DSE 521 Operator's Manual

DSE Model 521 Remote Start Engine Management System - Operators Manual

DSE 521 ISSUE 4 4/4/02 MR 1

Deep Sea Electronics Plc

MODEL 521

REMOTE START ENGINE

MANAGEMENT SYSTEM

Author:- Miles Revell

Deep Sea Electronics Plc

Highfield House

Hunmanby

North Yorkshire

YO14 OPH

England

Tel: [phone]
Fax: [phone]

E-Mail: [e-mail]

DSE Model 521 Remote Start Engine Management System - Operators Manual

DSE 521 ISSUE 4 4/4/02 MR

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TABLE OF CONTENTS

Section Page

INTRODUCTION ................................................................................................................................3

CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION........................................3

1. OPERATION...................................................................................................................................4

1.1 CONTROL.................................................................................................................................4

FIG 1.....................................................................................................................................4

1.2 AUTOMATIC MODE OF OPERATION.....................................................................................4

1.3 MANUAL OPERATION .............................................................................................................5

MANUAL OPERATION WITH EXTERNAL START AND STOP PUSHBUTTONS ....................6

2. PROTECTIONS ..........................................................................................................................7

2.1 WARNINGS...............................................................................................................................7

2.2 SHUTDOWNS...........................................................................................................................7

3. INSTALLATION INSTRUCTIONS ..................................................................................................9

3.1 PANEL CUT-OUT .....................................................................................................................9

FIG 2.....................................................................................................................................9

3.2 COOLING..................................................................................................................................9

3.3 UNIT DIMENSIONS ..................................................................................................................9

FIG 3.....................................................................................................................................9

3.4 FRONT PANEL LAYOUT........................................................................................................10

FIG 4...................................................................................................................................10

3.5 REAR PANEL LAYOUT ..........................................................................................................10

FIG 5...................................................................................................................................10

4. ELECTRICAL CONNECTIONS ....................................................................................................11

4.1 CONNECTION DETAILS ........................................................................................................11

PLUG “A” 13 WAY.....................................................................................................................11

PLUG “B” 10 WAY.....................................................................................................................11

4.2 CONNECTOR FUNCTION DETAILS .....................................................................................12

PLUG “A” 13 WAY.....................................................................................................................12

PLUG “B” 10 WAY.....................................................................................................................12

CALIBRATION SOCKET...........................................................................................................13

5. SPECIFICATION...........................................................................................................................13

6. COMMISSIONING........................................................................................................................14

PRE-COMMISSIONING ............................................................................................................14

7. FAULT FINDING...........................................................................................................................14

8. TYPICAL WIRING DIAGRAM.......................................................................................................16

9. CALIBRATION..............................................................................................................................17

9.1 PC INTERFACE MODULE 808...............................................................................................17

10. ICON DESCRIPTIONS...............................................................................................................17

10.1 ICONS...................................................................................................................................17

11. APPENDIX.................................................................................................................................18

11.1 LED IDENTIFICATION DIAGRAM........................................................................................18

FIG 6..............................................................................................................................................18

11.2 FACTORY DEFAULT CONFIGURATION ............................................................................18

DSE Model 521 Remote Start Engine Management System - Operators Manual

DSE 521 ISSUE 4 4/4/02 MR 3

INTRODUCTION

The DSE 521 Remote Start Module, has been designed to allow the OEM to meet most of the
industry’s complex specifications. It has been primarily designed to start a generator when a remote
start signal from a remote transfer switch or other monitoring system applies an earthing signal to
the remote start input of the 521. Transfer the load to the generator when the operating criteria
have been met, then shutdown the engine on removal of the remote start signal.

Once activated the 521 module carries out all the start and stop procedures of 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 LED and other simultaneous
faults by a steady LED. This information is indicated by the LED’s on the front panel.

Selective operational sequences, timers and alarm trips can be altered by the customer. Alterations
to the system are made by using a PC with the 808 interface.

Access to critical operational sequences and setting for use by qualified engineers, are barred by a
security code. Timers are protected by a separated code allowing operator changes to be made.

The module is housed in a robust plastic case for the front panel mounting. Connections to the
module are via locking plug and sockets.

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.

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DEEP SEA ELECTRONICS PLC own the copyright to this manual,
which cannot be copied, reproduced or disclosed to a third party
without prior written permission.

DSE Model 521 Remote Start Engine Management System - Operators Manual

DSE 521 ISSUE 4 4/4/02 MR

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1. OPERATION

On connection of the DC power supply to the module, the module becomes active. This is
indicated by the Power On LED illuminating.

1.1 CONTROL

Control of the 521 module is by a three position rotary switch or key-switch (specified on ordering),
mounted on the front of the module with OFF, AUTO and MANUAL positions.

O

I

AUTO

Deep Se a Elect roni cs plc

Model 521

FIG 1

1.2 AUTOMATIC MODE OF OPERATION

The module is activated by turning the selector switch to the AUTO position.
When a

Remote Start signal is applied to the remote start input, the following sequence is

initiated:­The

Remote Start Present LED illuminates.

To allow for false signals the

Start Delay timer is initiated, after this delay, if the pre-heat output

option is selected this timer is then initiated, and the corresponding auxiliary output which is
selected energises.

NOTE:- If the Remote Start signal is removed during the Start Delay timer the unit will

return to a stand-by state.

After the above delays the Fuel Solenoid is energised, then the Starter Motor is engaged.
The engine is cranked for a pre-set time period. If the engine fails to fire during this cranking

attempt then the starter motor is disengaged for the pre-set rest period. Should this sequence
continue beyond the set number of attempts, the start sequence will be terminated and

Fail to

Start

fault will be displayed by a flashing LED.

DSE Model 521 Remote Start Engine Management System - Operators Manual

DSE 521 ISSUE 4 4/4/02 MR 5

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

808 interface.) The warning lamp output of

the charge alternator can also be used to disconnect the starter motor, however it cannot be used
for underspeed or overspeed. This is explained in the calibration section.

After the starter motor has disengaged, the

Safety On timer is activated, allowing Oil Pressure,

High Engine Temperature, Underspeed, 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 O il Pressure has risen and the Oil

Pressure switch has operated. Thus preventing excessive wear on the engine.

On removal of the Remote Start signal, the Stop delay timer is initiated, once it expires the load

Transfer

signal is de-energised, removing the load. The Cooling timer is then initiated, allowing the

engine a cooling down period off load before shutting down. Once the

Cooling timer expires the

Fuel Solenoid is de-energised, bringing the generator to a stop.

Should the

Remote Start signal be re-activated during the cooling down period, the set will return

on load after the Warming Timer has expired.

1.3 MANUAL OPERATION

NOTE:- The following sequence is only applicable to controllers not using external

start/stop push-button control.

To initiate a start sequence in MANUAL, turn the selector switch to MANUAL.

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 is energised, then the Starter Motor is engaged.

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

Fail to

Start

fault will be displayed by a flashing LED.

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

808 interface.) The warning lamp output of

the charge alternator can also be used to disconnect the starter motor, however it cannot be used
for underspeed or overspeed.

After the starter motor has disengaged, the

Safety On timer is activated, allowing Oil Pressure,

High Engine Temperature, Underspeed, Charge Fail and any delayed Auxiliary fault inputs to
stabilise without triggering the fault.

Once the engine is running, the

Warm Up timer, if selected is initiated, allowing the engine to

stabilise before it can be loaded.

DSE Model 521 Remote Start Engine Management System - Operators Manual

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The generator will run off load, unless a

Remote Start signal is applied, and if Load Transfer has

been selected as a control source, the appropriate auxiliary output selected will active.
If the

Remote Start signal is removed, the generator will continue to run On load until the selector

switch is turned to

Auto. The Remote Stop Delay Timer will time out, the load is then

disconnected. The generator will then run

off load allowing the engine a cooling down period.

Turning the selector to

STOP de-energises the FUEL SOLENOID, bringing the generator to a stop.

MANUAL OPERATION WITH EXTERNAL START AND STOP PUSHBUTTONS

If the module has been configured to use external Start and Stop pushbuttons the normal ‘Manual’
mode of operation is over-ridden and the following sequence is observed;

Turn the selector switch to

MANUAL.

To start the set operate the

‘Start’ Push-button, the pre-heat output (if selected) will energise and

the timer is initiated.
Once the above delay has expired the

Fuel Solenoid is energised, then the Starter Motor is

engaged.
The engine is cranked for a pre-set time period. If the engine fails to fire during this cranking

attempt then the starter motor is disengaged for the pre-set rest period. Should this sequence
continue beyond the set number of attempts, the start sequence will be terminated and

Fail to

Start

fault will be displayed by a flashing LED.

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

808 interface.) The warning lamp output of

the charge alternator can also be used to disconnect the starter motor, however it cannot be used
for underspeed or overspeed.

After the starter motor has disengaged, the

Safety On timer is activated, allowing Oil Pressure,

High Engine Temperature, Underspeed, Charge Fail and any delayed Auxiliary fault inputs to
stabilise without triggering the fault.

Once the engine is running, the

Warm Up timer, if selected is initiated, allowing the engine to

stabilise before it can be loaded.
The generator will run off load, unless a

Remote Start signal is applied, and then if Load Transfer

has been selected as a control source, the appropriate auxiliary output selected will be activated.
If the

Remote Start signal is removed, the generator will continue to run On load until the selector

switch is turned to

Auto. The Remote Stop Delay Timer will time out, the load is then

disconnected. The generator will then run

off load allowing the engine a cooling down period.

Turning the selector to

STOP or pressing the ‘Stop’ Pushbutton de-energises the FUEL

SOLENOID

, bringing the generator to a stop.