Deep Sea Electronics Plc 5520 Operator's Manual

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DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual

5520 OPERATING MANUAL ISSUE 1 04/02/05 AM 1

Deep Sea Electronics Plc

5520 Operators Manual

Author – Tony Manton

Deep Sea Electronics Plc

Highfield House

Hunmanby Industrial Estate

North Yorkshire

YO14 0PH ENGLAND

Tel +44 (0) 1723 890099

Fax +44 (0) 1723 893303

Email : sales@deepseaplc.com

DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual

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TABLE OF CONTENTS

Section Page

1 INTRODUCTION .............................................................................................. 5

1.1 CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION. ........................6

2 OPERATION..................................................................................................... 7

2.1 CONTROL ......................................................................................................................7

2.2 AUTOMATIC MODE OF OPERATION............................................................................8

2.3 MANUAL OPERATION .................................................................................................10

2.4 TEST OPERATION.......................................................................................................12

3 PROTECTIONS ..............................................................................................14

3.1 WARNINGS...................................................................................................................15

3.2 ANALOGUE PRE-ALARMS..........................................................................................17

3.3 SHUTDOWNS ...............................................................................................................19

3.4 ELECTRICAL TRIPS .................................................................................................... 23

DESCRIPTION OF CONTROLS .......................................................................... 24

3.5 TYPICAL LCD DISPLAY SCREENS.............................................................................24

3.5.1 TYPICAL STATUS DISPLAY..................................................................................24

3.5.2 TYPICAL INSTRUMENT DISPLAY......................................................................... 25

3.5.3 TYPICAL ALARM DISPLAY....................................................................................25

3.5.4 TYPICAL EVENT DISPLAY ....................................................................................25

3.6 VIEWING THE INSTRUMENT AND EVENT LOG PAGES............................................26

3.6.1 SYNCHROSCOPE OPERATION............................................................................ 27

3.7 COMPLETE INSTRUMENTATION LIST.......................................................................28

3.7.1 BASIC INSTRUMENTATION..................................................................................28

3.7.2 ENHANCED J1939 INSTRUMENTATION ..............................................................28

3.8 OPERATOR CONFIGURATION MODE ........................................................................29

3.9 ACCESSING THE FRONT PANEL CONFIGURATION EDITOR ..................................29

3.9.1 ENTERING THE PIN NUMBER ..............................................................................29

3.9.2 EDITING VALUES ..................................................................................................30

3.9.3 LIST OF ADJUSTABLE PARAMETERS .................................................................31

3.10 LED INDICATORS ........................................................................................................32

3.11 CONTROL PUSH-BUTTONS........................................................................................ 33

4 INSTALLATION INSTRUCTIONS.................................................................. 36

4.1 PANEL CUT-OUT ......................................................................................................... 36

4.2 COOLING .....................................................................................................................36

4.3 UNIT DIMENSIONS ......................................................................................................36

4.4 FRONT PANEL LAYOUT.............................................................................................. 37

5 ELECTRICAL CONNECTIONS...................................................................... 38

5.1 CONNECTION DETAILS ..............................................................................................38

5.1.1 PLUG “A” 8 WAY....................................................................................................38

5.1.2 PLUG “B” 11 WAY ..................................................................................................38

5.1.3 PLUG “C” 9 WAY....................................................................................................39

5.1.4 PLUG “D” 3 WAY....................................................................................................39

5.1.5 PLUG “E” 5 WAY....................................................................................................39

5.1.6 PLUG “F” 8 WAY....................................................................................................40

5.1.7 PLUG “G” 4 WAY...................................................................................................40

5.1.8 PLUG “H” 12 WAY..................................................................................................40

5.1.9 PC CONFIGURATION INTERFACE CONNECTOR ...............................................41

5.1.10 EXPANSION INTERFACE CONNECTOR ..............................................................41

5.2 CONNECTOR FUNCTION DETAILS ............................................................................42

5.3 CONNECTION DETAILS ..............................................................................................42

5.3.1 PLUG “A” 8 WAY....................................................................................................42

5.3.2 PLUG “B” 11 WAY.................................................................................................. 42

5.3.3 PLUG “C” 9 WAY....................................................................................................43

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5.3.4 PLUG “D” 3 WAY................................................................................................... 43

5.3.5 PLUG “E” 5 WAY................................................................................................... 44

5.3.6 PLUG “F” 8 WAY................................................................................................... 44

5.3.7 PLUG “G” 4 WAY................................................................................................... 44

5.3.8 PLUG “H” 12 WAY ................................................................................................. 45

5.4 ELECTRICAL CONNECTIONS TO J1939 ENABLED CONTROLLERS ...................... 46

5.4.1 CUMMINS ISB / ISBE ............................................................................................ 46

PLUG “A” 8 WAY.............................................................................................................. 46

PLUG “C” 9 WAY............................................................................................................. 46

5.4.2 DEUTZ EMR2 ........................................................................................................ 47

PLUG “A” 8 WAY.............................................................................................................. 47

PLUG “C” 9 WAY............................................................................................................. 47

5.4.3 JOHN DEERE........................................................................................................ 48

PLUG “A” 8 WAY.............................................................................................................. 48

PLUG “C” 9 WAY............................................................................................................. 48

5.4.4 PERKINS 2800 SERIES......................................................................................... 49

PLUG “A” 8 WAY.............................................................................................................. 49

PLUG “C” 9 WAY............................................................................................................. 49

5.4.5 SCANIA S6 ............................................................................................................ 50

PLUG “A” 8 WAY.............................................................................................................. 50

PLUG “C” 9 WAY............................................................................................................. 50

5.4.6 VOLVO TAD9 / TAD16........................................................................................... 51

PLUG “A” 8 WAY.............................................................................................................. 51

PLUG “C” 9 WAY............................................................................................................. 51

5.4.7 VOLVO TAD12....................................................................................................... 52

PLUG “A” 8 WAY.............................................................................................................. 52

PLUG “C” 9 WAY............................................................................................................. 52

6 SPECIFICATION ............................................................................................ 53

7 COMMISSIONING.......................................................................................... 54

7.1.1 PRE-COMMISSIONING ......................................................................................... 54

8 FAULT FINDING ............................................................................................ 55

9 TYPICAL WIRING DIAGRAM ........................................................................ 56

10 FACTORY DEFAULT CONFIGURATION .................................................. 57

10. ICONS AND LED IDENTIFICATION........................................................... 61

10.1 ICON DESCRIPTIONS ................................................................................................. 61

10.2 CONFIGURABLE LED IDENTIFICATION DIAGRAM................................................... 62

10.3 SENDER WIRING RECOMMENDATIONS ................................................................... 62

10.3.1 USING EARTH RETURN (SINGLE WIRE) SENDERS........................................... 62

10.3.2 USING INSULATED RETURN (TWO WIRE) SENDERS. ...................................... 63

12. APPENDIX .................................................................................................. 64

10.3.3 5520 IDMT TRIPPING CURVES (TYPICAL) .......................................................... 64

12.2 5520 SHORT CIRCUIT TRIPPING CURVES (TYPICAL)........................................... 65

10.4 OUTPUT EXPANSION ................................................................................................. 66

10.4.1 RELAY OUTPUT EXPANSION (157) ..................................................................... 66

10.4.2 LED OUTPUT EXPANSION (548).......................................................................... 66

10.5 INPUT EXPANSION ..................................................................................................... 66

13. SYNCHRONISING NOTES ......................................................................... 67

10.5.1 CHECK SYNC........................................................................................................ 67

10.5.2 AUTO SYNC .......................................................................................................... 67

10.5.3 LOAD CONTROL................................................................................................... 67

10.5.4 13.3 TYPICAL PEAK LOPPING SYSTEM.............................................................. 68

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1 INTRODUCTION

The DSE 5520 Module, has been designed to allow the OEM to meet demand for increased capability within the industry. It has been primarily designed to allow the user to start and stop the generator and if required, transfer the load to the generator either manually or automatically, or in the event of the module detecting a mains failure. The user also has facility to view all the system operating parameters via the LCD display. Utilising the inbuilt synchronising, volts matching and paralleling functions, the 5520 can also be used to parallel with the mains supply for no break return, peak lopping or power export fucntionality.

The DSE 5520 module monitors the incoming AC mains supply for under or over voltage / under or over frequency and instructs the generating set to start and to supply the load.

The DSE 5520 module also monitors the engine, indicating the operational status and fault conditions; automatically shutting down the engine and giving a true first-up fault condition of an engine failure by a flashing COMMON ALARM LED. Exact failure mode information is indicated by the LCD display on the front panel.

The powerful Micro-processor contained within the module allows for a range of enhanced features to be incorporated as standard;

 Full Multi-lingual LCD display (including non-western character fonts).  True RMS voltage monitoring.  Power measurement instrumentation.  Communications capability (RS485 or RS232 including GSM/SMS functions)  Check Sync capability  Automatic Sync capability  Load control capability  Fully configurable inputs for use as alarms or a range of different functions.  Extensive range of output functions using built in relay outputs or relay expansion available.  SAE J1939 instrumentation and diagnostics when connected to a compatible J1939 engine

controller.

Selective operational sequences, timers and alarm trips can be altered by the customer via a PC

using the 5xxx For Windows ™ software and 810 interface or via the integral front panel

configuration editor.

Access to critical operational sequences and timers for use by qualified engineers, is barred by a security code. Module access is barred 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.

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1.1 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.



Deep Sea Electronics Plc owns the copyright to this manual, which cannot be copied, reproduced or disclosed to a third party without prior written permission.

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2 OPERATION

2.1 CONTROL

Control of the DSE 5520 module is via push buttons mounted on the front of the module with STOP/RESET, MANUAL, TEST, AUTO, LAMP TEST and ALARM MUTE and START functions.

For normal operation these are the only controls which need to be operated. The smaller push buttons are used to access further information such as engine instruments and load switching operations. Detail of their operation is covered later in this document.

The following descriptions detail the sequences followed by a module containing the standard

‘factory configuration’. Always refer to your configuration source for the exact sequences and

timers observed by any particular module in the field.

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2.2 AUTOMATIC MODE OF OPERATION

NOTE:- If a digital input configured to panel lock is active, changing module

modes will not be possible. Viewing the instruments and

is NOT affected by

panel lock. If panel lock is active the Panel lock indicator (if configured) illuminates.

This mode is activated by pressing the pushbutton. An LED indicator beside the button confirms this action.

Should the mains (utility) supply fall outside the configurable limits for longer than the period of the mains transient delay timer, the mains (utility) available GREEN indicator LED extinguishes. Additionally, while in AUTO mode, the remote start input (if configured) is monitored. If active, the Remote Start Active indicator (if configured) illuminates.

Whether the start sequence is initiated by mains (utility failure) or by remote start input, the following sequence is followed :

To allow for short term mains supply transient conditions or false remote start signals, the Start Delay timer is initiated. After this delay, if the pre-heat output option is selected then the pre-heat timer is initiated and the corresponding auxiliary output (if configured) will energise.

NOTE:- If the mains supply returns within limits, ( or the Remote Start signal is removed if the start sequence was initiated by remote start) during the Start Delay timer, the unit will return to a stand-by state.

After the above delays the Fuel Solenoid (or enable ECU output if configured) is energised, then one second later, the Starter Motor is engaged.

NOTE:- If the unit has been configured for J1939, compatible ECU’s will receive

the start command via J1939.

The engine is cranked for a pre-set time. If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and Fail to Start fault will be displayed.

Alarm

Shutdown Failed to start

When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency measured from the alternator output. Alternatively a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is selected by PC using the 5xxx series configuration software). Rising oil pressure can also be used to disconnect the starter motor, however it cannot be used for underspeed or overspeed detection.

NOTE:- If the unit has been configured for J1939, speed sensing is via J1939.

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After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault.

Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to stabilise before accepting the load.

If an auxiliary output has been selected to give a load transfer signal, this would then activate.

NOTE:-A load transfer will not be initiated until the Oil Pressure has risen. Thus

preventing excessive wear on the engine.

On the return of the mains supply, (or removal of the Remote Start signal if the set was started by remote signal), the Stop delay timer is initiated. Once it has timed out, the set is synchronised and paralleled with the mains supply. The load Transfer signal is then de-energised, removing the

load from the genset and completing the “no break return”.

The Cooling timer is then initiated, allowing the engine a cooling down period off load before shutting down. Once the Cooling timer expires the Fuel Solenoid is de-energised, bringing the generator to a stop.

Should the mains supply fall outside limits again (or the Remote Start signal be re-activated) during the cooling down period, the set will return on load.

NOTE:- When synchronising is enabled, the mains supply is checked before closing any load switching device. If the supply is live, synchronising will take place before any closure takes place.

NOTE:- Synchronising can be disabled if the application does not require this function. Contact your genset supplier in the first instance for further details.

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2.3 MANUAL OPERATION

NOTE:- If a digital input configured to panel lock is active, changing module

modes will not be possible. Viewing the instruments and event logs

is NOT affected by panel lock. If panel lock is active the Panel lock indicator (if configured) illuminates.

To initiate a start sequence in MANUAL, press the pushbutton. When the controller is in the manual mode (indicated by an LED indicator beside the button), pressing the START (I) button

will initiate the start sequence.

NOTE:- There is no Start Delay in this mode of operation.

If the pre-heat output option is selected this timer is then initiated and the auxiliary output selected is energised.

After the above delay the Fuel Solenoid (or ECU output if configured) is energised, then one second later, the Starter Motor is engaged.

NOTE:- If the unit has been configured for J1939, compatible ECU’s will receive

the start command via J1939.

Alarm

Shutdown Failed to start

When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency measured from the Alternator output. Alternatively, a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is selected by PC using the 5xxx series configuration software). Rising oil pressure can also be used to disconnect the starter motor, however it cannot be used for underspeed or overspeed detection.

NOTE:- If the unit has been configured for J1939, speed sensing is via J1939.

Once the engine is running, the Warm Up timer (if selected) is initiated, allowing the engine to stabilise before it can be loaded.

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The generator will run off load unless:

1. The mains supply fails,

2. A Remote Start on load signal is applied,

3. The Close Generator button is pressed.

If any of the above signals are received, the generator is synchronised and paralleled with the mains supply (if available).

When in parallel:

 A further press of the Close Generator button will transfer the load fully to the

generators, removing the load from the mains supply.

 A press of the Close Mains button will open the generator load switching device,

transferring the load fully to the mains supply.

The generator will continue to run on load regardless of the state of the mains supply or remote

start input until the Close Mains/Open Generator button is pressed or the Auto mode is selected.

If Auto mode is selected and the mains supply is healthy with the remote start on load signal not active, then the Remote Stop Delay Timer begins, after which, the load is disconnected. The generator will then run off load allowing the engine a cooling period.

Selecting STOP (O) de-energises the FUEL SOLENOID, bringing the generator to a stop.

NOTE:- When synchronising is enabled, the mains supply is checked before closing any load switching device. If the supply is live, synchronising will take place before any closure takes place.

NOTE:- Synchronising can be disabled if the application does not require this function. Contact your genset supplier in the first instance for further details.

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2.4 TEST OPERATION

NOTE:- If a digital input configured to panel lock is active, changing module

modes will not be possible. Viewing the instruments and event logs

is NOT affected by panel lock. If panel lock is active the Panel lock indicator (if configured) illuminates.

To initiate a start sequence in TEST, press the pushbutton. When the controller is in the test mode (indicated by an LED indicator beside the button), pressing the START (I) button will initiate

the start sequence.

NOTE:- There is no Start Delay in this mode of operation.

If the pre-heat output option is selected this timer is then initiated and the auxiliary output selected is energised.

After the above delay the Fuel Solenoid (or ECU output if configured) is energised, then one second later, the Starter Motor is engaged.

NOTE:- If the unit has been configured for J1939, compatible ECU’s will receive

the start command via J1939.

Alarm

Shutdown Failed to start

When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from the Alternator output. Alternatively, a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is selected by PC using the 5xxx series configuration software). Rising oil pressure can also be used to disconnect the starter motor, however it cannot be used for underspeed or overspeed detection.

NOTE:- If the unit has been configured for J1939, speed sensing is via J1939.

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Once the engine is running, the Warm Up timer (if selected) is initiated, allowing the engine to stabilise before it can be loaded. The set is then synchronised and paralleled with the mains supply, before the mains load switching device is opened.

The generator will continue to run on load regardless of the state of the mains supply or remote start input until the Auto mode is selected. If Auto mode is selected and the mains supply is healthy with the remote start on load signal not active, then the Remote Stop Delay Timer begins, after which, the load is disconnected. The generator will then run off load allowing the engine a cooling period.

Selecting STOP (O) removes the Close Generator output (if configured) and de-energises the FUEL SOLENOID, bringing the generator to a stop.

NOTE:- When synchronising is enabled, the mains supply is checked before closing any load switching device. If the supply is live, synchronising will take place before any closure takes place. Contact your genset supplier in the first instance for further details.

NOTE:- The module can be configured to run the set continuously in parallel rather than transferring the load fully to the gensets.

NOTE:- Synchronising can be disabled if the application does not require this function. Contact your genset supplier in the first instance for further details.

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3 PROTECTIONS

When an alarm is present the Audible Alarm will sound and the Common alarm LED (if configured) will illuminate.

The audible alarm can be silenced by pressing the ‘Mute’ button

The LCD display will jump from the ‘Information page’ to display the Alarm Page

Alarm

The type of alarm. Shutdown or warning

Warning Low oil pressure

The nature of alarm, e.g. Low oil pressure.

The LCD will display multiple alarms e.g. “High Engine Temperature shutdown”, “Emergency Stop” and “Low Coolant Warning” alarms have been triggered. These will automatically scroll

round in the order that they occurred;

Status

Generator available

Manual mode

If no alarms are present the LCD will display this default page.

In the event of a warning alarm the LCD will display the appropriate text. If a shutdown then occurs the module will again display the appropriate text. Example:-

Alarm

Shutdown High engine temperature

Followed by….

Alarm

Shutdown Emergency stop

Followed by….

Alarm

Warning Low coolant level

The unit will scroll through all active alarms in a continuous loop.

Alarm

Shutdown High engine temperature

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3.1 WARNINGS

Warnings are non-critical alarm conditions and do not affect the operation of the generator system. They draw the operators attention to an undesirable condition.

In the event of an alarm the LCD will jump to the alarms page and scroll through all active warnings and shutdowns.

BATTERY CHARGE FAILURE, will be displayed if the module does not detect a voltage from the warning light terminal on the auxiliary charge alternator.

Alarm

Warning Charge fail

BATTERY LOW VOLTAGE, will be displayed if the module detects that the plant DC supply has fallen below the low volts setting level. The Battery Low Voltage alarm is delayed by the Low DC Volts Delay timer.

Alarm

Warning Low battery volts

BATTERY HIGH VOLTAGE, will be displayed if the module detects that the plant DC supply has risen above the high volts setting level. The Battery High Voltage alarm is delayed by the High DC Volts Delay timer.

Alarm

Warning High battery volts

FAIL TO STOP, will be displayed if the module detects the engine is still running when the ‘Fail to stop timer’ expires.

Alarm

Fail to stop

NOTE:- ‘Fail to Stop’ could indicate a faulty oil pressure sender - If engine is at

rest check oil sender wiring and configuration.

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AUXILIARY INPUTS, auxiliary inputs can be user configured and will display the message as written by the user.

Example

Alarm

Warning Bearing temp high

LOW FUEL LEVEL, will be displayed if the fuel level detected by the fuel level sender falls below the low fuel level setting.

Alarm

Warning Low fuel level

GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the pre-set trip a warning is initiated. Alarm Warning High Current will be displayed. If this high current condition continues for an excess period of time, then the alarm is escalated to a shutdown condition. For further details of the high current alarm, please see High Current Shutdown Alarm.

Alarm

Warning High current

The following alarms are only applicable if synchronising is enabled :

FAILED TO SYNCHRONISE, if the module cannot synchronise within the timer allowed by the Synchronising timer a warning is initiated. The LCD will indicate ‘FAILED TO SYNC’and the COMMON ALARM LED will illuminate.

Alarm

Warning Failed to synchronise

BUS PHASE SEQUENCE WRONG, if the module detects a bus phase rotation error a warning is initiated. The LCD will indicate ‘BUS PHASE SEQ WRONG’and the COMMON ALARM LED will illuminate.

Alarm

Warning Bus Phase Seq Wrong

MAINS PHASE SEQUENCE WRONG, if the module detects a MAINS phase rotation error a warning is initiated. The LCD will indicate ‘MAINS PHASE SEQ WRONG’and the COMMON ALARM LED will illuminate.

Alarm

Warning Bus Phase Seq Wrong

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3.2 ANALOGUE PRE-ALARMS

The following alarms are termed ‘pre-alarms’ as they pre warn the operator of a potentially more

serious alarm condition. For instance, if the engine temperature rises past the pre alarm level, a warning condition will occur to notify the operator. If the temperature falls below this level, then the alarm ceases and the set will continue to run as normal. However if the temperature continues to rise until the coolant temperature trip point is reached, the warning is escalated and a high coolant temperature shutdown is initiated.

LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low oil pressure pre-alarm setting level after the Safety On timer has expired, a warning will occur. Alarm Warning Low Oil Pressure will be displayed.

Alarm

Warning Low oil pressure

HIGH ENGINE TEMPERATURE, if the module detects that the engine coolant temperature has exceeded the high engine temperature pre-alarm setting level after the Safety On timer has expired, a warning will occur. Alarm Warning High Coolant Temperature will be displayed.

Alarm

Warning High temperature

LOW ENGINE TEMPERATURE, if the module detects that the engine coolant temperature has fallen below the low engine temperature pre-alarm setting level after the Safety On timer has expired, a warning will occur. Alarm Warning Low Coolant Temp will be displayed.

Alarm

Warning Low Coolant Temp

OVERSPEED, if the engine speed exceeds the pre-alarm trip a warning is initiated. Alarm Warning Overspeed will be displayed. It is an immediate warning.

Alarm

Warning Overspeed

UNDERSPEED, if the engine speed falls below the pre-set pre-alarm after the Safety On timer has expired, a warning is initiated. Alarm Warning Underspeed will be displayed.

Alarm

Warning Underspeed

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GENERATOR HIGH FREQUENCY, if the module detects a generator output frequency in excess of the pre-set pre-alarm, a warning is initiated. Alarm W arning High frequency will be displayed, it is an immediate warning.

Alarm

Warning Over frequency

GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the pre-set pre-alarm after the Safety On timer has expired, a warning is initiated. Alarm W arning Low Frequency will be displayed

Alarm

Warning Under frequency

GENERATOR HIGH VOLTAGE, if the module detects a generator output voltage in excess of the pre-set pre-alarm, a warning is initiated. Alarm Warning High voltage will be displayed, it is an immediate warning.

Alarm

Warning AC Overvolts

GENERATOR LOW VOLTAGE, if the module detects a generator output voltage below the preset pre-alarm after the Safety On timer has expired, a warning is initiated. Alarm Warning Low Voltage will be displayed.

Alarm

Warning AC Undervolts

CAN ECU ERROR, If the module is configured for J1939 instruments and receives an

“error” message from the engine control unit, ‘Can ECU error” is shown on the module’s

display and a warning alarm is generated.

Example

Alarm Alarm

Can ECU error Exhaust high temperature

The display will alternate between the text display and the manufacturers error codes

Can ECU error SPNnnnnnnn FMInnnnnnn

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3.3 SHUTDOWNS

Shutdowns are latching and stop the Generator. The alarm must be cleared and the fault removed to reset the module.

NOTE:- The alarm condition must be rectified before a reset will take place. If the alarm condition remains it will not be possible to reset the unit (The exception to this

is the Low Oil Pressure alarm and similar ‘delayed alarms’, as the oil pressure will be

low with the engine at rest).

FAIL TO START, if the engine does not fire after the pre-set number of attempts has been made a shutdown will be initiated. Alarm Shutdown Fail To Start will be displayed.

Alarm

Shutdown Failed to start

EMERGENCY STOP, removal of the +ve DC Supply from the Emergency Stop input initiates the following sequence, firstly it will initiate a shutdown of the Generator and prevent any attempt to restart the Generator until the Emergency Stop push-button has been reset. Additionally it removes the +ve DC supply from both the Fuel Solenoid and Starter Solenoid.

Alarm Shutdown Emergency Stop will be displayed.

Alarm

Shutdown Emergency stop

NOTE:- The Emergency Stop +Ve signal must be present otherwise the unit will shutdown.

LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low oil pressure trip setting level after the Safety On timer has expired, a shutdown will occur. Alarm Shutdown Low Oil Pressure will be displayed.

Alarm

Shutdown Low oil pressure

HIGH ENGINE TEMPERATURE, if the module detects that the engine coolant temperature has exceeded the high engine temperature trip setting level after the Safety On timer has expired, a shutdown will occur. Alarm Shutdown High Engine Temperature will be displayed.

Alarm

Shutdown High temperature

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OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated. Alarm Shutdown Overspeed will be displayed. Overspeed is not delayed, it is an immediate shutdown.

Alarm

Shutdown Overspeed

NOTE:-During the start-up sequence the overspeed trip logic can be configured to allow an extra trip level margin. This is used to prevent nuisance tripping on startup - Refer to the 55xx series configuration software manual under heading

‘Overspeed Overshoot’ for details.

UNDERSPEED, if the engine speed falls below the pre-set trip after the Safety On timer has expired, a shutdown is initiated. Alarm Shutdown Underspeed will be displayed.

Alarm

Shutdown Underspeed

GENERATOR HIGH FREQUENCY, if the module detects a generator output frequency in excess of the pre-set trip a shutdown is initiated. Alarm Shutdown High Frequency will be displayed, it is an immediate shutdown.

Alarm

Shutdown Over frequency

GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the pre-set trip after the Safety On timer has expired, a shutdown is initiated. Alarm Shutdown Low Frequency will be displayed.

Alarm

Shutdown Under frequency

GENERATOR HIGH VOLTAGE, if the module detects a generator output voltage in excess of the pre-set trip a shutdown is initiated. Alarm Shutdown High Volts will be displayed, it is an immediate shutdown.

Alarm

Shutdown AC Overvolts

GENERATOR LOW VOLTAGE, if the module detects a generator output voltage below the preset trip after the Safety On timer has expired, a shutdown is initiated. Alarm Shutdown Low Volts will be displayed.

Alarm

Shutdown AC Undervolts

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OIL PRESSURE SENDER OPEN CIRCUIT, if the module detects a loss of signal from the oil

pressure sender (open circuit) a shutdown is initiated. Alarm Shutdown Sender Fault will be displayed. Sender failure is not delayed, it is an immediate shutdown.

Alarm

Shutdown Oil pressure sender fault

AUXILIARY INPUTS, if an auxiliary input has been configured as a shutdown the appropriate message will be displayed as configured by the user.

Alarm

Shutdown Bearing temp high

LOSS OF SPEED SIGNAL, if the speed sensing signal is lost during cranking, a shutdown is initiated. Alarm Shutdown Loss Of Speed Signal will be displayed.

Alarm

Shutdown Loss of speed signal

NOTE:- This will only occur if the magnetic pickup speed sensing signal is lost during cranking or during the safety on timer. If the signal is lost during normal operation the Generator will shutdown with an Under-speed alarm.

CAN DATA FAIL, If the module is configured for J1939 operation and does not detect

data on the engine CANbus datalink, a shutdown will occur and ‘Can data fail’ is shown on the module’s display.

Alarm

Shutdown Can data fail

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CAN ECU FAIL, If the module is configured for J1939 instruments and receives a “fail” message from the engine control unit, the engine is shutdown and ‘Can ECU fail” is shown on the module’s display.

Example

Alarm Alarm

Can ECU fail Fuel pressure low

The display will alternate between the text display and the manufacturers error codes

Can ECU fail SPNnnnnnnn FMInnnnnnn

NOTE:- If the CAN message is a manufacturers specific code, it may not be displayed as text. If this is the case the display will show the generic manufacturers code only, which must be cross-referenced with the engine manufacturers literature. Please contact the engine manufacturer for further assistance.

Example

Alarm

Can ECU fail SPNnnnnn FMInnnn

GENERATOR EARTH FAULT, if the module detects a generator earth fault current in excess of

the pre-set trip a shutdown is initiated. The LCD will indicate ‘EARTH FAULT’. This alarm is configurable between Warning, Shutdown and Electrical Trip. “Shutdown” is the factory default

setting.

Alarm

Shutdown Earth Fault

GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the pre-set trip a warning is initiated. This warning will continue for a period of time depending upon the level of overload that the generator is subjected to and the configuration setting for Generator High Current in the 5xxx series configuration software.

Alarm

Shutdown High current trip

For instance the factory default settings for Generator High Current allow for a loading of the generator to 110% for one hour. That is to say if the generator load level exceeds the trip point by 10%, a warning alarm will occur while the overload condition exists. If the load level does not drop to normal levels within one hour, the set is stopped, the 5520 module displaying either shutdown alarm or electrical trip alarm depending upon module configuration.

NOTE:- Higher overload levels will result in a faster acting shutdown condition. For instance with the factory default configuration, an overload level twice that of the trip level ( typically 200%) will result in a Generator High Current shutdown condition after 36 seconds. For details of the relationship between the overload and the shutdown time, please see the Appendix section of this manual.

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3.4 ELECTRICAL TRIPS

Electrical trips are latching and stop the Generator but in a controlled manner. On initiation of the electrical trip condition the module will de-energise the ‘Close Generator’ Output to remove the load from the generator. Once this has occurred the module will start the Cooling timer and allow the engine to cool off-load before shutting down the engine. The alarm must be accepted and cleared and the fault removed to reset the module.

AUXILIARY INPUTS, if an auxiliary input has been configured as an electrical trip the appropriate message will be displayed as configured by the user.

Example

Alarm

Electrical trip Negative Phase Sequence

The following alarms are configurable between Warning, Shutdown and Electrical Trip. “Electrical Trip” is the factory default setting.

GENERATOR OVER CURRENT, If the module detects a generator output current in excess of the pre-set trip, a warning is initiated. If this high current condition continues for an excess period, then the alarm is escalated to either a shutdown or electrical trip condition (depending upon module configuration). For further details of the high current alarm, please see High Current Shutdown Alarm.

Alarm

Electrical trip High current

GENERATOR REVERSE POWER , if the module detects a generator reverse power current in excess of the pre-set trip a shutdown is initiated. The LCD will indicate ‘GEN REVERSE POWER’.

Alarm

Electrical trip Gen Reverse Power

GENERATOR SHORT CIRCUIT, if the module detects a generator fault current in excess of the pre-set trip a shutdown is initiated. The LCD will indicate ‘GEN SHORT CIRCUIT’.

Alarm

Electrical trip Gen Short Circuit

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DESCRIPTION OF CONTROLS

The following section details the function and meaning of the various controls on the module.

3.5 TYPICAL LCD DISPLAY SCREENS

3.5.1 TYPICAL STATUS DISPLAY

Status

Waiting in Auto Mains on load

Indicates that the module is in Automatic and that the mains is on load (closed). The unit will respond to either a mains failure or an active remote start.

Starting in auto 10s

Mains on load Cranking attempt 1

Indicates that the module is in automatic and that a start sequence has been initiated, either by a mains failure or remote start input. The module is attempting to crank the generator.

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3.5.2 TYPICAL INSTRUMENT DISPLAY

Engine oil pressure

0.0 bar 0 kPa

0 PSI

The display of the engine oil pressure

Coolant temerature

74 C

165 F

The display of the engine coolant temperature

Generator Amps

L1 50A L2 52A L3 50A

The display of all three generator line currents.

3.5.3 TYPICAL ALARM DISPLAY

Alarm

Warning Low oil pressure

The module is warning that the engine oil pressure has fallen below a pre set level. The generator is not shutdown.

Alarm

Shutdown Low oil pressure

The oil pressure has fallen below a second pre set value and has shutdown the generator.

Alarm

Warning Low battery Volts

The module is warning that the battery voltage is below a pre set value.

3.5.4 TYPICAL EVENT DISPLAY

Event log 1

17 Jan 2005 16:29:49 Mains failure

On the 17thJanuary 2005 at 16:29 the unit detected a mains failure condition

Event log 2

8 Sep 2004 20:10:05 Emergency stop Shutdown

On the 8thSeptember 2004 at 20:10. The emergency stop button was pressed and the generator was shutdown.

Event log 3

7 Sep 2004 08:46:00 Over Volts Shutdown

On the 7thSeptember 2004 at 08:46 the unit detected that the generator output volts exceeded pre-set trip level and has shutdown the generator.

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3.6 VIEWING THE INSTRUMENT AND EVENT LOG PAGES

To view a particular instrument operate the “Page” button to move to the required

page. The LCD will display the page title and then will automatically commence scrolling down the various instruments. On reaching the last instrument the LCD display will then jump back to the page title and resume scrolling down the page. This sequence will be repeated until either the

user moves off the page or after a period of inactivity the module will revert to the ‘StatusPage’.

Engine speed

0 RPM

Engine oil pressure

1.0 bar 0 kPa

0 PSI

Coolant temperature

74 C

165 F

Etc….

It is also possible to manually scroll to display the different instruments using the and buttons. Once selected the instrument will remain on the LCD display until the user selects a

different instrument or page, or after a period of inactivity the module will revert to the ‘Status page’.

NOTE:-This description of operation is also true for the other instrument pages

and for viewing the records in the event log.

NOTE:- The factory default setting is to show all instruments in a single list. It is

possible to change this configuration to a “page” style display using the 5xxx

configuration software. When configured to the page style, the instruments are

grouped into separate pages – ie Engine instruments, Gen instruments, Mains

instruments.

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3.6.1 SYNCHROSCOPE OPERATION

(When enabled)

Display Detail

Hz +2.9

V +0.2

Initial stage of Synchronising display will only show the difference between the Mains Supply and the Generator Output. Here the display is showing a frequency mismatch of +2.9Hz - The genset frequency is too high and should be reduced (indicated by the arrow). The voltage is +0.2 volts high, but is within the limits set for synchronising.

Hz +0.9

V +0.2

Once the difference between the Mains supply and the Generator output has been reduced the

‘Synchroscope’ display will become active. The

moving bar will roll from left to right or right to left depending on the mismatch between the Mains supply and the generator output. The area in the centre of the scope indicates the set limits for synchronising to occur.

Hz -0.2

V +0.2

Synchronising will only occur when both the Frequency and the voltage differences are within

acceptable limits - Indicated by ‘Tick’ marks on the

top of the display. Then the moving bar display will show the phase difference. The engine speed should be adjusted until the moving bar enters the centre of the scope.

Hz -0.2

V +0.2

Once the Mains and the generator are synchronised the moving bar will be in the centre of the scope and module will initiate a breaker close to load the generator onto the Mains. Should synchronism be broken the moving bar will pass out of the synchronising window.

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3.7 COMPLETE INSTRUMENTATION LIST

3.7.1 BASIC INSTRUMENTATION

Engine Speed Engine Oil pressure Coolant temperature Battery voltage Charge alt volts Engine run time Number of starts Next maintenance (if enabled) Fuel level Generator volts (L1-N, L2-N, L3-N) Generator volts (L1-L2, L2-L3, L3-L1) Gen Hz Generator Amps Generator earth current Generator kW (L1,L2,L3) Generator total kW Generator pf (L1,L2,L3) Generator average pf Generator kVAr (L1,L2,L3) Generator total kVAr Generator kWh Generator kVAh Generator kVArh Generator phase sequence Synchroscope (when enabled) Mains volts (L1-N, L2-N, L3-N) Mains volts (L1-L2, L2-L3, L3-L1) Mains Hz Mains phase sequence Generator kVA (L1,L2,L3) Generator total kVA

3.7.2 ENHANCED J1939 INSTRUMENTATION

(When supported by the SAE J1939 engine ECU)

Engine oil temperature Inlet manifold temperature Coolant pressure Fuel pressure Fuel consumption Total fuel used Turbo pressure

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3.8 OPERATOR CONFIGURATION MODE

This configuration mode allows the operator limited customising of the way the module operates.

3.9 ACCESSING THE FRONT PANEL CONFIGURATION EDITOR

Operation Detail

To enter the ‘Operator configuration mode’press both the INFO and STOP buttons together.

3.9.1 ENTERING THE PIN NUMBER

If the module PIN number has been set, the PIN number request is then shown. The configuration cannot be viewed or changed until the PIN number is correctly entered. If no PIN has been set, then skip to the next section.

Enter pin

****

The first * is flashing. Press + or – buttons to adjust it to the

correct value for the first digit of the PIN number. Press when the first digit is correctly entered.

Enter pin

1***

The second * is now flashing. Press + or – buttons to adjust it to

the correct value for the second digit of the PIN number. Press when the second digit is correctly entered.

Enter pin

12**

The third * is now flashing. Press + or – buttons to adjust it to the

correct value for the third digit of the PIN number. Press when the third digit is correctly entered.

Enter pin

123*

The fourth * is now flashing. Press + or – buttons to adjust it to the

correct value for the fourth digit of the PIN number. Press when the fourth digit is correctly entered.

NOTE:- When  is pressed after editing the final PIN digit, the PIN is checked for

validity. If the number is not correct, the editor is automatically exited. To retry you must re-enter the editor as described above.

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3.9.2 EDITING VALUES

If the PIN number has not been set, or has been correctly entered :

Operation Detail

The LCD will then display:

CONFIGURATION

To view the different configuration functions press the + or - buttons.

CONFIGURATION Oil Pressure Pre-alarm

The LCD will then display:

1.30 Bar 18 PSI 130 kPa

Pressing the button will enter edit mode :

CONFIGURATION Oil Pressure Pre-alarm

The parameter being changed will flash.

Pressing + or – buttons will change the parameter to the

desired value.

1.30 Bar 18 PSI 130 kPa

Press to save the change. The parameter will stop flashing as the edit mode is exited.

To view the different configuration functions press the + or - buttons.

To exit the ‘Operator configuration mode’save your

current value change if you haven’t already done so

(press to exit the flashing edit mode), then press Stop/Reset to exit configuration mode.

The module will then return to the ‘Status Page’ display.

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3.9.3 LIST OF ADJUSTABLE PARAMETERS

(Factory default settings are shown in bold italicised text)

Section Parameter as shown on display Values

Input settings

Oil Pressure Pre Alarm

0 bar -4bar (1.17bar)

Oil Pressure Shutdown

0 bar -4bar (1.03bar)

High Coolant Temp Pre Alarm

80C -140C (115C)

High Coolant Temp Shutdown

80C -140C (120C)

Low Coolant Temp Alarm

67C -137C (disabled)

Low Fuel Level Alarm

0%-100% (disabled)

Timers

Mains Transient Delay

0-10s (2s)

Gen Transient Delay

0 -10s (0s)

Start Delay

0 -60m (5s)

Pre Heat Time

0 -60m (0s)

Crank Time

0 -60s (10s)

Crank Rest Time

0-60s (10s)

Safety On Delay

0-30s (10s)

Overspeed Overshoot Delay

0-10s (0s)

Warm Up Time

0-60m (0s)

Transfer Delay

0-10s (0.75s)

Return Delay

0 -60m (30s)

Cooling Run Time

0-60m (30s)

Fail To Stop Delay

0-30s (30s)

Low Battery Delay

0-10m (1m)

High Battery Delay

0-10m (1m)

Gen Reverse Power Delay

0-30s (2s)

Mains

Mains Under Voltage Alarm

50V-360V ph-N (184V)

Mains Over Voltage Alarm

50V-360V ph-N (277V)

Mains Under Frequency Alarm

0Hz -75Hz (45Hz)

Mains Over Frequency Alarm

0Hz -75Hz (55Hz)

Generator

Generator Under Voltage Shutdown

50V-360V ph-N (184V)

Generator Under Voltage Pre Alarm

50V-360V ph-N (196V)

Generator Nominal Voltage

52V-330V(230V)

Generator Over Voltage Pre Alarm

50V-360V ph-N (265V)

Generator Over Voltage Shutdown

50V-360V ph-N (277V)

Generator Under Frequency Shutdown

0Hz -75Hz (40Hz)

Generator Under Frequency Pre Alarm

0Hz -75Hz (42Hz)

Generator Nominal Frequency

0Hz – 74Hz (50Hz)

Generator Over Frequency Pre Alarm

0 -75Hz (55Hz)

Generator Over Frequency Shutdown

0 -75Hz (57Hz)

Generator Over Current Trip

100-200% full load rating (100%)

Generator Short Circuit Trip

50%-300% full load rating (200%)

Generator Reverse Power Trip

0%-200% full load rating (35kW)

Earth Fault Trip

1%-100% full load rating (10%)

Engine

Overspeed Overshoot

0-10 (0%)

Plant Battery Under Volt Alarm

0-24V (10V)

Plant Battery Over Volt Alarm

0-24V (30V)

Charge Alternator Failure Alarm

0-24V (6V)

Engine Underspeed Shutdown

0-6000RPM (disabled)

Engine Underspeed Pre Alarm

0-6000RPM (disabled)

Engine Overspeed Pre Alarm

0-6000RPM (disabled)

Engine Overspeed Shutdown

0-6000RPM (disabled)

Display

Language

ENGL ISH

, OTHERS

(see note below)

Contrast

|

Clock

Date and Time

dd mmm yyyy hh:mm

Misc

Auto Scroll Time

0-10s (2.0s)

NOTE:- More comprehensive module configuration is possible using the 5xxx series PC configuration software in conjunction with the P810 PC interface. Please contact us for further details.

NOTE:- Languages are subject to change as the modules are updated. Please contact our us for the list of latest supported languages.

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3.10 LED INDICATORS

USER CONFIGURABLE LED’s

These LEDs can be configured by the user to indicate any one of 100+ different functions based around the following: INDICATIONS - Monitoring of a digital input and

indicating associated functioning user’s equipment -

Such as Battery Charger On or Louvres Open, etc.

 WARNINGS and SHUTDOWNS - Specific indication

of a particular warning or shutdown condition, backed up by LCD indication - Such as Low Oil

Pressure Shutdown, Low Coolant level, etc.

 STATUS INDICATIONS - Indication of specific

functions or sequences derived from the modules operating state - Such as Safety On, Pre-heating,

Panel Locked, Generator Available, etc.

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3.11 CONTROL PUSH-BUTTONS

STOP/RESET

This push-button places the module into it’s Stop/reset mode. This will clear any alarm conditions for which the triggering criteria have been removed. If the engine is running and this push-button is operated, the module will automatically instruct the change-over device to unload the generator (‘Load transfer’ becomes in-active (if used)). The fuel supply will be removed and engine will be brought to a standstill. Should a remote start signal be present while operating in the Stop/reset mode, a remote start will not occur.

MANUAL

This push-button is used to allow manual control of the generator functions. Entering this mode from any other mode will initially not cause any change of operating state, but allows further push-buttons to be used to control the generator operation. For example once in Manual mode it is possible to manually start the engine by using the ‘START’ push- button. If the engine is running off-load in the Manual mode and a remote start signal becomes present, the module will automatically instruct the change-over device to place the generator on load (‘Load transfer’ becomes active (if used)). Should the remote start signal then be removed the generator will remain on load until either the ‘STOP/RESET’ or ‘AUTO’push-buttons are operated.

START

This push-button is used to manually start the engine. The module must first be placed in the ‘MANUAL’ mode of operation. The ‘START’button should then be operated. The engine will then automatically attempt to start. Should it fail on the first attempt it will re-try until either the engine fires or the pre-set number of attempts have been made. To stop the engine the ‘STOP/RESET’button should be operated. It is also possible to configure the module such that the start push-button must be held to maintain engine cranking.

NOTE:-Different modes of operation are possible - Please refer to your configuration source for details.

AUTO

This push-button places the module into it’s ‘Automatic’ mode. This mode allows the module to control the function of the generator automatically. The module will monitor the remote start input and once a start condition is signalled the set will be automatically started and placed on load (‘Load transfer’ becomes active (if used)). If the starting signal is removed the module will automatically transfer the load from the generator and shut the set down observing the stop delay timer and cooling timer as necessary. The module will then await the next start event. For further details please see the more detailed description of

‘Auto Operation’ earlier in this manual.

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TEST

This push-button places the module into it’s ‘Test’ mode. This mode is used to test the function and timing of the generator start and load sequence. The mode is initiated by pressing the ‘Start’ Buttonand the set will be automatically started and placed on load. The set will run on load continuously. To test the off-loading and stopping sequence return the set to the ‘Auto’mode, the module will automatically transfer the load from the generator and shut the set down observing the stop delay timer and cooling timer as necessary. The module will then await the next start event. For further details please see the more detailed

description of ‘Test Operation’ earlier in this manual.

ALARM MUTE

This push-button is used to silence the internal alarm sounder and also any external sounder devices fed from the audible alarm output. Any further alarm conditions will reactivate the sounder. Once the alarm has been muted and investigated it may then be cleared.

Refer to the ‘Protections’ section of this manual for details.

When the Alarm Mute is operated a Lamp test function will also be implemented and all LED indicators will be illuminated.

TRANSFER TO GENERATOR

This push button is used to control the closure of the generator load switching device and has three modes of operation :

1. Synchronising is NOT enabled. Pressing this button when the generator is running off load and in MANUAL mode, the mains load switch is opened. After a delay (load transfer time), the generator load switch is closed. Further presses of this button will have no effect.

2. Synchronising is enabled. Pressing this button when the generator is running and in MANUAL mode, the 5520 controller will volts match and synchronise with the mains supply. The generator load switch is then closed in parallel with the mains supply.

3. Synchronising is enabled. Pressing this button when the generator is running in parallel with the mains supply and in MANUAL mode, will open the mains load switch and after a delay (load transfer time), the mains load switch is opened (transferring the load to the generator supply).

NOTE:- This button is only active in MANUAL mode.

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TRANSFER TO MAINS

This push button is used to control the closure of the mains load switching device and has three modes of operation :

1. Synchronising is NOT enabled. Pressing this button when the generator is running on load and in MANUAL mode, the generator load switch is opened. After a delay (load transfer time), the mains load switch is closed. Further presses of this button will have no effect.

2. Synchronising is enabled. Pressing this button when the generator is running on load and in MANUAL mode, the 5520 controller will volts match and synchronise with the mains supply. The generator load switch is then closed in parallel with the mains supply.

3. Synchronising is enabled. Pressing this button when the generator is in MANUAL mode and running in parallel with the mains supply will open the generator load switch, transferring the load back to the mains supply only.

NOTE:- This button is only active in MANUAL mode.

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4 INSTALLATION INSTRUCTIONS

The model DSE 5520 Module has been designed for front panel mounting. Fixing is by 4 clips for easy assembly.

4.1 PANEL CUT-OUT

220.00mm

(8.7”)

Maximum panel thickness – 8mm (0.3”)

In conditions of excessive vibration, the module should be mounted on suitable anti-vibration mountings.

4.2 COOLING

The module has been designed to operate over a wide temperature range -30 to +70º C. Allowances should be made for the temperature rise within the control panel enclosure. Care should be taken NOT to mount possible heat sources near the module unless adequate ventilation is provided. The relative humidity inside the control panel enclosure should not exceed 95%.

4.3 UNIT DIMENSIONS

Panel cutout 220mm x 160mm ( 8.7” x 6.3”)

160.00mm

(6.3”)

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4.4 FRONT PANEL LAYOUT

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5 ELECTRICAL CONNECTIONS

Connections to the Module are via plug and sockets.

5.1 CONNECTION DETAILS

The following describes the connections and recommended cable sizes to the 8 plugs and sockets on the rear of the Module.

5.1.1 PLUG “A” 8 WAY

DESCRIPTION CABLE

SIZE

NOTES

1 DC Plant Supply Input

(-ve)

2.5mm

2 DC Plant Supply Input

(+ve)

2.5mm (Recommended Fuse 20A Max.)

3 Emergency Stop Input 2.5mm Plant Supply +ve. Also supplies fuel & start

outputs. (Recommended Fuse 32A Max.) 4 Fuel relay Output 2.5mm Plant Supply +ve from pin 3. 16 Amp rated. 5 Start relay Output 2.5mm Plant Supply +ve from pin 3. 16 Amp rated. 6 Auxiliary Output relay 1 1.0mm Plant Supply +ve. 5 Amp rated. 7 Auxiliary Output relay 2 1.0mm Plant Supply +ve. 5 Amp rated. 8 Auxiliary Output relay 3 1.0mm Plant Supply +ve. 5 Amp rated.

5.1.2 PLUG “B” 11 WAY

DESCRIPTION CABLE

SIZE

NOTES

9 Charge Fail Input/ Excitation

Output

1.0mm Must NOT be connected to plant supply -ve.

10 Auxiliary Input 1 0.5mm Switch to -ve 11 Auxiliary Input 2 0.5mm Switch to -ve 12 Auxiliary Input 3 0.5mm Switch to -ve 13 Auxiliary Input 4 0.5mm Switch to -ve 14 Auxiliary Input 5 0.5mm Switch to -ve 15 Auxiliary Input 6 0.5mm Switch to -ve 16 Auxiliary Input 7 0.5mm Switch to -ve 17 Auxiliary Input 8 0.5mm Switch to -ve 18 Auxiliary Input 9 0.5mm Switch to -ve 19 Functional Earth 2.5mm Connect to system earth

WARNING!:- Do not disconnect plug ‘B’ when the gen-set is running.

Disconnection will open circuit the secondary of the CT’s and dangerous voltages

may then develop. Always ensure the gen-set is at rest before making or breaking connections to the module.

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5.1.3 PLUG “C” 9 WAY

DESCRIPTION CABLE

SIZE

NOTES

20 Magnetic pickup screen 0.5mm Connect at module end only! 21 Magnetic pickup 0.5mm Connect to magnetic pickup device 22 Magnetic pickup 0.5mm Connect to magnetic pickup device 23 SAE J1939 Engine ECU

Screen

0.5mm Connect screen at one end only

24 SAE J1939 Engine ECU H 0.5mm

120 impedance CanBus cable

25 SAE J1939 Engine ECU L 0.5mm

120 impedance CanBus cable 26 Unused Do not connect 27 Unused Do not connect 28 Unused Do not connect

NOTE:- Screened cable must be used for connecting the Magnetic Pickup,

ensuring that the screen is earthed at one end ONLY.

NOTE:- Screened 120 impedance cable specified for use with CANBUS must be

used for the SAE J1939 link.

5.1.4 PLUG “D” 3 WAY

DESCRIPTION CABLE

SIZE

NOTES

29 RS485 SCREEN 0.5mm Screen for RS485 30 RS485 B 0.5mm

120 impedance RS485 cable 31 RS485 A 0.5mm

120 impedance RS485 cable

NOTE:- Screened 120 impedance cable specified for use with RS485 must be

used.

5.1.5 PLUG “E” 5 WAY

DESCRIPTION CABLE

SIZE

NOTES

32 Governor output B 0.5mm Connect to governor for speed/load control 33 Governor output A 0.5mm Connect to governor for speed/load control 34 Unused Do not connect 35 AVR output B 0.5mm Connect to governor for volts/VAr control 36 AVR output A 0.5mm Connect to governor for volts/VAr control

NOTE:- It is recommended to use screened cable for the Governor and AVR

output connections.

NOTE:- For details of connections to governors / AVRs refer to the DSE Guide to

Synchronising Part 2.

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5.1.6 PLUG “F” 8 WAY

DESCRIPTION CABLE

SIZE

NOTES

37 Mains Loading Relay

Normally Closed Contact

2.5mm Connect to mains contactor coil feed supply.

38 Mains Loading Relay

Normally Closed Contact

2.5mm Connect to mains contactor coil.

39 Generator Loading Relay

Normally Open Contact

2.5mm Connect to generator contactor coil feed supply.

40 Generator Loading Relay

Normally Open Contact

2.5mm Connect to generator contactor coil.

41 Mains volts L1 1.0mm Connect to Mains L1 42 Mains volts L2 1.0mm Connect to Mains L2 43 Mains volts L3 1.0mm Connect to Mains L3 44 Mains volts N 1.0mm Connect to Mains N

5.1.7 PLUG “G” 4 WAY

DESCRIPTION CABLE

SIZE

NOTES

45 Generator volts L1 1.0mm Connect to Generator L1 46 Generator volts L2 1.0mm Connect to Generator L2 47 Generator volts L3 1.0mm Connect to Generator L3 48 Generator volts N 1.0mm Connect to Generator N

5.1.8 PLUG “H” 12 WAY

DESCRIPTION CABLE

SIZE

NOTES

CT Secondary for generator L1

2.5mm Connect to secondary of generator L1 monitoring CT

CT Secondary for generator L2

2.5mm Connect to secondary of generator L2 monitoring CT

CT Secondary for generator L3

2.5mm Connect to secondary of generator L3 monitoring CT

CT Secondary for generator N

2.5mm Connect to secondary of generator N (earth fault) monitoring CT

Generator CT secondary common

2.5mm Connect to secondary of all monitoring

CT’s

Not used Do not connect

Low oil pressure sender 1.0mm Connect to low oil pressure sender

Coolant temperature sender

1.0mm Connect to Coolant temperature sender

Fuel level sender 1.0mm Connect to Fuel level sender

Sender common 1.0mm Connect to sender common

NOTE*:- If using single terminal senders refer to connection diagram. If using

earth return type senders connect return terminals to pin 60 and connect pin 60 to

earth. This is detailed in the Appendix section entitled “Sender wiring recommendations” elsewhere in this manual.

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5.1.9 PC CONFIGURATION INTERFACE CONNECTOR

8-way connector allows connection to PC via 810 configuration interface. Module can then be re-configured

utilising the 5xxx for Windows™ software.

5.1.10 EXPANSION INTERFACE CONNECTOR

4-way connector allows connection to the 130 input expansion, 157 relay expansion module or 545/548 LED expansion modules. A maximum of 2 relay or LED expansion modules may be connected in series to this port.

CAUTION! - Do not connect the 808 configuration interface to this port, as it is not

possible to use the 808 software to configure the 5520 module.

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5.2 CONNECTOR FUNCTION DETAILS

The following describes the functions of the 4 connectors on the rear of the module. See rear panel layout.

5.3 CONNECTION DETAILS

The following describes the connections and recommended cable sizes to the 8 plugs and sockets on the rear of the Module.

5.3.1 PLUG “A” 8 WAY

PIN No DESCRIPTION

1 DC Supply -ve. System DC negative input. (Battery Negative). 2 DC Supply +ve. System DC positive input. (Battery Positive). 3 Emergency Stop input. Internally linked to Starter and Fuel outputs. If this input is not

connected to positive the module will be locked out and if the engine is running it will shutdown immediately. The Positive Supply is also removed from Starter and Fuel therefore only a single pole Emergency Shutdown button is required.

4 Fuel Relay output. Plant Supply +ve from pin 3. Used to control the fuel solenoid or

engine fuel control system. 5 Starter Relay output. Plant Supply +ve from pin 3. Used to control the Starter Motor. 6 Auxiliary Relay output 1. Plant Supply +ve. Configurable output, see Calibration Manual

for options available. 7 Auxiliary Relay output 2. Plant Supply +ve. Configurable output, see Calibration Manual

for options available. 8 Auxiliary Relay output 3. Plant Supply +ve. Configurable output, see Calibration Manual

for options available.

5.3.2 PLUG “B” 11 WAY

DESCRIPTION

9 Charge Fail input / Excitation output. Supplies excitation to the Plant Battery Charging

Alternator, also an input for the Charge Fail detection circuitry.

10 Auxiliary input 1. This is a negative switched configurable input, see Calibration Manual for

options available. It is possible to configure the input to be a normally closed signal or a normally open signal.

11 Auxiliary input 2. This is a negative switched configurable input, see Calibration Manual for

options available. It is possible to configure the input to be a normally closed signal or a normally open signal.

12 Auxiliary input 3. This is a negative switched configurable input, see Calibration Manual for

options available. It is possible to configure the input to be a normally closed signal or a normally open signal.

13 Auxiliary input 4. This is a negative switched configurable input, see Calibration Manual for

options available. It is possible to configure the input to be a normally closed signal or a normally open signal.

14 Auxiliary input 5. This is a negative switched configurable input, see Calibration Manual for

options available. It is possible to configure the input to be a normally closed signal or a normally open signal.

15 Auxiliary input 6. This is a negative switched configurable input, see Calibration Manual for

options available. It is possible to configure the input to be a normally closed signal or a normally open signal.

16 Auxiliary input 7. This is a negative switched configurable input, see Calibration Manual for

options available. It is possible to configure the input to be a normally closed signal or a normally open signal.

17 Auxiliary input 8. This is a negative switched configurable input, see Calibration Manual for

options available. It is possible to configure the input to be a normally closed signal or a normally open signal.

18 Auxiliary input 9. This is a negative switched configurable input, see Calibration Manual for

options available. It is possible to configure the input to be a normally closed signal or a normally open signal.

19 Functional earth

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CAUTION!:- Refer to Typical wiring Diagram for different wiring topologies.

WARNING!:- Do not disconnect plug ‘B’ when the genset is running.

Disconnection will open circuit the secondary of the CT’s and dangerous voltages

may then develop. Always ensure the genset is at rest before making or breaking connections to the module.

5.3.3 PLUG “C” 9 WAY

DESCRIPTION

20 Magnetic pickup screen 21 Magnetic Input +ve. An AC signal from the magnetic pickup +ve for speed sensing. 22 Magnetic Input -ve. An AC signal from the magnetic pickup -ve for speed sensing. 23 SAE J1939 Engine ECU Screen 24 SAE J1939 Engine ECU H. For connection to the Engine ECU CanBus J1939 terminal H 25 SAE J1939 Engine ECU L. For connection to the Engine ECU CanBus J1939 terminal L 26 Unused 27 Unused 28 Unused

NOTE:- Screened cable must be used for connecting the Magnetic Pickup,

ensuring that the screen is earthed at one end ONLY.

NOTE:- Screened 120 impedance cable specified for use with CANBUS must be

used for both the SAE J1939 link and the Multiset comms link

5.3.4 PLUG “D” 3 WAY

DESCRIPTION

29 RS485 SCREEN 30 RS485 B. For connection to other RS485 controllers in a multidrop RS485 communications

system.

31 RS485 A. For connection to other RS485 controllers in a multidrop RS485 communications

system.

NOTE:- Screened 120 impedance cable specified for use with RS485 must be

used.

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5.3.5 PLUG “E” 5 WAY

DESCRIPTION

32 Governor output B. For connection to electronic speed governors for synchronising / load

sharing.

33 Governor output A. For connection to electronic speed governors for synchronising / load

sharing. 34 Unused 35 AVR output B. For connection to automatic voltage regulators for volts matching / VAr

sharing. 36 AVR output A. For connection to automatic voltage regulators for volts matching / VAr

sharing.

NOTE:- It is recommended to use screened cable for the Governor and AVR

output connections.

NOTE:- For details of connections to governors / AVRs refer to the DSE Guide to

Synchronising Part 2.

5.3.6 PLUG “F” 8 WAY

DESCRIPTION

37 Mains Loading Relay, Normally closed. Volts free contacts to 38. Used to connect to Mains

contactor or circuit breaker. 38 Mains Loading Relay, Normally closed. Volts free contacts to 37. Used to connect to Mains

contactor or circuit breaker. 39 Generator Loading Relay, Normally open. Volts free contacts to 40. Used to connect to

generator contactor or circuit breaker. 40 Generator Loading Relay, Normally open. Volts free contacts to 39. Used to connect to

generator contactor or circuit breaker. 41 Mains volts L1. Used for sensing the voltage/frequency of mains L1. 42 Mains volts L2. Used for sensing the voltage/frequency of mains L2. 43 Mains volts L3. Used for sensing the voltage/frequency of mains L3. 44 Mains volts N .Used for sensing the mains voltage/frequency.

5.3.7 PLUG “G” 4 WAY

DESCRIPTION

45 Generator volts L1. Used for sensing the voltage/frequency of generator L1. 46 Generator volts L2. Used for sensing the voltage/frequency of generator L2. 47 Generator volts L3. Used for sensing the voltage/frequency of generator L3. 48 Generator volts N. Used for sensing the voltage/frequency of the generator output.

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5.3.8 PLUG “H” 12 WAY

DESCRIPTION

CT Secondary for generator I1

CT Secondary for generator I2

CT Secondary for generator I3

CT Secondary for generator IN

Generator CT secondary common

54 Not used 55 Not used 56 Not used 57 Low oil pressure sender 58 Coolant temperature sender 59 Fuel level sender 60 Sender common

NOTE*:- If using single terminal senders refer to connection diagram. If using

earth return type senders connect return terminals to pin 60 and connect pin 60 to

earth. This is detailed in the Appendix section entitled “Sender wiring recommendations” elsewhere in this manual.

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5.4 ELECTRICAL CONNECTIONS TO J1939 ENABLED CONTROLLERS

This section of the manual is intended to describe only the connections between the 55xx controller and J1939 enabled controllers. All other connection details are described in the previous sections.

NOTE:- The CANbus specification, used by J1939, requires that a 120 terminator is

fitted to each end of the communications link. This termination resistor is fitted internally into the 55xx controller so is not required externally. Ensure that the 55xx controller is the

‘last’ device on the communications link where more than one device is connected to the engine ECU’s J1939 connector.

5.4.1 CUMMINS ISB / ISBE

PLUG “A” 8 WAY

55xx

DESCRIPTION

Cummins ISB OEM

Harness connector B

NOTES

4 Fuel relay

output

39 Key switch input.

5 Start relay

output

- Connects directly to engine starter solenoid.

6 Aux output 1 Use to control a 30A

external slave relay to

supply DC battery power to

01,07,12,13

Using 55xx select the relevant

engine and configure 55xx ‘aux output 1’ to be “Enable ECU”

PLUG “C” 9 WAY

55xx

DESCRIPTION

Cummins ISB 9 pin Deutsch connector

NOTES

SAE J1939 shield Screen for the J1939 cable.

Connect at Cummins ECU end only.

24 CANbus H SAE J1939 signal

J1939 + Use only screened 120 impedance cable approved specifically for use in CANbus applications.

25 CANbus L SAE J1939 return

J1939 - Use only screened 120 impedance cable approved specifically for use in CANbus applications.

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5.4.2 DEUTZ EMR2

PLUG “A” 8 WAY

55xx

DESCRIPTION

Deutz Vehicle side (F)

connector

NOTES

5 Crank output Connects directly to engine starter

solenoid.

6 Aux output 1 Use to control a 30A

external slave relay to

supply DC battery power to

pin 14. Fuse at 16 amps.

Using 5xxx select the relevant

engine and configure 55xx ‘aux output 1’ to be “Enable ECU”

1 Connects directly to battery

negative

PLUG “C” 9 WAY

55xx

DESCRIPTION

Deutz Vehicle side (F)

connector

NOTES

23 CANbus

common

- Screen for the J1939 cable. Connect at 55xx end only.

24 CANbus H 12

J1939 + Use only screened 120 impedance cable approved specifically for use in CANbus applications.

25 CANbus L 13

J1939 - Use only screened 120 impedance cable approved specifically for use in CANbus applications.

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5.4.3 JOHN DEERE

PLUG “A” 8 WAY

55xx

DESCRIPTION

John Deere 21-pin Deutsch

connector

NOTES

4 Fuel relay

output

G, J G = Switched ECU power, J =

Ignition

5 Start relay

output

D Start

PLUG “C” 9 WAY

55xx

DESCRIPTION

John Deere 21-pin Deutsch

connector

NOTES

23 CANbus

common

- Screen for the J1939 cable. Connect at 55xx end only.

24 CANbus H V

J1939 + Use only screened 120 impedance cable approved specifically for use in CANbus applications.

25 CANbus L U

J1939 - Use only screened 120 impedance cable approved specifically for use in CANbus applications.

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5.4.4 PERKINS 2800 SERIES

PLUG “A” 8 WAY

55xx

DESCRIPTION

Perkins Customer interface

connector

NOTES

4 Fuel relay

output

1, 10, 15, 33, 34 Powers up ECU and enables the

injectors.

5 Start relay

output

- Connects directly to engine starter solenoid.

PLUG “C” 9 WAY

55xx

DESCRIPTION

Perkins Customer interface

connector

NOTES

23 CANbus

common

- Screen for the J1939 cable. Connect at 55xx end only.

24 CANbus H 31

J1939 + Use only screened 120 impedance cable approved specifically for use in CANbus applications.

25 CANbus L 32

J1939 - Use only screened 120 impedance cable approved specifically for use in CANbus applications.

NOTE:- According to Perkins, warning lamps or equivalent must be connected to

Perkins customer interface connector terminals 3, 4, 5, 8, 9, 16, 17. Failure to

connect to these terminals will results in “open circuit” alarms from the ECU. Perkins

have advised that a suitable equivalent for the warning lamp is a 220 5W resistor. Be aware that outputs on terminals 4,5, & 16 are battery positive outputs. The outputs on terminals 3, 6, 8, 9 & 17 are battery negative outputs.

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5.4.5 SCANIA S6

DSE 55xx controller has support for the Scania Keyword 2000 protocol. This is used to read

diagnostic ‘trouble codes’ from the engine ECU, removing the need to use Scania diagnostic tools.

PLUG “A” 8 WAY

55xx

PIN No

55xx

DESCRIPTION

Scania EMS B1

connector

NOTES

4 Fuel relay

output

3 Ignition U15

5 Start relay

output

- Connects directly to engine starter solenoid.

PLUG “C” 9 WAY

55xx

PIN No

55xx

DESCRIPTION

Scania EMS B1

connector

NOTES

23 CANbus

common

- Screen for the J1939 cable. Connect at 55xx end only.

24 CANbus H 9

J1939 + Use only screened 120 impedance cable approved specifically for use in CANbus applications.

25 CANbus L 10

J1939 - Use only screened 120 impedance cable approved specifically for use in CANbus applications.

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5.4.6 VOLVO TAD9 / TAD16

PLUG “A” 8 WAY

55xx PIN No 55xx DESCRIPTION Volvo TAD9/16

EDC III connector

NOTES

6 Aux output 1

Configure to “ECU STOP”

6 TAD9/16 STOP input.

7 Aux output 2

Configure to “ECU POWER”

5 TAD9/16 START input.

3 DC Supply negative 4 DC Supply positive

PLUG “C” 9 WAY

55xx

PIN No

55xx

DESCRIPTION

Volvo TAD9/16

EDC III connector

NOTES

23 CANbus common - Screen for the J1939 cable. Connect at

55xx end only.

24 CANbus H 1 (Hi)

J1939 + Use only screened 120 impedance cable approved specifically for use in CANbus applications.

25 CANbus L 2 (Lo)

J1939 – Use only screened 120

impedance cable approved specifically for use in CANbus applications.

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5.4.7 VOLVO TAD12

PLUG “A” 8 WAY

55xx

DESCRIPTION

Volvo TAD12 ‘Stand alone

connector’ terminal

NOTES

4 Fuel relay

output

H TAD12 STOP input.

5 Start relay

output

E TAD12 START input.

6 Aux output 1 P Using 5xxx select the relevant

engine and configure 55xx ‘aux output 1’ to be “Enable ECU”

NOTE:- Alternatively, TAD12 terminal P can be connected to the contacts of a slave relay, driven by the FUEL output of the 55xx (terminal 4). This must be a separate relay and cannot be simply connected to TAD12 terminal H.

PLUG “C” 9 WAY

55xx

DESCRIPTION

Volvo TAD12 ‘Data bus

connector’ terminal

NOTES

23 CANbus

common

- Screen for the J1939 cable. Connect at 55xx end only.

24 CANbus H 1 (Hi)

J1939 + Use only screened 120 impedance cable approved specifically for use in CANbus applications.

25 CANbus L 2 (Lo)

J1939 - Use only screened 120 impedance cable approved specifically for use in CANbus applications.

NOTE:- Should the TAD12 ECU detect an engine fault not monitored by the 55xx,

an ‘external reset’ must be provided to reset the ECU.

Volvo specify that the reset is performed using external pushbuttons to give an input to TAD12 Standalone connector terminal J (diagnostics), P (power) and H(stop). According to Volvo, the reset sequence is : Press and hold down the diagnostic button (terminal J) and apply power to H (stop)

Apply power to P (but don’t start the engine).

Hold these inputs for three seconds. Release the diagnostic button (terminal J). Remove power from H (stop). Remove power from P (power).

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6 SPECIFICATION

DC Supply

8.0 to 35 V Continuous.

Cranking Dropouts

Able to survive 0 V for 50 mS, providing supply was at least 10 V before dropout and supply recovers to 5V .This is

achieved without the need for internal batteries.

Max. Operating Current

460mA at 12 V. 245 mA at 24 V.

Max. Standby Current

375 mA at 12 V. 200 mA at 24 V.

Alternator Input Range

15V - 277(ph-N) 3 Phase 4wire AC (+20%)

Alternator Input Frequency

50 - 60 Hz at rated engine speed (Minimum 15V AC Ph-N)

Magnetic Input Range (if fitted)

+/- 0.5 V to 70 V Peak

Magnetic Input Frequency

10,000 Hz (max) at rated engine speed.

Start Relay Output

16 Amp DC at supply voltage.

Fuel Relay Output

16 Amp DC at supply voltage.

Auxiliary Relay Outputs 1-3

5 Amp DC at supply voltage.

Dimensions

240mm x 172 mm x 57mm

(9 ½“ x 3 ¾” x 2 ¼”)

Charge Fail / Excitation Range

0 V to 35 V

Operating Temperature Range

-30 to +70°C

CT Burden

0.5VA

CT Secondary

CT Class

Class 1 required for instrumentation Protection class required if using for protection.

Mains Input Voltage Range

15V - 277(ph-N) 3 Phase 4wire AC (+20%)

Mains Input Frequency

50 - 60 Hz (Minimum 15V AC Ph-N)

Gen / Mains Loading Relays (4 &

8 Amp 250V AC RMS rated

Electromagnetic Compatibility

BS EN 50081-2 EMC Generic Emission Standard (Industrial) BS EN 50082-2 EMC Generic Emission Standard (Industrial)

Electrical Safety

BS EN 60950

Cold Temperature

BS EN 60068-2-1 to -30oC

Hot Temperature

BS EN 60068-2-2 to +70oC

Humidity

BS2011-2-1 to 93% RH@40oC for 48 Hours

Vibration

BS EN60068-2-6 10 sweeps at 1 octave/minute in each of 3 major axes. 5Hz to 8Hz @ +/-7.5mm constant displacement 8Hz to 500Hz @ 2gn constant acceleration

Shock

BS EN 60068-2-27 3 Half sine shocks in each of 3 major axes 15gn amplitude, 11mS duration

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7 COMMISSIONING

7.1.1 PRE-COMMISSIONING

Before the system is started, it is recommended that the following checks are made:-

6.1. The unit is adequately cooled and all the wiring to the module is of a standard and rating compatible with the system.

6.2. The unit DC supply is fused and connected to the battery and that it is of the correct polarity.

6.3. The Emergency Stop input is wired to an external normally closed switch connected to DC positive.

NOTE:- If Emergency Stop feature is not required link this input to the DC Positive. The module will not operate unless either the Emergency Stop is fitted correctly OR Pin 3 is connected to DC positive (+ve)

6.1. To check the start cycle operation take appropriate measures to prevent the engine from

starting (disable the operation of the fuel solenoid). After a visual inspection to ensure it is safe to proceed, connect the battery supply. Press the “MANUAL” pushbutton, then press

the ‘START’ pushbutton for a short time. The unit start sequence will commence.

6.2. The starter will engage and operate for the pre-set crank period. After the starter motor has

attempted to start the engine for the pre-set number of attempts the LCD will display ‘Shutdown Failed to start’. Press the STOP/RESET pushbutton to reset the unit.

6.3. Restore the engine to operational status (reconnect the fuel solenoid), again select

“MANUAL”and operate the ‘START’pushbutton, this time the engine should start and the starter motor should disengage automatically. If not then check that the engine is fully operational (fuel available, etc.) and that the fuel solenoid is operating. The engine should now run up to operating speed. If not and an alarm is present, check the alarm condition for validity, then check input wiring. The engine should continue to run for an indefinite period. It will be possible at this time to view the engine and alternator parameters - refer to the

‘Description of Controls’ section of this manual.

6.4. Select “AUTO”on the front panel, the engine will run for the pre-set cooling down period,

then stop. The generator should stay in the standby mode. If not check that there is not a signal present on the Remote Start input.

6.5. Initiate an automatic start by supplying the remote start signal. The start sequence will

commence and the engine will run up to operational speed. Once the generator is available a load transfer will take place, the Generator will accept the load. If not, check the wiring to the Generator Contactor Coil (if used). Check the Warming timer has timed out.

6.6. Remove the remote start signal, the return sequence will start. After the pre-set time period,

the load will be removed from the generator. The generator will then run for the pre-set

cooling down period, then shutdown into it’s standby mode.

6.7. Further details on synchronising and load sharing can be found in the DSE Guide to Load

Share system Design and Commissioning and the DSE Guide to Synchronising and load sharing Part1 and Part2.

6.8. If despite repeated checking of the connections between the 5520 and the customer’s

system, satisfactory operation cannot be achieved, then the customer is requested to contact the factory for further advice on:-

Should you have any queries arising from this manual please contact our Technical Department:

INTERNATIONAL TEL: +44 (0) 1723 890099 INTERNATIONAL FAX: +44 (0) 1723 893303

E-mail: support@deepseaplc.com Web: http://www.deepseaplc.com

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8 FAULT FINDING

SYMPTOM POSSIBLE REMEDY

Unit is inoperative Check the battery and wiring to the unit. Check the DC

supply. Check the DC fuse.

Unit shuts down Check DC supply voltage is not above 35 Volts or below 9

Volts Check the operating temperature is not above 55 °C. Check the DC fuse.

Unit locks out on Emergency Stop If an Emergency Stop Switch is not fitted, ensure that a

positive is connected to the Emergency Stop input. Check emergency stop switch is functioning correctly. Check

Wiring is not open circuit. Intermittent Magnetic Pick-up sensor fault

Ensure that Magnetic pick-up screen is only connected at

one end, if connected at both ends this enables the screen

to act as an aerial and will pick up random voltages. Low oil Pressure fault operates after engine has fired

Check engine oil pressure. Check oil pressure

switch/sender and wiring. Check configured polarity (if

applicable) is correct (i.e. Normally Open or Normally

Closed) or that sender is compatible with the 5520

Module. High engine temperature fault operates after engine has fired.

Check engine temperature. Check switch/sender and

wiring. Check configured polarity (if applicable) is correct

(i.e. Normally Open or Normally Closed) or that sender is

compatible with the 5520 Module. Shutdown fault operates Check relevant switch and wiring of fault indicated on LCD

display. Check configuration of input. Warning fault operates Check relevant switch and wiring of fault indicated on LCD

display. Check configuration of input. Fail to Start is activated after pre-set number of attempts to start

Check wiring of fuel solenoid. Check fuel. Check battery

supply. Check battery supply is present on the Fuel output

of the module. Check the speed sensing signal is present

on the 5520 inputs. Refer to engine manual. Continuous starting of generator when in AUTO

Check that there is no signal present on the “Remote

Start” input. Check configured polarity is correct.

Generator fails to start on receipt of Remote Start signal or under mains failure conditions.

Check Start Delay timer has timed out. If remote start

fault, check signal is on “Remote Start” input. Confirm

input is configured to be used as “Remote Start”.

Pre-heat inoperative Check wiring to engine heater plugs. Check battery supply.

Check battery supply is present on the Pre-heat output of

module. Check pre-heat has been selected in your

configuration. Starter motor inoperative Check wiring to starter solenoid. Check battery supply.

Check battery supply is present on the Starter output of

module. Ensure that the Emergency Stop input is at +Ve. Engine runs but generator will not take load

Check Warm up timer has timed out. Ensure generator

load inhibit signal is not present on the module inputs.

NOTE:- The above fault finding is provided as a guide check-list only. As it is possible for the module to be configured to provide a wide range of different features always refer to the source of your module configuration if in doubt.

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9 TYPICAL WIRING DIAGRAM

LOW FUEL LEVEL

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10 FACTORY DEFAULT CONFIGURATION

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1.0s

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15s

DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual

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Simplified Chinese

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10. ICONS AND LED IDENTIFICATION

10.1 ICON DESCRIPTIONS

Symbol Meaning Description

Stop/Reset

Stop the generator and reset any alarm conditions. Refer to Section 1 of this Manual.

Start Start the generator (if in an appropriate mode).

Auto

The controller will automatically start the generator when given a remote start command.

Manual

The controller will start the generator under manual control. (Separate Start command may be necessary)

Mains Failure Simulation (Test)

On AMF modules this is used to simulate a mains failure event. (On-load test)

Alarm Mute Silences the audible warning device.

Information Changes the display to another page

Up Selects the previous item on the page

Down Selects the next item on the page

Close mains

Close mains load switching device (manual mode only)

Close generator

Close generator load switching device (manual mode only)



Edit or save current selection (configuration mode only)

Increase Increase current selection (configuration mode only)

Decrease Decrease current selection (configuration mode only)

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10.2 CONFIGURABLE LED IDENTIFICATION DIAGRAM

LED 1

LED 2

LED 3

LED 4

10.3 SENDER WIRING RECOMMENDATIONS

10.3.1 USING EARTH RETURN (SINGLE WIRE) SENDERS.

59 57 60 58

Fuel level

Oil

Pressure

EARTH

Coolant

temperature

NOTE:- . It is important that terminal 60 ( sender common ) is soundly connected to an earth point on the ENGINE BLOCK, not within the control panel and must be a sound electrical connection to the sender bodies.

NOTE:- . If you use PTFE insulating tape on the sender thread when using earth return senders, ensure you do not insulate the entire thread as this will prevent the sender body from being earthed via the engine block.

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10.3.2 USING INSULATED RETURN (TWO WIRE) SENDERS.

59 57 60 58

Fuel

level

Oil

Pressure

EARTH

Coolant

temperature

NOTE:- . It is important that terminal 60 ( sender common ) is soundly connected

to an earth point on the ENGINE BLOCK, not within the control panel.

DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual

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12. APPENDIX

10.3.3 5520 IDMT TRIPPING CURVES (TYPICAL)

5520 Delayed over-current protection

100

1000

10000

100000

1000000

1 2 3

Current as amultipleof the trip-point setting

Trippin g time in secon ds

At default settingof t= 36

DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual

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12.2 5520 SHORT CIRCUIT TRIPPING CURVES (TYPICAL)

Model 5520 Short circuit & Earth fault curves for a 3 phase fault @ 50 Hz

100

1000

10000

100000

1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2

Current as a multiple of the trip-point setting

Detection time in milliseconds

Curve 8200

Curve 6800

Curce 5600

Curve 4700

Curve 3900

Curve 3300

Curve 2700

Curve 2200

Curve 1800

Curve 1500

Curve 1200

Curve 1000

DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual

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10.4 OUTPUT EXPANSION

There are several methods of output expansion available for the 5xxx module:-

10.4.1 RELAY OUTPUT EXPANSION (157)

An expansion module is available, which connects to the configuration socket and enables the 5xxx to use eight additional relays on the 157 relay module, providing Volt-free contacts for customer connection. A maximum of 2 off 157 relay modules can be connected, there are

identified as ‘A’ and ‘B’ and give a total of 16 extra relay outputs.

Refer to technical data sheet on the 157 relay module for further details.

10.4.2 LED OUTPUT EXPANSION (548)

An expansion module is available, which connects to the configuration socket and enables the

5xxx to use eight additional LED’s on the 548 module, providing remote LED’s indication up to 50 metres away. A maximum of 2 off 548 LED modules can be connected, there are identified as ‘A’ and ‘B’ and give a total of 16 extra LED outputs.

It is possible to use a mix of 157 and 548 modules to give both relay and LED expansion if required (Please refer to our Technical Support department for details.).

10.5 INPUT EXPANSION

It is possible to increase the number of monitored inputs available by utilising either :

 DSE P130 input expansion  54x Protection Expansion/Annunciator.

Please refer to the relevant product documentation for further details.

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13. SYNCHRONISING NOTES

Optionally, the 5520 controller can be configured to synchronise, volts match and parallel with the mains supply. This facility can be used to supply a fixed amount of power to the load and/or mains supply or provide no-break (closed transition) transfers to and from the generator supply.

10.5.1 CHECK SYNC

(If enabled)

The module will control the operation of the load-switching device to allow parallel operation with the mains supply only when the two supplies are in Sync. These functions can be used to provide manual Peak lopping/ Peak shaving and short duration no-break or bump-less transfers back to the mains supply following a mains failure.

10.5.2 AUTO SYNC

(If enabled)

The module provides control signals to the Engine Governor and the Alternator AVR to control the speed and voltage output from the generating set.

These functions can be used to provide peak lopping/ peak shaving (without load share control) and true no-break or bump-less transfers back to the mains supply following a mains failure.

The 5xxx module provides the ability to control the generator by adjusting the speed (frequency) and voltage being output. Several methods of providing this control are available. The following pages gives a schematic overview of the interface with the engine governor and alternator AVR.

Refer to the 5xxx software manual for further details.

10.5.3 LOAD CONTROL

(If enabled) The module features all the functions associated with the Check sync and autosync features and in addition it provides control signals to the Engine Governor and the Alternator AVR while in parallel with the mains (utility) supply to provide soft loading (load ramping) and control the amount of load (kW and kVAr) supplied by the generating set.

These functions can be used to provide peak lopping/ peak shaving and true no-break or bumpless transfers back to the mains supply following a mains failure.

Refer to the 5xxx software manual for further details.

DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual

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10.5.4 13.3 TYPICAL PEAK LOPPING SYSTEM

For further details on this subject you are referred to the Deep Sea Electronics Guide to Synchronising and Load Sharing. This document includes diagrams to show connections to many of the most common electronic governors and interfaces.

Deep Sea Electronics Plc 5520 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual