DSE DSE8610 User Manual

DSE8610 Operator Manual Issue 8
DEEP SEA ELECTRONICS PLC
DSE8610 Control Module
Document number 057-115
Author : Anthony Manton
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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
DSE Model 8610 series Control and Instrumentation System Operators 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 provisions 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 trademark 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 since last publication
Issue no. Comments 1 First Release 2 Added ROCOF & Vector shift 3 Added Ethernet 4 Added ‘MSC OLD UNITS ON BUS’ alarm description 5 Added Data logging 6 V5.0 Added Dead Bus synchronising V5.1
V5.1 Added MSC compatibility with 55xx and 75xx series modules Increase configurable Gencon (Derived information) PLC added more Nodes 200-to- 400 / Number of PLC Timers & PLC Counters increased 10-to-20, Output sources- every alarm and input now has equivalent outputs. Control by SMS messages , Remote start off/on load / cancel , Put into stop mode, put into Auto mode. Added extended SMS message to include oil pressure, coolant temp and engine hours run Option to send SMS message as an alarm/flash message, Fuel level SMS Messages Logging Starts / stops in the event log Added new feature to Start Next Set on Warning
Added Configurable Editor Screens 7 V6.0 Added Cool Down in Stop Mode and Maintenance Reset on Module Front Panel 8 Updated to suit 8610 V6.3 additions
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.
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WARNING!
Indicates a procedure or practice, which could result in injury to personnel or loss of life if not followed correctly.
TABLE OF CONTENTS
Section Page
1 BIBLIOGRAPHY ............................................................................................... 7
1.1 INSTALLATION INSTRUCTIONS ................................................................................... 7
1.2 TRAINING GUIDES ........................................................................................................ 7
1.3 MANUALS....................................................................................................................... 7
3 SPECIFICATIONS ............................................................................................ 9
3.1 PART NUMBERING ........................................................................................................ 9
3.1.1 SHORT NAMES ....................................................................................................... 9
3.3 POWER SUPPLY REQUIREMENTS ............................................................................ 10
3.4 GENERATOR AND BUS 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 RESISTIVE INPUTS .......................................................................... 13
COOLANT ........................................................................................................................ 13
3.6.3 ANALOGUE FLEXIBLE INPUT ............................................................................... 14
3.6.4 CHARGE FAIL INPUT ............................................................................................ 15
3.6.5 MAGNETIC PICKUP .............................................................................................. 15
3.7 OUTPUTS ..................................................................................................................... 16
3.7.1 OUTPUTS A & B .................................................................................................... 16
3.7.2 OUTPUTS C & D .................................................................................................... 16
CONTACTOR COILS ........................................................................................................ 16
UNDERVOLTAGE (UV COILS) ......................................................................................... 16
OPENING COILS / SHUNT TRIP COILS .......................................................................... 17
3.7.3 OUTPUTS E,F,G,H, I & J ....................................................................................... 17
3.8 COMMUNICATION PORTS .......................................................................................... 18
3.9 COMMUNICATION PORT USAGE .............................................................................. 18
3.9.1 CAN INTERFACE .................................................................................................. 18
3.9.2 USB CONNECTION ............................................................................................... 19
3.9.3 USB HOST-MASTER (USB DRIVE CONNECTION)............................................... 19
3.9.4 RS232 .................................................................................................................... 20
3.9.5 RS485 .................................................................................................................... 22
3.9.6 MSC ....................................................................................................................... 23
3.9.7 ETHERNET ............................................................................................................ 24
DIRECT PC CONNECTION .............................................................................................. 24
CONNECTION TO BASIC ETHERNET............................................................................. 25
CONNECTION TO COMPANY INFRASTRUCTURE ETHERNET .................................... 26
CONNECTION TO THE INTERNET ................................................................................. 27
3.10 DSENET® FOR EXPANSION MODULES ................................................................ 30
3.10.1 DSENET® USED FOR MODBUS ENGINE CONNECTION .................................... 30
3.11 SOUNDER ................................................................................................................. 31
3.11.1 ADDING AN EXTERNAL SOUNDER TO THE APPLICATION ................................ 31
3.12 ACCUMULATED INSTRUMENTATION .................................................................... 31
3.13 DIMENSIONS AND MOUNTING ................................................................................ 32
DIMENSIONS ................................................................................................................... 32
3.13.1 FIXING CLIPS ........................................................................................................ 33
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3.13.2 CABLE TIE FIXING POINTS .................................................................................. 34
3.13.3 SILICON SEALING GASKET ................................................................................. 34
3.14 APPLICABLE STANDARDS ..................................................................................... 35
3.14.1 ENCLOSURE CLASSIFICATIONS ......................................................................... 36
IP CLASSIFICATIONS ...................................................................................................... 36
NEMA CLASSIFICATIONS ............................................................................................... 37
4 INSTALLATION ............................................................................................. 38
4.1 TERMINAL DESCRIPTION........................................................................................... 38
4.1.1 DC SUPPLY, FUEL AND START OUTPUTS ......................................................... 38
4.1.2 ANALOGUE SENSORS ......................................................................................... 39
4.1.3 MAGNETIC PICKUP, CAN AND EXPANSION ....................................................... 40
4.1.4 LOAD SWITCHING AND GENERATOR VOLTAGE SENSING .............................. 41
4.1.5 BUS 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 3 PHASE, 4 WIRE WITH RESTRICTED EARTH FAULT PROTECTION ............... 47
4.2.2 3 PHASE, 4 WIRE WITHOUT EARTH FAULT PROTECTION ............................... 48
4.2.3 3 PHASE 4 WIRE W ITH UNRESTRICTED EARTH FAULT PROTECTION ........... 49
4.2.4 EARTH SYSTEMS ................................................................................................. 50
NEGATIVE EARTH........................................................................................................... 50
POSITIVE EARTH ............................................................................................................ 50
FLOATING EARTH ........................................................................................................... 50
4.3 ALTERNATIVE TOPOLOGIES ..................................................................................... 51
4.3.1 SINGLE PHASE WITH RESTRICTED EARTH FAULT ........................................... 51
4.3.2 SINGLE PHASE WITHOUT EARTH FAULT........................................................... 52
4.3.3 2 PHASE (L1 & L2) 3 WIRE WITH RESTRICTED EARTH FAULT ......................... 53
4.3.4 2 PHASE (L1 & L2) 3 WIRE WITHOUT EARTH FAULT ......................................... 54
4.3.5 2 PHASE (L1 & L3) 3 WIRE WITH RESTRICTED EARTH FAULT ......................... 55
4.3.6 2 PHASE (L1 & L3) 3 WIRE WITHOUT EARTH FAULT MEASURING ................... 56
4.4 TYPICAL ARRANGEMENT OF DSENET® .................................................................. 57
5 DESCRIPTION OF CONTROLS .................................................................... 58
5.1 DSE8610 AUTOSTART CONTROL MODULE.............................................................. 58
5.2 QUICKSTART GUIDE................................................................................................... 60
5.2.1 STARTING THE ENGINE....................................................................................... 60
5.2.2 STOPPING THE ENGINE ...................................................................................... 60
5.3 VIEWING THE INSTRUMENT PAGES ......................................................................... 61
5.3.1 STATUS ................................................................................................................. 62
5.3.2 CONFIGURABLE EDITOR SCREENS ................................................................... 63
5.3.3 ENGINE ................................................................................................................. 64
5.3.4 GENERATOR......................................................................................................... 65
5.3.5 BUS........................................................................................................................ 65
5.3.6 RS232 SERIAL PORT ............................................................................................ 66
5.3.7 RS485 SERIAL PORT ............................................................................................ 69
5.3.8 ABOUT ................................................................................................................... 70
ETHERNET PAGES ......................................................................................................... 70
DATA LOGGING PAGES ................................................................................................. 71
5.3.9 CAN ERROR MESSAGES ..................................................................................... 72
5.4 VIEWING THE EVENT LOG ......................................................................................... 73
5.5 USER CONFIGURABLE INDICATORS ........................................................................ 74
5.6 CONTROLS .................................................................................................................. 75
START .............................................................................................................................. 75
6 OPERATION .................................................................................................. 77
6.1 ALTERNATIVE CONFIGURATIONS ............................................................................ 77
6.2 DUMMY LOAD / LOAD SHEDDING CONTROL ........................................................... 78
6.2.1 DUMMY LOAD CONTROL ..................................................................................... 78
6.2.2 LOAD SHEDDING CONTROL ................................................................................ 79
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6.3 SMS CONTROL ............................................................................................................ 80
6.4 STOP MODE ................................................................................................................. 81
6.4.1 ECU OVERRIDE .................................................................................................... 82
6.5 AUTOMATIC MODE ..................................................................................................... 83
6.5.1 WAITING IN AUTO MODE ..................................................................................... 83
6.5.2 STARTING SEQUENCE......................................................................................... 83
6.5.3 ENGINE RUNNING ................................................................................................ 84
6.5.4 STOPPING SEQUENCE ........................................................................................ 84
6.6 MANUAL MODE ........................................................................................................... 85
6.6.1 WAITING IN MANUAL MODE ................................................................................ 85
6.6.2 STARTING SEQUENCE......................................................................................... 85
6.6.3 ENGINE RUNNING ................................................................................................ 86
6.6.4 MANUAL FUEL PUMP CONTROL ......................................................................... 86
6.6.5 MANUAL SPEED CONTROL ................................................................................. 86
6.6.6 STOPPING SEQUENCE ........................................................................................ 86
7 DEAD BUS SYNCHRONISING (AUTO MODE) ............................................. 87
7.1.1 OPERATION .......................................................................................................... 87
DEAD BUS SYNCHRONISING ............................................................................................ 87
7.1.2 HARDWARE REQUIREMENTS ............................................................................. 88
8 PROTECTIONS .............................................................................................. 89
8.1 PROTECTIONS DISABLED.......................................................................................... 90
8.1.1 INDICATION / WARNING ALARMS ....................................................................... 90
8.1.2 SHUTDOWN / ELECTRICAL TRIP ALARMS ......................................................... 90
8.2 INDICATIONS ............................................................................................................... 91
8.3 WARNINGS................................................................................................................... 92
8.4 HIGH CURRENT WARNING ALARM ............................................................................ 93
8.5 SHUTDOWNS ............................................................................................................... 94
8.6 ELECTRICAL TRIPS .................................................................................................... 96
8.7 HIGH CURRENT SHUTDOWN / ELECTRICAL TRIP ALARM ...................................... 98
8.7.1 IMMEDIATE WARNING ......................................................................................... 98
8.7.2 IDMT ALARM ......................................................................................................... 98
8.8 SHORT CIRCUIT AND EARTH FAULT SHUTDOWN / ELECTRICAL TRIP ALARM . 100
8.8.1 EARTH FAULT TRIPPING CURVES .................................................................... 101
8.8.2 SHORT CIRCUIT TRIPPING CURVES ................................................................ 102
8.9 ROCOF / VECTOR SHIFT .......................................................................................... 103
9 MAINTENANCE ALARM .............................................................................. 104
10 SCHEDULER ............................................................................................. 106
10.1.1 STOP MODE ........................................................................................................ 106
10.1.2 MANUAL MODE ................................................................................................... 106
10.1.3 AUTO MODE ........................................................................................................ 106
11 FRONT PANEL CONFIGURATION .......................................................... 107
11.1 ACCESSING THE MAIN FRONT PANEL CONFIGURATION EDITOR ................... 108
11.1.1 EDITING A PARAMETER..................................................................................... 109
11.1.2 ADJUSTABLE PARAMETERS ............................................................................. 110
11.2 ACCESSING THE ‘RUNNING’ CONFIGURATION EDITOR ................................... 111
11.2.1 EDITING A PARAMETER..................................................................................... 111
11.2.2 ADJUSTABLE PARAMETERS (RUNNING EDITOR) ........................................... 111
12 COMMISSIONING ..................................................................................... 112
12.1.1 PRE-COMMISSIONING ....................................................................................... 112
13 FAULT FINDING........................................................................................ 113
14 DSE 4 STEPS TO SUCCESSFUL SYNCHRONISING .............................. 115
14.1 CONTROL ............................................................................................................... 115
14.2 METERING .............................................................................................................. 115
14.3 COMMUNICATIONS................................................................................................ 115
14.4 SYNC CHECKS ....................................................................................................... 115
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15 MAINTENANCE, SPARES, REPAIR AND SERVICING ........................... 116
15.1 PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE .......................... 116
INDIVIDUAL PLUGS ....................................................................................................... 116
15.2 PURCHASING ADDITIONAL FIXING CLIPS FROM DSE ....................................... 116
15.3 PURCHASING ADDITIONAL SEALING GASKET FROM DSE ............................... 116
15.4 DSENET EXPANSION MODULES .......................................................................... 117
16 WARRANTY .............................................................................................. 118
17 DISPOSAL ................................................................................................ 118
17.1 WEEE (WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT) ......................... 118
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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
053-069 DSE8610 Installation Instructions 053-129 DSE8620 Installation Instructions 053-070 DES8660 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 056-006 Introduction to Comms 056-010 Overcurrent Protection 056-013 Load Demand Scheme 056-018 Negative Phase Sequence 056-019 Earth Fault Protection 056-020 Loss of Excitation 056-021 Mains Decoupling 056-022 Breaker Control 056-023 Adding New CAN Files 056-024 GSM Modem 056-026 kW & kVAr 056-029 Smoke Limiting
056-030 Module PIN Codes 056-032 xx60 With No Bus Breaker 056-042 Bus or Mains Mode 056-057 SW1 and SW2 056-059 xx10 in Fixed Export
1.3 MANUALS
DSE PART DESCRIPTION
057-004 Electronic Engines And DSE Wiring Manual 057-082 DSE2130 Input Expansion Manual 057-083 DSE2157 Output 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 057-084 DSE2548 Annunciator Expansion Manual 057-119 DSE8600 Series Configuration Software Manual 057-120 DSE8660 ATS Operator Manual
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2 INTRODUCTION
This document details the installation and operation requirements of the DSE8610 Series modules, part of the DSEPower® 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 DSE8600 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 DSE8600 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.
Synchronsing and Load Sharing features are included within the controller, along with the necessary protections for such a system.
The user also has the facility to view the system operating parameters via the LCD display.
The DSE8600 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.
Engine parameter monitoring.
Fully configurable inputs for use as alarms or a range of different functions.
Engine ECU interface to electronic engines.
Direct connection to governor / AVR for synchronising and load sharing
R.O.C.O.F. and Vector shift for detection of mains failure when in parallel with the mains supply.
Using a PC and the Configuration Suite software allows alteration of selected operational sequences, timers and alarms.
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.
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3 SPECIFICATIONS
3.1 PART NUMBERING
8610 - 001 - 00
Issolated Can Port
At the time of this document production, there are no variants of this product.
3.1.1 SHORT NAMES
Short name Description
DSE8600, DSE86xx All modules in the DSE8600 Series
Product type
DSE 8610 Autostart Module
8610
Variant
Standard product
00
Hardware revision
Initial module release
001
002
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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. This is more than sufficient to allow the module to operate during engine cranking where the battery supply often falls as low as 4V (on a 12V system!)
This is achieved without the need for internal batteries or other external
requirements. Maximum supply voltage 35V continuous (60V protection for surges) Reverse polarity protection -35V continuous
Maximum operating current
300mA at 24V
600mA at 12V
Maximum standby current
190mA at 24V
390mA 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)
3.4 GENERATOR AND BUS 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 (±3.33V ph-N)
±2% of full scale phase to phase (±11.52V ph-ph) Minimum frequency 3.5Hz Maximum frequency 75.0Hz Frequency resolution 0.1Hz Frequency accuracy ±0.2Hz
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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 DSE8610 module on the CTs is 0.5VA. However depending upon the type and length of cabling between the CTs and the DSE8610 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 measuring
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.
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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 level you wish to protect against, and at the accuracy level 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
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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 RESISTIVE INPUTS
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
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
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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 ANALOGUE FLEXIBLE INPUT
An additional flexible analogue input is provided and can be configured as Digital or Resistive.
3.6.3.1 FLEXIBLE SENSOR AS DIGITAL
Arrangement Contact between input terminal and battery negative Low level threshold 2.1 V minimum High level threshold 6.6 V maximum Max input voltage +60 V DC with respect to battery negative Min input voltage -24 V DC with respect to battery negative Contact wetting current 7 mA typical Open circuit voltage 12 V typical
3.6.3.2 FLEXIBLE SENSOR AS RESISTIVE
Arrangement Differential resistance measurement input with individual common
terminals for each sensor input Measurement current 9.3 mA typical Full scale
480 Sensor fail Values greater than full scale return an over range sentinel that may be
interpreted as sensor fail if appropriate (host controller dependant) Resolution 1% of full scale Accuracy ±-2 % of full scale resistance, excluding transducer (sensor) error Maximum common mode voltage
3 V
Transducer (sensor type)
Configurable in host controller
Use with contacts Inputs may be used with a contact to ground providing the corresponding
common terminal is grounded. (ie can be used as digital inputs if correctly
configured in the host controller)
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3.6.4 CHARGE FAIL INPUT
Minimum voltage 0V Maximum voltage 35V (plant supply) Resolution 0.2V Accuracy ±1% of max measured voltage (±0.35V) Excitation Active circuit constant power output Output Power 2.5W Nominal @12V and 24V Current at 12V 210mA Current at 24V 104mA
. 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.
3.6.5 MAGNETIC PICKUP
Type Differential input Minimum voltage 0.5V RMS Max common mode voltage ±2V Maximum voltage Clamped to ±70V by transient suppressors 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 devices. For example, one device can often supply the signal to both the DSE8600 series module and the engine governor. The possibility of this depends upon the amount of current that the magnetic pickup can supply.
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3.7 OUTPUTS
Ten (10) digital outputs are fitted to the DSE8610 controller. Additional outputs are provided for by adding up to ten (10) external relay boards (DSE2157). This allows for up to 80 additional digital outputs.
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 OUTPUTS C & D
Type Voltage free relays, fully configurable, normally used for generator / mains load switch control. Rating 8A resistive @ 250 V AC
Contactor coils
Use output D, the normally open relay:
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 Generator 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.
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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:
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:
t
h e
3.7.3 OUTPUTS E,F,G,H, I & J
Number 6 Type Fully configurable, supplied from DC supply terminal 2. Rating 3A resistive @ 35V
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-energised (opening the internal relay).
Generator:
When the DSE module requires the breaker open, the output energises (closing the internal relay).
Generator:
When the DSE module requires the breaker open, the output energises (closing the internal relay) for the period of the breaker trip pulse.
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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 and provide independent operation RS232 Serial port
Non – Isolated port
Max Baud rate 115.2K 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 115200
External termination required (120)
Max common mode offset 70V (on board protection transorb)
Max distance 1.2km (¾ mile) MSC Multi Set Communication Port Multi Set Communication Port (connection to other DSE modules)
Data connection 2 wire + common
Issolated
External termination required (120)
Max common mode offset 70V (on board protection transorb)
Max distance 250M using Belden 9841 Cable or equivalent CAN Port Engine CAN Port
Standard implementation of ‘Slow mode’, up to 250K bits/s
Non-Isolated.
Internal Termination provided (120)
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 such as the DSE8600 series to access these engine parameters with no physical connection to the sensor device.
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
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3.9.2 USB CONNECTION
The USB port is provided to give a simple means of connection between a PC and the DSE8600 series 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 DSE8600 series module to a PC by USB, the following items are required:
DSE8600 series module
DSE 8600 series configuration 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 DSE8600 series Configuration Suite Manual (DSE part 057-119) for further details on
configuring, monitoring and control.
3.9.3 USB HOST-MASTER (USB DRIVE CONNECTION)
Capability to add USB Host facility for USB ‘Pendrive’ type interface for data recording Connector Type A. For data logging max maximum size 16Gb.(see viewing the instrument pages)
NOTE:- Refer to DSE8600 series Configuration Suite Manual (DSE part 057-119) for further details on
configuring, monitoring and control.
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3.9.4 RS232
The RS232 port on the DSE8600 series 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 DSE86xx series 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.
Recommended PC Serial Port add-ons (for computers without internal RS232 port): 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.
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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)
Wavecom Fastrak Supreme GSM modem kit (PSU, Antenna and modem)* DSE Part number 0830-001-01
Brodersen GSM Industrial Modem* DSE Part number 020-245
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.
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3.9.5 RS485
The RS485 port on the DSE8600 series controller supports the Modbus RTU protocol. The DSE Gencomm register table for the controller is available 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 DSE8600 series 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).
Recommended PC Serial Port add-ons (for computers without internal RS485 port). 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.
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3.9.6 MSC
The MSC (Multi System control) is used to communicate with other DSE modules in a system.
The MSC is used for point-to-point cable connection of more than one device (maximum 32 Generator controller and another 8 Mains / Bus tie devices giving a maximum of 40 units)
The maximum distance is 250M using Belden 9841, 120ohm impedance screened twisted pair cable. This can be extended using DSE124 Can Bus Extender
NOTE: - Version 86xx V 5.0 included a change to the MSC link protocol which is not compatible with lower versions until the lower versions have been upgraded to version 5.0 (This can be done using “Update Firmware” in Configuration Suite Software) .
NOTE:- At version 5.1+ The MSC communication changed to enable 86xx ranges to communicate with 55xx and 75xx range of modules.
When using 55xx or 75xx with 86xx the MSC capability lowers to that of the 55xx/ 75xx series. i.e. Max units that can be used together in the case of 55xx,75xx would be 16 generators on the MSC link at anyone time, not the 32 Gen sets that the DSE86xx is specified.
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3.9.7 ETHERNET
The DSE8610 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
DIRECT PC CONNECTION
Requirements
DSE8610
Crossover Ethernet cable (see Below)
PC with Ethernet port and Windows Internet Explorer 6 or above, Firefox
Crossover network cable
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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.
CONNECTION TO BASIC ETHERNET
Requirements
DSE8610
Ethernet cable (see below)
Working Ethernet (company or home network)
PC with Ethernet port and Windows Internet Explorer 6 or above, Firefox
For the advanced Engineer, a crossover cable is a CAT5 cable with one end terminated as T568A and the other end terminated as T568B.
Ethernet router or ADSL router
Ethernet cable
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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.
CONNECTION TO COMPANY INFRASTRUCTURE ETHERNET
Requirements
DSE8610
Ethernet cable (see below)
Working Ethernet (company or home network)
PC with Ethernet port and Windows Internet Explorer 6 or above, Firefox
For the advanced Engineer, this cable has both ends terminated as T568A (as shown below) or T568B.
Ethernet cable
PC Network wall connection sockets
Ethernet router or ADSL router
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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.
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 T568A (as shown below) or T568B.
Ethernet cable
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 to the DSE850
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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 T568A (as shown below) or T568B.
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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 DSE8610. 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 DSE8610 makes its data available over Modbus TCP and as such communicates over the Ethernet using a Port configured via the DSE config 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 DSE8610 cannot be used and another port must be used .
Outgoing Firewall rule
As the DSE8610 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 DSE8610 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 requests reaches the modem/router, we want this passed to a ‘virtual server’ for handling, in our case this is the DSE8610 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 (DSE8610) for handling.
NOTE:- Refer to DSE8600 series Configuration Suite Manual (DSE part 057-119) for further details on
configuring, monitoring and control.
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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 80 additional relay outputs
Maximum 80 additional LED indicators
Maximum 32 additional inputs (16 of which can be analogue inputs if required)
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 : DSE8600 series does not support the 2510/2520 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:
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