 b M r n 0 r B l r r i e i t e t H o d g 0 P t 5 . a 5 . g H m x 8 i 5 n 5 l . o 8 a 4 h 7 n 0 u 4 e 9 E 1 O 2 C 7 B 2 C 2 E 5 N 3 N 1
t n e s e r P m r a l A m r a o l N A
1 t x e T m r a l A
2 t x e T m r a t c l A e
… c t e … 1 2 3 4 n n n n o o i o o i t i t t i t a a a a c i c i c i c i d d d d n n n n I I I I D D D D C C C C L L L L
9 4
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
12.APPENDIX 12.1 55X IDMT TRIPPING CURVES (TYPICAL) 55x Delayed over-current protection
1000000
100000
10000
s d n o c e s n i e m i t g n i p p i r T
1000
100
10
1 1
2
Current as a multiple of the trip-point setting At default setting of t = 36
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550 OPERATING MANUAL ISSUE 6 29/07/2003 MR
3
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
12.2 55X SHORT CIRCUIT TRIPPING CURVES (TYPICAL) Model 55x Short circuit & Earth fault curves for a 3 phase fault @ 50 Hz
100000
s d n o c e s i l l i m n i e m i t n o i t c e t e D
Curve 8200
10000
Curve 6800 Curce 5600 Curve 4700 Curve 3900 Curve 3300 Curve 2700 Curve 2200 Curve 1800 Curve 1500 Curve 1200
1000
Curve 1000
100 1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Current as a multiple of the trip-point setting
51
1.8
1.9
2
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
12.4 55X DEAD BUS OPERATION Modules fitted with Check sync or auto sync option only It is frequently required that two or more generators should start at the same time, and that the first one to reach stabilised running conditions should connect to the dead bus leaving the remainder to synchronise onto the bus, as they become available. In this scenario, two or even more generators can reach stabilised running conditions at the same moment in time and therefore some form of ‘election’ process is required to ensure that generators do not attempt to close onto the dead bus simultaneously. Failure to do this will almost certainly result in out-of-phase paralleling at some time in the lifetime of the installation. The problem arises from the fact that it is impossible to predict just when each of the generators’ ‘ready for load’ signal will occur and therefore two or more could occur at exactly the same time. Under these circumstance, applying the ‘ready for load’ signal directly to the contactor or breaker is not satisfactory since both contactors will attempt to close together, and using N/C interlock contacts and dead bus sensing does not resolve this problem. There may not be a problem in the case of a two set system where both sets are always required on the bus. In this case the ‘bus’ input to the synchroniser can be derived from the generator side of the other set’s contactor, then at the point of synchronism, both contactors can be closed onto the dead bus at the same time. However, this approach is not possible for more than two sets, and in addition, the application may require that the first available set be connected to the bus in the shortest possible time without waiting for the successful completion of the synchronising process. The following figure shows one of the solutions using external electrically interlocked interposing relays in conjunction with the 550 unit having the check synchronising option. If the ‘close request’ outputs appear simultaneously, then both interposing relays Ra/2 & Rb/2 will start to close but because of their interlock contacts Ra2 & Rb2, one relay will become closed and the other will be locked out. This will occur very quickly and before contacts Ra1 or Rb1 close. Thus only one of the contacts Ra1 or Rb1 closes and only one of the contactor coils becomes energised by this route. When one of the contactor auxiliary contacts Ma1 or Mb1 closes it will cause a closing command to appears at terminal 36 and the close request signal at terminal 40 will disappear. If neither the auxiliary contacts Ma1 or Mb1 close within 1.5 seconds, then this will indicate that there is an external fault, perhaps through contact Ra1 or Rb1 or with the contactor its-self. In this case the close request output at terminal 40 will disappear allowing another set the chance of becoming first on the bus. As soon as one of the generators has connected to the bus in the above manner, so others will synchronise to the bus, and when in synchronism a closing command will appear at their respective terminal 36. This signal will remain for as long as the generator is to remain on load. This scheme can be extended to cover a number of parallel gen-sets.
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550 OPERATING MANUAL ISSUE 6 29/07/2003 MR
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
Two generators with 550 synchronising controllers The interposing relays Ra & Rb ensure that only one generator attempts to close onto the dead bus Key:
R = Interposing relay a = 1st generator
M = Main contactor b = 2nd generator
L1
L1
F
F
39
35
550 unit a Aux IP
39
35
550 unit b Close request
Close command 36
40 Ma1
Aux IP
Mb2
36
Ra2
DC -ve
Ma2
Ra1 Ra/2
Close command
40 Mb 1
Rb2
DC -ve
Close request
Rb1 Ma
N
Rb/2
Mb
N
Modules fitted with Load share option only When using a module fitted with the load share option, then the modules must be connected together and ‘talking’ correctly on the Mutli-set Communications Link. Once the link is established then the modules will perform the task of getting the first set on the bus themselves without the need for the additional circuit shown above. Simply connect the contactor or breaker to the close generator output (normally 5) and then the modules will ensure that only one set is allowed on the dead bus. Once the set is available it will transmit a message onto the MSC link to say that it can close onto the dead bus, if there is no objection from the other units it will then go ahead and close. Should another gen-set report that it is also ready to go, then the modules will vote as to who going to actually close. Once the decision has been made to close onto the bus all other sets will be instructed over the MSC link that the bus is live and that they must synchronise first before closing. This system ensures that only one module can close onto the dead bus at once and the sets on the MSC are aware of each others actions. Once the first set is on the bus, and then the others synchronise and close, normal load sharing and s equencing will then take place, regardless of who was first on the bus.
53
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
12.3 USING THE 55X MODULE WITH ACB’S The standard configuration allows the 55x module to be connected to contactors and the like. However, it may be required to connect the to 55x module to breakers such as ACB’s, etc. If so the following connection scheme is recommended as considered a ‘fail-safe’ method.
Output 5 Configure as: Energise - Close Generato
Closing Supply
Output 3 Configure as: De-Energise - Trip Generator
38 Internal DC Supply
19
39
36
Internal DC Supply
55x Module 18
40
35
UV Coil Supply DC Slave Relay
Generator Closing Coil
*Or use DC trip Coil
Generator Undervolts Coil
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550 OPERATING MANUAL ISSUE 6 29/07/2003 MR
DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
12.4 OUTPUT EXPANSION There are several methods of output expansion available for the 55x module:-
12.4.1 RELAY OUTPUT EXPANSION (157) An expansion module is available, which connects to the configuration socket, and enables the 55x to use eight additional relays on the 157 relay module, providing Volt-free contacts for customer connection. A maximum of 2 off 157 relays 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.
12.4.2 LED OUTPUT EXPANSION (548) An expansion module is available, which connects to the configuration socket, and enables the 55x 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.
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 if required (Please refer to our Technical Support department for details.).
12.5 INPUT EXPANSION It is possible to increase the number of monitored inputs available by utilising a DSE 54x Protection Expansion/Annunciator. Please refer to our Technical department for details.
55
