DSEGenset DSE7400 User manual

DSE7400 Operator Manual ISSUE 1
DEEP SEA ELECTRONICS PLC
DSE7400 Operator Manual
Document Number 057-161
Author: Ashley Senior

DSE7400 Operator Manual
2
DEEP SEA ELECTRONICS PLC
Highfield House
Hunmanby
North Yorkshire
YO14 0PH
ENGLAND
Sales Tel: [phone]
Sales Fax: [phone]
E-mail : s[email protected]
Website : www.deepseaplc.com
DSE7400 Operator Manual
© Deep Sea Electronics Plc
All rights reserved. No part of this publication may be reproduced in any material form (including
photocopying or storing in any medium by electronic means or other) without the written permission of
the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents
Act 1988.
Applications for the copyright holder’s written permission to reproduce any part of this publication
should be addressed to Deep Sea Electronics Plc at the address above.
The DSE logo is a UK registered trademarks of Deep Sea Electronics PLC.
Any reference to trademarked product names used within this publication is owned by their respective
companies.
Deep Sea Electronics Plc reserves the right to change the contents of this document without prior
notice.
Amendments List
Issue Comments Minimum
Module
version
required
Minimum
Configuration Suite
Version required
1 Initial release V1.0.0 2011.10v1.0.7
Typeface: The typeface used in this document is Arial. Care should be taken not to mistake the upper case letter I with the numeral 1. The numeral
1 has a top serif to avoid this confusion.
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.

DSE7400 Operator Manual
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TABLE OF CONTENTS
Section Page
1 BIBLIOGRAPHY..............................................................................................7
1.1 INSTALLATION INSTRUCTIONS.......................................................................................7
1.2 TRAINING GUIDES.............................................................................................................7
1.3 MANUALS ...........................................................................................................................7
1.4 THIRD PARTY DOCUMENTS.............................................................................................7
2 INTRODUCTION..............................................................................................8
3 SPECIFICATIONS............................................................................................9
3.1 PART NUMBERING ............................................................................................................9
3.1.1 SHORT NAMES............................................................................................................9
3.2 TERMINAL SPECIFICATION............................................................................................10
3.3 POWER SUPPLY REQUIREMENTS................................................................................10
3.4 GENERATOR VOLTAGE / FREQUENCY SENSING.......................................................10
3.5 GENERATOR CURRENT SENSING ................................................................................11
3.5.1 VA RATING OF THE CTS..........................................................................................11
3.5.2 CT POLARITY ............................................................................................................12
3.5.3 CT PHASING..............................................................................................................12
3.5.4 CT CLASS ..................................................................................................................12
3.6 INPUTS..............................................................................................................................13
3.6.1 DIGITAL INPUTS........................................................................................................13
3.6.2 ANALOGUE INPUTS..................................................................................................13
3.6.2.1 OIL PRESSURE..................................................................................................13
3.6.2.2 COOLANT TEMPERATURE...............................................................................13
3.6.2.3 FUEL LEVEL .......................................................................................................13
3.6.2.4 FLEXIBLE SENSOR............................................................................................14
3.6.3 CHARGE FAIL INPUT................................................................................................14
3.6.4 MAGNETIC PICKUP...................................................................................................14
3.7 OUTPUTS..........................................................................................................................15
3.7.1 OUTPUTS A & B.........................................................................................................15
3.7.2 CONFIGURABLE OUTPUTS C & D (LOAD SWITCHING) .......................................15
3.7.2.1 CONTACTOR COILS..........................................................................................15
3.7.2.2 UNDERVOLTAGE (UV COILS)...........................................................................15
3.7.2.3 CLOSING COILS.................................................................................................16
3.7.2.4 OPENING COILS / SHUNT TRIP COILS............................................................16
3.7.3 OUTPUTS E,F,G,H, I & J ...........................................................................................16
3.8 COMMUNICATION PORTS ..............................................................................................17
3.9 COMMUNICATION PORT USAGE..................................................................................17
3.9.1 CAN INTERFACE......................................................................................................17
3.9.2 USB CONNECTION ...................................................................................................18
3.9.3 USB HOST-MASTER (USB DRIVE CONNECTION).................................................18
3.9.4 RS232.........................................................................................................................19
3.9.4.1 RECOMMENDED PC RS232 SERIAL PORT ADD-ONS...................................19
3.9.4.2 RECOMMENDED EXTERNAL MODEMS: .........................................................20
3.9.5 RS485.........................................................................................................................21
3.9.5.1 RECOMMENDED PC RS485 SERIAL PORT ADD-ONS...................................21
3.9.6 ETHERNET.................................................................................................................22
3.9.6.1 DIRECT PC CONNECTION................................................................................22
3.9.6.2 CONNECTION TO BASIC ETHERNET..............................................................23
3.9.6.3 CONNECTION TO COMPANY INFRASTRUCTURE ETHERNET.....................24
3.9.6.4 CONNECTION TO THE INTERNET...................................................................25
3.9.6.5 FIREWALL CONFIGURATION FOR INTERNET ACCESS................................27
3.10 DSENET® FOR EXPANSION MODULES....................................................................28
3.10.1 DSENET® USED FOR MODBUS ENGINE CONNECTION......................................28
3.11 SOUNDER......................................................................................................................29

DSE7400 Operator Manual
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3.11.1 ADDING AN EXTERNAL SOUNDER TO THE APPLICATION..................................29
3.12 ACCUMULATED INSTRUMENTATION........................................................................29
3.13 DIMENSIONS AND MOUNTING ...................................................................................30
3.13.1 DIMENSIONS.............................................................................................................30
3.13.2 PANEL CUTOUT........................................................................................................30
3.13.3 WEIGHT .....................................................................................................................30
3.13.4 FIXING CLIPS.............................................................................................................31
3.13.5 CABLE TIE FIXING POINTS......................................................................................32
3.13.6 SILICON SEALING GASKET .....................................................................................32
3.14 APPLICABLE STANDARDS .........................................................................................33
3.14.1 ENCLOSURE CLASSIFICATIONS.............................................................................35
3.14.2 NEMA CLASSIFICATIONS.........................................................................................36
4 INSTALLATION .............................................................................................37
4.1 TERMINAL DESCRIPTION...............................................................................................37
4.1.1 DC SUPPLY, FUEL AND START OUTPUTS, OUTPUTS E-J...................................38
4.1.2 ANALOGUE SENSOR................................................................................................39
4.1.3 MAGNETIC PICKUP, CAN AND EXPANSION ..........................................................40
4.1.4 LOAD SWITCHING AND V1 GENERATOR VOLTAGE SENSING...........................41
4.1.5 V2 BUS/MAINS VOLTAGE SENSING........................................................................41
4.1.6 GENERATOR CURRENT TRANSFORMERS...........................................................42
4.1.7 CONFIGURABLE DIGITAL INPUTS ..........................................................................44
4.1.8 PC CONFIGURATION INTERFACE CONNECTOR..................................................44
4.1.9 RS485 CONNECTOR.................................................................................................45
4.1.10 RS232 CONNECTOR.................................................................................................45
4.2 TYPICAL WIRING DIAGRAMS.........................................................................................46
4.2.1 DSE7410 3 PHASE, 4 WIRE WITH RESTRICTED EARTH FAULT PROTECTION.47
4.2.2 DSE7420 3 PHASE, 4 WIRE WITH RESTRICTED EARTH FAULT PROTECTION.48
4.3 ALTERNATIVE TOPOLOGIES .........................................................................................49
4.3.1 3 PHASE, 4 WIRE WITHOUT EARTH FAULT PROTECTION..................................49
4.3.2 SINGLE PHASE WITH RESTRICTED EARTH FAULT .............................................50
4.3.3 SINGLE PHASE WITHOUT EARTH FAULT..............................................................50
4.3.4 2 PHASE (L1 & L2) 3 WIRE WITH RESTRICTED EARTH FAULT...........................51
4.3.5 2 PHASE (L1 & L2) 3 WIRE WITHOUT EARTH FAULT............................................51
4.3.6 2 PHASE (L1 & L3) 3 WIRE WITH RESTRICTED EARTH FAULT...........................52
4.3.7 2 PHASE (L1 & L3) 3 WIRE WITHOUT EARTH FAULT MEASURING.....................52
4.3.8 3 PHASE 4 WIRE WITH UNRESTRICTED EARTH FAULT MEASURING...............53
4.4 EARTH SYSTEMS.............................................................................................................54
4.4.1 NEGATIVE EARTH.....................................................................................................54
4.4.2 POSITIVE EARTH......................................................................................................54
4.4.3 FLOATING EARTH.....................................................................................................54
4.5 TYPICAL ARRANGEMENT OF DSENET® ......................................................................54
5 DESCRIPTION OF CONTROLS....................................................................55
5.1 DSE7410 AUTO START CONTROL MODULE................................................................55
5.2 DSE7420 AUTO START CONTROL MODULE................................................................56
5.3 QUICKSTART GUIDE .......................................................................................................57
5.3.1 STARTING THE ENGINE...........................................................................................57
5.3.2 STOPPING THE ENGINE ..........................................................................................57
5.4 VIEWING THE INSTRUMENT PAGES.............................................................................58
5.4.1 STATUS......................................................................................................................59
5.4.2 ENGINE......................................................................................................................60
5.4.3 GENERATOR.............................................................................................................61
5.4.4 BUS (DSE7410 ONLY)...............................................................................................62
5.4.5 MAINS (DSE7420 ONLY)...........................................................................................62
5.4.6 RS232 SERIAL PORT................................................................................................62
5.4.7 RS485 SERIAL PORT................................................................................................65
5.4.8 ABOUT........................................................................................................................66
5.4.8.1 ETHERNET PAGES............................................................................................67
5.4.8.2 DATA LOGGING PAGES....................................................................................68
5.4.9 CAN ERROR MESSAGES.........................................................................................69

DSE7400 Operator Manual
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5.5 VIEWING THE EVENT LOG..............................................................................................70
5.6 USER CONFIGURABLE INDICATORS............................................................................71
6 OPERATION ..................................................................................................72
6.1 CONTROL .........................................................................................................................72
6.2 CONTROL PUSH-BUTTONS............................................................................................73
6.3 ALTERNATIVE CONFIGURATIONS ................................................................................74
6.4 DUMMY LOAD / LOAD SHEDDING CONTROL ..............................................................75
6.5 STOP MODE......................................................................................................................76
6.5.1 ECU OVERRIDE.........................................................................................................77
6.6 MANUAL MODE................................................................................................................78
6.6.1 WAITING IN MANUAL MODE....................................................................................78
6.6.2 STARTING SEQUENCE.............................................................................................78
6.6.3 ENGINE RUNNING ....................................................................................................79
6.6.4 MANUAL FUEL PUMP CONTROL.............................................................................79
6.6.5 MANUAL SPEED CONTROL.....................................................................................79
6.6.6 STOPPING SEQUENCE............................................................................................80
6.7 TEST MODE......................................................................................................................80
6.7.1 WAITING IN TEST MODE..........................................................................................80
6.7.2 STARTING SEQUENCE.............................................................................................80
6.7.3 ENGINE RUNNING ....................................................................................................81
6.8 AUTOMATIC MODE..........................................................................................................82
6.8.1 WAITING IN AUTO MODE.........................................................................................82
6.8.2 STARTING SEQUENCE.............................................................................................82
6.8.3 ENGINE RUNNING ....................................................................................................83
6.8.4 STOPPING SEQUENCE............................................................................................83
7 PROTECTIONS..............................................................................................84
7.1 PROTECTIONS DISABLED..............................................................................................85
7.1.1 INDICATION / WARNING ALARMS...........................................................................85
7.1.2 SHUTDOWN / ELECTRICAL TRIP ALARMS............................................................85
7.1.3 CAN ALARMS.............................................................................................................86
7.2 INDICATIONS....................................................................................................................87
7.3 WARNINGS .......................................................................................................................88
7.4 HIGH CURRENT WARNING ALARM ...............................................................................89
7.5 SHUTDOWNS....................................................................................................................90
7.6 ELECTRICAL TRIPS.........................................................................................................92
7.7 HIGH CURRENT SHUTDOWN / ELECTRICAL TRIP ALARM ........................................93
7.7.1 IMMEDIATE WARNING .............................................................................................93
7.7.2 IDMT ALARM..............................................................................................................93
7.8 EARTH FAULT SHUTDOWN / ELECTRICAL TRIP ALARM...........................................96
7.9 SHORT CIRCUIT ALARM.................................................................................................97
7.10 MAINTENANCE ALARM ...............................................................................................98
8 SCHEDULER.................................................................................................99
8.1.1 STOP MODE ..............................................................................................................99
8.1.2 MANUAL MODE.........................................................................................................99
8.1.3 AUTO MODE..............................................................................................................99
9 FRONT PANEL CONFIGURATION.............................................................100
9.1 ACCESSING THE MAIN FRONT PANEL CONFIGURATION EDITOR.........................101
9.1.1 EDITING A PARAMETER.........................................................................................102
9.2 ADJUSTABLE PARAMETERS.......................................................................................103
9.3 ACCESSING THE ‘RUNNING’ CONFIGURATION EDITOR..........................................104
9.3.1 EDITING A PARAMETER.........................................................................................104
9.3.2 ADJUSTABLE PARAMETERS (RUNNING EDITOR)..............................................104
10 COMMISSIONING.....................................................................................105
10.1 PRE-COMMISSIONING...............................................................................................105
11 FAULT FINDING .......................................................................................106

DSE7400 Operator Manual
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11.1 STARTING ...................................................................................................................106
11.2 LOADING.....................................................................................................................106
11.3 ALARMS ......................................................................................................................107
11.4 COMMUNICATIONS....................................................................................................108
11.5 INSTRUMENTS ...........................................................................................................109
11.6 MISCELLANEOUS ......................................................................................................109
12 MAINTENANCE, SPARES, REPAIR AND SERVICING...........................110
12.1 PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE.............................110
12.1.1 PACK OF PLUGS.....................................................................................................110
12.1.2 INDIVIDUAL PLUGS.................................................................................................110
12.2 PURCHASING ADDITIONAL FIXING CLIPS FROM DSE..........................................110
12.3 PURCHASING ADDITIONAL SEALING GASKET FROM DSE .................................110
12.4 DSENET EXPANSION MODULES..............................................................................111
13 WARRANTY..............................................................................................112
14 DISPOSAL ................................................................................................112
14.1 WEEE (WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT)...........................112
14.2 ROHS (RESTRICTION OF HAZARDOUS SUBSTANCES)........................................112

Bibliography
7
1 BIBLIOGRAPHY
This document refers to and is referred to by the following DSE publications which can be obtained
from the DSE website: www.deepseaplc.com
1.1 INSTALLATION INSTRUCTIONS
Installation instructions are supplied with the product in the box and are intended as a ‘quick start’
guide only.
DSE PART DESCRIPTION
053-085 DSE7410 Installation Instructions
053-088 DSE7420 Installation Instructions
053-032 DSE2548 LED Expansion Annunciator Installation Instructions
053-033 DSE2130 Input Expansion Installation Instructions
053-034 DSE2157 Output Expansion Installation Instructions
053-125 DSE2131 Ratio-metric Input Expansion Installation Instructions
053-126 DSE2133 RTD/Thermocouple Input Expansion Installation Instructions
053-134 DSE2152 Ratio-metric Output Expansion Installation Instructions
1.2 TRAINING GUIDES
Training Guides are produced to give ‘handout’ sheets on specific subjects during training sessions
DSE PART DESCRIPTION
056-005 Using CTs With DSE Products
056-010 Overcurrent Protection
056-018 Negative Phase Sequence
056-019 Earth Fault Protection
056-020 Loss of Excitation
056-022 Breaker Control
056-024 GSM Modem
056-026 kW & kVAr
056-029 Smoke Limiting
056-030 Module PIN Codes
1.3 MANUALS
Product manuals are can be downloaded from the DSE website: www.deepseaplc.com
DSE PART DESCRIPTION
057-004 Electronic Engines and DSE Wiring
057-160 DSE7400 Series Configuration Software Manual
057-082 DSE2130 Input Expansion Manual
057-083 DSE2157 Output Expansion Manual
057-084 DSE2548 Annunciator Expansion Manual
057-139 DSE2131 Ratio-metric Input Expansion Manual
057-140 DSE2133 RTD/Thermocouple Expansion Manual
057-141 DSE2152 Ratio-metric Output Expansion Manual
1.4 THIRD PARTY DOCUMENTS
The following third party documents are also referred to:
REFERENCE DESCRIPTION
ISBN 1-55937-879-4 IEEE Std C37.2-1996 IEEE Standard Electrical Power System Device Function
Numbers and Contact Designations. Institute of Electrical and Electronics Engineers Inc
ISBN 0-7506-1147-2 Diesel generator handbook. L.L.J.Mahon
ISBN 0-9625949-3-8 On-Site Power Generation. EGSA Education Committee.

Introduction
8
2 INTRODUCTION
This document details the installation and operation requirements of the DSE7400 Series modules,
part of the DSEGenset® range of products.
The manual forms part of the product and should be kept for the entire life of the product. If the
product is passed or supplied to another party, ensure that this document is passed to them for
reference purposes.
This is not a controlled document. You will not be automatically informed of updates. Any future
updates of this document will be included on the DSE website at www.deepseaplc.com
The DSE7400 series is designed to provide differing levels of functionality across a common platform.
This allows the generator OEM greater flexibility in the choice of controller to use for a specific
application.
The DSE7400 series module has been designed to allow the operator to start and stop the generator,
and if required, transfer the load to the generator either manually (via fascia mounted push-buttons) or
automatically. Additionally, the DSE7420 automatically starts and stops the generator set depending
upon the status of the mains (utility) supply.
The user also has the facility to view the system operating parameters via the LCD display.
The DSE7400 module monitors the engine, indicating the operational status and fault conditions,
automatically shutting down the engine and giving a true first up fault condition of an engine failure by a
COMMON AUDIBLE ALARM. The LCD display indicates the fault.
The powerful ARM microprocessor contained within the module allows for incorporation of a range of
complex features:
•Text based LCD display (supporting multiple languages).
•True RMS Voltage, Current and Power monitoring.
•Communications capability (RS485, RS232 or Ethernet)
•Engine parameter monitoring.
•Fully configurable inputs for use as alarms or a range of different functions.
•Engine ECU interface to electronic engines.
Using a PC and the DSE Configuration Suite software allows alteration of selected operational
sequences, timers, alarms and operational sequences. Additionally, the module’s integral fascia
configuration editor allows adjustment of a subset of this information.
A robust plastic case designed for front panel mounting houses the module. Connections are via
locking plug and sockets..
Access to critical operational sequences and timers for use by qualified engineers, can be protected by
a security code. Module access can also be protected by PIN code. Selected parameters can be
changed from the module’s front panel.
The module is housed in a robust plastic case suitable for panel mounting. Connections to the module
are via locking plug and sockets.

Specification
9
3 SPECIFICATIONS
3.1 PART NUMBERING
7410 - 001 - 01
At the time of this document production, there have been no revisions to the module hardware.
3.1.1 SHORT NAMES
Short name Description
DSE7000,DSE7xxx All modules in the DSE7000 range.
DSE7400,DSE74xx All modules in the DSE7400 range.
DSE7410 DSE7410 module/controller
DSE7420 DSE7420 module/controller
Product type
DSE7410
Autostart Module 7410
Variant
Standard version 01
Hardware revision
Initial Release 001
DSE7420
Automatic Mains
Failure Module
7420

Specification
10
3.2 TERMINAL SPECIFICATION
Connection type Two part connector.
•Male part fitted to
module
•Female part supplied in
module packing case -
Screw terminal, rising
clamp, no internal
spring.
Example showing cable entry and screw
terminals of a 10 way connector
Minimum cable size 0.5mm² (AWG 24)
Maximum cable size 2.5mm² (AWG 10)
NOTE:
NOTE: NOTE:
NOTE: -
--
- For purchasing additional connector plugs from DSE, please see the sec
For purchasing additional connector plugs from DSE, please see the secFor purchasing additional connector plugs from DSE, please see the sec
For purchasing additional connector plugs from DSE, please see the section
tion tion
tion
entitled Maintenance, Spares, Repair and Servicing else here in this document.
entitled Maintenance, Spares, Repair and Servicing else here in this document.entitled Maintenance, Spares, Repair and Servicing else here in this document.
entitled Maintenance, Spares, Repair and Servicing else here in this document.
3.3 POWER SUPPLY REQUIREMENTS
Minimum supply voltage 8V continuous
Cranking dropouts Able to survive 0V for 50mS providing the supply was at least 10V
before the dropout and recovers to 5V afterwards.
Maximum supply voltage 35V continuous (60V protection)
Reverse polarity protection -35V continuous
Maximum operating current 130mA at 24V
260mA at 12V
Maximum standby current 65mA at 24V
120mA at 12V
Plant supply instrumentation display
Range 0V-70V DC (note Maximum continuous operating voltage of 35V DC)
Resolution 0.1V
Accuracy 1% full scale (±0.7V)
3.4 GENERATOR VOLTAGE / FREQUENCY SENSING
Measurement type True RMS conversion
Sample Rate 5KHz or better
Harmonics Up to 10
th
or better
Input Impedance 300K Ωph-N
Phase to Neutral 15V (minimum required for sensing frequency ) to 333V AC (absolute maximum)
Suitable for 110V to 277V nominal
(±20% for under/overvoltage detection)
Phase to Phase 26V (minimum required for sensing frequency ) to 576V AC (absolute maximum)
Suitable for 190V ph-ph to 479V ph-ph nominal
(±20% for under/overvoltage detection)
Common mode offset from
Earth 100V AC (max)
Resolution 1V AC phase to neutral
2V AC phase to phase
Accuracy ±1% of full scale phase to neutral
±2% of full scale phase to phase
Minimum frequency 3.5Hz
Maximum frequency 75.0Hz
Frequency resolution 0.1Hz
Frequency accuracy ±0.2Hz