DSE DSE7410, DSE7420 Operator's Manual

DSE7410 & DSE7420 Operator Manual ISSUE: 2
DEEP SEA ELECTRONICS PLC
DSE7410 & DSE7420 Operator Manual
Document Number: 057-161
Author: Ashley Senior
DSE7410 & DSE7420 Operator Manual
2
DEEP SEA ELECTRONICS PLC
Highfield House Hunmanby North Yorkshire YO14 0PH ENGLAND
Sales Tel: +44 (0) 1723 890099 Sales Fax: +44 (0) 1723 893303
E-mail : sales@deepseaplc.com Website : www.deepseaplc.com
DSE7410 & DSE7420 Operator Manual
© Deep Sea Electronics Plc All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means or other) without the written permission of the copyright holder except in accordance with the prov isions of the Copyright, Designs and Patents Act 1988. Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to Deep Sea Electronics Plc at the address above.
The DSE logo is a UK registered trademarks of Deep Sea Electronics PLC.
Any reference to trademarked product names used within this publication is owned by their respective companies.
Deep Sea Electronics Plc reserves the right to change the contents of this document without prior notice.
Amendments List
Issue Comments Minimum
Module version
required
Minimum
Configuration Suite
Version required
1 Initial release V1.0.0 2011.10v1.0.7
1.1 Amended fault in DSE7410 Diagram 2 Added wiring information for CT Location. V1.3 2015.21 V1.251.2
Typeface: The typeface used in this document is Arial. Care should be taken not to mistake the upper case letter I with the numeral 1. T he numeral 1 has a top serif to avoid this confusion.
Clarification of notation used within this publication.
NOTE:
Highlights an essential element of a procedure to ensure correctness.
CAUTION!
Indicates a procedure or practice, which, if not strictly observed, could result in damage or destruction of equipment.
WARNING!
Indicates a procedure or practice, which could result in injury to personnel or loss of life if not followed correctly.
DSE7410 & DSE7420 Operator Manual
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TABLE OF CONTENTS
Section Page
1 BIBLIOGRAPHY............................................................................................... 7
1.1 INSTALLATION INSTRUCTIONS ................................................................................... 7
1.2 TRAINING GUIDES......................................................................................................... 7
1.3 MANUALS ....................................................................................................................... 7
1.4 THIRD PARTY DOCUMENTS ......................................................................................... 7
2 INTRODUCTION .............................................................................................. 8
3 SPECIFICATIONS ............................................................................................ 9
3.1 SHORT NAMES .............................................................................................................. 9
3.2 TERMINAL SPECIFICATION .......................................................................................... 9
3.3 POWER SUPPLY REQUIREMENTS .............................................................................. 9
3.4 GENERATOR VOLTAGE / FREQUENCY SENSING .................................................... 10
3.5 GENERATOR CURRENT SENSING ............................................................................. 11
3.5.1 VA RATING OF THE CTS ...................................................................................... 11
3.5.2 CT POLARITY ........................................................................................................ 12
3.5.3 CT PHASING.......................................................................................................... 12
3.5.4 CT CLASS .............................................................................................................. 12
3.6 INPUTS ......................................................................................................................... 13
3.6.1 DIGITAL INPUTS ................................................................................................... 13
3.6.2 ANALOGUE INPUTS .............................................................................................. 13
3.6.2.1 OIL PRESSURE .............................................................................................. 13
3.6.2.2 COOLANT TEMPERATURE ............................................................................ 13
3.6.2.3 FUEL LEVEL ................................................................................................... 13
3.6.2.4 FLEXIBLE SENSOR ........................................................................................ 14
3.6.3 CHARGE FAIL INPUT ............................................................................................ 14
3.6.4 MAGNETIC PICKUP .............................................................................................. 14
3.7 OUTPUTS ..................................................................................................................... 15
3.7.1 OUTPUTS A & B .................................................................................................... 15
3.7.2 CONFIGURABLE OUTPUTS C & D (LOAD SWITCHING) ..................................... 15
3.7.2.1 CONTACTOR COILS ...................................................................................... 1 5
3.7.2.2 UNDERVOLTAGE (UV COILS) ....................................................................... 15
3.7.2.3 CLOSING COILS ............................................................................................. 16
3.7.2.4 OPENING COILS / SHUNT TRIP COILS ......................................................... 16
3.7.3 OUTPUTS E,F,G,H, I & J ....................................................................................... 16
3.8 COMMUNICATION PORTS .......................................................................................... 17
3.9 COMMUNICATION PORT USAGE .............................................................................. 17
3.9.1 CAN INTERFACE .................................................................................................. 17
3.9.2 USB CONNECTION ............................................................................................... 18
3.9.3 USB HOST-MASTER (USB DRIVE CONNECTION) ............................................... 18
3.9.4 RS232 .................................................................................................................... 19
3.9.4.1 RECOMMENDED PC RS232 SERIAL PORT ADD-ONS ................................. 19
3.9.4.2 RECOMMENDED EXTERNAL MODEMS: ....................................................... 20
3.9.5 RS485 .................................................................................................................... 21
3.9.5.1 RECOMMENDED PC RS485 SERIAL PORT ADD-ONS ................................. 21
3.9.6 ETHERNET ............................................................................................................ 22
3.9.6.1 DIRECT PC CONNECTION ............................................................................. 22
3.9.6.2 CONNECTION TO BASIC ETHERNET ........................................................... 23
3.9.6.3 CONNECTION TO COMPANY INFRASTRUCTURE ETHERNET ................... 24
3.9.6.4 CONNECTION TO THE INTERNET ................................................................ 25
3.9.6.5 FIREWALL CONFIGURATION FOR INTERNET ACCESS .............................. 27
3.10 DSENET® FOR EXPANSION MODULES ................................................................ 28
3.10.1 DSENET® USED FOR MODBUS ENGINE CONNECTION .................................... 28
3.11 SOUNDER ................................................................................................................. 29
3.11.1 ADDING AN EXTERNAL SOUNDER TO THE APPLICATION ................................ 29
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3.12 ACCUMULATED INSTRUMENT AT IO N . .. .. ............................................................... 29
3.13 DIMENSIONS AND MOUNTING ................................................................................ 30
3.13.1 DIMENSIONS ......................................................................................................... 30
3.13.2 PANEL CUTOUT .................................................................................................... 30
3.13.3 WEIGHT ................................................................................................................. 30
3.13.4 FIXING CLIPS ........................................................................................................ 31
3.13.5 CABLE TIE FIXING POINTS .................................................................................. 32
3.13.6 SILICON SEALING GASKET.................................................................................. 32
3.14 APPL ICABLE STANDARDS............ .. .. .. .. .................................................................. 33
3.14.1 ENCLOSURE CLASSIFICATIONS ......................................................................... 35
3.14.2 NEMA CLASSIFICATIONS ..................................................................................... 36
4 INSTALLATION.............................................................................................. 37
4.1 TERMINAL DESCRIPTION ........................................................................................... 37
4.1.1 DC SUPPLY, FUEL AND START OUTPUTS, OUTPUTS E-J ................................. 38
4.1.2 ANALOGUE SENSOR ............................................................................................ 39
4.1.3 MAGNETIC PICKUP, CAN AND EXPANSION ....................................................... 40
4.1.4 LOAD SWITCHING AND V1 GENERATOR VOLTAGE SENSING ......................... 41
4.1.5 V2 BUS/MAINS VOLTAGE SENSING .................................................................... 41
4.1.6 GENERATOR CURRENT TRANSFORMERS ........................................................ 42
4.1.7 CONFIGURABLE DIGITAL INPUTS ....................................................................... 44
4.1.8 PC CONFIGURATION INTERFACE CONNECTOR ............................................... 44
4.1.9 RS485 CONNECTOR ............................................................................................. 45
4.1.10 RS232 CONNECTOR ............................................................................................. 45
4.2 TYPICAL WIRING DIAGRAMS ..................................................................................... 46
4.2.1 DSE7410 3 PHASE, 4 WIRE W ITH RESTRICTED EARTH FAULT PROTECTION 47
4.2.2 DSE7420 3 PHASE, 4 WIRE W ITH RESTRICTED EARTH FAULT PROTECTION 48
4.3 ALT ERNATIVE T OPOLOGIES ..................................................................................... 49
4.3.1 3 PHASE, 4 WIRE WITHOUT EARTH FAULT PROTECTION ............................... 49
4.3.2 SINGLE PHASE WITH RESTRICTED EARTH FAULT ........................................... 50
4.3.3 SINGLE PHASE WITHOUT EARTH FAULT ........................................................... 50
4.3.4 2 PHASE (L1 & L2) 3 WIRE WITH RESTRICTED EARTH FAULT ......................... 51
4.3.5 2 PHASE (L1 & L2) 3 WIRE WITHOUT EARTH FAULT ......................................... 51
4.3.6 2 PHASE (L1 & L3) 3 WIRE WITH RESTRICTED EARTH FAULT ......................... 52
4.3.7 2 PHASE (L1 & L3) 3 WIRE WITHOUT EARTH FAULT MEASURING ................... 52
4.3.8 3 PHASE 4 WIRE WITH UNRESTRICTED EARTH FAULT MEASURING ............. 53
4.3.9 CT LOCATION ....................................................................................................... 54
4.4 EARTH SYSTEMS ........................................................................................................ 56
4.4.1 NEGATIVE EARTH ................................................................................................ 56
4.4.2 POSITIVE EARTH .................................................................................................. 56
4.4.3 FLOATING EARTH................................................................................................. 56
4.5 TYPICAL ARRANGEMENT OF DSENET® ................................................................... 56
5 DESCRIPTION OF CONTROLS .................................................................... 58
5.1 DSE7410 AUTO START CONTROL MODULE ............................................................. 58
5.2 DSE7420 AUTO START CONTROL MODULE ............................................................. 59
5.3 QUICKSTART GUIDE ................................................................................................... 60
5.3.1 STARTING THE ENGINE ....................................................................................... 60
5.3.2 STOPPING THE ENGINE ...................................................................................... 60
5.4 VIEWING THE INSTRUMENT PAGES ......................................................................... 6 1
5.4.1 STATUS ................................................................................................................. 62
5.4.2 ENGINE.................................................................................................................. 63
5.4.3 GENERATOR ......................................................................................................... 64
5.4.4 BUS (DSE7410 ONLY) ........................................................................................... 64
5.4.5 MAINS (DSE7420 ONLY) ....................................................................................... 64
5.4.6 RS232 SERIAL PORT ............................................................................................ 65
5.4.7 RS485 SERIAL PORT ............................................................................................ 68
5.4.8 ABOUT ................................................................................................................... 69
5.4.8.1 ETHERNET PAGES ........................................................................................ 70
5.4.8.2 DATA LOGGING PAGES ................................................................................ 71
DSE7410 & DSE7420 Operator Manual
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5.4.9 CAN ERROR MESSAGES ..................................................................................... 72
5.5 VIEWING THE EVENT LOG ......................................................................................... 73
5.6 USER CONFIGURABLE INDICATORS ........................................................................ 74
6 OPERATION................................................................................................... 75
6.1 CONTROL .................................................................................................................... 75
6.2 CONTROL PUSH-BUTTONS........................................................................................ 76
6.3 ALTERNATIVE CONFIGURATIONS ............................................................................ 77
6.4 DUMMY LOAD / LOAD SHEDDING CONTROL ........................................................... 78
6.5 STOP MODE ................................................................................................................. 79
6.5.1 ECU OVERRIDE .................................................................................................... 80
6.6 MANUAL MODE ........................................................................................................... 81
6.6.1 WAITING IN MANUAL MODE ................................................................................ 81
6.6.2 STARTING SEQUENCE ......................................................................................... 81
6.6.3 ENGINE RUNNING ................................................................................................ 82
6.6.4 MANUAL FUEL PUMP CONTROL ......................................................................... 82
6.6.5 MANUAL SPEED CONTROL.................................................................................. 8 2
6.6.6 STOPPING SEQUENCE ........................................................................................ 83
6.7 TEST MODE ................................................................................................................. 83
6.7.1 WAITING IN TEST MODE ...................................................................................... 83
6.7.2 STARTING SEQUENCE ......................................................................................... 83
6.7.3 ENGINE RUNNING ................................................................................................ 84
6.8 AUTOMATIC MODE ..................................................................................................... 85
6.8.1 WAITING IN AUTO MODE ..................................................................................... 85
6.8.2 STARTING SEQUENCE ......................................................................................... 85
6.8.3 ENGINE RUNNING ................................................................................................ 86
6.8.4 STOPPING SEQUENCE ........................................................................................ 86
7 PROTECTIONS .............................................................................................. 87
7.1 PROTECTIONS DISABLED .......................................................................................... 88
7.1.1 INDICATION / WARNING ALARMS ....................................................................... 88
7.1.2 SHUTDOWN / ELECTRICAL TRIP ALARMS ......................................................... 88
7.1.3 CAN ALARMS ........................................................................................................ 89
7.2 INDICATIONS ............................................................................................................... 90
7.3 WARNINGS ................................................................................................................... 91
7.4 HIGH CURRENT WARNING ALARM ............................................................................ 92
7.5 SHUTDOWNS ............................................................................................................... 93
7.6 ELECTRICAL TRIPS .................................................................................................... 95
7.7 HIGH CURRENT SHUTDOWN / ELECTRICAL TRIP ALARM ...................................... 96
7.7.1 IMMEDIATE WARNING ......................................................................................... 96
7.7.2 IDMT ALARM ......................................................................................................... 96
7.8 EARTH FAULT SHUTDOWN / ELECTRICAL TRIP ALARM ........................................ 99
7.9 SHORT CIRCUIT ALARM ........................................................................................... 100
7.10 MAINTENANCE ALARM ......................................................................................... 101
8 SCHEDULER................................................................................................ 102
8.1.1 STOP MODE ........................................................................................................ 102
8.1.2 MANUAL MODE ................................................................................................... 102
8.1.3 AUTO MODE ........................................................................................................ 102
9 FRONT PANEL CONFIGURATION ............................................................. 103
9.1 ACCESSING THE MAIN FRONT PANEL CONFIGURATION EDITOR ...................... 104
9.1.1 EDITING A PARAMETER ..................................................................................... 105
9.2 ADJUSTABLE PARAMETERS ................................................................................... 106
9.3 ACCESSING THE ‘RUNNING’ CONFIGURAT ION EDITOR ....................................... 107
9.3.1 EDITING A PARAMETER ..................................................................................... 107
9.3.2 ADJUSTABLE PARAMETERS (RUNNING EDITOR)............................................ 107
10 COMMISSIONING ..................................................................................... 108
10.1 PRE-COMMISSIONING ........................................................................................... 108
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11 FAULT FINDING ....................................................................................... 109
11.1 STARTING .............................................................................................................. 109
11.2 LOADING ................................................................................................................ 109
11.3 ALARMS .................................................................................................................. 110
11.4 COMMUNICATIONS ................................................................................................ 111
11.5 INSTRUMENTS ....................................................................................................... 112
11.6 MISCELLANEOUS .................................................................................................. 112
12 MAINTENANCE, SPARES, REPAIR AND SERVICING ............................ 113
12.1 PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE .......................... 113
12.1.1 PACK OF PLUGS ................................................................................................. 113
12.1.2 INDIVIDUAL PLUGS............................................................................................. 113
12.2 PURCHASING ADDITIONAL FIXING CLIPS FROM DSE ....................................... 113
12.3 PURCHASING ADDITIONAL SEALING GASKET FROM DSE ............................... 113
12.4 DSENET EXPANSION MODULES .......................................................................... 114
13 WARRANTY .............................................................................................. 117
14 DISPOSAL ................................................................................................. 117
14.1 WEEE (WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT) ......................... 117
14.2 ROHS (RESTRICTION OF HAZARDOUS SUBSTANCES) ..................................... 117
Bibliography
7
1 BIBLIOGRAPHY
This document refers to and is referred to by the following DSE publications which can be obtained from the DSE website: www.deepseaplc.com
1.1 INSTALLATION INSTRUCTIONS
Installation instructions are supplied with the product in the box and are intended as a ‘quick start’ guide only.
DSE PART DESCRIPTION
053-085 DSE7410 Installation Instructions 053-088 DSE7420 Installation Instructions 053-032 DSE2548 LED Expansion Annunciator Installation Instructions 053-033 DSE2130 Input Expansion Installation Instructions 053-034 DSE2157 Output Expansion Installation Instructions 053-125 DSE2131 Ratio-metric Input Expansion Installation Instructions 053-126 DSE2133 RTD/Thermocouple Input Expansion Installation Instructions 053-134 DSE2152 Ratio-metric Output Expansion Installation Instructions
1.2 TRAINING GUIDES
Training Guides are produced to give ‘handout’ sheets on specific subjects during training sessions
DSE PART DESCRIPTION
056-005 Using CTs With DSE Products 056-010 Overcurrent Protection 056-018 Negative Phase Sequence 056-019 Earth Fault Protection 056-020 Loss of Excitation 056-022 Breaker Control 056-024 GSM Modem 056-026 kW & kVAr 056-029 Smoke Limiting 056-030 Module PIN Codes
1.3 MANUALS
Product manuals are can be downloaded from the DSE website: www.deepseaplc.com
DSE PART DESCRIPTION
057-004 Electronic Engines and DSE Wiring 057-160 DSE7400 Series Configuration Software Manual 057-082 DSE2130 Input Expansion Manual 057-083 DSE2157 Output Expansion Manual 057-084 DSE2548 Annunciator Expansion Manual 057-139 DSE2131 Ratio-metric Input Expansion Manual 057-140 DSE2133 RTD/Thermocouple Expansion Manual 057-141 DSE2152 Ratio-metric Output Expansion Manual
1.4 THIRD PARTY DOCUMENTS
The following third party documents are also referred to:
REFERENCE DESCRIPTION
ISBN 1-55937-879-4 IEEE Std C37.2-1996 IEEE Standard Electrical Power System Device Function
Numbers and Contact Designations. Institute of Electrical and Electronics Engineers
Inc ISBN 0-7506-1147-2 Diesel generator handbook. L.L.J.Mahon ISBN 0-9625949-3-8 On-Site Power Generation. EGSA Education Committee.
Introduction
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2 INTRODUCTION
This document details the installation and operation requirements of the DSE7400 Series modules, part of the
DSEGenset® range of products.
The manual forms part of the product and should be kept for the entire life of the product. If the product is passed or supplied to another party, ensure that this document is passed to them for reference purposes. This is not a controlled document. You will not be automatically informed of updates. Any future updates of this document will be included on the DSE website at www.deepseaplc.com
The DSE7400 series is designed to provide differing levels of functionality across a common platform. This allows the generator OEM greater flexibility in the choice of controller to use for a specific application.
The DSE7400 series module has been designed to allow the operator to start and stop the generator, and if required, transfer the load to the generator either manually (via fascia mounted push-buttons) or automatically. Additionally, the DSE7420 automatically starts and stops the generator set depending upon the status of the mains (utility) supply. The user also has the facility to view the system operating parameters via the LCD display.
The DSE7400 module monitors the engine, indicating the operational status and fault conditions, automatically shutting down the engine and giving a true first up fault condition of an engine failure by a COMMON AUDIBLE ALARM. The LCD display indicates the fault.
The powerful ARM microprocessor contained within the module allows for incorporation of a range of complex features:
Text based LCD display (supporting multiple languages).
True RMS Voltage, Current and Power monitoring.
Communications capability (RS485, RS232 or Ethernet)
Engine parameter monitoring.
Fully configurable inputs for use as alarms or a range of different functions.
Engine ECU interface to electronic engines.
Using a PC and the DSE Configuration Suite software allows alteration of selected operational sequences, timers, alarms and operational sequences. Additionally, the module’s integral fascia configuration editor allows adjustment of a subset of this information.
A robust plastic case designed for front panel mounting houses the module. Connections are via locking plug and sockets..
Access to critical operational sequences and timers for use by qualified engineers, can be protected by a security code. Module access can also be protected by PIN code. Selected parameters can be changed from the module’s front panel.
The module is housed in a robust plastic case suitable for panel mounting. Connections to the module are via locking plug and sockets.
Specification
9
3 SPECIFICATIONS
3.1 SHORT NAMES
Short name Description
DSE7000,DSE7xxx All modules in the DSE7000 range. DSE7400,DSE74xx All modules in the DSE7400 range. DSE7410 DSE7410 module/controller DSE7420 DSE7420 module/controller
3.2 TERMINAL SPECIFICATION
Connection type Two part connector.
• Male part fitted to module
• Female part supplied in module packing case ­Screw terminal, rising clamp, no internal spring.
Example showing cable entry and screw
terminals of a 10 way connector
Minimum cable size 0.5mm² (AWG 24) Maximum cable size 2.5mm² (AWG 10)
NOTE: - For purchasing additional connector plugs from DSE, please see the section
entitled Maintenance, Spares, Repair and Servicing elsewhere in this document.
3.3 POWER SUPPLY REQUIREMENTS
Minimum supply voltage 8V continuous
Cranking dropouts
Able to survive 0V for 50mS providing the supply was at least 10V
before the dropout and recovers to 5V afterwards. Maximum supply voltage 35V continuous (60V protection) Reverse polarity protection -35V continuous
Maximum operating current
130mA at 24V
260mA at 12V
Maximum standby current
65mA at 24V
120mA at 12V
Plant supply instrumentation display
Range 0V-70V DC (note Maximum continuous operating voltage of 35V DC) Resolution 0.1V Accuracy 1% full scale (±0.7V)
Specification
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3.4 GENERATOR VOLTAGE / FREQUENCY SENSING
Measurement type True RMS conversion Sample Rate 5KHz or better Harmonics Up to 10th or better Input Impedance
300K ph-N Phase to Neutral 15V
(minimum required for sensing frequency
)
to 333V AC
(absolute maximum)
Suitable for 110V to 277V nominal
(±20% for under/overvoltage detection)
Phase to Phase 26V
(minimum required for sensing frequency
)
to 576V AC
(absolute maximum)
Suitable for 190V ph-ph to 479V ph-ph nominal
(±20% for under/overvoltage detection)
Common mode offset from Earth
100V AC (max)
Resolution 1V AC phase to neutral
2V AC phase to phase Accuracy ±1% of full scale phase to neutral
±2% of full scale phase to phase Minimum frequency 3.5Hz Maximum frequency 75.0Hz Frequency resolution 0.1Hz Frequency accuracy ±0.2Hz
Specification
11
3.5 GENERATOR CURRENT SENSING
Measurement type True RMS conversion Sample Rate 5KHz or better Harmonics Up to 10th or better Nominal CT secondary rating 1A or 5A (5A recommended) Maximum continuous current 5A Overload Measurement 3 x Nominal Range setting Absolute maximum overload 50A for 1 second Burden
0.5VA (0.02 current shunts) common mode offset ±2V peak plant ground to CT common terminal Resolution 0.5% of 5A Accuracy ±1% of Nominal (1A or 5A) (excluding CT error)
3.5.1 VA RATING OF THE CTS
The VA burden of the module on the CTs is 0.5VA. However depending upon the type and length of cabling between the CTs and the module, CTs with a greater VA rating than the module are required.
The distance between the CTs and the
measuring module should be estimated and cross-referenced against the chart opposite to find the VA burden of the cable itself.
If the CTs are fitted within the alternator top box, the star point (common) of the CTs should be
connected to system ground (earth) as
close as possible to the CTs. This minimises the length of cable used to connect the CTs to the DSE module.
Example. If 1.5mm² cable is used and the distance from the CT to the measurin
g
module is 20m, then the burden of the
cable alone is approximately 15VA. As
the burden of the DSE controller is
0.5VA, then a CT with a rating of at least 15+0.5V = 15.5VA must be used. If 2.5mm² cables are used over the same distance of 20m, then the burden of the cable on the CT is approximately 7VA. CT’s required in this instance is at least 7.5VA (7+0.5).
NOTE: - Details for 4mm² cables are shown for reference only. The connectors on the DSE
modules are only suitable for cables up to 2.5mm².
NOTE: - CTs with 5A secondary windings are recommended with DSE modules. 1A CTs can be used if necessary however, the resolution of the readings is 5 times better when using 5A CTs.
Specification
12
3.5.2 CT POLARITY
Take care to ensure the correct polarity of the CTs. Incorrect CT orientation will lead to negative kW readings when the set is supplying power. Take note that paper stick-on labels on CTs that show the orientation are often incorrectly placed on the CT (!). It is more reliable to use the labelling in the case moulding as an indicator to orientation (if available). To test orientation, run the generator in island mode (not in parallel with any other supply) and load the generator to around 10% of the set rating. Ensure the DSE module shows positive kW for all three individual phase readings.
TO GENERATOR
TO LOAD SWITCH DEVICE
POLARITY OF CT PRIMARY
NOTE:- Take care to ensure correct polarity of the CT primary as shown above. If in doubt, check with the CT supplier.
3.5.3 CT PHASING
Take particular care that the CTs are connected to the correct phases. For instance, ensure that the CT on phase 1 is connected to the terminal on the DSE module intended for connection to the CT for phase 1. Additionally ensure that the voltage sensing for phase 1 is actually connected to generator phase 1. Incorrect connection of the phases as described above will result in incorrect power factor (pf) measurements, which in turn results in incorrect kW measurements. One way to check for this is to make use of a single-phase load. Place the load on each phase in turn, run the generator and ensure the kW value appears in the correct phase. For instance if the load is connected to phase 3, ensure the kW figure appears in phase 3 display and not in the display for phase 1 or 2.
3.5.4 CT CLASS
Ensure the correct CT type is chosen. For instance if the DSE module is providing overcurrent protection, ensure the CT is capable of measuring the overload lev el you wish to protect against, and at the accuracy lev el you require. For instance, this may mean fitting a protection class CT (P10 type) to maintain high accuracy while the CT is measuring overload currents. Conversely, if the DSE module is using the CT for instrumentation only (current protection is disabled or not fitted to the controller), then measurement class CTs can be used. Again, bear in mind the accuracy you require. The DSE module is accurate to better than 1% of the full-scale current reading. To maintain this accuracy you should fit Class 0.5 or Class 1 CTs.
You should check with your CT manufacturer for further advice on selecting your CTs
labelled as p1,
k
or K
labelled as p2,
l
or L
Specification
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3.6 INPUTS
3.6.1 DIGITAL INPUTS
Number 11 configurable inputs Arrangement Contact between terminal and ground Low level threshold 2.1V minimum High level threshold 6.6V maximum Maximum input voltage +50V DC with respect to plant supply negative Minimum input voltage -24V DC with respect to plant supply negative Contact wetting current 7mA typical Open circuit voltage 12V typical
3.6.2 ANALOGUE INPUTS
3.6.2.1 OIL PRESSURE
Configurable if engine ECU link provides oil pressure measurement Measurement type Resistance measurement by measuring voltage across sensor
with a fixed current applied Arrangement Differential resistance measurement input Measurement current 15mA Full scale
240 Over range / fail
270 Resolution 0.1 Bar (1-2 PSI) Accuracy
±2% of full scale resistance (±4.8) excluding transducer error Max common mode voltage ±2V Display range 13.7 bar (0-200 PSI) subject to limits of the sensor
3.6.2.2 COOLANT TEMPERATURE
Configurable if engine ECU link provides coolant temp measurement Measurement type Resistance measurement by measuring voltage across sensor with a fixed
current applied Arrangement Differential resistance measurement input Measurement current
10mA
Full scale
480 Over range / fail
540 Resolution
1°C (2°F) Accuracy
+/-2% of full scale resistance (±9.6) excluding transducer error Max common mode voltage
±2V
Display range
0°C -140°C (32°F - 284°F) subject to limits of the sensor
3.6.2.3 FUEL LEVEL
Measurement type Resistance measurement by measuring voltage across sensor with a fixed
current applied Arrangement Differential resistance measurement input Measurement current
10mA
Full scale
480 Over range / fail
540 Resolution
1°C (2°F) Accuracy
+/-2% of full scale resistance (±9.6) excluding transducer error Max common mode voltage
±2V
Display range 0-250%
Specification
14
3.6.2.4 FLEXIBLE SENSOR
Number 2 Measurement type Resistance measurement by measuring voltage across sensor with a
fixed current applied Arrangement Differential resistance measurement input Measurement current 10mA Full scale
480 Over range / fail
540 Resolution 1% Accuracy
±2% of full scale resistance (±9.6) excluding transducer error Max common mode voltage ±2V Display range 0-250%
3.6.3 CHARGE FAIL INPUT
Minimum voltage 0V Maximum voltage 35V (plant supply) Resolution 0.2V Accuracy ± 1% of max measured voltage Excitation Active circuit constant power output Output Power 2.5W Nominal @12V and 24V Current at 12V 210mA Current at 24V 105mA
The charge fail input is actually a combined input and output. Whenever the generator is required to run, the terminal provides excitation current to the charge alternator field winding. When the charge alternator is correctly charging the battery, the voltage of the terminal is close to the plant battery supply voltage. In a failed charge situation, the voltage of this terminal is pulled down to a low voltage. It is this drop in voltage that triggers the charge failure alarm. The level at which this operates and whether this triggers a warning or shutdown alarm is configurable using the DSE Config Suite Software.
3.6.4 MAGNETIC PICKUP
Type Single ended input, capacitive coupled Minimum voltage 0.5V RMS Max common mode voltage ±2V Maximum voltage Clamped to ±70V by transient suppressers, dissipation not to
exceed 1W . Maximum frequency 10,000Hz Resolution 6.25 RPM Accuracy ±25 RPM Flywheel teeth 10 to 500
NOTE : DSE can supply a suitable magnetic pickup device, available in two body thread lengths : DSE Part number 020-012 - Magnetic Pickup probe 5/8 UNF 2½” thread length DSE Part number 020-013 - Magnetic Pickup probe 5/8 UNF 4” thread length
Magnetic Pickup devices can often be ‘shared’ between two or more dev ices. For example, one device can often supply the signal to both the module and the engine governor. The possibility of this depends upon the amount of current that the magnetic pickup can supply.
Specification
15
3.7 OUTPUTS
Ten (10) outputs are fitted to the controller.
3.7.1 OUTPUTS A & B
Type Normally used for Fuel / Start outputs. Fully configurable for other purposes if the
module is configured to control an electronic engine. Supplied from Emergency Stop terminal 3.
Rating 15A resistive @ 35V
3.7.2 CONFIGURABLE OUTPUTS C & D (LOAD SWITCHING)
Type Fully configurable volts free relays. Output C – Normally Closed, Output D – Normally
Open Rating 8A resistive@ 250V AC Protection Protected against over current & over temperature. Built in load dump feature.
3.7.2.1 CONTACTOR COILS
Use output D, the normally open relay:
3.7.2.2 UNDERVOLTAGE (UV COILS)
Use output C, the normally closed relay :
Generator
DSE output drives the contactor coil, via external slave relay if required. When the DSE module requires the contactor closed, the output energises (closing the internal relay) When the DSE module requires the contactor to be open, the output is de-energised (opening the internal relay)
Generator
DSE output drives the UV coil, via external slave relay if required. When the generator starts, the UV is powered via the normally closed relay. The breaker is now ready for the close signal to be given. When the breaker is to be opened, the Open Gen erator Pulse relay is operated, removing power from the UV coil for one second. This
causes the
breaker to trip (open) as the UV is no longer
powered. The Open Generator Pulse relay switches
back to its closed state, ready to power the UV coil the next time the generator starts.
Specification
16
3.7.2.3 CLOSING COILS
For continuous closing signals (close signal is present continuously when the breaker is closed), follow the instructions above as for Contactor Coils. For momentary (pulsed) closing signals, use OUTPUT D, the normally open relay:
3.7.2.4 OPENING COILS / SHUNT TRIP COILS
For Continuous opening signal, use output D, the normally open relay:
For momentary (pulsed) closing signals, use a normally open relay:
3.7.3 OUTPUTS E,F,G,H, I & J
Number 6 Type Fully configurable, supplied from DC supply terminal 2. Rating 3A resistiv e @ 35V
Generator:
When the DSE module requires the breaker open, the output energises (c los ing th e intern al r elay).
Generator:
When the DSE module requires the breaker open, the output energises (c los ing th e intern al r elay) for the period of the breaker trip pulse.
Generator
When the DSE module requires the breaker closed, the output energises (closing the internal relay) for the period of the Breaker Close Pulse timer after which the output is de-ener gis ed (opening the internal relay).
Specification
17
3.8 COMMUNICATION PORTS
USB Port USB2.0 Device for connection to PC running DSE configuration
suite only Max distance 6m (yards)
Serial Communication RS232 and RS485 are both fitted but and provide independent
operation
RS232 Serial port
Non – Isolated port Max Baud rate 115K baud subject to S/W TX, RX, RTS, CTS, DSR, DTR, DCD Male 9 way D type connector Max distance 15m (50 feet)
RS485 Serial port
Isolated Data connection 2 wire + common Half Duplex Data direction control for Transmit (by s/w protocol) Max Baud Rate 19200 External termination required (120) Max common mode offset 70V (on board protection transorb) Max distance 1.2km (¾ mile)
CAN Port Engine CAN Port
Standard implementation of ‘Slow mode’, up to 250K bits/s Non-Isolated. Internal Termination provided (120Ω ) Max distance 40m (133 feet)
NOTE:- For additional length, the DSE124 CAN Extender is available. Please refer to DSE Publication: 057-116 DSE124 Operator Manual for more information.
Ethernet Auto detecting 10/100 Ethernet port.
3.9 COMMUNICATION PORT USAGE
3.9.1 CAN INTERFACE
Modules are fitted with the CAN interface as standard and are capable of receiving engine data from engine CAN controllers compliant with the CAN standard. CAN enabled engine controllers monitor the engine’s operating
parameters such as engine speed, oil pressure, engine temperature (among others) in order to closely monitor and control the engine. The industry standard communications interface (CAN) transports data gathered by the engine controller interface. This allows generator controllers to access these engine parameters with no physical connection to the sensor dev ice.
NOTE:- For further details for connections to CAN enabled engines and the functions available with each engine type, refer to the manual Electronic Engines and DSE Wiring. Part No. 057-004
Specification
18
3.9.2 USB CONNECTION
The USB port is provided to give a simple means of connection between a PC and the controller. Using the DSE Configuration Suite Software, the operator is then able to control the module, starting or stopping the generator, selecting operating modes, etc. Additionally, the various operating parameters (such as output volts, oil pressure, etc.) of the remote generator are available to be viewed or changed.
To connect a module to a PC by USB, the following items are required:
DSE7400 series module
DSE Configuration Suite PC Software
(Supplied on configuration suite software CD or available from www.deepseaplc.com).
• USB cable Type A to Type B. (This is the same cable as often used between a PC and a USB printer)
DSE can supply this cable if required : PC Configuration interface lead (USB type A – type B) DSE Part No 016-125
NOTE:- The DC supply must be connected to the module for configuration by PC.
NOTE:- Refer to DSE7400 Series Configuration Suite Manual (DSE part 057-160) for further
details on configuring, monitoring and control.
3.9.3 USB HOST-MASTER (USB DRIVE CONNECTION)
USB Type A connection for USB Host facility for USB storage device for data recording. Maximum size of externally storage device is 16Gb.(see viewing the instrument pages)
NOTE:- Refer to DSE7400 Series Configuration Suite Manual (DSE part 057-160) for further
details on configuring, monitoring and control.
Specification
19
3.9.4 RS232
The RS232 port on the controller supports the Modbus RTU protocol. The Gencomm register table for the controller is available upon request from the DSE Technical Support Department.
RS232 is for short distance communication (max 15m) and is typically used to connect the controller to a telephone or GSM modem for more remote communications.
Many PCs are not fitted with an internal RS232 serial port. DSE DOES NOT recommend the use of USB to RS232 convertors but can recommend PC add-ons to provide the computer with an RS232 port.
3.9.4.1 RECOMMENDED PC RS232 SERIAL PORT ADD-ONS
Remember to check these parts are suitable for your PC. Consult your PC supplier for further advice.
Brainboxes PM143 PCMCIA RS232 card (for laptop PCs)
Brainboxes VX-001 Express Card RS232 (for laptops and nettops PCs)
Brainboxes UC246 PCI RS232 card (for desktop PCs)
Brainboxes PX-246 PCI Express 1 Port RS232 1 x 9 Pin (for desktop
PCs)
Supplier:
Brainboxes Tel: +44 (0)151 220 2500 Web: http://www.brainboxes.com Email: Sales: sales@brainboxes.com
NB DSE Have no business tie to Brainboxes. Over many years, our own engineers have used these
products and are happy to recommend them.
Specification
20
3.9.4.2 RECOMMENDED EXTERNAL MODEMS:
• Multitech Global Modem MultiModem ZBA (PSTN) DSE Part Number 020-252 (Contact DSE Sales for details of localisation kits for these modems)
• Sierra Fastrak Xtend GSM modem kit (PSU, Antenna and modem)* DSE Part number 0830-001-01
NOTE: *For GSM modems a SIM card is required, supplied by your GSM network provider
:
• For SMS only, a normal’ voice SIM card is required. This enables the controller to send SMS messages to designated mobile phones upon status and alarm conditions.
• For a data connection to a PC running DSE Configuration Suite Software, a ‘special’ CSD (Circuit Switched Data) SIM card is required that will enable the modem to answer an incoming data call. Many ‘pay as you go’ services will not provide a CSD (Circuit Switched Data) SIM card.
Specification
21
3.9.5 RS485
The RS485 port on the series controller supports the Modbus RTU protocol. The DSE Gencomm register table for the controller is av ailable upon request from the DSE Technical Support Department.
RS485 is used for point-to-point cable connection of more than one device (maximum 32 devices) and allows for connection to PCs, PLCs and Building Management Systems (to name just a few devices).
One advantage of the RS485 interface is the large distance specification (1.2km when using Belden 9841 (or equivalent) cable. This allows for a large distance between the module and a PC running the DSE Configuration Suite software. The operator is then able to control the module, starting or stopping the generator, selecting operating modes, etc. The various operating parameters (such as output volts, oil pressure, etc.) of the remote generator can be viewed or changed.
NOTE:- For a single module to PC connection and distances up to 6m (8yds) the USB
connection method is more suitable and provides for a lower cost alternative to RS485 (which is more suited to longer distance connections).
3.9.5.1 RECOMMENDED PC RS485 SERIAL PORT ADD-ONS
Remember to check these parts are suitable for your PC. Consult your PC supplier for further advice.
• Brainboxes PM154 PCMCIA RS485 card (for laptops PCs) Set to ‘Half Duplex, Autogating” with ‘CTS True’ set to ‘enabled’
• Brainboxes VX-023 ExpressCard 1 Port RS422/485 (for laptops and nettop PCs)
• Brainboxes UC320 PCI Velocity RS485 card (for desktop PCs) Set to ‘Half Duplex, Autogating” with ‘CTS True’ set to ‘enabled’
• Brainboxes PX-324 PCI Express 1 Port RS422/485 (for desktop PCs)
Supplier:
Brainboxes Tel: +44 (0)151 220 2500 Web: http://www.brainboxes.com Email: Sales: sales@brainboxes.com
NB DSE have no business tie to Brainboxes. Over many years,our own engineers have used these products and are happy to recommend them.
Specification
22
3.9.6 ETHERNET
The module is fitted with ETHERNET socket for connection to LAN (local area networks)
Description
1
TX+
2
TX-
3
RX+
4
Do not connect
5
Do not connect
6
RX-
7
Do not connect
8
Do not connect
3.9.6.1 DIRECT PC CONNECTION
Requirements
DSE7400 series module
Crossover Ethernet cable (see Below)
PC with Ethernet port
Crossover network cable
Specification
23
Crossover cable wiring detail
Two pairs crossed, two pairs uncrossed 10baseT/100baseTX crossover
Pi
n
Connection 1 (T568A)
Connection 2 (T568B)
1
white/green stripe
white/orange stripe
2
green solid
orange solid
3
white/orange stripe
white/green stripe
4
blue solid
blue solid
5
white/blue stripe
white/blue stripe
6
orange solid
green solid
7
white/brown stripe
white/brown stripe
8
brown solid
brown solid
NOTE:- This cable can be purchased from any good PC or IT store.
3.9.6.2 CONNECTION TO BASIC ETHERNET
Requirements
DSE7400 series module
Ethernet cable (see below)
Working Ethernet (company or home network)
PC with Ethernet port
For the advanced Engineer, a cross over cable is a CAT5 cable with one end terminated as T 568A and the other end terminated as T 568B.
Ethernet router or ADSL router
Ethernet cable
Specification
24
Ethernet cable wiring detail
.
10baseT/100baseT
Pi
n
Connection 1 (T568A)
Connection 2 (T568A)
1
white/green stripe
white/green stripe
2
green solid
green solid
3
white/orange stripe
white/orange stripe
4
blue solid
blue solid
5
white/blue stripe
white/blue stripe
6
orange solid
orange solid
7
white/brown stripe
white/brown stripe
8
brown solid
brown solid
NOTE:- DSE Stock a 2m (2yds) Ethernet Cable – Part number 016-137. Alternatively they
can be purchased from any good PC or IT store.
3.9.6.3 CONNECTION TO COMPANY INFRASTRUCTURE ETHERNET
Requirements
DSE7400 series module
Ethernet cable (see below)
Working Ethernet (company or home network)
PC with Ethernet port
For the advanced Engineer, this cable has both ends terminated as T 568A (as shown below) or T568B.
Ethernet cable
PC Network wall connection sockets
Ethernet router or ADSL router
Specification
25
Ethernet cable wiring detail
10baseT/100baseT
Pi
n
Connection 1 (T568A)
Connection 2 (T568A)
1
white/green stripe
white/green stripe
2
green solid
green solid
3
white/orange stripe
white/orange stripe
4
blue solid
blue solid
5
white/blue stripe
white/blue stripe
6
orange solid
orange solid
7
white/brown stripe
white/brown stripe
8
brown solid
brown solid
NOTE:- DSE Stock a 2m (2yds) Ethernet Cable – Part number 016-137. Alternatively they
can be purchased from any good PC or IT store.
3.9.6.4 CONNECTION TO THE INTERNET
Requirements
Ethernet cable (see below)
Working Ethernet (company or home network)
Working Internet connection (ADSL or DSL recommended)
For the advanced Engineer, this cable has both ends terminated as T 568A (as shown below) or T568B.
DSL or ADSL
router
Optional ‘Local’
site PC
INTERNET
DSL or ADSL
router
PC remote
from generator
The DSL/ADSL router will route external network traffic.
Ethernet cable
Specification
26
Ethernet cable wiring detail
10baseT/100baseT
Pi
n
Connection 1 (T568A)
Connection 2 (T568A)
1
white/green stripe
white/green stripe
2
green solid
green solid
3
white/orange stripe
white/orange stripe
4
blue solid
blue solid
5
white/blue stripe
white/blue stripe
6
orange solid
orange solid
7
white/brown stripe
white/brown stripe
8
brown solid
brown solid
NOTE:- DSE Stock a 2m (2yds) Ethernet Cable – Part number 016-137. Alternatively they
can be purchased from any good PC or IT store.
For the advanced Engineer, this cable has both ends terminated as T 568A (as shown below) or T568B.
Specification
27
3.9.6.5 FIREWALL CONFIGURATION FOR INTERNET ACCESS
As modem/routers differ enormously in their configuration, it is not possible for DSE to give a complete guide to their use with the module. However it is possible to give a description of the requirements in generic terms. For details of how to achieve the connection to your modem/router you are referred to the supplier of your modem/router equipment.
The module makes its data available over Modbus TCP and as such communicates over the Ethernet using a Port configured via the DSE Configuration Suite software..
You must configure your modem/router to allow inbound traffic on this port. For more information you are referred to your WAN interface device (modem/router) manufacturer.
It is also important to note that if the port assigned (setting from software “Modbus Port Number”) is already in use on the LAN, the module cannot be used and another port must be used .
Outgoing Firewall rule
As the module makes its user interface available to standard web browsers, all communication uses the chosen port. It is usual for a firewall to make the same port outgoing open for communication.
Incoming traffic (virtual server)
Network Address and Port Translation (NAPT) allows a single device, such as the modem/router gateway, to act as an agent between the Internet (or "public external network") and a local (or "internal private") network. This means that only a single, unique IP address is required to represent an entire group of computers.
For our application, this means that the WAN IP address of the modem/router is the IP address we need to access the site from an external (internet) location.
When the requests reach the modem/router, we want this passed to a ‘virtual serv er’ for handling, in our case this is the module.
Result : Traffic arriving from the WAN (internet) on port xxx is automatically sent to IP address set within the configuration software on the LAN for handling.
NOTE:- Refer to DSE7400 Series Configuration Suite Manual (DSE part 057-160) for further
details on configuring, monitoring and control.
Specification
28
3.10 DSENET® FOR EXPANSION MODULES
DSENet® is the interconnection cable between the host controller and the expansion module(s) and must not be connect to any device other than DSE equipment designed for connection to the DSENet®
Cable type Two core screened twisted pair Cable characteristic impedance
120
Recommended cable Belden 9841
Belden 9271
Maximum cable length 1200m (¾ mile) when using Belden 9841 or direct equivalent.
600m (666 yds) when using Belden 9271 or direct equivalent. DSENet® topology “Daisy Chain” Bus with no stubs (spurs) DSENet® termination
120. Fitted internally to host controller. Must be fitted externally to
the ‘last’ expansion module by the customer. Maximum expansion modules
Total 20 devices made up of DSE2130 (up to 4), DSE2131 (up to 4),
DSE2133 (up to 4), DSE2152 (up to 4), DSE2157 (up to 10), DSE2548
(up to 10)
This gives the possibility of :
Maximum 32 additional 0-10V or 4-20mA outputs (DSE2152)
Maximum 80 additional relay outputs (DSE2157)
Maximum 80 additional LED indicators
Maximum 24 additional Ratio-metric or Thermocouple inputs
(DSE2133).
Maximum 40 additional inputs (All can be configured as either digital,
resistive, 0-10V or 4-20mA when using DSE2131)
NOTE: As a termination resistor is internally fitted to the host controller, the host controller must be the ‘first’ unit on the DSENet®. A termination resistor MUST be fitted to the ‘last’ unit on the DSENet®. For connection details, you are referred to the section entitled ‘typical wiring diagram’ elsewhere in this document.
NOTE : DSE7400 series module does not support the DSE2510/2520 display modules.
3.10.1 DSENET® USED FOR MODBUS ENGINE CONNECTION
As DSENet® utilises an RS485 hardware interface, this port can be configured for connection to Cummins Modbus engines (Engines fitted with Cummins GCS). This leaves the RS485 interface free for connection to remote monitoring equipment (i.e. Building Management System, PLC or PC RS485 port).
While this is a very useful feature in some applications, the obvious drawback is that the DSENet® interface is no longer available for connection to expansion devices.
Example of configuring the DSENet® for connection to Cummins QST GCS using the DSE Configuration Suite Software:
Specification
29
3.11 SOUNDER
The module features an internal sounder to draw attention to warning, shutdown and electrical trip alarms.
Sounder level 64db @ 1m
3.11.1 ADDING AN EXTERNAL SOUNDER TO THE APPLICATION
Should an external alarm or indicator be required, this can be achieved by using the DSE Configuration Suite PC software to configure an auxiliary output for “Audible Alarm”, and by configuring an auxiliary input for “Alarm Mute” (if required). The audible alarm output activates and de-activates at the same time as the module’s internal sounder. The Alarm mute input and internal alarm mute button activate ‘in parallel’ with each other. Either signal will mute both the internal sounder and audible alarm output.
Example of configuration to achieve external sounder with external alarm mute button:
3.12 ACCUMULATED INSTRUMENTATION
NOTE: When an accumulated instrumentation value exceeds the maximum number as listed below, it will reset and begin counting from zero again.
Engine hours run Maximum 99999 hrs 59 minutes (approximately 11yrs 4months) Number of starts 1,000,000 (1 million)
The number of logged Engine Hours and Number of Starts can be set/reset using the DSE Configuration Suite PC software. Depending upon module configuration, this may have been PIN number locked by your generator supplier
Specification
30
3.13 DIMENSIONS AND MOUNTING
3.13.1 DIMENSIONS
240.0mm x 181.1mm x 41.7mm
(9.4” x 7.1” x 1.6”)
3.13.2 PANEL CUTOUT
220mm x 160mm
(8.7” x 6.3”)
3.13.3 WEIGHT
0.7kg (1.4lb)
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