DSE 5210 User manual

DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual
057-011 5210 OPERATING MANUAL ISSUE 5.1 18/06/2007 AM 1
COMPLEX SOLUTIONS
MADE SIMPLE.
DEEP SEA ELECTRONICS PLC
DSE5210
AUTOSTART CONTROL MODULE
OPERATING MANUAL
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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual
2057-011 5210 OPERATING MANUAL ISSUE 5.1 18/06/2007 AM
Deep Sea Electronics Plc
Highfield House
Hunmanby
North Yorkshire
YO14 0PH
ENGLAND
Sales Tel: [phone]
Sales Fax: [phone]
E-mail: [email protected]
Website: www.deepseaplc.com
DSE Model 5210 Control and Instrumentation System Operators Manual
© Deep Sea Electronics Plc
All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any
medium by electronic means or other) without the written permission of the copyright holder except in accordance with the
provisions of the Copyright, Designs and Patents Act 1988.
Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to Deep
Sea Electronics Plc at the address above.
Any reference to trademarked product names used within this publication is owned by their respective companies.
Deep Sea Electronics Plc reserves the right to change the contents of this document without prior notice.
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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual
057-011 5210 OPERATING MANUAL ISSUE 5.1 18/06/2007 AM 3
TABLE OF CONTENTS
Section Page
1INTRODUCTION ..............................................................................................5
2CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION.........5
3OPERATION ....................................................................................................6
3.1 AUTOMATIC MODE OF OPERATION ...............................................................................6
3.2 MANUAL OPERATION.......................................................................................................8
4PROTECTIONS................................................................................................9
4.1 WARNINGS .......................................................................................................................10
4.2 ANALOGUE PRE-ALARMS..............................................................................................10
4.3 HIGH CURRENT WARNING ALARM...............................................................................11
4.4 SHUTDOWNS....................................................................................................................12
4.5 HIGH CURRENT SHUTDOWN ALARM ...........................................................................14
4.6 ELECTRICAL TRIPS.........................................................................................................14
5LCD INDICATORS AND LOGO INSERT.......................................................15
6DESCRIPTION OF CONTROLS ....................................................................16
6.1 TYPICAL LCD DISPLAY SCREENS ................................................................................17
6.2 LCD DISPLAY AREAS......................................................................................................18
6.3 VIEWING THE INSTRUMENTS ........................................................................................19
6.4 VIEWING THE EVENT LOG..............................................................................................20
6.5 INDICATORS.....................................................................................................................21
6.6 CONTROLS.......................................................................................................................21
7FRONT PANEL CONFIGURATION...............................................................22
7.1 ACCESSING THE FRONT PANEL CONFIGURATION EDITOR.....................................22
7.1.1 ENTERING THE CONFIGURATION EDITOR PIN NUMBER ...................................22
7.2 EDITING AN ANALOGUE VALUE....................................................................................23
7.2.1 EDITING THE CURRENT DATE/TIME......................................................................25
8INSTALLATION INSTRUCTIONS..................................................................26
8.1 PANEL CUT-OUT..............................................................................................................26
8.2 COOLING...........................................................................................................................26
8.3 UNIT DIMENSIONS...........................................................................................................26
8.4 FRONT PANEL LAYOUT..................................................................................................27
8.5 REAR PANEL LAYOUT....................................................................................................27
9ELECTRICAL CONNECTIONS......................................................................28
9.1 CONNECTION DETAILS...................................................................................................28
9.1.1 PLUG “A” 8 WAY........................................................................................................28
9.1.2 PLUG “B” 11 WAY......................................................................................................28
9.1.3 PLUG “D” 4 WAY (OPTIONAL) ..................................................................................29
9.1.4 PLUG “F” 4 WAY ........................................................................................................29
9.1.5 PLUG “G” 5 WAY........................................................................................................29
9.1.6 PLUG “H” 4 WAY........................................................................................................29
9.1.7 PC CONFIGURATION INTERFACE CONNECTOR..................................................29
9.1.8 EXPANSION OUTPUT CONNECTOR.......................................................................29
9.2 CONNECTOR FUNCTION DETAILS................................................................................30
9.2.1 PLUG “A” 8 WAY........................................................................................................30
9.2.2 PLUG “B” 11 WAY......................................................................................................30
9.2.3 PLUG “D” 4 WAY (OPTIONAL, FITTED TO RS485 CONTROLERS ONLY) ............31
9.2.4 PLUG “F” 4 WAY ........................................................................................................31
9.2.5 PLUG “G” 5 WAY........................................................................................................31
9.2.6 PLUG “H” 4 WAY........................................................................................................31
9.2.7 PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE............................31
10 SPECIFICATION.........................................................................................32
11 COMMISSIONING.......................................................................................34
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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual
4057-011 5210 OPERATING MANUAL ISSUE 5.1 18/06/2007 AM
11.1.1 PRE-COMMISSIONING..............................................................................................34
12 FAULT FINDING..........................................................................................35
13 TYPICAL WIRING DIAGRAM......................................................................36
14 FACTORY DEFAULT CONFIGURATION...................................................37
15 ICONS AND LCD IDENTIFICATION...........................................................40
15.1 PUSH BUTTONS............................................................................................................40
15.2 STATUS / MEASUREMENT UNITS ..............................................................................40
15.3 ALARM INDICATIONS ..................................................................................................40
16 APPENDIX...................................................................................................41
16.1 ALTERNATIVE WIRING TOPOLOGIES .......................................................................41
16.1.1 3 PHASE, 3 WIRE.......................................................................................................41
16.1.2 1 PHASE, 2 WIRE.......................................................................................................41
16.1.3 2 PHASE, 3 WIRE ( 2 PHASE CENTRE TAP NEUTRAL).........................................42
16.2 5210 IDMT TRIPPING CURVES (TYPICAL).................................................................43
16.3 SENDER WIRING RECOMMENDATIONS....................................................................44
16.3.1 EARTH RETURN SENDERS......................................................................................44
16.3.2 INSULATED RETURN SENDERS..............................................................................44
16.3.3 FUEL LEVEL SENDERS ............................................................................................45
16.4 5200 SERIES CONFIGURATION SOFTWARE AND P810 INTERFACE MODULE....46
16.5 OUTPUT EXPANSION...................................................................................................46
16.5.1 RELAY OUTPUT EXPANSION (157).........................................................................46
16.5.2 LED OUTPUT EXPANSION (548)..............................................................................46
16.6 INPUT EXPANSION.......................................................................................................46
16.7 STANDBY GENERATING SET?...................................................................................46
16.8 FULLY INTEGRATED AUTO MAINS FAILURE...........................................................46
16.9 ENCLOSURE CLASSIFICATIONS................................................................................47
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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual
057-011 5210 OPERATING MANUAL ISSUE 5.1 18/06/2007 AM 5
1 INTRODUCTION
The DSE 5210 autostart module has been designed to allow the OEM to meet most of the industry’s complex
specifications. It has been primarily designed to allow the user to start and stop the generator, and if required,
transfer the load to the generator either manually (via external push-buttons) or automatically. The user also has
facility to view all the system operating parameters via the LCD display.
The DSE 5210 module monitors the engine, indicating the operational status and fault conditions; automatically
shutting down the engine and giving a true first up fault condition of an engine failure by a flashing COMMON
ALARM LED. Exact failure mode information is indicated by the LCD display on the front panel.
The powerful Microprocessor contained within the module allows for a range of complex features to be
incorporated as standard;
•Graphical Icon based LCD display (excluding the need for translations and languages).
•Voltage, Current and Power monitoring.
•Engine parameter monitoring.
•Fully configurable inputs for use as alarms or a range of different functions.
•Extensive range output functions using built in relay outputs or relay expansion available.
Selective operational sequences, timers and alarm trips can be altered by the customer via a PC using the 5200
series configuration software and P810 interface.
Access to critical operational sequences and timers for use by qualified engineers, are barred by a security code.
The module is housed in a robust plastic case for front panel mounting. Connections to the module are via locking
plug and sockets.
2 CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION.
NOTE:
Highlights an essential element of a procedure to ensure
correctness.
CAUTION!
Indicates a procedure or practice which, if not strictly observed,
could result in damage or destruction of equipment.
WARNING!
Indicates a procedure or practice, which could result in injury to
personnel or loss of life if not followed correctly.
©
Dee
p
Sea Electronics Plc owns the co
py
ri
g
ht to this manual, which
cannot be copied, reproduced or disclosed to a third party without
prior written permission.
Com
p
liant with BS EN 60950 Low Volta
g
e Directive
Compliant with BS EN 50081-2 EMC Directive
Compliant with BS EN 50082-2 EMC Directive
Year 2000 Compliant
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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual
6057-011 5210 OPERATING MANUAL ISSUE 5.1 18/06/2007 AM
3 OPERATION
The following description details the sequences followed by a module containing the standard ‘factory
configuration’. Always refer to your configuration source for the exact sequences and timers observed by any
particular module in the field.
3.1 AUTOMATIC MODE OF OPERATION
NOTE:- If a digital input configured to panel lock is active, the LCD will display the
icon. When in panel lock, changing module modes will not be possible. Viewing the instruments and event logs
is NOT affected by panel lock.
This mode is activated by pressing the pushbutton. An LED indicator beside the button confirms this
action.
When a Remote Start signal is applied to the remote start input, the following sequence is initiated:-
The Remote Start Active indicator illuminates (if configured).
To allow for false signals the Start Delay timer is initiated. After this delay, if the pre-heat output option is selected
then the pre-heat timer is initiated, and the corresponding auxiliary output (if configured) will energise.
NOTE:- If the Remote Start signal is removed during the Start Delay timer, the unit will return to a
stand-by state.
After the above delays, the Fuel Solenoid is energised, and then one second later, the Starter Motor is engaged.
The engine is cranked for a pre-set time period. If the engine fails to fire during this cranking attempt then the
starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the set number of
attempts, the start sequence will be terminated and
Fail to Start fault will be displayed accompanied by a flashing shutdown symbol.
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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual
057-011 5210 OPERATING MANUAL ISSUE 5.1 18/06/2007 AM 7
When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from the Alternator
output. Alternatively, a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is
selected by PC using the 5200 series configuration software). Rising oil pressure can also be used to disconnect
the starter motor; however, it cannot be used for underspeed or overspeed detection.
After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine
Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the
fault.
Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to stabilise before
accepting the load.
If an auxiliary output has been selected to give a load transfer signal, this would then activate.
NOTE:-A load transfer will not be initiated until the Oil Pressure has risen. Thus preventing excessive
wear on the engine.
On removal of the Remote Start signal, the Stop delay timer is initiated, once it has timed out, the load Transfer
signal is de-energised, removing the load. The Cooling timer is then initiated, allowing the engine a cooling down
period off load before shutting down. Once the Cooling timer expires, the Fuel Solenoid is de-energised, bringing
the generator to a stop.
Should the Remote Start signal be re-activated during the cooling down period, the generating set will return to an
on load condition.
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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual
8057-011 5210 OPERATING MANUAL ISSUE 5.1 18/06/2007 AM
3.2 MANUAL OPERATION
NOTE:- If a digital input configured to panel lock is active, the LCD will display the
icon. When in panel lock, changing module modes will not be possible. Viewing the instruments and event logs
is NOT affected by panel lock.
To initiate a start sequence in MANUAL, press the pushbutton. When the controller is in the manual mode
(indicated by an LED indicator beside the button), pressing the START (I) button will initiate the start sequence.
NOTE:- There is no Start Delay in this mode of operation.
If the pre-heat output option is selected this timer is then initiated, and the auxiliary output selected is energised.
The Fuel Solenoid is energised, and then the Starter Motor is engaged.
The engine is cranked for a pre-set time period. If the engine fails to fire during this cranking attempt then the
starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the set number of
attempts, the start sequence will be terminated and
Fail to Start fault will be displayed accompanied by a flashing shutdown indicator.
When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from the Alternator
output. Alternatively, a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is
selected by PC using the 5200 series configuration software). Rising oil pressure can also be used to disconnect
the starter motor; however, it cannot be used for underspeed or overspeed detection.
After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine
Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the
fault.
Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to stabilise before it can
be loaded.
The generator will run off load, unless a Remote Start signal is applied, and if Load Transfer has been selected
as a control source, the appropriate auxiliary output selected will activate.
If the Remote Start signal is removed, the generator will continue to run On load until the Auto mode is selected.
The Remote Stop Delay Timer will time out, the load is then disconnected. The generator will then run off load
allowing the engine a cooling down period.
Selecting STOP (O) de-energises the FUEL SOLENOID, bringing the generator to a stop.
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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual
057-011 5210 OPERATING MANUAL ISSUE 5.1 18/06/2007 AM 9
4 PROTECTIONS
The module will indicate that an alarm has occurred in several ways;
The LCD display will indicate a ‘common alarm’ either :
(warning) or (shutdown)
If appropriate, the LCD display or LED indicators will
display the appropriate alarm icon i.e. for battery
charging failure :
NOTE:- Alarm icons in the LED display area are ‘hid until lit’. This means that the display area
appears totally clear, and ‘free from clutter’. The advantage of this is that when an alarm does occur, the
respective LED icon will illuminate on the otherwise blank fascia. This makes alarm identification much
clearer.
If no alarms are present the LCD
will extinguish any alarm icons.
In the event of a warning alarm, the LCD will display the appropriate icon. If a shutdown then occurs, the module
will display the appropriate icon. The original warning alarm icon will remain displayed.
Example:-
Low battery volts warning (all symbols steady)
Followed by….
Low battery volts warning indicator still
present, common alarm indicator has
changed to a shutdown symbol and is
now flashing.
Also present is the flashing underspeed
LED.
Underspeed and Shutdown alarm Icons are displayed flashing. The original warning will remain displayed as long
at the triggering conditions remain. Any subsequent warnings or shutdowns that occur will be displayed steady,
therefore only the first-up shutdown will appear flashing.
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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual
10 057-011 5210 OPERATING MANUAL ISSUE 5.1 18/06/2007 AM
4.1 WARNINGS
Warnings are non-critical alarm conditions and do not affect the operation of the generator system, they serve to
draw the operators attention to an undesirable condition.
In the event of a warning alarm, the LCD will display:-
BATTERY CHARGE FAILURE, if the module does not detect a voltage from the warning light terminal on the
auxiliary charge alternator the icon will illuminate.
BATTERY LOW VOLTAGE, if the module detects that the plant DC supply has fallen below the low volts setting
level, the module will display:-
V
The Battery Low Voltage alarm is delayed by the Low DC Volts Delay timer.
BATTERY HIGH VOLTAGE, if the module detects that the plant DC supply has risen above the high volts setting
level, the module will display:-
V
FAIL TO STOP, If the module detects the engine is still running when the ‘Fail to stop timer’ expires, then the
module will display:-
NOTE:- ‘Fail to Stop’ could indicate a faulty oil pressure sender - If engine is at rest check oil sender
wiring and configuration.
AUXILIARY INPUTS, if an auxiliary input has been configured as a warning the appropriate LCD segment will be
displayed:-
!
LOW FUEL LEVEL. If the fuel level detected by the fuel level sender falls below the low fuel level setting, a
warning will occur.
The icon will illuminate.
4.2 ANALOGUE PRE-ALARMS
The following alarms are termed ‘pre-alarms’ as they pre warn the operator of a potentially more serious alarm
condition. For instance, if the engine temperature rises past the pre alarm level, a warning condition will occur to
notify the operator. If the temperature falls below the level, then the alarm ceases, and the set will continue to run
as normal. However if the temperature continues to rise until the coolant temperature trip point is reached, the
warning is escalated and a high coolant temperature shutdown is initiated.
During a pre-alarm condition, the warning symbol is displayed on the LCD display, along with the appropriate
icon:
LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low oil pressure pre-
alarm setting level after the Safety On timer has expired, a warning will occur.
The icon will illuminate.
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