FG Wilson DCP-10 User manual

Manual
DCP
-
10
Genset Controller

DCP-10
I
The interpretation of the Symbol:
WARNING:
A WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death, serious personal injury or property
damage.
CAUTION:
A CAUTION indicates a potentially hazardous situation which, if not
avoided, could result in damage to equipment or property.
NOTE:
A NOTE provides other helpful information that does not fall under the
warning or caution categories.

DCP-10
II
WARNING:
Read this entire manual pertaining to the work to be performed before
installing, operating, or servicing this controller. Practice all plant and
safety instructions and precautions. Failure to follow instructions can
cause personal injury and/or property damage.
The engine or other type of prime mover should be equipped with an
overspeed shutdown device to protect against runaway or damage to
the prime mover with possible personal injury, loss of life, or property
damage.
The overspeed shutdown device must be totally independent of the
prime mover control system. An over temperature or low pressure
shutdown device may also be needed for safety, as appropriate.
CAUTION—BATTERY CHARGING
To prevent damage to a controller that uses an alternator or battery-
charging device, make sure the charging device is turned off before
disconnecting the battery from the system.
Controllers contain static-sensitive parts. Observe the following
precautions to prevent damage to these parts:
Do not disassemble the rear back of controller or touch the
components and conductors on a printed circuit board.

DCP-10
III
Contents
1. Description……………………………………………………………………………………………………
2. Outline Dimension Drawings and Controller Wiring…………………………………………………
3. Panel Operation……………………………………………………………………………………………
4. Installation Guide…………………………………………………………………………………………
5. Control and Operation Instruction………………………………………………………………………
6. Measure and Display Data………………………………………………………………………………
7. Pre-alarm and Shutdown Alarm…………………………………………………………………………
8. Parameter Settings………………………………………………………………………………………
9. LCD Display and Menu System…………………………………………………………………………
10. Preparation before Starting the Controller……………………………………………………………
11. Technical Specification…………………………………………………………………………………
1
2
5
6
7
12
13
17
23
28
27

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1. Description
The DCP-10 is an Automatic Controller for generator. When running in “AUTO” mode, it starts the
Genset after receiving remote start signal and on failure automatically stops the Genset. The
generator’s controlling procedure and protection parameters can be modified, which fully meets the
Genset’s requirements of automatic start, stop control and basic protection.
The module displays fault conditions, operational status and related metering data on panel LCD.
LCD has a backlight function so that the operator can read running parameters clearly even in the
shadow.
The controller has 2 modes: AUTO and MANUAL. Either can be chosen through the panel push
button.
Measures and displays generator’s output voltage, current, oil pressure, coolant temperature,
frequency, DC source voltage, etc.
True RMS measure of voltage and current, which ensures the data more accurate.
Control the close/open of generator output switch.
Equipped with built-in communication interface to configure parameters by PC.
All connections of controller are by secure plug and socket, for ease and convenience to connect,
move, maintain and replace the device.
This manual is only suitable for DCP-10 Automatic control module, user must carefully read
this manual first.

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2. Outline Dimension Drawings and Controller Wiring
2.1 Following Details:
Module Dimensions W120mm×H102mm
Panel Cutout W110mm×H92mm
Thickness D48mm (without connection)

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2.2 Terminal Connections:
Pin no.
Function Description Signal Dim
1 GEN. V
L1-N
input 0-300Vac 1mm²
2 GEN. V
L2-N
input 0-300Vac 1mm²
3 GEN. V
L3-N
input 0-300Vac 1mm²
4 GEN. Neutral 1mm²
5 Not used
6 Not used
7 I1 Gen current input 0-5A 2.5mm²
8 I2 Gen current input 0-5A 2.5mm²
9 I3 Gen current input 0-5A 2.5mm²
10 Common port for current input 0-5A 2.5mm²
11 LOP sensor or switch signal LOP sensor (<2KΩ) 1mm²
12 HET sensor or switch signal HET sensor (<2KΩ) 1mm²
13 Configurable digital input signal 1 low level is active 1mm²
14 Configurable digital input signal 2 low level is active 1mm²
15 Configurable digital input signal 3 low level is active 1mm²
16 Charge excitation power output if notused, do not connect to negative 1mm²
17 Configurable relay output 1 N.O. contact, 3A/30Vdc 1mm²
18 Configurable relay output 2 N.O. contact, 3A/30Vdc 1mm²
19 Configurable relay output 3 N.O. contact, 3A/30Vdc 1mm²
20 +5V supply Max 100mA, 1mm²
21 Start (Crank)relay output N.O. contact, 3A/30Vdc 1mm²
22 Fuel solenoidrelayoutput N.O. contact, 3A/30Vdc 1mm²
23 Battery supply (+B) 1mm²
24 Battery supply (-B) 12V/24V (8-35Vdc continuous) 1mm²

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2.3 Typical Wiring Diagram
(12/24V) DC POWER
CRANKFUEL
CONFIG.OUTPUT
LOAD
M
CONFIG. INPUT
REMOTE START
COOLANT TEMP.
(OR TEMP. SWITCH)
OIL PRESSURE
(OR OIL SWITCH)
DCP-10
Fuse protection with a rating of 0.5A must be provided externally to the Controller.

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3. Panel Operation
The operation panel consists of 3 sections: LCD display indicating measurement parameters, LED
indicator for common failure, and push buttons for Genset and selection of control modes.
The LCD circularly displays different measuring parameters. When failure occurs, LCD displays the
corresponding fault icon. LCD also has a backlight so that the operator can clearly read information day
or night. After pressing any button the backlight will automatically turn off in a certain time.
The LCD display and its control push buttons provide a friendly operation interface for the operator to
conveniently read information and parameter setting.
3.1 Control buttons and LEDs
Function Description Tag
Scroll Button
Enter into submenu / Modify / confirm modification / scroll menu to
display.
MUTE / LAMP TEST Button
When failure occurs, alarm buzzer sounds. Pressing mute button will
mute the sound. LCD displays mute icon. Press and hold mute button
for 2sec, all LEDs illuminate simultaneously.
AUTO Mode Button / LED
The push button is used for selecting “AUTO mode”. When the
controller is running in AUTO mode, the LED above the push button
illuminated. The activation and deactivation of the “remote start signal
input” controls the starting and stopping of the Genset.
MAN Mode Button / LED
The push button is used for selecting “manual mode”. When the
controller is running in MANUAL mode, the LED above the push button
illuminated. The Start and Stop push buttons control the starting and
stopping of the Genset..
START / VALUE INCREASE “+” Push Button
The push button is used for manually start the Genset .When the
controller is in MANUAL mode, press this push button to start the
generator.
When in parameter setting mode, this push button is used to increase
values.
STOP / RESET / VALUE DECREASE “-” Push Button
The push button is used for MANUALLY stops the Genset. When the
controller is in MAN mode, press and hold this button more than 2sec
to stop the Genset.
If failure occurs, press this button, the shutdown alarm lockout can be
cleared.
When in parameter setting mode, this push button is used to decrease
values.
COMMEN FAILURE LED
LED will flash when pre-alarm (Warning) occurs.
LED will illuminate permanently when shutdown alarm occurs.

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4. Installation Guide
4.1 The cutout dimensional drawing installed on panel as above attached.
The controller is fixed by 2 special fittings. The shock-proof equipment must be mounted if the
enclosure is mounted on Genset or other heavy vibrant device. A readily accessible disconnect
device shall be incorporated external to the equipment.
4.2 Please refer to the above Typical Wiring Diagram 2.3 for connection.
4.3 Installation of engine LOP and HET sensors:
1211
Terminal
12
Battery negative (Genset enclosure)
11
Description
Sensor Com. Port
HET sensor/ temp switch
LOP sensor/ LOP switch
DCP-10
CONTROLLER
CAUTION:
Pin no. “11” and “12” is for “LOP sensor or switch signal” and “HET
sensor or switch signal” input respectively. Either switch or sensor can be
chosen. When sensor is used, according to the actual situation, increase
the cross section area of cable to reduce the cable resistance from
controller to engine, which ensures the accuracy of measured values for
both oil pressure and engine temperature.
If both switches and sensors are required for oil pressure and engine
temperature, connect Pin no. “11” and “12” as above, and connect 2
configurable inputs to the switches of oil pressure and temperature, then
configure parameters by setting.

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5. Control and Operation Instruction
5.1 Operation Mode Setting:
The controller has 2 modes: AUTO and MANUAL.
Operation Description
Press and hold the “AUTO” button for 2sec, the LED above the button
is illuminated; the controller is running in “AUTO” mode.
Press and hold the “MAN” button for 2sec, the LED above the button is
illuminated; the controller is running in “MAN” mode.
NOTE: Only1 mode can be selected from above 2 modes.
5.2 AUTO control Sequence:
Controller is running in “AUTO” mode.
First of all, one of configurable inputs must be defined as Remote Start Signal.
When the remote start signal is active,thecontrollerimplements following procedure:
The Start delay timer is activated, when it times out the Preheat relay output is energized (if preheat
function selected), the timer starts. When it times out, the fuel relay output is energized, and operates the
fuel solenoid of the engine. After 300ms delay, the start (crank) relay output is energized; the start motor
engages and begins to crank. When the engine speed reaches the crank cutout RPM, the start relay
output is de-energized and the safety-on delay starts. When the safety-on times out, if the controller
detects that the parameters of the Genset such as voltage, frequency, oil pressure, coolant temperature
are normal, and no other failure is detected this indicates the Genset has successfully started and running
normally. The LCD displays the Genset Measuremen parameters.
When the voltage and frequency of Generator is normal, Gen. Normal LED illuminates, the timer for
Gen. On delay is activated, when it times out, GCB close/open relay closes,the transfer switch switches
on Gen. The Gen Aux. Switch’s contact feeds back a signal to a configurable input on our controller.
GCB closed LED illuminates.
NOTE:
When remote signal is active, the start-delay timer is activated. During
this period, if remote start signal is inactive, the start delay timer
terminates immediately; the controller will recovers to the original standby
status.
During cranking or idle period, if remote start signal is inactive, controller
stops the start procedure and recovers to original standby status.

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NOTE:
While cranking, engine ignites. The start motor will power off when the
output frequency of generator reaches the preset value (configurable
crank cutout value), or if there are one of the following conditions occur:
A. Generator’s voltage reaches 80% of rated voltage;
B. Cranking time’s up,
C. LOP switch is opened and the delay time’s up.
D. Oil pressure switch is opened or oil pressure is higher than crank
cutout value.
E. Cutout P-delay time’s up.
Controller can not implement crank procedure if the frequency of
generator reaches the preset value (configurable cranking cutout value)
or LOP switch is opened.
CAUTION:
To avoid damage to the start motor please make sure the generator’s
voltage is higher than the measurable value of controller while cranking,
since the crank cutout signal is sensed from the generator voltage and
frequency.
NOTE:
Above control procedure, assumes that one of configurable inputs has
been configured as Gen Aux. Switch Closed and connects the switch’s
N.O. Aux. contact signal to this port. If you do not configure an input as
Gen Aux. Switch Closed, then the GCB closed LED illuminates is only
an indication that the GCB close/open relay should have been closed.
If you have selected idle function, the idle relay will be closed at the same time as the crank relay is
closed. The timers of idle and safety-on delay will begin counting down at the same time, and in priority
to display the shorter one on the LCD, and the following procedure is the same as above.
During the crank period, if the engine can not ignite and controller will not output start signal during crank
rest, Fail to Start icon on LCD flashes at this time. Once crank rest timer times out the start relay
energizes once again and will attempt to start engine again.
The above procedure will be repeated until engine successfully ignites or reaches the preset number of
crank attempt. However, if any shutdown alarm occurs during crank, controller will stop cranking
immediately and only can be restarted after clearing failure and reset.
Fail to Start: when the above procedure repeats again and again and reaches the preset number of
crank attempt, the crank relay output is then de-energized. The failure LED illuminates and the LCD
displays Fail to Start.
CAUTION:
If Fail to Start occurs, operator must check the whole Genset system to
find out failure reason, only after clearing the failure can press
“STOP/RESET” button to relieve fault lock out status, and restart the
Genset.
Generator shutdown sequence:
When the remote start signal is deactivated, the timer for cool down is activated, When it times out, the
fuel relay de-energizes, the timer for cool down is activated,

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Stop Failure: When cool down times out, the fuel relay opens and the timer for Stop delay begins.
When it times out, if controller detects that the voltage and frequency of generator or oil pressure of
engine are greater than the preset values, the Fail to stop LED illuminates and the LCD displays Fail to
stop.
NOTE:
After stop failure, the controller will not energize the crank relay output if
the failure has not been removed and the controller reset.
5.3 MAN control sequence:
Controller is in “MANUAL” mode.
Generator starting sequence:
Pressing “START” button the fuel relay energises, and operates the fuel solenoid of engine.After 300ms
delay, the start relay output is energized, the start motor engages and begins to crank. When the engine
speed reaches the crank cutout RPM, the start relay output is de-energized and the safety-on delay starts.
When the safety-on times out, if the controller detects that the parameters of the Genset such as voltage,
frequency, oil pressure and coolant temperature are normal, and no other failure is detected this indicates
the Genset has successfully started and running normally. The LCD displays the Genset Measurement
parameters.
When generator is running normally, GCB close/open relay will not close automatically. Manually close
the Gen switch, Gen is on load, the Gen Aux. Switch’s contact feeds back the signal to a configurable
input on our controller, Gen. Normal LED illuminates.
5.4 The start and stop sequence of engine whose fuel solenoid is N. O. type:
Start control sequence:
During the starting sequence, the fuel relay of controller will not energize, fuel solenoid is no power, so
no signal is required for fuel solenoid to activate.
Stop control sequence:
During the stopping sequence, the fuel relay energizes, fuel solenoid is on power and energizes, and
the engine begins to stop. After a delay (same as stop delay) fuel relay de-energizes, disconnecting the
supply for the fuel solenoid.
Other control sequence is same as engine whose fuel solenoid is N. C. type.
NOTE:
When the controller is in “MANUAL” mode and Gen. Normal LED
illuminates, you must define one configurable input as Gen Aux. Switch
Closed and connect the switch’s N.O. Aux. contact signal to this port,
otherwise the GCB closed LED will not illuminate.

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5.5 Idle function:
For idle function configure one of the configurable outputs as idle.
Refer to the flow chart 5.7 for start and stop for idle control flows.
5.6 Preheat function:
For Preheat function, configure one of the configurable outputs as Preheat. The controller has 3
selectable preheat control modes as below:
Mode 1 — during preheat time, preheat relay output energizes.
Mode 2 — during preheat time, preheat relay output energizes until the successful ignition.
Mode 3 — during preheat time, preheat relay output energizes until safety-on delay times out.
During crank period, the Preheat relay output will not energize in any of above modes.
Refer to the flow chart 5.7 for start and stop for Preheat control flows.
When the Preheat relay output energizes, LCD displays the icon of preheat operating status:

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5.7 Flow chart for start and stop
T1－start delay
T2－crank time
T3－pre-heat time
T4－safety-on delay
T5－idle time
T6－stop delay
NOTE:
If T4 is longer than T5, low oil pressure protection is ignored during T5.
If T4 is shorter than T5, low oil pressure protection becomes effective
after T4 in T5.

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6. Measure and Display Data
Gen phase voltage L1-N L2-N L3-N
Gen line voltage L1-L2 L2-L3 L3-L1
Generator current I1 I2 I3
Generator frequency Hz
Engine speed RPM (signal derived from generator frequency)
Engine oil pressure BAR / PSI (signal from engine LOP sensor)
Engine coolant temperature ℃/℉ (signal from engine HET sensor)
Battery voltage Vdc
Genset Running hour Hour

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7. Pre-alarm and Shutdown Alarm
7.1 Pre-alarm (Warning)
NOTE: (Pre-alarms are non-critical failure conditions and do not affect the operation of the generator
system, they serve for drawing the operators’ attention to an undesirable condition so they can remove
it to ensure continuous running of the system. When Pre-alarms occur, the LED indicator flashes, but
failure will not be locked out and the unit will not shutdown. Once the Pre-alarm failure is removed the
Pre-alarm LED will automatically turn off.)
Pre-alarm / Description LCD Display
CHARGE FAILURE: After safety-on times up, if the charging voltage
from the excitation contact of alternator is lower than the “charge V
Pre-alarm”, the common failure LED indicator ( ) flashes, the LCD
displays Charge failure icon:
BATT. UNDER VOLT: if controller detects that battery voltage has
fallen below the “Batt. Under volt”, common failure LED indicator
flashes. For example, “Batt. Under volt” preset as: 23.6V, when battery
voltage falls below this value, LCD flashing low value icon:
BATT. OVER VOLT: if controller detects that battery voltage has
exceeded the “Batt. Over volt”, common failure LED indicator flashes.
For example, “Batt. Over volt” preset as preset as: 28.2V, when battery
voltage exceeds this value, LCD flashing high value icon:
LOW OIL PRESS: if controller detects that the engine oil pressure has
fallen below the “Oil-P low preALM” after the safety-on timer expired,
common failure LED indicator flashes. For example, “Oil-P low preALM”
preset as: 2.2BAR, when engine oil pressure falls below this value,
LCD flashing low value icon:
HIGH TEMP: if controller detects that engine coolant temperature has
exceeded the “high temp pre-alarm”, common failure LED indicator
flashes. For example, “high temp pre-alarm” preset as: 95℃
℃℃
℃, when
engine coolant temperature exceeds this value, LCD flashing high
value icon:
OVER SPEED: if engine speed exceeds the “Over SP preALM”,
common failure LED indicator flashes. For example, “Over SP
preALM” preset as: 1600RPM, when engine speed exceeds this value,
LCD flashing high value icon:
UNDER SPEED: if engine speed falls below the “Under SP preALM”
after the safety-on timer has expired, common failure LED indicator
flashes. For example, “Under SP preALM” preset as: 1440RPM, when
engine speed falls below this value, LCD flashing low value icon:

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OVER CURRENT: if any phase output current of generator exceeds the
“over current pre-alarm” after the safety-on timer has expired, common
failure LED indicator flashes. For example, “over current pre-alarm”
preset as: 850A, when any phase output current of generator exceeds
this value, LCD flashing high value icon for corresponding phase:
GEN. OVER VOLT: if controller detects that any phase output voltage
of generator has exceeded the “GEN-V over preALM”after the safety-
on timer has expired, common failure LED indicator flashes. For
example, “Rated ph-voltage” preset as: 220V, “GEN-V over preALM”
preset as: 115%, when any phase output voltage of generator exceeds
this value, LCD flashing high value icon for corresponding phase:
GEN. UNDER VOLT: if controller detects that any phase output voltage
of generator has fallen below the “GEN-V under preALM”after the
safety-on timer has expired, common failure LED indicator flashes. For
example, “Rated ph-voltage” preset as: 220V, “GEN-V under
preALM”preset as: 90%, when any phase output voltage of generator
falls below this value, LCD flashing low value icon for corresponding
phase:
LOW FUEL LEVEL: If a configurable input has been defined as low
fuel level, when the input signal is active, common failure LED
indicator flashes, LCD displaying low fuel level icon:
AUXILIARY PRE-ALARM: if a configurable input is defined as pre-alarm,
when the input signal is active, common failure LED indicator flashes.
LCD displaying Aux. pre-alarm icon:
NOTE:
To make “low oil pressure” and “high temperature” pre-alarm active, you
must use LOP sensor and HET sensor, if you only use LOP and HET
switches, both pre-alarms are inactive.
NOTE:
Controller continuously detects battery voltage during standby and
Battery Low/High Voltage pre-alarms are active.
BatteryLowVoltagepre-alarmisinactiveduringcranking.
CAUTION:
Under the period of safety-on delay, some pre-alarms (e.g.: under speed,
low voltage and low oil pressure) are inactive, the safety-on delay must
be carefully and properly set to make Genset have full protection.

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7.2 Shutdown Alarm
NOTE: (shutdown alarm failures immediately lock out the system and stop the Genset. The failure must
be removed and the controller reset before restarting the Genset.)
Shutdown Alarm / Description LCD Display
START FAILURE: if engine does not fire after the preset number of
crank attempt has been made, the Shutdown alarm LED illuminates.
LCD displays “start failure” icon:
STOP FAILURE: if engine does not stop after the stop delay expired,
the Shutdown alarm LED illuminates. LCD displays stop failure icon:
EMERGENCY STOP: Configure a configurable input as emergency stop,
when the input signal is active, controller immediately stops all relay
control outputs except alarm,Genset is shut down, the Shutdown alarm
LED illuminates, LCD displays emergency stop icon:
LOW OIL PRESS: if controller detects that the oil pressure level still falls
below “Oil-P low Alarm” or LOP switch closes after the safety-on timer
has expired, engine stops immediately, the Shutdown alarm LED
illuminates. LCD displays low oil pressure icon:
ENGINE HIGH TEMP: if controller detects that engine coolant
temperature has exceeded the “Coolant Alarm” or HET switch closes,
engine stops immediately, the Shutdown alarm LED illuminates. LCD
displays high temperature icon:
OVER SPEED: if controller detects that engine speed exceeds “Over SP
Alarm”, engine stops immediately, the Shutdown alarm LED illuminates.
LCD displays over speed icon:
OVER CURRENT: After safety-on delay time out, if controller detects
that any phase output current of generator exceeds the “over current
alarm”, the Genset will be shut down immediately, the Shutdown
alarm LED illuminates.
GEN. OVER VOLT: After safety-on delay times out, if controller detects
that one of the phase voltage exceeds the“GEN-V over Alarm”, the
engine will be shut down immediately, the Shutdown alarm LED
illuminates.
GEN. UNDER VOLT: After safety-on delay times up, if controller
detects that any phase output voltage is lower than the “Vac low
alarm”, the engine will be shut down immediately, common failure LED
illuminates.
AUXILIARY FAILURE: If a configurable input has been defined as
Shutdown Alarm, when the input signal is active, common failure LED
illuminates. LCD displays Aux. shutdown alarm icon:

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Code Table for Failure:
Name Code Name Code
CHARGE FAILURE
ENGINEHIGHTEMP
BATT. UNDER VOLT
OVER SPEED
BATT. OVER VOLT
UNDER SPEED
START FAILURE
OVER CURRENT
STOP FAILURE
GEN. OVER VOLT
EMERGENCY STOP
GEN. UNDER VOLT
LOW OIL PRESS
P-SENSOR OPEN
NOTE:
Engine speed signal is derived from the frequency of generator output
voltage, it is used for control and failure protection parameters, for the
convenience of user, some data is expressed by RPM, RPM = Hz * 60 /
pair of poles.
While the Genset is running, if there are high coolant temperature, low oil
pressure or over speed failure occurs, the controller will shutdown it
immediately without delay. During the cool down period, if there is low oil
pressure failure, the alarm will be active no matter if there is idle function.
CAUTION:
During the period of safety-on delay, low oil pressure protection is
inactive. To avoid starting an engine with no oil, you must make sure the
oil levels are normal and the safety-on delay shall be carefully and
properly set for the first commissioning.