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DSE Model 5220 Automatic Mains Failure & Instrumentation System Operators Manual
DEEP SEA ELECTRONICS PLC
5220 AUTOMATIC MAINS FAILURE MODULE OPERATING MANUAL
Author:- Anthony Manton
Deep Sea Electronics Plc Highfield House Hunmanby North Yorkshire YO14 0PH England Tel: +44 (0) Fax: +44 (0) email: Sales@Deepseaplc.com
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5220 OPERATING MANUAL ISSUE 2
TABLE OF CONTENTS Section
INTRODUCTION.... 5 CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION. 5 OPERATION.... 6
3.1 3.2 3.3 AUTOMATIC MODE OF OPERATION... 6 MANUAL OPERATION... 8 TEST OPERATION.... 9 WARNINGS.... 11 ANALOGUE PRE-ALARMS... 11 HIGH CURRENT WARNING ALARM... 12 SHUTDOWNS.... 13 HIGH CURRENT SHUTDOWN ALARM... 15 ELECTRICAL TRIPS.... 15
4.1 4.2 4.3 4.4 4.5 4.6
DESCRIPTION OF CONTROLS... 16
5.1 TYPICAL LCD DISPLAY SCREENS... 17 5.2 LCD DISPLAY AREAS....18 5.3 VIEWING THE INSTRUMENTS... 19 5.3.1 CANBUS MESSAGES... 20 5.4 VIEWING THE EVENT LOG.... 21 5.5 INDICATORS.... 22 5.6 CONTROLS.... 22
FRONT PANEL CONFIGURATION... 23
6.1 ACCESSING THE FRONT PANEL CONFIGURATION EDITOR. 23 6.1.1 EDITING AN ANALOGUE VALUE.... 24 6.1.2 EDITING THE CURRENT DATE/TIME... 26
INSTALLATION INSTRUCTIONS... 27
7.1 7.2 7.3 7.4 7.5 PANEL CUT-OUT....27 COOLING..... 27 UNIT DIMENSIONS.... 27 FRONT PANEL LAYOUT... 28 REAR PANEL LAYOUT.... 28
ELECTRICAL CONNECTIONS... 29
8.1 CONNECTION DETAILS.... 29 8.1.1 PLUG A 8 WAY.... 29 8.1.2 PLUG B 11 WAY.... 29 8.1.3 PLUG C 3 WAY (OPTIONAL).... 29 8.1.4 PLUG D 4 WAY (OPTIONAL).... 30 8.1.5 PLUG E 8 WAY.... 30 8.1.6 PLUG F 4 WAY.... 30 8.1.7 PLUG G 5 WAY.... 30 8.1.8 PLUG H 4 WAY.... 31 8.1.9 PC CONFIGURATION INTERFACE CONNECTOR.. 32 8.1.10 EXPANSION OUTPUT CONNECTOR... 32 8.2 CONNECTOR FUNCTION DETAILS... 33 8.2.1 PLUG A 8 WAY.... 33 8.2.2 PLUG B 11 WAY.... 33 8.2.3 PLUG C 3 WAY (OPTIONAL).... 34 8.2.4 PLUG D 4 WAY (OPTIONAL).... 34 8.2.5 PLUG E 8 WAY.... 34 8.2.6 PLUG F 4 WAY.... 34 8.2.7 PLUG G 5 WAY.... 34 8.2.8 PLUG H 4 WAY.... 35
8.2.9 PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE..35 8.3 ELECTRICAL CONNECTIONS TO J1939 ENABLED CONTROLLERS..36 8.3.1 CUMMINS ISB / ISBE....36 8.3.2 JOHN DEERE....37 8.3.3 PERKINS 2800 SERIES...38 8.3.4 SCANIA S6....39 8.3.5 VOLVO TAD12...40
FAULT FINDING...43 FACTORY DEFAULT CONFIGURATION...44 TYPICAL WIRING DIAGRAM...47 APPENDIX....48
13.1 ALTERNATIVE WIRING TOPOLOGIES...48 13.1.PHASE, 3 WIRE...48 13.1.PHASE, 2 WIRE...48 13.1.PHASE, 3 WIRE ( 2 PHASE CENTRE TAP NEUTRAL)...49 13.2 ICONS AND LCD IDENTIFICATION...50 13.2.1 PUSH BUTTONS....50 13.2.2 STATUS / MEASUREMENT UNITS...50 13.2.3 ALARM INDICATIONS...50 13.IDMT TRIPPING CURVES (TYPICAL)...51 13.4 SENDER WIRING RECOMMENDATIONS...52 13.4.1 EARTH RETURN SENDERS...52 13.4.2 INSULATED RETURN SENDERS....52 13.4.3 FUEL LEVEL SENDERS....53 13.5 J1939 CANBUS INTERFACE (OPTIONAL)...54 13.5.1 EXAMPLE OF CONNECTING 5220 CONTROLLER TO ENGINE CANBUS.54 13.SERIES CONFIGURATION SOFTWARE AND P810 INTERFACE MODULE.55 13.7 OUTPUT EXPANSION....55 13.7.1 RELAY OUTPUT EXPANSION (157)...55 13.7.2 LED OUTPUT EXPANSION (548)...55 13.8 INPUT EXPANSION....56
The DSE 5220 automatic mains failure module has been designed to allow the OEM to meet most of the industrys complex specifications. It has been primarily designed to monitor the mains (utility) supply, starting the generator automatically should it fall out of limits. Transfer of the load is automatic upon a mains supply failure. If required the generator and can be started and stopped manually, and if required, the user can transfer the load to the generator either manually (via external push-buttons) or automatically. The user also has the facility to view all the system operating parameters via the LCD display. The DSE 5220 module monitors the mains (utility) supply indicating the status of the mains on the modules integral LCD display. Additionally the 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 flashing common alarm LCD indicator. The exact failure mode is indicated by combined hidden til lit LEDs and the LCD display on the front panel. The powerful microprocessor contained within the module allows for a range of complex features to be incorporated as standard: Graphical Icon based LCD display (excluding the need for translations and languages). Voltage, Current and Power monitoring. Engine parameter monitoring. Fully configurable inputs for use as alarms or a range of different functions. Extensive range output functions using built in relay outputs or relay expansion available.
When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from the Alternator output. Alternatively a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is selected by PC using the 5200 series configuration software). Rising oil pressure can also be used to disconnect the starter motor, however it cannot be used for underspeed or overspeed detection. After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault. Once the engine is running, the Warm Up timer, if selected, is initiated, allowing the engine to stabilise before it can be loaded. The generator will run off load, unless the mains supply fails or a Remote Start on load signal is applied. If Close generator has been selected as a control source, the appropriate auxiliary output will then activate. The generator will continue to run On load regardless of the state of the mains supply or remote start input until the Auto mode is selected. If Auto mode is selected, and the mains supply is healthy with the remote start on load signal not active, then the Remote Stop Delay Timer begins, after which, the load is disconnected. The generator will then run off load allowing the engine a cooling down period. Selecting STOP (O) de-energises the FUEL SOLENOID, bringing the generator to a stop.
To initiate a start sequence in TEST, press the
pushbutton. When the controller is in the test mode (indicated
by an LED indicator beside the button), pressing the START (I) button will initiate the start sequence. NOTE:- There is no Start Delay in this mode of operation. If the pre-heat output option is selected this timer is then initiated, and the auxiliary output selected is energised. After the above delay the Fuel Solenoid is energised, then the Starter Motor is engaged. The engine is cranked for a pre-set time period. If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and Fail to Start flashing shutdown indicator. fault will be displayed accompanied by a
OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated. icon will illuminate. The Overspeed is not delayed, it is an immediate shutdown. NOTE:-During the start-up sequence the overspeed trip logic can be configured to allow an extra trip level margin. This is used to prevent nuisance tripping on start-up - Refer to the 5200 series configuration software manual under heading Overspeed Overshoot for details. UNDERSPEED, if the engine speed falls below the pre-set trip after the Safety On timer has expired, a shutdown is initiated. The icon will illuminate.
GENERATOR HIGH FREQUENCY if the module detects a generator output frequency in excess of the pre-set trip a shutdown is initiated. icon will illuminate. The Generator High Frequency is not delayed, it is an immediate shutdown. GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the pre-set trip after the Safety On timer has expired, a shutdown is initiated. The icon will illuminate.
GENERATOR HIGH VOLTAGE if the module detects a generator output voltage in excess of the pre-set trip a shutdown is initiated. The V icon will illuminate. High voltage is not delayed, it is an immediate shutdown. GENERATOR LOW VOLTAGE if the module detects a generator output voltage below the below the pre-set trip after the Safety On timer has expired, a shutdown is initiated. The
OIL PRESSURE SENDER OPEN CIRCUIT, if the module detects a loss of signal from the oil pressure sender (open circuit) a shutdown is initiated. The LCD will indicate:(Steady) (And ----- on the engine oil pressure instrument). Sender failure is not delayed, it is an immediate shutdown. AUXILIARY INPUTS, if an auxiliary input has been configured as a shutdown the appropriate LCD segment will be displayed:-
LOSS OF SPEED SIGNAL, if the speed sensing signal is lost during cranking, a shutdown is initiated. The icon will illuminate. (Steady) (And ----- on the engine RPM instrument). NOTE:- This will only occur if the speed sensing signal is lost during cranking or during the safety on timer. If the signal is lost during normal operation the Generator will shutdown with an Under-speed alarm. CAN DATA FAIL If the module is configured for J1939 operation and does not detect data on the engine CANbus datalink, a shutdown will occur and Can data fail is shown on the modules display CAN ECU FAIL If the module is configured for J1939 operation and receives a fail message from the engine control unit, the engine is shutdown and Can ECU fail is shown on the modules display. Usually, an associated failure code is also displayed, detailing the exact failure detected. For details on these code meanings, refer to the ECU instructions provided by the engine manufacturer.
Pressing the DOWN button the LCD will then show (Generator L-N voltages)
Pressing the DOWN button the LCD will then show (Generator L-L voltages)
button again will scroll through each individual instrument eventually returning to the original Pressing the instrument displayed. NOTE:-Once selected the instrument will remain on the LCD display until the user selects a different instrument or after a period of inactivity the module will revert to the initial display.
On J1939 enabled 52xx controllers connected to a CanBus ECU, alarm status messages are transmitted to the 52xx controller and displayed on the CanBus message instrumentation page. Can alarm message Suspect Parameter Number (SPN) = 102 Failure Mode Indicator (FMI) = 16
Examples of SPN / FMI numbers, taken from the Volvo Penta TAD12 manual are :
SPN 110 Engine coolant temperature FMI 0 Out of range FMI 3 Above normal FMI 4 Below normal
NOTE:- For details on these code meanings, refer to the ECU instructions provided by the engine manufacturer.
NOTE:- When using 52xx configuration and instrumentation PC software, hovering the mouse cursor over the SPN/FMI numbers will display the J1939 messages where appropriate.
VIEWING THE EVENT LOG
The model 5220 remote start module maintains a log of the last 15 shutdown alarms to enable the operator or engineer to view the past alarms history. Only shutdown and electrical trip alarms are logged; warning alarms are not logged. Once the log is full (15 shutdown alarms), any subsequent shutdown alarms will overwrite the oldest entry in the log. Hence the log will always contain the 15 most recent shutdown alarms. The alarm is logged, along with the date and time of the event in the format shown in this example. To view the event log, press the log button the event log has been entered. The LCD display will flash the log symbol to confirm that
In this example, the oil can symbol represents an oil pressure shutdown, backed up by the flashing shutdown symbol in the LCD display. The value displayed means that the oil pressure shutdown occurred on November 1st 2002 at 8:17.
to view the next most recent shutdown alarm: In this example, the hand/button symbol represents an emergency stop shutdown, backed up by the flashing shutdown symbol in the LCD display. The value displayed means that the emergency stop button was pressed on November 1st 2002 at 11:50.
will cycle through the past alarms until all 15 logged alarms have been viewed, Continuing to press down after which the most recent alarm will again be showed and the cycle will begin again. To exit the event log and return to viewing the instruments, press the log button.
COMMON ALARM LCD indicators These indicate when an alarm condition is present. The Alarm icons or LEDs will detail the exact nature of the alarm. USER CONFIGURABLE LCD INDICATORS These LCDs can be configured by the user to indicate any on of the different functions based around the following: INDICATIONS - Monitoring of a digital input and indicating associated functioning users equipment - Such as Battery Charger On or Louvres Open, etc. WARNINGS and SHUTDOWNS - Specific indication of a particular warning or shutdown condition, backed up by LCD indication (!)Such as Low Oil Pressure Shutdown, Low Coolant level, etc. STATUS INDICATIONS - Indication of specific functions or sequences derived from the modules operating state - Such as Safety On, Pre-heating, Generator Available, etc.
6 FRONT PANEL CONFIGURATION
Although full configuration of the module is possible using the 5200 series configuration software, selected parameters that may require adjustment in the field are able to be adjusted via the modules fascia. NOTE:- Care should be taken to ensure that changes made via the front panel editor are carefully recorded and fed back to the generator supplier if applicable. This is to safeguard against using the 5200 series configuration software to configure the module at a later date, possibly overwriting the changes made using the front panel editor. When using the 5200 series configuration software to make configuration changes, the first operation should be to read configuration from controller to ensure that any changes made to the controllers configuration by the front panel editor are loaded into the PC before any changes are made. Full details of this procedure can be found in the 5200 series configuration software manual.
ACCESSING THE FRONT PANEL CONFIGURATION EDITOR
and Stop/Reset buttons simultaneously. The LCD configure indicator button and the will
Press the configure/log
flash to indicate that the module is in configuration mode. Release the Stop/Reset configure/log button.
The first configurable parameter is then displayed : The parameter being displayed in this example is the Low Oil Pressure prealarm, being indicated by the illuminated oil can. is indicating that it is the The warning symbol warning (pre-alarm) parameter that is being displayed.
NOTE:- To exit the front panel configuration editor at any time, press the Stop/Reset Ensure you have saved any changes you have made by pressing the button first.
EDITING AN ANALOGUE VALUE
Press the button to enter edit mode. This is indicated by the flashing parameter. In this example, entering edit mode will cause the 1.2 value to flash. When in edit mode, pressing the + or buttons will adjust the parameter to the desired value. Press the button to save the value. The value will stop flashing to confirm that it has been saved. To select another value to edit, press the + button : The next parameter being displayed in this example is the Low Oil Pressure shutdown, being indicated by the illuminated oil can. is indicating that it is The shutdown symbol the shutdown (trip) parameter that is being displayed. Continuing to press the + or
(Recommended Maximum Fuse 21A) Plant Supply +ve. Also supplies fuel & start outputs. (Recommended Maximum Fuse 32A) Plant Supply +ve from pin 3. 16 Amp rated. Plant Supply +ve from pin 3. 16 Amp rated. Plant Supply +ve. 5 Amp rated. Plant Supply +ve. 5 Amp rated. Plant Supply +ve. 5 Amp rated.
PIN No 19
PLUG B 11 WAY
DESCRIPTION Charge fail / excite Auxiliary input 1 Auxiliary input 2 Auxiliary input 3 Auxiliary input 4 Auxiliary input 5 Auxiliary input 6 Functional Earth Magnetic pickup +ve Magnetic pickup -ve Not connected CABLE SIZE 2.5mm 0.5mm 0.5mm 0.5mm 0.5mm 0.5mm 0.5mm 2.5mm 0.5mm 0.5mm NOTES Do not connect to ground (battery ve) Switch to -ve Switch to -ve Switch to -ve Switch to -ve Switch to -ve Switch to -ve Connect to a good clean earth point Connect to Magnetic Pickup device Connect to Magnetic Pickup device
NOTE:- Ensure magnetic pickup screen is connected to ground at one end only.
NOTE:- When the module is configured for CanBus J1939 operation, terminals 17 & 18 should be left unconnected. Engine speed is transmitted to the 52xx controller on the CanBus link.
PIN No 22
PLUG C 3 WAY (OPTIONAL)
DESCRIPTION CanBus port Common CanBus port H CanBus port L CABLE SIZE 0.5mm 0.5mm 0.5mm NOTES Use only 120 CanBus approved cable Use only 120 CanBus approved cable Use only 120 CanBus approved cable
PIN No 25 26
PLUG D 4 WAY (OPTIONAL)
DESCRIPTION RS485 port Common RS485 port B RS485 port A Not connected CABLE SIZE 0.5mm 0.5mm 0.5mm NOTES Use only 120 RS485 approved cable Use only 120 RS485 approved cable Use only 120 RS485 approved cable
PIN No 33 34
PLUG E 8 WAY
DESCRIPTION Mains loading relay Mains loading relay Generator loading relay Generator loading relay Mains (utility) L1 voltage monitoring input Mains (utility) L2 voltage monitoring input Mains (utility) L3 voltage monitoring input Mains (utility)Neutral input CABLE SIZE 1.0mm 1.0mm 1.0mm 1.0mm 1.0mm 1.0mm 1.0mm 1.0mm NOTES Connect to mains contactor coil Connect to mains contactor feed supply Connect to generator contactor coil Connect to generator contactor feed supply Connect to mains L1 (AC) (Recommend 2A fuse) Connect to mains L2 (AC) (Recommend 2A fuse) Connect to mains L3 (AC) (Recommend 2A fuse) Connect to mains Neutral (AC)
PIN No 37 38
PLUG F 4 WAY
DESCRIPTION Generator L1 voltage monitoring input Generator L2 voltage monitoring input Generator L3 voltage monitoring input Generator Neutral input CABLE SIZE 1.0mm 1.0mm 1.0mm 1.0mm NOTES Connect to generator L1 output (AC) (Recommend 2A fuse) Connect to generator L2 output (AC) (Recommend 2A fuse) Connect to generator L3 output (AC) (Recommend 2A fuse) Connect to generator Neutral terminal (AC)
PIN No 43
PLUG G 5 WAY
DESCRIPTION CT Secondary for L1 CT Secondary for L2 CT Secondary for L3 CT secondary common Not connected CABLE SIZE 2.5mm 2.5mm 2.5mm 2.5mm NOTES Connect to secondary of L1 monitoring CT Connect to secondary of L2 monitoring CT Connect to secondary of L3 monitoring CT Connect to secondary of all monitoring CTs
PIN No 46 47
PLUG H 4 WAY
DESCRIPTION Oil Pressure Input Coolant Temperature Input Fuel Level input Sender Common Return CABLE SIZE 0.5mm 0.5mm 0.5mm 0.5mm NOTES Connect to Oil pressure sender Connect to Coolant Temperature sender Connect to Fuel Level sender Return feed for senders*.
NOTE*:- If using single terminal senders refer to connection diagram. If using earth return type senders connect return terminals to pin 47 and also connect pin 47 to earth. This is detailed in the Appendix section entitled Sender wiring recommendations elsewhere in this manual.
NOTE:- When the module is configured for CanBus J1939 operation, terminals 44 & 45 should be left unconnected. Engine oil pressure and coolant temperature is transmitted to the 52xx controller on the CanBus link.
PC CONFIGURATION INTERFACE CONNECTOR
8-way connector allows connection to PC via the 810 configuration interface. Module can then be re-configured utilising the 5200 series configuration software.
8.1.10 EXPANSION OUTPUT CONNECTOR
The expansion connector allows connection to the 157 relay expansion module or to the 548 LED Remote annunciator module.
PIN No 3
CONNECTOR FUNCTION DETAILS
DESCRIPTION DC Supply -ve. System DC negative input. (Battery Negative). DC Supply +ve. System DC positive input. (Battery Positive). Emergency Stop input. Internally linked to Starter and Fuel outputs. If this input is not connected to positive the module will be locked out, and if the engine is running it will shutdown immediately. The Positive Supply is also removed from Starter and Fuel outputs, therefore only a single pole Emergency Shutdown button is required. Fuel Relay output. Plant Supply +ve from pin 3. Used to control the fuel solenoid or engine fuel control system. Starter Relay output. Plant Supply +ve from pin 3. Used to control the Starter Motor. Auxiliary Relay output 1. Plant Supply +ve. Configurable output, see Calibration Manual for options available. Auxiliary Relay output 2. Plant Supply +ve. Configurable output, see Calibration Manual for options available. Auxiliary Relay output 3. Plant Supply +ve. Configurable output, see Calibration Manual for options available.
If you require additional plugs from DSE, please contact our Sales department using the part numbers below. 5220 Terminal 1-8 9-19 20-22 23-26 27-34 35-38 39-43 44-47
ELECTRICAL CONNECTIONS TO J1939 ENABLED CONTROLLERS
This section of the manual is intended to describe only the connections between the 52xx controller and J1939 enabled controllers. All other connection details are described in the previous sections. NOTE:- The CANbus specification, used by J1939, requires that a 120 terminator is fitted to each end of the communications link. This termination resistor is fitted internally into the 52xx controller so is not required externally. Ensure that the 52xx controller is the last device on the communications link where more than one device is connected to the engine ECUs J1939 connector.
CUMMINS ISB / ISBE
Cummins ISB OEM Harness connector B 39 Use to control a 30A external slave relay to supply DC battery power to 01,07,12,13 NOTES key switch input. Connects directly to engine starter solenoid. Configure 52xx aux op 1 to be Louvre control and configure 52xx ETS Hold Timer to 20 seconds. This is used to power down the engine ECU 20seconds after the set comes to rest.
PLUG A 8 WAY 52xx 52xx PIN No DESCRIPTION 4 Fuel relay output 5 Start relay output 6 Aux output 1
PLUG C 3 WAY 52xx 52xx PIN No DESCRIPTION
Cummins ISB 9 pin Deutsch connector SAE J1939 shield SAE J1939 signal
NOTES Screen for the J1939 cable. Connect at Cummins ECU end only. J1939 + Use only screened 120 impedance cable approved specifically for use in CANbus applications. J1939 - Use only screened 120 impedance cable approved specifically for use in CANbus applications.
SAE J1939 return
John Deere 21-pin Deutsch connector G, J D NOTES G = Switched ECU power, J = Ignition Start
PLUG A 8 WAY 52xx 52xx PIN No DESCRIPTION 4 Fuel relay output 5 Start relay output PLUG C 3 WAY 52xx 52xx PIN No DESCRIPTION 20 CANbus common 21 CANbus H
John Deere 21-pin Deutsch connector V
NOTES Screen for the J1939 cable. Connect at 52xx end only. J1939 + Use only screened 120 impedance cable approved specifically for use in CANbus applications. J1939 - Use only screened 120 impedance cable approved specifically for use in CANbus applications.
PERKINS 2800 SERIES
Perkins Customer interface connector 1, 10, 15, 33, 34 NOTES Powers up ECU and enables the injectors. Connects directly to engine starter solenoid.
PLUG A 8 WAY 52xx 52xx PIN No DESCRIPTION 4 Fuel relay output 5 Start relay output
PLUG C 3 WAY 52xx 52xx PIN No DESCRIPTION 20 CANbus common 21 CANbus H
Perkins Customer interface connector 31
NOTE:- According to Perkins, warning lamps or equivalent must be connected to Perkins customer interface connector terminals 3, 4, 5, 8, 9, 16, 17. Failure to connect to these terminals will results in open circuit alarms from the ECU. Perkins have advised that a suitable equivalent for the warning lamp is a 220 5W resistor. Be aware that outputs on terminals 4,5, & 16 are battery positive outputs. The outputs on terminals 3, 6, 8, 9 & 17 are battery negative outputs.
Before the system is started, it is recommended that the following checks are made:7.1. The unit is adequately cooled and all the wiring to the module is of a standard and rating compatible with the system. 7.2. The unit DC supply is fused and connected to the battery and that it is of the correct polarity. 7.3. The Emergency Stop input is wired to an external normally closed switch connected to DC positive. NOTE:- If Emergency Stop feature is not required link this input to the DC Positive. The module will not operate unless either the Emergency Stop is fitted correctly OR Pin 3 is connected to DC positive (+ve) 7.4. To check the start cycle operation take appropriate measures to prevent the engine from starting (disable the operation of the fuel solenoid). After a visual inspection to ensure it is safe to proceed, connect the battery supply. Select MANUAL, the unit start sequence will commence. 7.5. The starter will engage and operate for the pre-set crank period. After the starter motor has attempted to start the engine for the pre-set number of attempts the LCD will display its icon indicating; Failed to start Select the STOP/RESET position to reset the unit.
7.6. Restore the engine to operational status (reconnect the fuel solenoid), again select MANUAL, this time the engine should start and the starter motor should disengage automatically. If not then check that the engine is fully operational (fuel available, etc.) and that the fuel solenoid is operating. The engine should now run up to operating speed. If not, and an alarm is present, check the alarm condition for validity, then check input wiring. The engine should continue to run for an indefinite period. It will be possible at this time to view the engine and alternator parameters - refer to the Description of Controls section of this manual. 7.7. Select AUTO on the front panel, the engine will run for the pre-set cooling down period, then stop. The generator should stay in the standby mode. If not check that there is not a signal present on the Remote start input and that the mains (utility) supply is healthy and available. 7.8. Initiate an automatic start by supplying the remote start signal or failing the mains(utility) supply. The start sequence will commence and the engine will run up to operational speed. Once the generator is available a load transfer will take place, the Generator will accept the load. If not, check the wiring to the Generator Contactor Coil (if used). Check the Warming timer has timed out. 7.9. Remove the remote start signal and/or ensure the mains (utility) supply is healthy, the return sequence will start. After the pre-set time period, the load will be removed from the generator. The generator will then run for the pre-set cooling down period, then shutdown into its standby mode. 7.10. Set the modules internal clock/calendar to ensure correct operation of the scheduler and event logging functions. For details of this procedure see section entitled Front Panel Configuration Editing the date/time. 7.11. If despite repeated checking of the connections between the 5220 and the customers system, satisfactory operation cannot be achieved, then the customer is requested to contact the factory for further advice on:INTERNATIONAL TEL: +44 (0) INTERNATIONAL FAX: +44 (0) E-mail: Support@Deepseaplc.com Website : www.deepseaplc.com
10 FAULT FINDING SYMPTOM
Unit is inoperative Unit shuts down Unit locks out on Emergency Stop Intermittent Magnetic Pick-up sensor fault Low oil Pressure fault operates after engine has fired High engine temperature fault operates after engine has fired. Shutdown fault operates Warning fault operates Fail to Start is activated after preset number of attempts to start Continuous starting of generator when in AUTO Generator fails to start on receipt of Remote Start signal or mains (utility) supply failure. Pre-heat inoperative Starter motor inoperative Engine runs but generator will not take load Incorrect reading on Engine gauges
Check the battery and wiring to the unit. Check the DC supply. Check the DC fuse. Check DC supply voltage is not above 35 Volts or below 9 Volts Check the operating temperature is not above 70 C. Check the DC fuse. If an Emergency Stop Switch is not fitted, ensure that a positive is connected to the Emergency Stop input. Check emergency stop switch is functioning correctly. Check Wiring is not open circuit. Ensure that Magnetic pick-up screen is only connected at one end, if connected at both ends, this enables the screen to act as an aerial and will pick up random voltages. Check engine oil pressure. Check oil pressure switch/sender and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sender is compatible with the 5220 Module and is correctly configured. Check engine temperature. Check switch/sender and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sender is compatible with the 5220 Module. Check relevant switch and wiring of fault indicated on LCD display. Check configuration of input. Check relevant switch and wiring of fault indicated on LCD display. Check configuration of input. Check wiring of fuel solenoid. Check fuel. Check battery supply. Check battery supply is present on the Fuel output of the module. Check the speed sensing signal is present on the 5220 inputs. Refer to engine manual. Check that mains (utility) supply is healthy and check that its protection fuses are in place and are not blown Check that there is no signal present on the Remote Start input. Check configured polarity is correct. Check Start Delay timer has timed out. If remote start fault, check signal is on Remote Start input. Confirm input is configured to be used as Remote Start. Check wiring to engine heater plugs. Check battery supply. Check battery supply is present on the Pre-heat output of module. Check pre-heat has been selected in your configuration. Check wiring to starter solenoid. Check battery supply. Check battery supply is present on the Starter output of module. Ensure that the Emergency Stop input is at +Ve. Check Warm up timer has timed out. Ensure generator load inhibit signal is not present on the module inputs. Check engine is operating correctly. Check sender and wiring paying particular attention to the wiring to terminal 47 (refer to appendix). Check that sender is compatible with the 5220 Module and is correctly configured.
NOTE:- The above fault finding is provided as a guide check-list only. As it is possible for the module to be configured to provide a wide range of different features always refer to the source of your module configuration if in doubt.
11 FACTORY DEFAULT CONFIGURATION
In the tables below, the icon indicates an item that can be adjusted from the modules front panel editor. Absence of the icon beside an item means that adjustment of this parameter is only possible using the 5200 series configuration software in conjunction with the P810 interface. For further details on adjustment from the front panel editor, see the section entitled Front panel configuration elsewhere within this manual. 5200 series configuration software. Configuration for 5220 module. Filename 5220a.XCF Printed on 29/10/02 10:42:03 Module settings Base module Value 5220 automatic mains failure module Value Yes 4 No No 3 phase, 4 wire Disabled Enabled 3 No Disabled Value VDO 10 bar Trip 1.17 Bar 17.0 PSI 1.03 Bar 14.9 PSI Return 1.24 Bar 18.0 PSI N/A
Miscellaneous settings Alternator fitted Poles Magnetic pickup fitted J1939 enabled AC System VT Ratio Mains failure detection Number of start attempts Enable fast loading feature Immediate mains dropout
Input settings Analogue | Oil pressure Low oil pressure input type Low oil pressure pre-alarm Low oil pressure shutdown
Input settings Analogue | Coolant temp High coolant temp input type High coolant temp pre-alarm High coolant temp shutdown Input settings Analogue | Fuel level Fuel level input type Fuel pump control Low fuel level Input settings - Digital 1 Remote start 2 Lamp test 3 User configured 4 User configured 5 User configured 6 User configured
Value VDO 120 degrees C 115C 239F 120C 248F Value VDO Ohm Range No 10% 110C 230F N/A
Value Close to activate Close to activate Close to activate, Warning Active from safety on Close to activate, Shutdown Always active Close to activate, Shutdown Active from safety on Close to activate, Electrical trip Always active
Output settings Relay 1 Energise 2 Energise 3 Energise 4 Energise 5 De-energise
13.4.2 INSULATED RETURN SENDERS
NOTE:-. It is important that terminal 47 ( sender common ) is soundly connected to an earth point on the ENGINE BLOCK, not within the control panel.
13.4.3 FUEL LEVEL SENDERS
The resistive fuel level senders supported by the 5200 series controllers are devices that translate fuel level into resistance. A change in fuel level translates directly to a change in the resistance of the sender. In the case of a parallel sided fuel tank, an accurate measure of the fuel level can easily be made, however as shown in the example below, this is not the case with non-parallel sided fuel tanks. Therefore it is recommended that only parallel sided fuel tanks are used to ensure correct fuel level detection. The fuel sender measures the distance between the top of the tank and the fuel level. Typically, they use a ball float. In this example, the distance between the top of the tank and the level of the fuel is 50% of the height of the tank. The fuel level sender will report the tank correctly as being 50% full. For a parallel-sided tank like this one, 50% distance between the top of the tank and the level of the fuel will occur when the tank is 50% full of fuel. In this example, the distance between the top of the tank and the level of the fuel is again 50% of the height of the tank, the fuel level sender will report the tank as being 50% full. However, as the bottom of the tank is curved, the actual amount of fuel in the tank is only about 40%. The fuel sender is incorrectly reporting the amount of remaining fuel.
13.5 J1939 CANBUS INTERFACE (OPTIONAL)
Modules fitted with the J1939 CANbus interface (specify on ordering) are capable of receiving engine data from engine CANbus controllers compliant with the J1939 standard. Canbus enabled engine controllers monitor the engines operating parameters such as engine speed, oil pressure, engine temperature (among others) in order to closely monitor and control the engine. The data that is gathered by the engine controller is then transmitted on an industry standard communications interface (Canbus J1939). This allows generator controllers such as the DSE 52xx range to access these engine parameters with no physical connection to the sensor device.
13.5.1 EXAMPLE OF CONNECTING 5220 CONTROLLER TO ENGINE CANBUS.
L1 L2 Mains (utility) L3 F2A F2A F2A G
L2 Generator L3 N
F2A Optional RS232
29 Generator loading relay
27 Mains loading relay
Not connected 19 Not connected 26 To plant supply +ve Not connected Not connected 17 18
16 Functional Earth
Configurable auxiliary input 2
Configurable auxiliary input 3
Configurable auxiliary input 5
Configurable auxiliary input 1
Configurable auxiliary input 4
Configurable auxiliary input 6
Configurable auxiliary output 1
13.SERIES CONFIGURATION SOFTWARE AND P810 INTERFACE MODULE
The 5220 module can be calibrated by using PC with Interface Module 810 and 5200 series configuration software. The 5200 series configuration software kit comprises the following: 810 Interface Module 25 to 9 way adapter RJ45 (8 Pin) Connecting Lead DSE SoftwareCD with configuration software
13.7 OUTPUT EXPANSION
There are several methods of output expansion available for the 5220 module:-
13.7.1 RELAY OUTPUT EXPANSION (157)
An expansion module is available, which connects to the configuration socket, and enables the 5220 to use eight additional relays, providing Volt-free contacts for customer connection.
POWER ON LED RELAY ACTIVE LED'S
LINK LOST LED FUNCTION SELECTOR
Refer to technical data sheet on the 157 relay module for further details.
13.7.2 LED OUTPUT EXPANSION (548)
An expansion module is available, which connects to the configuration socket, and enables the 5220 to use eight additional LEDs, providing remote LED indication up to 50 metres away.
Refer to technical data sheet on the 548 LED module for further details. It is possible to use a mix of 157 and 548 modules to give both relay and LED expansion of the same 8 items if required (Please refer to our Technical Support department for details.).
265 - 1000 kVA / 212 - 800 kW
High quality, reliable, long life and complete power unit. Compact design. Easy start and maintenance possibility. Every generating set is subject to a comprehensive test programme which includes full load testing and checking and providing of all control and safety shut down functions testing. Fully engineered with a wide range of options and accessories: Electrical, mechanical, soundproof canopy and mobile units.
400 / 230 V - 50 Hz Generating Set Model APD 265 C
Power Pf. 0,8 Standby Prime kVA kVA 265 242
APD 350 C
APD 375 C
APD 680 C
APD 1000 C
Standby : Continuous running at variable load for duration of an emergency. No overload is permitted on these ratings. In accordance with ISO 3046. Prime : Continuous running at variable load for unlimited periods with 10 % overload available for 1 hour in any 12 hour period. In accordance with ISO 8528, ISO 3046. Contact us for the other running periods.
STANDARD GENSET SPECIFICATIONS
CUMMINS heavy - duty diesel engine. Four stroke, water cooled, turbo charged. Direct injection fuel system. 24 Volt D.C. starter and charge alternator. Replaceable fuel filter, oil filter and dry element air filter. Cooling radiator and fan. Starter battery (with lead acid) including Rack and Cables. Flexible fuel connection hoses and manual sump oil drain valve. Industrial capacity exhaust silencer and steel bellows. Jacket water heater (automatic models). Operation manuals and circuit diagram documents. 1. a) b) c) d) 2.
Control supervision and protection panel is mounted on the genset base frame. The control panel is equipped as follows: Auto. Mains Failure Control Panel P 2020: Control panel equipments: Control with DSE, model 5220 module. Static battery charger. Emergency stop push button. Generating Set Control Module DSE 5220 Features: The module is used to monitor a mains supply and automatically start a standby generating set. Microprocessor based design. Monitors engine performance and AC power output. LED and LCD alarm indication. Front panel configuration of timers and alarm trip points. Provide signal to change over switch panel. Event logging of shutdown alarms. Remote communication via RS232 port or RS485 modbus output. Easy push button control. STOP / RESET - MANUAL - AUTO - TEST - START. Operation indicators accesed by the LCD display scroll push button. Metering via LCD Display: Generator volt (L - L / L - N). Engine temperature (C & F). Generator ampere (L1, L2, L3). Generator (kVA - kW). Generator frequency (Hz). Generator Cos j. Engine hours run. Mains frequency (Hz). Engine oil pressure (PSI & Bar). Mains volts (L - L / L - N). Engine speed (RPM). Plant battery volts. Automatic Shutdown on Fault Conditions: Under / Over speed. Fail to start. High engine temperature. Fail to stop. Low oil pressure. Charge fail. Under / Over generator volts. Over current. Under / Over generator frequency. Emergency stop. Under / Over mains frequency. CAN data fail. Under / Over mains voltage. CAN ECU fail. Low / High battery volts. LED Indications: Mains available. Generator available. Mains on load. Generator on load. Power Outlet Terminal Board Mounted on the Genset Baseframe (APD 1000 C is excepted).
Brushless, single bearing system, flexible disc, 4 poles. Insulation class H. Standard degree of protection IP21. Self - exciting and self - regulating. Impregnation with tropicalised epoxy varnish. Solid state Automatic Voltage Regulator.
The complete generating set is mounted as whole on a heavy - duty fabricated, steel base frame. Antivibration pads are fixed between the engine / alternator feet and the base frame. Base frame design incorporates an integral fuel tank. Fuel tank is seperate from base frame for APD 680 C and APD 1000 C. The generating set can be lifted or carefully pushed / pulled by the base frame. Dial type fuel gauge and drain plug on the fuel tank.
All canopy parts are designed with modular principles. Without welding assembly. Doors on each side. All metal canopy parts are painted by electrostatic polyester powder paint. Emergency stop push button is installed outside of canopy. Easy lifting and moving. Easy mainteneance and operation. APD 1000 C assembly in container.
T E CH NI C AL DAT A
DIESEL GENERATING SETS 400 / 230 V - 50 Hz
MODEL APD 265 C
kVA kW kVA kW 242 193
Cummins - In Line x : 1 Electronic 65
Cummins - In Line x : 1 Electronic 70
APD 680 C APD 1000 C
Cummins 18,- In Line x : 1 Electronic 75
Power Pf. 0,8 Engine Make Model
Cummins KTA 38 - G2A - V x 159 14,5 : 1 Electronic 136
6LTAA 8,9 - G2 NTA 855 - G1B
NTA 855 - G2A KTAA 19 - G6A
Engine Power Output (at rated rpm) Aspiration and Cooling Cubic Capacity
kWm HP Litre rpm mm. x mm.
8,- In Line x : 1 Electronic
Turbo Charged and AC* Turbo Charged and AC* Turbo Charged and AC* Turbo Charged and AC* Turbo Charged and AC*
Cylinders and Build Engine Rated Speed Bore and Stroke Compression Ratio Governor Type Fuel Consumption at full load Fuel Tank Capacity Total Oil Capacity Radiator Cooling Air Air Intake Engine Exhaust Gas Flow Exhaust Gas Temperature Heat Radiated to Ambient L. / h. Litre Litre
Coolant Capacity (raditor and engine) Litre m3 / min.
m3 / min. m3 / min.
* AC: After Cooled.
Dimensions (length x width x height) Dry Weight m. kg. 3 x 1,15 x 1,3,2 x 1,15 x 2,2 3,2 x 1,15 x 2,3250 3,7 x 1,45 x 2,2 4,3 x 1,77 x 2,7600
SOUND ATTENUATED TYPES
Dimensions (length x width x height) Dry Weight Fuel Tank Capacity m. kg. Litre 4150 650
4,55 x 1,46 x 2,650
5,8 x 1,62 x 2,53 7,92 x 2,3 x 2,35
o Manufacturer reserves the right to make changes in model, technical specifications, color, equipment and accessories without prior notice.
Diesel Engine o Remote radiator (except APD 265 C and APD 680 C). o Oil heater. Alternator o 3 pole output circuit breaker. o Anti - condensation heater. Panel o Charge ammeter. o Transfer switch 3 pole. o Transfer switch 4 pole. o Earth fault, single set. Accessories o Bulk fuel tank. o Automatic or manual fuel filling system. o Fuel water separator filter. o Manual fuel filling system. o Low fuel level alarm. o Residential silencer. o Enclosure or sound proof canopy. o Trailer. o Manual oil drain pump. o Tool kit for maintenance.
Aksa Jenerator Sanayi A.S. Gulbahar Caddesi 1. Sokak 34212 Gunesli - Istanbul / Turkey Tel: +66 (pbx) Fax: +16 e-mail: email@example.com www.aksa.com.tr
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