Winco DSE7300 User Manual

DSECONTROL®

DSE7200 / DSE7300 Series Control Module

Document number 057-074

Author : Anthony Manton

DSE Model 7000 Series Control and Instrumentation System Operators Manual

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:

DSE Model 7200 / 7300 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 and the names DSEUltra, DSEControl, DSEPower, DSEExtra, DSEMarine and DSENet are 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 since last publication

Amd. No. Comments 1 Added Maintenance Alarm 2 Added manual fuel pump and manual speed control (Issue 2.1) 3 Added more detail to many sections of the manual (Issue 2.1) including CTs, Earth Fault, Overcurrent, RS232,

4 Added changes to Dual Mutual, Fuel usage, dummy load control, load shedding, protections disabled, 2500 5 Additions for V5 modules including modem diagnostics and updated front panel editor details including

www.deepseaplc.com

Modem, RS485, external sounder, expansion modules (DSE2100 series), series display (for version 4 module additions) scheduler editing.

Clarification of notation used within this publication.

Highlights an essential element of a procedure to ensure correctness.

NOTE:

Indicates a procedure or practice, which, if not strictly observed, could result in damage or

CAUTION!

destruction of equipment. Indicates a procedure or practice, which could result in injury to personnel or loss of life if not

WARNING!

followed correctly.

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TABLE OF CONTENTS

Section Page

1 BIBLIOGRAPHY .............................................................................................. 6

1.1 INSTALLATION INSTRUCTIONS ....................................................................................... 6

1.2 TRAINING GUIDES ............................................................................................................. 6

1.3 MANUALS ............................................................................................................................ 6

2 INTRODUCTION .............................................................................................. 7

3 SPECIFICATIONS ............................................................................................ 8

3.1 PART NUMBERING ............................................................................................................ 8

3.2 MODEL NAMING ................................................................................................................. 8

3.2.1 SHORT NAMES ............................................................................................................ 8

3.3 TERMINAL SPECIFICATION .............................................................................................. 9

3.4 POWER SUPPLY REQUIREMENTS .................................................................................. 9

3.5 GENERATOR AND MAINS VOLTAGE / FREQUENCY SENSING .................................... 9

3.6 GENERATOR CURRENT SENSING ................................................................................. 10

3.7 INPUTS .............................................................................................................................. 10

3.7.1 DIGITAL INPUTS ........................................................................................................ 10

3.7.2 ANALOGUE INPUTS .................................................................................................. 10

3.7.3 CHARGE FAIL INPUT ................................................................................................ 11

3.7.4 MAGNETIC PICKUP ................................................................................................... 12

3.8 OUTPUTS .......................................................................................................................... 12

3.8.1 OUTPUTS A & B ......................................................................................................... 12

3.8.2 OUTPUTS C & D ........................................................................................................ 12

3.8.3 OUTPUTS E,F,G & H ................................................................................................. 12

3.9 COMMUNICATION PORTS .............................................................................................. 13

3.10

COMMUNICATION PORT USAGE .............................................................................. 13

3.10.1 CAN INTERFACE ...................................................................................................... 13

3.10.2 USB CONNECTION ................................................................................................... 14

3.10.3 RS232 ......................................................................................................................... 15

3.10.4 RS485 ......................................................................................................................... 16

3.11

DSENET® FOR EXPANSION MODULES .................................................................... 17

3.11.1 DSENET® USED FOR MODBUS ENGINE CONNECTION ...................................... 17

3.12

SOUNDER ...................................................................................................................... 18

3.12.1 ADDING AN EXTERNAL SOUNDER TO THE APPLICATION .................................. 18

3.13

ACCUMULATED INSTRUMENTATION ........................................................................ 18

3.14

DIMENSIONS AND MOUNTING ................................................................................... 19

3.14.1.1

DIMENSIONS .................................................................................................................................. 19

3.14.2 FIXING CLIPS ............................................................................................................. 20

3.14.3 CABLE TIE FIXING POINTS ...................................................................................... 21

3.14.4 SILICON SEALING GASKET...................................................................................... 21

3.15

APPLICABLE STANDARDS .......................................................................................... 22

3.15.1 ENCLOSURE CLASSIFICATIONS ............................................................................. 23

IP CLASSIFICATIONS ........................................................................................................................................... 23

NEMA CLASSIFICATIONS .................................................................................................................................... 24

4 INSTALLATION .............................................................................................. 25

4.1 USER CONNECTIONS ...................................................................................................... 25

4.2 TERMINAL DESCRIPTION ............................................................................................... 26

4.2.1 DC SUPPLY, FUEL AND START OUTPUTS ............................................................. 26

4.2.2 ANALOGUE SENSORS .............................................................................................. 27

4.2.3 MAGNETIC PICKUP, CAN AND EXPANSION .......................................................... 28

4.2.4 LOAD SWITCHING AND GENERATOR VOLTAGE SENSING ................................. 29

4.2.5 MAINS VOLTAGE SENSING...................................................................................... 29

4.2.6 GENERATOR CURRENT TRANSFORMERS ........................................................... 30

4.2.7 CONFIGURABLE DIGITAL INPUTS .......................................................................... 32

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4.2.8 PC CONFIGURATION INTERFACE CONNECTOR .................................................. 32

4.2.9 RS485 CONNECTOR ................................................................................................. 33

4.2.10 RS232 CONNECTOR ................................................................................................. 33

4.3 TYPICAL WIRING DIAGRAMS ......................................................................................... 34

4.3.1 7210 AUTOSTART CONTROLLER ............................................................................ 35

4.3.2 7220 AMF CONTROLLER .......................................................................................... 36

4.3.3 7310 AUTOSTART CONTROLLER ............................................................................ 37

4.3.4 7320 AMF CONTROLLER .......................................................................................... 38

4.3.5 DSENET® ................................................................................................................... 39

4.3.6 CONNECTIONS FOR DUAL MUTUAL STANDBY ..................................................... 40

4.3.7 EARTH SYSTEMS ...................................................................................................... 41

4.3.7.1 NEGATIVE EARTH .............................................................................................................................. 41

4.3.7.2 POSITIVE EARTH ............................................................................................................................... 41

4.3.7.3 FLOATING EARTH .............................................................................................................................. 41

4.4 ALTERNATIVE TOPOLOGIES .......................................................................................... 42

4.4.1 3 PHASE, 4 WIRE WITHOUT EARTH FAULT PROTECTION .................................. 42

4.4.2 SINGLE PHASE WITH RESTRICTED EARTH FAULT .............................................. 43

4.4.3 SINGLE PHASE WITHOUT EARTH FAULT .............................................................. 44

4.4.4 2 PHASE (L1 & L2) 3 WIRE WITH RESTRICTED EARTH FAULT ............................ 45

4.4.5 2 PHASE (L1 & L2) 3 WIRE WITHOUT EARTH FAULT ............................................ 46

4.4.6 2 PHASE (L1 & L3) 3 WIRE WITH RESTRICTED EARTH FAULT ............................ 47

4.4.7 2 PHASE (L1 & L3) 3 WIRE WITHOUT EARTH FAULT MEASURING ..................... 48

4.4.8 3 PHASE 4 WIRE WITH UNRESTRICTED EARTH FAULT MEASURING ............... 49

4.5 CT LOCATION ................................................................................................................... 50

4.6 TYPICAL ARRANGEMENT OF DSENET® ....................................................................... 51

5 DESCRIPTION OF CONTROLS .................................................................... 52

5.1 DSE7210 / DSE7310 AUTOSTART CONTROL MODULE ............................................... 52

5.2 DSE7220 / DSE7320 AMF CONTROL MODULE.............................................................. 54

5.3 QUICKSTART GUIDE ........................................................................................................ 56

5.3.1 STARTING THE ENGINE ........................................................................................... 56

5.3.2 STOPPING THE ENGINE ........................................................................................... 56

5.4 VIEWING THE INSTRUMENT PAGES .............................................................................. 57

5.4.1 STATUS ...................................................................................................................... 58

5.4.2 ENGINE ....................................................................................................................... 59

5.4.3 GENERATOR .............................................................................................................. 60

5.4.4 MAINS (DSE7220/DSE7320 ONLY) ........................................................................... 61

5.4.5 SERIAL PORT ............................................................................................................. 61

5.4.6 ABOUT ........................................................................................................................ 65

5.4.7 CAN ERROR MESSAGES .......................................................................................... 66

5.5 VIEWING THE EVENT LOG .............................................................................................. 67

5.6 USER CONFIGURABLE INDICATORS ............................................................................ 68

5.7 CONTROLS ....................................................................................................................... 69

5.7.1.1 TEST (DSE7220/DSE7320 ONLY) ...................................................................................................... 69

5.7.1.2 START ................................................................................................................................................. 69

6 OPERATION (STANDALONE) ...................................................................... 71

6.1 ALTERNATIVE CONFIGURATIONS ................................................................................. 71

6.2 DUMMY LOAD / LOAD SHEDDING CONTROL ............................................................... 72

6.2.1 DUMMY LOAD CONTROL ......................................................................................... 72

6.2.2 LOAD SHEDDING CONTROL .................................................................................... 73

6.3 STOP MODE ...................................................................................................................... 74

6.3.1 ECU OVERRIDE ......................................................................................................... 74

6.4 AUTOMATIC MODE .......................................................................................................... 75

6.4.1 WAITING IN AUTO MODE ......................................................................................... 75

6.4.2 STARTING SEQUENCE ............................................................................................. 75

6.4.3 ENGINE RUNNING ..................................................................................................... 76

6.4.4 STOPPING SEQUENCE ............................................................................................. 76

6.5 MANUAL MODE ................................................................................................................ 77

6.5.1 WAITING IN MANUAL MODE .................................................................................... 77

6.5.2 STARTING SEQUENCE ............................................................................................. 77

6.5.3 ENGINE RUNNING ..................................................................................................... 78

6.5.4 MANUAL FUEL PUMP CONTROL ............................................................................. 78

6.5.5 MANUAL SPEED CONTROL ...................................................................................... 78

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6.5.6 STOPPING SEQUENCE ............................................................................................ 79

6.6 TEST MODE ...................................................................................................................... 80

6.6.1 WAITING IN TEST MODE .......................................................................................... 80

6.6.2 STARTING SEQUENCE ............................................................................................. 80

6.6.3 ENGINE RUNNING..................................................................................................... 81

7 OPERATION (DUAL MUTUAL STANDBY) ................................................... 82

8 PROTECTIONS .............................................................................................. 83

8.1 PROTECTIONS DISABLED .............................................................................................. 84

8.1.1 INDICATION / WARNING ALARMS ........................................................................... 84

8.1.2 SHUTDOWN / ELECTRICAL TRIP ALARMS ............................................................ 84

8.2 INDICATIONS .................................................................................................................... 85

8.3 WARNINGS........................................................................................................................ 86

8.4 HIGH CURRENT WARNING ALARM ............................................................................... 87

8.5 SHUTDOWNS .................................................................................................................... 88

8.6 ELECTRICAL TRIPS ......................................................................................................... 90

8.7 HIGH CURRENT SHUTDOWN / ELECTRICAL TRIP ALARM ........................................ 91

8.7.1 IMMEDIATE WARNING.............................................................................................. 91

8.7.2 IDMT ALARM .............................................................................................................. 91

8.8 EARTH FAULT SHUTDOWN / ELECTRICAL TRIP ALARM ........................................... 93

8.8.1 EARTH FAULT TRIPPING CURVES ......................................................................... 93

8.9 MAINTENANCE ALARM ................................................................................................... 94

8.10

SCHEDULER ................................................................................................................. 95

8.10.1 STOP MODE............................................................................................................... 95

8.10.2 MANUAL MODE ......................................................................................................... 95

8.10.3 AUTO MODE .............................................................................................................. 95

8.11

FRONT PANEL CONFIGURATION ............................................................................... 96

8.12

ACCESSING THE MAIN FRONT PANEL CONFIGURATION EDITOR ....................... 97

8.12.1 EDITING A PARAMETER ........................................................................................... 98

8.12.2 ADJUSTABLE PARAMETERS ................................................................................... 99

8.13

ACCESSING THE ‘RUNNING’ CONFIGURATION EDITOR ...................................... 101

8.13.1 EDITING A PARAMETER ......................................................................................... 101

8.13.2 ADJUSTABLE PARAMETERS (RUNNING EDITOR) .............................................. 101

9 COMMISSIONING ........................................................................................ 102

9.1.1 PRE-COMMISSIONING............................................................................................ 102

10 FAULT FINDING ....................................................................................... 103

11 MAINTENANCE, SPARES, REPAIR AND SERVICING ........................... 105

11.1

PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE ............................. 105

11.1.1 DSE7200 SERIES ..................................................................................................... 105

11.1.1.1

11.1.1.2

11.1.2 DSE7300 SERIES ..................................................................................................... 106

11.1.2.1

11.1.2.2

11.2

11.3

11.4

11.5

PACK OF PLUGS .......................................................................................................................... 105

INDIVIDUAL PLUGS ...................................................................................................................... 105

PACK OF PLUGS .......................................................................................................................... 106

INDIVIDUAL PLUGS ...................................................................................................................... 106

PURCHASING ADDITIONAL FIXING CLIPS FROM DSE .......................................... 106

PURCHASING ADDITIONAL SEALING GASKET FROM DSE .................................. 106

EXPANSION MODULES .............................................................................................. 107

ETHERNET (LAN) CONNECTION .............................................................................. 108

12 WARRANTY .............................................................................................. 109

13 DISPOSAL................................................................................................. 109

13.1

WEEE (WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT) ........................... 109

13.2

ROHS (RESTRICTION OF HAZARDOUS SUBSTANCES) ........................................ 109

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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

053-026 DSE7210 Installation Instructions 053-027 DSE7220 Installation Instructions 053-028 DSE7310 Installation Instructions 053-029 DSE7320 Installation Instructions 053-032 DSE2548 LED Expansion Annunciator Installation Instructions 053-033 DSE2130 Input Expansion Installation Instructions 053-034 DSE2157 Output Expansion Installation Instructions 053-064 DSE2500 Series Display 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 056-022 Breaker Control 056-019 Earth Fault Protection 056-024 Gsm Modem 056-029 Smoke Limiting 056-030 Module PIN Codes

1.3 MANUALS

DSE PART DESCRIPTION

057-004 Electronic Engines And DSE Wiring Manual 057-077 DSE7000 Series Configuration Software Manual 057-082 DSE2130 Input Expansion Manual 057-083 DSE2157 Output Expansion Manual 057-084 DSE2548 Annunciator Expansion Manual 057-107 DSE2500 Series Display Operator Manual

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2 INTRODUCTION

This document does not contain operating instructions for the DSE7500 series synchronising and load sharing controllers. This is contained within DSE publications - part numbers 057-088 (DSE7510), 057-089 (DSE7520) and 057-090 (DSE7560).

This document details the installation and operation requirements of the DSE7200 and DSE7300 Series modules, part of the DSEControl® 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 DSE7000 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 DSE7000 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 DSE7320 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 DSE7000 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.

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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(no functional changes)

3 SPECIFICATIONS

3.1 PART NUMBERING

7210 - 002 - 00

Product type

DSE 7210 Autostart Module

DSE 7220 Automatic Mains Failure Module

DSE 7310 Autostart Module

DSE 7320 Automatic Mains Failure Module

At the time of this document production, there are no variants of this product. This document does not contain operating instructions for the DSE7500 series synchronising and load sharing

controllers. This is contained within DSE publications - part numbers 057-088 (DSE7510), 057-089 (DSE7520) and 057-090 (DSE7560).

7210

7220

7310

7320

Initial module release

Changes to module outputs to ease

(no functional changes)

Changes to circuit for UL

approval (no functional changes)

Changes to accommodate new

3.2 MODEL NAMING

72 10

Short name Description

DSE7000 All modules in the DSE7000 Series DSE7x10 All Autostart modules in the DSE7000 Series DSE7x20 All AMF modules in the DSE7000 Series DSE72x0 All modules in the DSE7200 series DSE73x0 All modules in the DSE7300 series

Series

DSE 7200 series

DSE 7300 series

3.2.1 SHORT NAMES

Variant

Standard product

Hardware revision

production process

LCD display

Function

Autostart (remote start) and manual start

Autostart, manual start and start upon mains failure

001

002

003

004

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3.3 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. Minimum cable size 0.5mm² (AWG 24) Maximum cable size 2.5mm² (AWG 10)

Example showing cable entry and screw

terminals of a 10 way connector

NOTE : For purchasing additional connector plugs from DSE, please see the section entitled

Maintenance, Spares, Repair and Servicing elsewhere in this document.

3.4 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 DSE7200 / DSE7300 Maximum standby current DSE7200 / DSE7300

160mA at 24V 340mA at 12V 80mA at 24V 160mA 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)

3.5 GENERATOR AND MAINS VOLTAGE / FREQUENCY SENSING

Measurement type True RMS conversion Sample Rate 5KHz or better Harmonics Up to 10th or better Input Impedance Phase to Neutral 15V

Phase to Phase 26V Common mode offset from Earth 100V AC (max)

Resolution 1V AC phase to neutral Accuracy ±1% of full scale phase to neutral (±3.33V ph-N) Minimum frequency 3.5Hz

Maximum frequency 75.0Hz Frequency resolution 0.1Hz Frequency accuracy ±0.2Hz

300K Ω ph-N

(minimum required for sensing frequency

Suitable for 110V to 277V nominal

(minimum required for sensing frequency

Suitable for 190V ph-ph to 479V ph-ph nominal

)

to 333V AC

(±20% for under/overvoltage detection)

)

to 576V AC

(absolute maximum)

(±20% for under/overvoltage detection)

2V AC phase to phase ±2% of full scale phase to phase (±11.52V ph-ph)

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3.6 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 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)

0.5VA (0.02Ω current shunts)

3.7 INPUTS

3.7.1 DIGITAL INPUTS

Number 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

3.7.2 ANALOGUE INPUTS

Oil Pressure

Measurement type Resistance measurement by measuring voltage across sensor with a fixed current Arrangement Differential resistance measurement input

Measurement current 15mA Full scale Over range / fail Resolution 1-2 PSI / 0.1 Bar Accuracy Max common mode voltage ±2V Display range 0-200 PSI / 13.7 bar subject to limits of the sensor

Coolant Temperature

Measurement type Resistance measurement by measuring voltage across sensor with a fixed current Arrangement Differential resistance measurement input

Measurement current 10mA Full scale Over range / fail Resolution Accuracy Max common mode voltage ±2V Display range

DSE7200 6 DSE7300 8

applied

240Ω 270Ω

±2% of full scale resistance (±4.8Ω) excluding transducer error

applied

480Ω 540Ω 1°C, 2°F +/-2% of full scale resistance (±9.6Ω) excluding transducer error

0°C -140°C, 32°F - 284°F Depending on sensor

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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 Over range / fail

480Ω

540Ω Resolution 1% Accuracy

+/-2% of full scale resistance (±9.6Ω) excluding transducer error Max common mode voltage ±2V Display range 0-250%

Flexible Sensor

NOTE : Flexible sensor is not available on DSE7200 series controllers

Measurement type Resistance measurement by measuring voltage across sensor with a fixed current

applied Arrangement Differential resistance measurement input Measurement current 10mA Full scale Over range / fail

480Ω

540Ω Resolution 1% Accuracy

+/-2% of full scale resistance (±9.6Ω) excluding transducer error Max common mode voltage ±2V Display range 0-250%

3.7.3 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

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3.7.4 MAGNETIC PICKUP

Type Differential input 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 devices. For example, one device can often supply the signal to both the DSE7000 series module and the engine governor. The possibility of this depends upon the amount of current that the magnetic pickup can supply.

3.8 OUTPUTS

3.8.1 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

3.8.2 OUTPUTS C & D

Type Voltage free relays, fully configurable, normally used for generator / mains load switch control. Rating 8A resistive @ 250 V AC

3.8.3 OUTPUTS E,F,G & H

Type Fully configurable, supplied from DC supply terminal 2. Rating 3A resistive @ 35V

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3.9 COMMUNICATION PORTS

USB Port USB2.0 Device for connection to PC running DSE configuration suite only

Max distance 6m (20 feet) Serial Communication (not available on DSE7200 series) RS232 Serial port (not available on DSE7200 series)

RS485 Serial port (not available on DSE7200 series)

CAN Port Engine CAN Port

RS232 and RS485 are both fitted but do NOT provide independent

operation

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)

Isolated

Data connection 2 wire + common

Half Duplex

Data direction control for Transmit (by s/w protocol)

Max Baud Rate 19200

External termination required (120Ω)

Max common mode offset 70V (on board protection transorb)

Max distance 1.2km (¾ mile)

Standard implementation of ‘Slow mode’, up to 250K bits/s

Non Isolated.

Internal Termination provided (120Ω)

Max distance 40m (133 feet)

3.10 COMMUNICATION PORT USAGE

3.10.1 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 DSE7000 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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3.10.2 USB CONNECTION

The USB port is provided to give a simple means of connection between a PC and the DSE7000 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 DSE7000 series module to a PC by USB, the following items are required:

• DSE7200 or DSE73000 series module

• DSE 7000 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 DSE7000 series Configuration Suite Manual for further details on configuring,

monitoring and control.

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3.10.3 RS232

NOTE: Modem and RS232 capability is not available with DSE7200 series controllers.

The RS232 port on the DSE7300 series controller support 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 DSE7300 series controller to a telephone or GSM modem for more remote communications.

Many PCs are not fitted with an internal RS232 serial port. DSE DO NOT recommend the use of USB to RS232 convertors but can recommend PC addons to provide the computer with an RS232 port.

Recommended PC Serial Port addons (for computers without internal RS232 port):

• Brainboxes PM143 PCMCIA RS232 card (for laptop PCs)

• Brainboxes UC246 PCI RS232 card (for desktop PCs)

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’ DATA ENABLED 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 DATA SIM card.

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3.10.4 RS485

NOTE:- RS485 capability is not available with DSE7200 series controllers.

The RS485 port on the DSE7300 series controller support 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 DSE7000 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 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) :

• Brainboxes PM154 PCMCIA RS485 card (for laptops) Set to ‘Half Duplex, Autogating” with ‘CTS True’ set to ‘enabled’

• Brainboxes UC320 PCI Velocity RS485 card (for desktop PCs) Set to ‘Half Duplex, Autogating” with ‘CTS True’ set to ‘enabled’

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3.11 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®

NOTE : DSENet® is not available on DSE7200 series controllers.

Cable type Two core screened twisted pair Cable characteristic impedance Recommended cable Belden 9841

Maximum cable length 1200m (¾ mile) when using Belden 9841 or direct equivalent. DSENet® topology “Daisy Chain” Bus with no stubs (spurs)

DSENet® termination Maximum expansion modules Refer to host controller documentation.

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.

120Ω Belden 9271 600m (666 yds) when using Belden 9271 or direct equivalent.

120Ω. Fitted internally to host controller. Must be fitted externally to the ‘last’ expansion module by the customer.

3.11.1 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 GCM (Generator Control Module)). This leaves the RS485 interface free for connection to remote monitoring equipment (ie 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 GMC using the DSE Configuration Suite Software :

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3.12 SOUNDER

DSE7000 Series features an internal sounder to draw attention to warning, shutdown and electrical trip alarms. Sounder level 84db @ 1m

3.12.1 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:

3.13 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

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3.14 DIMENSIONS AND MOUNTING

3.14.1.1 DIMENSIONS

240.0mm x 181.1mm x 41.7mm

PANEL CUTOUT

220mm x 160mm

(8.7” x 6.3”)

WEIGHT

0.7kg (1.4lb)

(9.4” x 7.1” x 1.6”)

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3.14.2 FIXING CLIPS

Supplied fixing clips hold the module into the panel fascia. Withdraw the fixing clip screw (turn anticlockwise) until only the pointed end is protruding from the clip.

• Insert the three ‘prongs’ of the fixing clip into the slots in the side of the 7000 series module case.

• Pull the fixing clip backwards (towards the back of the module) ensuring all three prongs of the clip are

inside their allotted slots.

• Turn the fixing clip screws clockwise until they make contact with the panel fascia.

• Turn the screws a little more to secure the module into the panel fascia. Take care not to over tighten the

fixing clip screws.

Fixing clip

Fixing clip fitted to module

NOTE:- In conditions of excessive vibration, mount the module on suitable anti-vibration mountings.

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3.14.3 CABLE TIE FIXING POINTS

Integral cable tie fixing points are included on the rear of the module’s case to aid wiring. This additionally provides strain relief to the cable loom by removing the weight of the loom from the screw connectors, thus reducing the chance of future connection failures. Care should be taken not to overtighten the cable tie (for instance with cable tie tools) to prevent the risk of damage to the module case.

Cable tie fixing point With cable and tie in place

3.14.4 SILICON SEALING GASKET

The supplied silicon gasket provides improved sealing between the 7000 series module and the panel fascia. The gasket is fitted to the module before installation into the panel fascia. Take care to ensure the gasket is correctly fitted to the module to maintain the integrity of the seal.

Sealing gasket

Gasket fitted to module

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3.15 APPLICABLE STANDARDS

BS 4884-1 BS 4884-2

BS 4884-3 BS EN 60068-2-1

(Minimum temperature)

BS EN 60068-2-2

(Maximum temperature)

BS EN 60950 BS EN 61000-6-2 BS EN 61000-6-4 BS EN 60529

(Degrees of protection provided by enclosures) (see overleaf)

UL508 NEMA rating

(Approximate) (see overleaf)

IEEE C37.2

(Standard Electrical Power System Device Function Numbers and Contact Designations)

In line with our policy of continual development, Deep Sea Electronics, reserve the right to change specification without notice.

This document conforms to BS4884-1 1992 Specification for presentation of essential information. This document conforms to BS4884-2 1993 Guide to content This document conforms to BS4884-3 1993 Guide to presentation

-30°C (-22°F) +70°C (158°F)

Safety of information technology equipment, including electrical business equipment EMC Generic Immunity Standard (Industrial) EMC Generic Emission Standard (Industrial) IP65 (front of module when installed into the control panel with the supplied sealing gasket) IP42 (front of module when installed into the control panel WITHOUT being sealed to the panel) 12 (Front of module when installed into the control panel with the supplied sealing gasket). 2 (Front of module when installed into the control panel WITHOUT being sealed to the panel) Under the scope of IEEE 37.2, function numbers can also be used to represent functions in microprocessor devices and software programs. The 7000 series controller is device number 11L-7000 (Multifunction device protecting Line (generator) – 7000 series module).

As the module is configurable by the generator OEM, the functions covered by the module will vary. Under the module’s factory configuration, the device numbers included within the module are :

2 – Time delay starting or closing relay 6 – Starting circuit breaker 27AC – AC undervoltage relay 27DC – DC undervoltage relay 30 – annunciator relay 42 – Running circuit breaker 50 – instantaneous overcurrent relay 51 – ac time overcurrent relay 52 – ac circuit breaker 53DC – exciter or dc generator relay 54 – turning gear engaging device 59AC – AC overvoltage relay 59DC – DC overvoltage relay 62 – time delay stopping or opening relay 63 – pressure switch 74– alarm relay 81 – frequency relay 86 – lockout relay

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3.15.1 ENCLOSURE CLASSIFICATIONS

IP CLASSIFICATIONS

7000 series specification under BS EN 60529 Degrees of protection provided by enclosures

IP65 (Front of module when module is installed into the control panel with the optional sealing gasket).

IP42 (front of module when module is installed into the control panel WITHOUT being sealed to the panel)

First Digit Second Digit

Protection against contact and ingress of solid objects Protection against ingress of water 0 No protection 0 No protection

1 Protected against ingress solid objects with a

diameter of more than 50 mm. No protection against

deliberate access, e.g. with a hand, but large

surfaces of the body are prevented from approach.

2 Protected against penetration by solid objects with a

diameter of more than 12 mm. Fingers or similar

objects prevented from approach.

3 Protected against ingress of solid objects with a

diameter of more than 2.5 mm. Tools, wires etc.

with a thickness of more than 2.5 mm are prevented

from approach.

4 Protected against ingress of solid objects with a

diameter of more than 1 mm. Tools, wires etc. with

a thickness of more than 1 mm are prevented from

approach.

5 Protected against harmful dust deposits. Ingress of

dust is not totally prevented but the dust must not

enter in sufficient quantity to interface with

satisfactory operation of the equipment. Complete

protection against contact.

6 Protection against ingress of dust (dust tight).

Complete protection against contact.

1 Protection against dripping water falling vertically. No

harmful effect must be produced (vertically falling drops).

2 Protection against dripping water falling vertically.

There must be no harmful effect when the equipment (enclosure) is tilted at an angle up to 15° from it s normal position (drops falling at an angle).

3 Protection against water falling at any angle up to 60°

from the vertical. There must be no harmful effect (spray water).

4 Protection against water splashed against the

equipment (enclosure) from any direction. There must be no harmful effect (splashing water).

5 Protection against water projected from a nozzle

against the equipment (enclosure) from any direction. There must be no harmful effect (water jet).

6 Protection against heavy seas or powerful water jets.

Water must not enter the equipment (enclosure) in harmful quantities (splashing over).

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NEMA CLASSIFICATIONS

7000 series NEMA Rating (Approximate)

12 (Front of module when module is installed into the control panel with the optional sealing gasket).

2 (front of module when module is installed into the control panel WITHOUT being sealed to the panel)

NOTE: - There is no direct equivalence between IP / NEMA ratings. IP figures shown are approximate

only.

IP30

Provides a degree of protection against contact with the enclosure equipment and against a limited amount of falling dirt.

IP31

IP64

IP32

4 (X)

IP66

12/12K

IP65

Provides a degree of protection against limited amounts of falling water and dirt.

Provides a degree of protection against windblown dust, rain and sleet; undamaged by the formation of ice on the enclosure.

Provides a degree of protection against rain and sleet:; undamaged by the formation of ice on the enclosure.

Provides a degree of protection against splashing water, windblown dust and rain, hose directed water; undamaged by the formation of ice on the enclosure. (Resist corrosion).

Provides a degree of protection against dust, falling dirt and dripping non corrosive liquids.

Provides a degree of protection against dust and spraying of water, oil and non corrosive coolants.

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4 INSTALLATION

The DSE7000 Series module is designed to be mounted on the panel fascia. For dimension and mounting details, see the section entitled Specification, Dimension and mounting elsewhere in this document.

4.1 USER CONNECTIONS

To aid user connection, icons on the rear of the module ease Identification of terminal functions.

NOTE : Availability of some terminals depends upon module version. The section entitled Terminal Description elsewhere in this manual details this further.

Terminals 39-46 Terminals 47-50 Terminals 51-55 Terminals 60-67

RS485 connection

RS232 connection

Terminals 1-11 Terminals 15-19

USB Connection

Terminals 22-30

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4.2 TERMINAL DESCRIPTION

4.2.1 DC SUPPLY, FUEL AND START OUTPUTS

Icon PIN

3 Emergency Stop Input

4 Output relay A (FUEL)

5 Output relay B (START)

6 Charge fail / excite

7 Functional Earth

8 Output relay E

9 Output relay F

10 Output relay G

11 Output relay H

DC Plant Supply Input (Negative)

DC Plant Supply Input (Positive)

DESCRIPTION CABLE

SIZE

2.5mm²

AWG 13

2.5 mm² AWG 13

2.5mm²

AWG 13

2.5mm²

AWG 13

2.5mm²

AWG 13

2.5mm²

AWG 13

2.5mm²

AWG 13

1.0mm²

AWG 18

1.0mm²

AWG 18

1.0mm²

AWG 18

1.0mm²

AWG 18

NOTES

(Recommended Maximum Fuse 15A anti-surge) Supplies the module (2A anti-surge requirement) and Output relays E,F,G & H

Plant Supply Positive. Also supplies outputs 1 & 2. (Recommended Maximum Fuse 20A)

Plant Supply Positive from terminal 3. 15 Amp rated. Fixed as FUEL relay if electronic engine is not configured.

Plant Supply Positive from terminal 3. 15 Amp rated. Fixed as START relay if electronic engine is not configured.

Do not connect to ground (battery negative). If charge alternator is not fitted, leave this terminal disconnected.

Connect to a good clean earth point.

Plant Supply Positive from terminal 2. 3 Amp rated.

Plant Supply Positive. from terminal 2. 3 Amp rated.

Plant Supply Positive from terminal 2. 3 Amp rated.

NOTE:- Terminals 12 to 14 are not fitted to the DSE7200/DSE7300 series controller.

NOTE:- When the module is configured for operation with an electronic engine, FUEL and START output requirements may be different. Refer to Electronic Engines and DSE Wiring for further information. DSE Part No. 057-004.

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4.2.2 ANALOGUE SENSORS

15 Sensor Common Return

16 Oil Pressure Input

17 Coolant Temperature Input

18 Fuel Level input

Flexible sensor (not available on 7200 series controller)

NOTE:- Terminals 20 and 21 are not fitted to the 7200/7300 series controller.

NOTE:- . It is VERY important that terminal 15 (sensor common) is soundly connected to an earth point on the ENGINE BLOCK, not within the control panel, and must be a sound electrical connection to the sensor bodies. This connection MUST NOT be used to provide an earth connection for other terminals or devices. The simplest way to achieve this is to run a SEPERATE earth connection from the system earth star point, to terminal 15 directly, and not use this earth for other connections.

DESCRIPTION CABLE

SIZE

0.5mm²

AWG 20

0.5mm²

AWG 20

0.5mm²

AWG 20

0.5mm²

AWG 20

0.5mm²

AWG 20

NOTES

Return feed for sensors

Connect to Oil pressure sensor

Connect to Coolant Temperature sensor

Connect to Fuel Level sensor

Connect to additional sensor (user configurable)

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

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4.2.3 MAGNETIC PICKUP, CAN AND EXPANSION

22 Magnetic pickup Positive 23 Magnetic pickup Negative 24 Magnetic pickup screen Shield Connect to ground at one end only 25 CAN port H 26 CAN port L 27 CAN port Common 28 + 29 30 SCR

NOTE:- Terminals 31 to 38 are not fitted to the 7200 / 7300 controller

DESCRIPTION CABLE

SIZE

0.5mm²

AWG 20

0.5mm²

AWG 20

0.5mm²

AWG 20

0.5mm²

AWG 20

0.5mm²

AWG 20

0.5mm²

AWG 20

0.5mm²

AWG 20

0.5mm²

AWG 20

Connect to Magnetic Pickup device Connect to Magnetic Pickup device

Use only 120Ω CAN approved cable Use only 120Ω CAN approved cable Use only 120Ω CAN approved cable Use only 120Ω RS485 approved cable Use only 120Ω RS485 approved cable Use only 120Ω RS485 approved cable

NOTES

NOTE:- Screened cable must be used for connecting the Magnetic Pickup, ensuring that the screen is

earthed at one end ONLY.

NOTE:- Screened 120ΩΩΩΩ impedance cable specified for use with CAN must be used for the CAN link and

the Multiset comms link. DSE stock and supply Belden cable 9841 which is a high quality 120ΩΩΩΩ impedance cable suitable for CAN use (DSE part number 016-030)

NOTE:- When the module is configured for CAN operation, terminals 22, 23 & 24 should be left unconnected. Engine speed is transmitted to the 7000 series controller on the CAN link. Refer to Electronic Engines and DSE Wiring for further information. Part No. 057-004.

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4.2.4 LOAD SWITCHING AND GENERATOR VOLTAGE SENSING

39 Output relay C 40 Output relay C 41 Output relay D 42 Output relay D 43 44 45 46 Generator Neutral (N) input

DESCRIPTION CABLE

Generator L1 (U) voltage monitoring Generator L2 (V) voltage monitoring input Generator L3 (W) voltage monitoring input

SIZE

1.0mm

AWG 18

1.0mm

AWG 18

1.0mm

AWG 18

1.0mm

AWG 18

1.0mm²

AWG 18

1.0mm²

AWG 18

1.0mm²

AWG 18

1.0mm²

AWG 18

NOTES

Normally configured to control mains contactor coil (Recommend 10A fuse)

Normally configured to control mains contactor coil Normally configured to control generator contactor coil

(Recommend 10A fuse) Normally configured to control generator contactor coil Connect to generator L1 (U) output (AC)

(Recommend 2A fuse) Connect to generator L2 (V) output (AC) (Recommend 2A fuse) Connect to generator L3 (W) output (AC) (Recommend 2A fuse)

Connect to generator Neutral terminal (AC)

NOTE:- The above table describes connections to a three phase, four wire alternator. For alternative

wiring topologies, please see the ALTERNATIVE AC TOPOLOGIES section of this manual.

4.2.5 MAINS VOLTAGE SENSING

47 Mains L1 (R) voltage monitoring 48 Mains L2 (S) voltage monitoring 49 Mains L3 (T) voltage monitoring 50 Mains Neutral (N) input

DESCRIPTION CABLE

SIZE

1.0mm

AWG 18

1.0mm

AWG 18

1.0mm

AWG 18

1.0mm

AWG 18

NOTES

Connect to Mains L1 (R) incoming supply (AC) (Recommend 2A fuse) Connect to Mains L1 (S) incoming supply (AC) (Recommend 2A fuse) Connect to Mains L1 (T) incoming supply (AC) (Recommend 2A fuse) Connect to Mains N incoming supply (AC)

NOTE:- Terminals 47-50 are not fitted to the 7210 / 7310 controller.

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4.2.6 GENERATOR CURRENT TRANSFORMERS

WARNING!:- Do not disconnect this plug when the CTs are carrying current. Disconnection will open circuit the secondary of the C.T.’s and dangerous voltages may then develop. Always ensure the CTs are not carrying current and the CTs are short circuit connected before making or breaking connections to the module.

NOTE:- The 7000 series module has a burden of 0.5VA on the CT. Ensure the CT is rated for the burden of the 7000 series controller, the cable length being used and any other equipment sharing the CT. If in doubt, consult your CT supplier.

NOTE:- Take care to ensure correct polarity of the CT primary as shown below. If in doubt, check with the CT supplier.

CT LABELLING

p1, k or K is the primary of the CT that ‘points’ towards the GENERATOR

p2, l or L is the primary of the CT that ‘points’ towards the LOAD

s1 is the secondary of the CT that connects to the DSE Module’s input for the CT measuring s2 is the secondary of the CT that should be commoned with the s2 connections of all the other CTs and connected

to the CT common terminal of the DSE7000 series modules.

CT labelled as p1, k or K

(I1,I2,I3)

To Load

To Supply

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CT labelled as p2, l or L

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