Auto-Maskin
Installation Manual
DCU 305 R3
DCU 305 R3 LT
Diesel Engine Control Unit
About this manual • ii
Page 3 (44)
Content
Document information ......................................................................... 5
Introduction .......................................................................................... 6
A
BOUT THIS MANUAL
....................................................................................................................... 6
A
BOUT THE
DCU 305 R3
AND
DCU 305 R3 LT ............................................................................... 6
C
LASSIFIED SYSTEM
....................................................................................................................... 7
S
YSTEM OVERVIEW
........................................................................................................................ 8
C
ONFIGURATION OVERVIEW
............................................................................................................. 9
T
ECHNICAL SPECIFICATIONS
............................................................................................................ 9
Cable connection ............................................................................... 11
I
N GENERAL
................................................................................................................................. 11
G
ROUNDING
................................................................................................................................ 11
C
ONNECTION ORDER
.................................................................................................................... 11
P
OWER SUPPLY
........................................................................................................................... 13
S
TART- AND STOP RELAY OUTPUTS
............................................................................................... 13
P
ICKUP SENSORS
......................................................................................................................... 14
S
WITCH INPUT CHANNELS
............................................................................................................. 14
A
NALOGUE INPUT CHANNELS
........................................................................................................ 16
J1939 CAN
CONNECTIONS
........................................................................................................... 18
M
ISCELLANEOUS CONNECTIONS
..................................................................................................... 20
T
HE AUTOMATIC FUSES ON THE
RK-66
MODULE
.............................................................................. 21
B
ACKUP SYSTEM CONFIGURATION
.................................................................................................. 22
B
UILT-IN ALARMS
......................................................................................................................... 24
A
DJUSTING THE
LCD
SCREEN
....................................................................................................... 25
O
VERSPEED TEST
........................................................................................................................ 26
Optional expansion modules ............................................................ 27
R
ELAY UNIT
MK-14 ...................................................................................................................... 27
A
NALOGUE UNIT
AK-6 .................................................................................................................. 30
Communication .................................................................................. 32
P
ROTOCOL AND PIN-CONFIGURATION
.............................................................................................. 32
M
ULTIDROP COMMUNICATION
........................................................................................................ 33
R
ETRIEVE THE LOG TO A
PC .......................................................................................................... 34
Schematic Drawings .......................................................................... 35
Page 4 (44)
S
AMPLE SCHEMATIC PAGE
1 ......................................................................................................... 35
S
AMPLE SCHEMATIC PAGE
2 ......................................................................................................... 36
O
PTIONAL RELAY UNIT
MK-14 ...................................................................................................... 37
O
PTIONAL ANALOGUE UNIT
AK-6 .................................................................................................. 38
C
ABLE SPECIFICATION
.................................................................................................................. 38
Wire Terminal Tables ......................................................................... 40
RK-66
WIRE TERMINAL UNIT
.......................................................................................................... 40
R
ELAY UNIT
MK-14 ...................................................................................................................... 42
A
NALOGUE UNIT
AK-6 .................................................................................................................. 43
Page 5 (44)
Document information
Document revisions
Date Revision
July 2005 Created
November 2007
July 2014
Minor adaptations for firmware 6.53 and onwards, because a new
menu layout.
DCU 305 R3 LT included, picture updates
Copyright © Auto-Maskin AS, 2014
Information given in this document may change without prior notice. This document
should not be copied without written permission from Auto-Maskin.
All trademarks acknowledged.
Related documents
DCU 305 R3 & R3 LT User’s Manual
DCU 305 R3 & R3 LT Communication Manual.
RSP 305 Remote Panel.
Rudolf R3 User’s Manual.
Rudolf R3 PC Configuration Software.
Page 6 (44)
Introduction
About this manual
This manual has been published primarily for professionals and
qualified personnel. A person using this material is assumed to have
basic knowledge in marine systems, and be able to carry out related
electrical work.
Work on the boats low-tension circuit should only be carried out by
qualified and experienced persons. Installation or work on the shore
power equipment must only be carried out by electricians authorised
to work with such installations.
It is the sole responsibility of the installer to ensure that the
installation work is carried out in a satisfactorily manner, that it is
operationally in good order, that the approved material and
accessories are used and that the installation meet all applicable rules
and regulations.
Note: Auto-Maskin continuously upgrades its products and reserves the
right to make changes and improvements without prior notice.
All information in this manual is based upon information at the time of
printing.
For updated information, please contact your dealer.
Assumptions
This document describes the DCU 305 R3 and DU 305 R3 LT, and it
will commonly be referred to as the DCU or the Control Unit.
When referring to voltages, we always assume DC-voltages. When
referring to AC-voltages it will be mentioned explicitly.
About the DCU 305 R3 and DCU 305 R3 LT
In general
The DCU 305 R3 is an electronic control unit for control and
monitoring of diesel engines used as propulsion engines or gensets.
Switches and senders from the engines are connected to the control
unit on the wire terminal card RK-66.
Page 7 (44)
The DCU 305 R3 can be connected directly to a printer for output of
all alarms and events, or it can be connected to a remote panel in a
network of control units.
Each project is unique, and the DCU 305 R3 is configured using a
configuration tool for Windows®, the Rudolf R3™ software.
DCU 305 R3 LT
The DCU 305 R3 LT is identical to the DCU 305 R3 with the
exception that the LT version is without CAN bus capability.
The DCU 305 R3 LT has the physical CAN bus port, but there is no
support for CAN bus internally.
Classified system
The DCU 305 R3 is classified by the following classification societies
with their respective certificate number as follows:
Classification Society Certificate Number
Det norske Veritas, DnV
Lloyd’s Register of Shipping, LR
Germanischer Lloyds, GL
Bureau Veritas, BV
Russian Maritime Register of Shipping, RS
Registro Italiano Navale, RINA
American Bureau of Shipping, ABS
Other certificates and approvals may exist.
Please see
www.auto-maskin.com for latest update.
Page 8 (44)
System Overview
The control unit and the wire terminal card with cables make a
complete genset monitoring system. Optional analogue cards and
relay cards may be added to further enhance the functionality and
flexibility.
The control unit is configured using a laptop PC with the
configuration software Rudolf™ installed. The configuration can be
printed and stored on disk.
Standard system
The DCU 305 and the RK-66 is part of the standard delivery that
makes a complete system. The other items are optional.
Remote panel
The optional RSP 305 Remote Panel can be added any time, as it
communicates directly towards the DCU 305 R3, and is selfconfiguring.
Page 9 (44)
The RSP 305 Remote Panel configures itself automatically when
connected to one to four DCU 305 units, and as such requires no extra
configuration.
Configuration overview
The control unit is fully customised using the Rudolf™ configuration
program. For safety reasons, no parameters are adjustable without
using the configuration tool Rudolf.
No settings are necessary in the DCU 305 R3, nor in Rudolf, to
connect and use the Rudolf program. Just connect the cable between
your laptop PC and port P3 on the control unit.
Discussion of the Rudolf configuration software is beyond the scope
of this manual. For more information, please see the Rudolf R3 User’s
Manual.
Technical Specifications
Part Value
Overall dimensions (1) 160 x 260 x 35mm (6.3 x 10.2 x 1.4”) [H x W x D]
Cut-out dimensions 146 x 230mm (5.8 x 9.1”) [H x W]
Overall depth inc. cables 105mm
Supply voltage (2) 24V smoothed, (18– 32VDC)
Power consumption (3) Typical: 500mA @ 24V DC
Maximum: 700mA @ 24VDC
A PC with the Rudolf ™ parameter program is used to customize
the DCU 305 R3.
Page 10 (44)
Part Value
Weight Control unit: 1250g
Protection level Front panel:
Back panel:
IP54
IP30
Ambient temperature Operation:
Storage:
0-70°C
-20-70°C
Air humidity Operation:
Storage:
<90%
Dry
Analogue alarm latency Built-in
channels:
Expansion card
AK-6:
~1 sec
~5 sec
RK-66 relays
120VAC
24VDC
1A
1A
Notes
(1) The cables on the backpanel add to the overall depth.
(2) LCD backlight disappears if primary supply is below 18 volts, and
reappears when primary supply is above 20 volts.
(3) Display brightness full, 5 x 50% (12mA) analogue inputs.
Page 11 (44)
Cable connection
In general
To protect against EMC noise, we recommend that all cables are
shielded.
The shield of all cables shall be connected to ground, not to 0V!
Some cables are to be grounded in one end only, others in both ends.
Some cables shall be separate – for instance pickup signal and power
supply. Others signals can be in a multi-cable with shield.
See the example schematics and cable specification for details.
Grounding
Please keep ground and 0V separated!
Please observe the
difference between ground
and 0 volt!
Ground and 0V should not be connected together. In a ship installation,
the hull is the “ground” whilst the battery negative is the 0V.
In the DCU 305 R3 system, +24V and 0V are filtered to ground using
special filter components. This is done to avoid noise in the system. If
ground and 0V is connected together, these filters do not work properly.
In general, all switches should be referenced to 0V.
Connection order
All connections are made on the RK-66 terminal unit. The only
exception is communication cables, and analogue/relay expansion
cables, which are connected directly on the back-panel.
Start by connecting the ground cable to terminal 60 on the RK-66
terminal unit.
Note! Terminal 60 is connected to the ground plane (not to 0V) on
the RK-66 unit.
Page 12 (44)
The RK-66 wire terminal unit
Now, connect the rest of the wires and complete the installation by
connecting power to the supply inputs.
Terminals 1 and 2 are for the start battery supply, and terminals 3 and
4 are from the auxiliary supply.
Switch setting
By removing the rubber lid on the front of the RK-66, four dipswitches numbered 1-4 will appear.
Switch Purpose Factory setting
1 When ON, start is enabled. This is the same as
connecting a jumper over terminals 39 and 40.
When OFF, no starts are possible!
A jumper between terminals 39 and 40 will
enable start.
ON
2 When ON, bypasses the return path diode to
start-battery negative (terminal 2), which in
some installations may reduce noise
interference.
Increases the measured battery voltage by 0.3V.
OFF
3 Noise filter between terminal 1 and 3 to ground.
Set the switch to ON to enable the filter.
OFF
4 Noise filter between terminal 2 and 4 to ground.
Set the switch to ON to enable the filter.
OFF
Connect the
two cables
between the
RK-66 and the
control unit.
Page 13 (44)
Power supply
24V supply
Use a twisted pair wire to minimize the effect of electrical
disturbances on the cable.
The start battery power shall be connected to terminals 1 and 2.
This is the primary supply.
The secondary (or auxiliary) supply shall be connected to terminal 3
and 4.
Note: In a classified system, a redundant supply must be connected to
terminals 3 and 4.
The control unit uses the highest voltage available from the two
supplies.
The primary voltage is constantly monitored and displayed on the
LCD. The control unit alarms if the primary supply is below the
configured value, or when the secondary supply is below 12V (fixed
setpoint).
The LCD light disappears if the primary voltage drops below 18V,
and reappear when the primary voltage rises above 20V.
12V supply installations
The DCU 305 R3 is a 24V system, but can be used in 12V systems
using an external DC/DC converter. The configuration in Rudolf must
be switched to fit a 12V system.
Connect the start battery to the primary input at terminal 1 and 2 as
above. This voltage is not high enough to make the control panel
work, but it measures the battery voltage.
Connect a 12/24V DC/DC converter to the 12V start battery, and
connect the 24V output to the secondary input, terminal 3 and 4.
Start- and Stop Relay Outputs
Connect auxiliary relays for Start (cranking), Stop, Run solenoid and
Shutdown solenoid.
Observe polarity if the relay coils are fitted with voltage suppressor
diodes.
Coil resistance on auxiliary relays must be in the range 250 ohm - 2
kohm.
Page 14 (44)
Pickup sensors
Connect the pickup 1 between terminal 5 and 6. Please verify that the
signal strength is between 2.5-30Vpp.
Note: The pickup cable must be shielded to ground, not to 0V.
Two pickups
If two pickups are being used, connect the second pickup to terminal
65 and 66. If the rpm differs >100rpm for 20 seconds, there will be an
alarm on the pickup with the lowest rpm.
The signal from pickup 1 has precedence, unless the frequency from
pickup 2 is >100rpm higher than pickup 1, where pickup 2 will be
used.
Note: Two Pickups must be enabled in Rudolf before it can be used.
Switch Input Channels
The control unit has 12 on/off input channels. All 12 channels can be
fully customised with text, delays and instructions to give a Warning,
Alarm or Shutdown.
Channel 1 2 3 4 5 6 7 8 9 10 11 12
Terminal # 7 8 9 10 11 12 13 14 15 16 17 18
Switch Input Channels and their corresponding wire terminal number on the RK-66
wire terminal card.
Inputs are connected to the Wire Terminal Card RK-66 as in the
above table.
The six first switch input channels can detect a broken wire situation,
and utilizes a backup system for shutdown purposes. See page 22 for
more information on the backup system.
Note: In a classified system, all shutdown switches must be connected to
switch inputs 1-6.
The following table illustrates the capabilities of the switch input
channels.
Page 15 (44)
Channel Broken Wire
Detection possibility
Backup on
Shutdown
channels
Warning, Alarm and
Shutdown possibility
1-6
Yes Yes Yes
7-12
No No Yes
Note: Do not connect +24V to the switch inputs! All input switches
must be connected via its corresponding wire terminal to 0V, not to
ground. Please see the schematic drawing page 35.
Connecting the Switches
Connect the warning, alarm and/or shutdown switches according to
the project documentation and drawings. All switches must be
connected between a wire terminal (7-18) and 0V.
An open (not connected) input is pulled ‘high’ internally. The
external switch must pull the input ‘low’ (0V).
Example: Switch channel 1 might be the Oil Pressure Low Shutdown.
The switch is then connected between Terminal 7 and 0V.
Wire break detection
Channel 1-6 has the ability to detect wire break. This is useful in
conjunction with the channel being used as a shutdown channel.
A 10k resistor (10 000 ohm) must be connected in parallel with the
switch. The resistor must withstand 1/8W (0.125W) or more.
Note: The Wire Break Detection feature must be enabled in Rudolf for
each of the channels 1
-
6 that are being used. Otherwise, there will not be
a Broken Wire alarm.
The control panel will now issue a “Broken Wire” alarm if the wire
into the control panel is broken. The alarm is delayed 5 seconds (fixed
time).
An alarm is displayed as:
* Broken Wire [T9]
Here, there is a broken wire on T9, terminal 9. Terminal 9 is switch
channel 3.
Considerations when using wire break detection
Make sure the return-path from the switch is connected to 0V
(terminal 29) at the connection card RK-66, not at the engine
Page 16 (44)
Example: a wire break detection installation on switch channel 1
should have a switch connected between terminal 7 (channel 1) and
terminal 29 (0V reference)
The 10k resistor must be connected across the switch, not across the
terminals 7 and 29.
Analogue Input Channels
The control unit has five industrial-standard 4-20mA inputs. These
may or may not be used, and – if used – are displayed on the LCD as
horizontal bars.
Note: An optional expansion card, the AK-6, is available to expand
the number of analogue inputs from 5 to 11. Please see page 27 for
details.
Using Rudolf, all 11 analogue channels can be configured as a 0
-
20mA or 4-20mA type.
Channel 1 can be configured as 0-10V.
Note: If channel 1 is used as 0-10V, use a separate shielded cable for
this signal as the 0-10V signal is highly susceptible to noise.
All analogue channels can be customised with text and delays and
whether to issue a Warning, Alarm or Shutdown.
Page 17 (44)
Note: Analogue channel one only, can be configured as a 0
-
10V
channel. The dipswitch J12 inside the unit must be set as follows:
0-20mA / 4-20mA
0-10V
Please note that this is applicable for analogue channel one only!
Default setting is 0-20mA / 4-20mA.
Analogue channel setpoints
In the display, the following markers are used to distinguish between
different types of setpoints:
None
No setpoint
Warning
Dashed line
Alarm
Single line
Shutdown
Double line
Analogue Sensor Failure
The alarm Analogue Sensor Failure appears if an enabled analogue
input is not connected, or if the signal strength is too low (<2mA).
Instead of a numeric value to the right of the bargraph, the sign “----“
will be displayed, for instance like this:
Oil Pressure OP1
---- Bar
Note! If 0-10V or 0-20mA is selected, the Analogue Sensor Failure
alarm will not appear.
Connecting the Analogue Sensors
Connect the sensors according to the project documentation and
drawings. All five analogue input channels are 0/4-20mA or 0-10V
(channel 1 only).
For PT100 and PT1000 sensors, an appropriate signal converter must
be used.
Page 18 (44)
RK-66 terminal number
Analogue
Channel
+24V supply to
sensor
Analogue input
1
19 20
2
21 22
3
23 24
4
25 26
5
27 28
Analogue Input Channels and the corresponding wire
terminal number on RK-66
Terminal 19, 21, 23, 25 and 27 are all +24V supply outputs. These
outputs are fused with a common, internal, automatic fuse (F3). The
fuse is located on the RK-66 card.
The fuse will automatically reset when the overload or short circuit is
removed. An alarm is given if the fuse blows and the alarm stays
activated as long as the short circuit is present.
For fuse sizes and characteristics, please see page 21.
Example: Analogue channel 1 might be the Oil Pressure sensor. The
sensor is then connected between terminal 19 (+24V supply) and
terminal 20 (4-20mA input).
J1939 CAN connections
The CAN bus cable
The CAN bus is a high speed data transmission network and requires
more from the cable installation than many other signal types.
The bus consists of two wires: CAN_H and CAN_L. Between units,
these wires should be connected CAN_H to CAN_H and CAN_L to
CAN_L, ie they should not be crossed.
Maximum cable length for the entire cable is 250m (820 feet).
The cable must be a twisted pair with shield. Minimum wire thickness
is 0.5mm^2 (20AWG) and maximum wire thickness is 0.8mm^2
(18AWG). The cable should be certified for CAN/J1939 use.
Minimum cable curve is 8x the cable diameter (ie it should not be
bent too sharp). It must not be deformed in any way.
On the DCU 305 R3 port P10, CAN_H is pin 7 and CAN_L is pin 2.
No other pins should be connected. The shield should normally be
connected at one end only, but in certain installations with a long
cable it may be favorable to connect it at both ends.
Page 19 (44)
Terminating Resistors
A CAN bus cable can connect many units. At each end of the bus, a
120ohm terminating resistor must be connected. If only two modules
are connected to the bus (which is common), each should have a
120ohm resistor connected at the end.
The DCU 305 R3 has a 120ohm resistor internally. If the DCU is not
at the end of the bus, a “CAN-card without J1” must be ordered and
fitted. Alternatively, the jumper J1 on the CAN-card can be removed
by competent personnel.
Note! The CAN bus might work even if there is a terminating resistor
too much or if one is missing, but it will not work if both terminating
resistors are missing.
If by accident, a 24VDC signal has been connected into the CAN bus,
the terminating resistor might be destroyed, and the CAN-card must
be sent in for repair.
Cable ducts
The CAN-cable can be strapped together with other communication
cables.
We recommend that the CAN-cable is not strapped together with
cables carrying high voltages, high currents, or cables connected to
inductive loads (power relays coil, electric engines, etc). Shielded
cables typically reduce the rub-off effect by 20dB, but do not remove
the problems completely.
In general, if the installation has cables carrying PWM-signals (high
frequency magnetic fields around the cable) for instance from a
frequency converter, these cables should be routed separately and in
good physical distance (5cm/2”) from parallel signal cables.
Distance between Engine ECM and DCU 305
If the CAN bus is routed to a different room/area on the ship that
might have a supply voltage different from the supply on the engine,
we strongly recommend using a CAN-repeater unit. The CANrepeater will be a galvanic isolation.
If using the same power supply as on the engine, a CAN-repeater is
not necessary.
The CAN bus in star network topologies
The CAN bus must not be connected in a star network. If this is
necessary, a CAN-repeater must be used. Maximum distance for the
branch is 30cm at 1Mbit/s.
The CAN-repeater and shield
When utilizing CAN-repeaters, the shields must not be connected
over to the new cable.
Page 20 (44)
Miscellaneous connections
Please also refer to the schematics, page 35, for the following
connections.
Remote Start
Remote Start works as the local Start Button.
Connect terminal 31 to terminal 30 to engage.
Remote Stop
Remote Stop works as the local Stop Button, except it is immediate
Connect terminal 32 to terminal 30 to engage.
Note: For safety reasons, local and remote Start and Stop works
regardless of the Manual and Standby setting.
Remote Reset (Acknowledge)
Connect terminal 37 to terminal 36 to activate Remote Reset.
This works as the local reset button on the front-panel, and reset all
the current alarms.
Blackout Start
When the control unit is set to Standby and receives this signal, it will
initiate the Automatic Start procedure. The number of start attempts is
configured in Rudolf.
Connect terminal 34 to terminal 33 to activate. See the schematics on
page 35.
When the engine has started, the signal can be removed. The engine
will not stop if the signal is removed.
Note: If Blackout Start and Delayed Stop are connected simultaneously,
Blackout Start is given priority.
The Delayed Stop signal has no effect if the Blackout Start signal is
present.
Delayed Stop
When the control unit receives the Delayed Stop signal, it will
disconnect the gen. breaker and run the genset for the predefined
cooling time before stopping.
Connect terminal 35 to terminal 33 to engage. Also, see schematic
page 35.
Page 21 (44)
Power-On
Terminal 63 can be used as an external power-on. Connect terminal
63 to +24V to activate.
Note! The jumper J1 inside the main unit must be removed for this
feature to work. With the jumper ON, the control unit is always
powered.
How to remove jumper J1
Remove the back lid. The jumper J1 is located in the bottom left
corner.
Shutdown override
On auxiliary gensets, shutdown may be overridden by connecting
terminal 38 to terminal 36.
All shutdowns are now disabled, except for overspeed. The shutdown
channels will trigger an alarm instead.
Note: If in shutdown, applying Shutdown Override will abandon the
current shutdown.
Configurable inputs
Terminal 61 and 62 are user defined. They are activated by
connecting the terminal to 0V.
For available functions, see the Rudolf R3 User’s Manual.
The automatic fuses on the RK-66 module
The RK-66 wire terminal card has six automatic fuses.
Fuses F1, F2 and F5 are used by the DCU 305 R3 to secure
internal circuits.
These fuses are of type Raychem Polyswitch™ type
RXE090. Maximum load must be less than 1.4A.
Fuse F6 secures the +24V power for the analogue channels at
terminal 19, 21, 23, 25 and 27.
Fuse F3 secures power for the relays connected to terminal
41-44. See the schematics on page 35.
Fuse F4 secures the 0V on terminals 29, 30, 33 and 36.
The fuses F3, F4 and F6 are of type Raychem Polyswitch™ type
RXE050. Maximum load must be less than 0.8A.
If the values are exceeded, the fuse will eventually blow. When
the overload is removed, the fuse repairs itself. Typical recovery
time is 15-20 seconds at 20°C ambient temperature.
Page 22 (44)
Backup system configuration
Note! The backup setting is automatically advised by the
configuration software Rudolf R3.
You may use these settings and skip this chapter entirely.
Overview
In the (unlikely) event of failure in the DCU 305 R3 main
microcontroller, the built-in backup system will detect this, and
activate the common alarm output relay.
Also, if the backup system fails, then the main microcontroller will
give the “Backup System Failure” alarm.
Note: The backup system setting is calculated automatically by
Rudolf R3.
Set the DIP-switches according to the Rudolf R3 recommendation.
The backup system monitors all of the enabled switch inputs channels
1-6, and overspeed. These are the only channels on which the backup
system can act.
Note: The backup system activates if the main microcontroller fails
only. When the control panel is working normally, the backup system is
enabled, but not activated.
The working of the backup system can be observed on the back panel as
a slowly flashing (~1Hz) green LED. If the LED is flashing quickly,
(~4Hz) the backup system has detected a main microcontroller failure
and is activated.
What it does
If the backup system is activated and a genuine shutdown appears, it
activates the Stop and Shutdown outputs on terminal 42 and 44.
These outputs are held active for 2 minutes before being released.
Configuration of dipswitches
All configurations of the backup system are made using switch S1-S4
on the back-panel. There are three settings to be made:
• Set pulses/revolution using hex-switch S1 and S2.
• Set the overspeed setpoint using hex-switch S3.
• Enable shutdown switch channels by setting dipswitch S4.
Page 23 (44)
Pulses/Revolution, S1 and S2
Set the pulses/revolution on pickup #1 (connected to terminals 5 and
6) by switching the two rotary hex-switches S1 and S2 to the correct
value.
See the Appendix page Error! Bookmark not defined. for details.
MS is the most significant value whereas LS is the least significant
value.
Example: A pickup issues 165 pulses/revolution. 165 decimal = A5
hex.
A is the MS; 5 is the LS.
S
et S1 = A
Set S2 = 5
Overspeed, S3
Note: The Backup System measures rpm from pickup 1 only.
Set correct overspeed setpoint by turning the hex-switch as follows:
Switch S3 Value [rpm] Switch S3 Value [rpm]
0 Disabled 8 1800
1 480 9 1885
2 670 A 2010
3 1025 B 2030
4 1370 C 2120
5 1670 D 2340
6 1720 E 2430
7 1760 F 2730
Select the next value that is above the Rudolf R3 overspeed setting.
Example: If the main configuration overspeed is set to 1740, then set
the S3 switch to 7, ie. 1760 rpm.
Shutdown channels, S4
There is a dipswitch in combination with each of the first six switch
channels.
Page 24 (44)
The DIP-settings are for selection of the shutdown channels. All of
the channels 1-6 that are configured as shutdown must have its
corresponding DIP set to ON.
In the example below, channels 1, 2 and 6 are set as shutdown
channels.
Note: The backup settings MUST correspond with the Rudolf R3
configuration.
When the DIP is set to ON, it means these channels will be monitored
by the backup system.
In the backup system, there is a four second delay before pulling the
stop-solenoid. Once activated, the stop-solenoid remains activated for
two minutes to allow the engine to completely stop. The stop-solenoid
then deactivates.
Shutdowns
Overspeed
Puls/Rev LS
Puls/Rev MS
Example of Backup System setting.
The above example is a system with shutdowns on channel 1, 2 and 6, overspeed set
to 1760 rpm and 165 pulses/revolution (see text above)
In the above example, channel 1, 2 and 6 are shutdown channels.
Here, channels 3, 4 and 5 may be configured as Warning or Alarm
channels, or may not be in use.
Built-in Alarms
The control unit has a number of internal alarms. These are always
displayed – in the language selected by Rudolf.
The following is a list of the built-in alarms.
Alarm text Comment
Low battery voltage Low voltage at the start battery.
The alarm is interlocked during starting (cranking) and
stopping.
Secondary battery low
voltage
Low voltage at the secondary battery source.
A 5 7
▀ ▀ ▄ ▄ ▄ ▀
S1 S2 S3 S4
Page 25 (44)
Alarm text Comment
Overspeed Engine running faster than the overspeed setpoint.
Engine Stopped Engine stopped for no known reason.
Engine failed to stop 60 seconds after issuing the stop command, the engine has
still not stopped.
Start Failure Engine failed to start after the last start attempt.
Pickup failure Unable to read the pickup signal while engine is running.
Output circuit overload Short circuit in one of the +24V outputs.
The outputs are secured with fuse F3 that makes an
automatic reset. Remove the overload to correct the
problem.
For details, see page 21.
Analogue sensor failure
[A7]
Detailed information on which analogue channel that is
below 2mA. Here channel 7.
Broken wire [T7 T9 T44] Information on which terminal has a broken wire. Here on
terminal 7, 9 and 44.
Adjusting the LCD screen
The control unit uses a graphical Liquid Crystal Display.
The optical performance of the display changes with temperature,
light conditions and age.
There is a built-in automatic compensation for temperature changes.
Still, from time to time, it may be necessary to adjust the display.
Automatic Backlight Shutoff
To preserve LCD lifetime, the display automatically shuts off after
the predefined amount of time, if no action has been observed in that
period.
The display turns on again at any key press, or if an event occurs in
the system.
Note: The terminals 61 and 62 can be configured as LCD Backlight
On. A 0V on the terminal will trigger the LCD Backlight On.
Contrast
Contrast is automatically compensated for with temperature.
If however the display seems dim or unclear, it may be necessary to
adjust it. Access the menu and select Contrast to adjust.
The new setting is automatically stored in internal memory, and stays
resident regardless of future power loss.
Page 26 (44)
Overspeed test
This section describes how to enter the RPM Test mode. In test mode,
the Overspeed Setpoint (typically 1725 rpm) is reduced to Nominal
Setpoint (typically 1500 rpm).
Note: The actual setpoints may vary from the above example. Consult
the Rudolf configuration.
How to enable the RPM test mode
Follow these steps to enable the RPM Test mode:
Access the menu and select Overspeed/RPM Test.
Note! It is not possible to enable the RPM Test mode unless the
control unit is in the Ready state.
The Overspeed Setpoint is now reduced to the Nominal Setpoint. The
bottom left status field displays “RPM TEST” to indicate and remind
of this.
Note: The test automatically times out after 4 minutes or after an
Overspeed shutdown. To leave the test earlier, toggle it again, as
described above.
Page 27 (44)
Optional expansion modules
Relay unit MK-14
In addition to the nine relays found on the RK-66 terminal board, an
optional relay unit may be connected.
The optional MK-14 unit, which add 14 relay channels to the DCU 305 R3. The
function on each relay is configured using the configuration tool Rudolf R3.
All relays can be given any function from an extensive signal pool.
The relay card is connected to the control unit with a shielded 15-pin
D-SUB connector cable, and is then ready for use.
For connections, please see page 42.
Page 28 (44)
Available signals to the relay unit
These are all the available signals in the DCU 305 R3 that can be
routed to any of the relays on the relay cards.
Relay K7 and K9 on the terminal card RK-66 are configurable in the
same manner.
Signal Comment
Acknowledge button Manual press of the Acknowledge button.
Analogue sensor
failure
An analogue input (4-20mA) is defined but the signal
is less than 2mA.
Backup system
failure
The backup system is not working.
Buzzer active Buzzer is activated.
Buzzer off button Manual press of the Buzzer Off button.
Common analogue
input current
overload
The sensor fuse is blown. The fuse resets itself when
the short circuit is removed.
Common shutdown Sum of all shutdown channels.
Common warning Sum of all warning channels
Cooling state The genset is cooling and running at no load.
Cranking state The Control Unit signals the start motor. The genset is
cranking. On between start attempts also.
Delayed stop
activated
The Control Unit has received signal saying the genset
will eventually stop.
Disconnect gen
breaker relay
activated
The generator circuit breaker relay is activated.
Downloading
parameters
A new configuration is being transmitted to the
control unit.
Engine started The Control Unit detects the engine is running but no
start signal has been detected.
Engine stopped for
unknown reason
The engine stopped for no known reason.
First start attempt
failed
The first of several start attempts failed during
automatic start.
Local mode LOCAL mode is selected, and no remote commands
will work.
Lamp test button Manual press of the Lamp test button.
Manual mode The Control Unit is set to Manual mode.
Manual stop Manual Stop button, local or remote.
Overspeed Engine speed too high. Stays until Acknowledged.
Pickup failure Unable to detect a valid pickup signal. Dependent
upon at least one defined Additional RUN Detection.
Sum of pickup 1 and 2.
Page 29 (44)
Signal Comment
Preheat Preheating before and during start attempts. Stays on
until engine has started or failed to start.
Ready to start The genset is ready to start.
Ready to take load The engine has reached the in Rudolf predefined rpm-
setting.
Running state The genset is running. On as long as the engine is
running. Same as green LED in the Start button.
Secondary battery
failure
The secondary battery is not connected or its voltage
is below 12V. Terminal 3 and 4.
Shutdown override
on
The Control Unit is disabling shutdowns, except
overspeed.
Shutdown override
off
The Control Unit has all configured shutdowns
enabled.
Standby mode The Control Unit is set to Standby mode. Automatic
starts can take place.
Start battery low
voltage
The engines start battery has low voltage. Terminal 1
and 2.
Start command
externally
Same as the Blackout signal, e.g. from main
switchboard. Terminal 34.
Start disabled The Control Unit is disabling local and remote start
attempts, also when set to Standby.
Start failure The engine did not start after final start attempt.
Stop failure A stop signal was given but after 40 seconds, the
engine is still running.
Stopped state The engine has stopped. Engine speed is less than
5rpm.
Stopping state The engine is about to stop.
All channels – analogue or switch – configured as a warning, alarm or
shutdown can be routed to any relay.
A screenshot from the configuration tool Rudolf R3, where signals
are selected to the relays.
Page 30 (44)
Analogue unit AK-6
The analogue unit AK-6 connects directly into the DCU 305 R3.
Another six 4-20 mA channels are then available in the control unit,
to make a total of 11 channels.
The unit has two 15-pin D-SUB connectors. One connects directly to
the control unit. The other connects to the optional relay expansion
unit MK-14, if used.
If any of the analogue channels 6-11 are activated in Rudolf, the
control unit assumes the AK-6 unit is connected.
All input channels on the AK-6 are of type 4-20mA.
Note: The update time for the six expansion channels is somewhat
longer than for the five standard channels. The standard channel five will
also have longer update interval when AK-6 is used. We recommend
connection of mostly “slow” media to the AK-6 card, eg. temp.
transmitters.
Note: When using the AK-6 card and the MK-14 card together, the last
three channels (channel 12, 13 and 14) on the MK-14 are unavailable for
use.
The optional AK-6 analogue card, which adds six 4-20 mA channels to the DCU 305
R3.
Page 31 (44)
Connections
The fifth analogue input on the RK-66 unit (terminal 27 and 28)
becomes the first analogue input on the AK-6 card.
If there is a connection at terminal 27 and 28 on the RK-66 card,
move these to terminal 1 and 2 on the AK-6 card.
Consider the following table when using the AK-6 analogue
expansion unit.
RK-66 terminal # AK-6 terminal #
Channel +24V 4-20mA +24V 4-20mA Screen
1
19 20 1
2
21 22 1
3
23 24 1
4
25 26 1
5
27
28 1 2 1
6
3 4 2
7
5 6 2
8
7 8 2
9
9 10 2
10
11 12 2
11
13 14 2
For further connection information, please see the schematics.
On the AK-6, connect terminal 27, 28 and 29 directly to terminal 27,
28 and 29 on the RK-66.
Terminal 29 on the AK-6 is a 0V that can be connected to sensors that
need a +24V and a 0V connection. Otherwise, disregard it.
Terminals 15 and 16 on the AK-6 are not in use and shall not be
connected
Displaying the analogue values.
As illustrated in the table above, channel 1-5 will be displayed in the
first analogue screen, along with the battery voltage (standard).
Note! Screen 2 displays channels 6-11. Screen 2 is not available if
none of the channels 6-11 are in use.
Page 32 (44)
Communication
The information from sensors and switches connected to the
DCU 305 R3 can be remotely monitored by utilising the built-in
communication channel.
Any common supervision systems like Factory Link®, InTouch®,
etc. that supports the Comli or Modbus protocol can be used.
The DCU 305 R3 supports the CAN J1939 standard for interface
between Engine ECM and DCU 305.
When connected, all data available on the DCU 305 R3 display is
available in the supervision system. In addition, commands such as
Start, Stop and Acknowledge can be done.
Protocol and pin-configuration
The DCU 305 R3 has the Comli and modbus communication protocol
built-in. It communicates at 9600 baud on its RS232 communication
port, P3.
In order to communicate, the control units ID-number must be
known. This ID-number may be any number in the range 1-239. The
printout documentation from Rudolf includes the ID-number. The IDnumber is also displayed in the Communication Status view.
The document DCU 305 R3 Communication Manual includes the
complete list of available signals and their address. Please refer to
this document when communicating towards the control panel.
In addition the DCU 305 R3 has the J1939 CAN bus communication
protocol built-in. On the DCU 305 R3 port P10 is dedicated to CAN
communication. For further description, please see installation
manual for DCU 305 R3.
Page 33 (44)
Port P3
The DCU 305 R3 has a 9-pin D-SUB male connector at port P3,
outlined as follows:
Pin # Description
2 RxD
3 TxD
4 DTR
5 SG
7 RTS
8 CTS
Port P10:
The DCU 305 R3 has a 9-pin D-SUB male connector at port P10,
outlined as follows:
Pin # Description
2 CAN-L
7 CAN-H
Multidrop communication
Several DCU 305 R3 units may be connected together in what is
known as a multidrop network.
For this to work correctly, each of the connected units must have its
unique ID-number in the range 1-239. This is done using the
parameter program Rudolf.
Further, the multi-drop net must be an RS-485 net. This means that
RS-232/RS-485 converter units, for instance the ICPCON
RS232/RS485 unit, must be connected close to the communication
port P3 of each DCU 305 R3 unit.
We recommend using a twisted pair cable with two pairs of at least
0.22 mm
2
, and capacity lower than 60pF/m.
Please contact your dealer or Auto-Maskin for correct dip setting and
cabling of these units in a network.
Page 34 (44)
Retrieve the log to a PC
The built-in event log in the control unit can be retrieved with simple
means.
• Connect the configuration software to the DCU 305 R3 using
the Rudolf cable.
• In the configuration software, select Communication –
Retrieve Log…
Wait while the log is uploaded into the PC.
Page 35 (44)
Schematic Drawings
Sample Schematic Page 1
Page 36 (44)
Sample Schematic Page 2
Page 37 (44)
Optional Relay Unit MK-14
Page 38 (44)
Optional Analogue Unit AK-6
Page 39 (44)
Cable Specification
Terminal Function Cable specifications Comment
1-2 Primary 24VDC supply
Twisted pair 1.5 mm
2
3-4 Secondary 24VDC supply
Twisted pair 1.5 mm
2
5-6 Pickup 1
Shielded cable 2 x 0.5 mm2
Separate cable
Shield to be connected
to GND at both ends
7-18 Digital inputs
Shielded cable 0.5 mm
2
Shield to be connected
to GND at both ends
19-20 Analogue input 1
Shielded cable 0.5
mm
2
Separate cable if used as 010VDC
Shield to be connected
to GND at both ends
21-29 Analogue input 2 - 5
Shielded cable 0.5 mm
2
Shield to be connected
to GND at both ends
30-32 Remote Start
Remote Stop
Shielded cable 0.5 mm2
Shield to be connected
to GND at both ends
33-35 Blackout Start
Delayed Stop
Shielded cable 0.5 mm
2
Shield to be connected
to GND at both ends
36-38 Remote Acknowledge
Shutdown Override
Shielded cable 0.5 mm2
Shield to be connected
to GND at both ends
39-40 Remote Keyswitch
Shielded cable 0.5 mm
2
Shield to be connected
to GND at both ends
41-44 Relays for Start/Stop
Shielded cable 0.5 mm2
45-59 Relay outputs Unshielded cable max 2.5
mm
2
60 GND
Unshielded 2.5 mm2
GND cable
Connect to noise-free
earth. L<1m
61-62 Configurable inputs
Shielded cable 0.5 mm2
Shield to be connected
to GND at both ends
63 External power-on
Shielded cable 0.5 mm2
Shield to be connected
to GND at both ends
64 Spare input - Not in use
65-66 Pickup 2
Shielded cable 2x0.5 mm2
Separate cable
Shield to be connected
to GND at both ends
DSUB
P3
- Rudolf Configuration
Comli/Modbus communication
Shielded cable 0.20 mm2
Separate cable
Shield to be connected
to DSUB housing at
DCU 305 R3 end only
DSUB
P7
AK-6, MK-14,
C1-C2-C3 cable
Expansion port
Shielded cable 0.20 mm2
Separate cable
Shield to be connected
to DSUB housing at
DCU 305 R3 end only
DSUB
P9
J1708, J1587
Shielded cable 0.20 mm
2
Separate cable
Shield to be connected
to DSUB housing at
DCU 305 R3 end only
DSUB
P10
CAN, J1939
Shielded cable 0.20 mm2
Separate cable
Shield to be connected
to DSUB housing at
DCU 305 R3 end only
Page 40 (44)
Wire Terminal Tables
RK-66 wire terminal unit
# DCU 305 R3 (RK-66) Comment
1 +24V Primary supply. Connect to start battery.
2 0V
3 +24V Secondary supply. Connect to auxiliary supply.
4 0V
5 Pickup 1 Used when one pickup only.
2.5 - 30Vpp. 6 Pickup 1
7 Switch input 1 Referenced to 0V, terminal 29
8 Switch input 2 Referenced to 0V, terminal 29
9 Switch input 3 Referenced to 0V, terminal 29
10 Switch input 4 Referenced to 0V, terminal 29
11 Switch input 5 Referenced to 0V, terminal 29
12 Switch input 6 Referenced to 0V, terminal 29
13 Switch input 7 Referenced to 0V, terminal 29
14 Switch input 8 Referenced to 0V, terminal 29
15 Switch input 9 Referenced to 0V, terminal 29
16 Switch input 10 Referenced to 0V, terminal 29
17 Switch input 11 Referenced to 0V, terminal 29
18 Switch input 12 Referenced to 0V, terminal 29
19 +24V Output, protected by fuse F6
20 Analogue input 1,
4-20mA
21 +24V Output, protected by fuse F6
22 Analogue Input 2,
4-20mA
23 +24V Output, protected by fuse F6
24 Analogue Input 3,
4-20mA
25 +24V Output, protected by fuse F6
26 Analogue Input 4,
4-20mA
27 +24V Output, protected by fuse F6
Page 41 (44)
# DCU 305 R3 (RK-66) Comment
28 Analogue Input 5,
4-20mA
29 0V Common 0V
30 0V Common 0V
31 Remote Start Connect to terminal 30 to activate
32 Remote Stop Connect to terminal 30 to activate
33 0V Common 0V
34 Blackout Start Connect to terminal 33 to activate
35 Delayed Stop Connect to terminal 33 to activate
36 0V Common 0V
37 Remote Reset Connect to terminal 36 to activate
38 Shutdown Override Connect to terminal 36 to activate
39 Keyswitch Start Disable Connect a wire between terminal 39 and 40 to enable start.1.
If the wire is removed, start is inhibited.
Set switch SW1 to jumper across terminal 39 and 40.
40 Keyswitch Start Disable
41 To Start Solenoid Relay K1.
+24V supply to auxiliary start relay
42 To Stop Solenoid, +24V Relay K2.
+24V supply to auxiliary stop relay
43 To Run Solenoid, +24V Relay K3.
+24V supply to auxiliary run relay
44 To Shutdown Solenoid Relay K4.
+24V supply to auxiliary shutdown solenoid.
45 Common Alarm, NO Relay K5.
The Common Alarm relay.
46 Common Alarm, C
47 Common Alarm, NC
48 Common Shutdown, NO Relay K6.
The common Shutdown relay. 49 Common Shutdown, C
50 Common Shutdown, NC
51 K7, NO Relay K7.
Configurable relay. 52 K7, C
53 K7, NC
54 Ready to Start, NO Relay K8.
Activates when ready to start, and not in LOCAL mode or
MANUAL mode.
55 Ready to Start, C
56 Ready to Start, NC
57 K9, NO Relay K9.
Configurable relay. 58 K9, C
59 K9, NC
60 GND – chassis – hull Connect to the hull.
1
The wire terminal card has a switch (SW1) connected over terminal 39 and 40. The switch is accessible from
underneath the rubber seal on top of the RK-66 terminal card.
Page 42 (44)
# DCU 305 R3 (RK-66) Comment
61 Config input 1 Configurable input.
62 Config input 2 Configurable input.
63 Power-on
2
Connect to +24V to power-on in parallel with the keyswitch
found on DCU 305 R3 P.
64 Reserved input For future expansion
65 Pickup 2 For pickup 2.
Use Pickup 1 inputs if there is one pickup only. 2.5-30Vpp. 66 Pickup 2
Relay unit MK-14
The functions on these optional relays are user defined using the
Rudolf configuration tool.
Relay Terminal Relay
K1 1 Relay 1, C
2 Relay 1, NC
3 Relay 1, NO
K2 4 Relay 2, C
5 Relay 2, NC
6 Relay 2, NO
K3 7 Relay 3, C
8 Relay 3, NC
9 Relay 3, NO
K4 10 Relay 4, C
11 Relay 4, NC
12 Relay 4, NO
K5 13 Relay 5, C
14 Relay 5, NC
15 Relay 5, NO
K6 16 Relay 6, C
17 Relay 6, NC
18 Relay 6, NO
K7
19 Relay 7, C
20 Relay 7, NC
21 Relay 7, NO
K8 22 Relay 8, C
23 Relay 8, NC
24 Relay 8, NO
2
This feature has no effect unless internal jumper J1 is removed.
Page 43 (44)
Relay Terminal Relay
K9 25 Relay 9, C
26 Relay 9, NC
27 Relay 9, NO
K10 28 Relay 10, C
29 Relay 10, NC
30 Relay 10, NO
K11 31 Relay 11, C
32 Relay 11, NC
33 Relay 11, NO
K12 34 Relay 12, C
35 Relay 12, NC
36 Relay 12, NO
K13 37 Relay 13, C
38 Relay 13, NC
39 Relay 13, NO
K14 #1 40 Relay 14, C1
41 Relay 14, NC1
42 Relay 14, NO1
K14 #2 43 Relay 14, C2
44 Relay 14, NC2
45 Relay 14, NO2
Note: Relay 14 has two changeover contacts.
Analogue unit AK-6
Please note that when using the optional AK-6 unit, analogue channel
5 is moved from the RK-66 to the AK-6 unit.
Terminal AI channel Signal type
1 5 +24V supply
2
4-20mA input
3 6 +24V supply
4
4-20mA input
5 7 +24V supply
6
4-20mA input
7 8 +24V supply
8
4-20mA input
Page 44 (44)
Terminal AI channel Signal type
9 9 +24V supply
10
4-20mA input
11 10 +24V supply
12
4-20mA input
13 11 +24V supply
14
4-20mA input
15 - NC
16 - NC
27 *) Connect to RK-66
terminal 27
28 *) Connect to RK-66
terminal 28
29 *) Connect to RK-66
terminal 29
*) Connect these three wires between RK-66 and AK-6.
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