JCB Generator Control Panels Service Repair Manual – PDF Download by www.heydownloads.com

JCB GENERATOR SERVICE MANUAL

CONTROL PANELS

Publication No.

9813/2550-01

World Class Customer Support Copyright Â© 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

Section 1 - 1

Notes:

1-0

9813/2550-01

1-0

Contents

Contents Page No. Description and Main Features ...................................................................... 1 Front Panel Components ............................................................................... 2 Backside Components ................................................................................... 5 Connection Terminals ............................................................................... 5 Micro-switches .......................................................................................... 6 Port RJ11 .................................................................................................. 7 Operation Modes ........................................................................................... 8 Recommendations ................................................................................... 8 Operation Modes ...................................................................................... 8 Connection Diagram ...................................................................................... 9 Technical Features ...................................................................................... 10 Most Outstanding Advantages .............................................................. 11 CP1 and CP2 Digital Control Panels Introduction .................................................................................................. 12 The Panel provides the following readings of the Electric Mains supply: ... 12 The panel provides the following Engine features information: .............. 12 The panel controls the following functions of the engine: ....................... 12 Password ................................................................................................ 13 Control Panel Front Views ........................................................................... 14 CP1 ........................................................................................................ 14 CP2 ........................................................................................................ 15 Control Panel Push Buttons ........................................................................ 16 Operating Mode Buttons ........................................................................ 16 Command buttons .................................................................................. 16 Display Buttons ...................................................................................... 17 Contactors Buttons (CP2 only) ............................................................... 17 Data LED’s .................................................................................................. 18 Engine Status LED’s ............................................................................... 18 Alarm LED’s ........................................................................................... 18 Electric Power Status LED’s ................................................................... 19 Starting and Stopping - Manual Mode ......................................................... 20 Starting ................................................................................................... 20 Stopping ................................................................................................. 20 Starting and Stopping - Automatic Mode ..................................................... 21 Operational Modes ...................................................................................... 22 Test Mode (CP2 only) ............................................................................. 22 Block Mode (CP1 only) ........................................................................... 22 Block Mode (CP2 only) ........................................................................... 22 Activation of Contactors (CP2 only) ....................................................... 23 Linking Generators and Transfer Panels ................................................ 23 Maintenance ................................................................................................ 24 Working Counters ................................................................................... 24 Maintenance Counters ........................................................................... 24 Fault History ........................................................................................... 25 Equipment List ........................................................................................ 25 Alarms ......................................................................................................... 26 Engine Alarms ........................................................................................ 26 Generator Set Alarms ............................................................................. 27 Mains Alarms (CP2 only) ........................................................................ 27 Programmable Alarms and Inputs .......................................................... 28 Transfer Fuel Pump (Optional) .................................................................... 36 Gauging system for the fuel tank: ........................................................... 36

Contents

Contents Page No. Inputs and Outputs ...................................................................................... 37 Digital Inputs ........................................................................................... 38 Annex I Parameters Tables ....................................................................................... 43 Annex Il Device Display Figures and Readings ................................................................................. 55 Status of the Device ............................................................................... 55 Generator Figures Displayed ................................................................. 55 Engine Status Display ............................................................................ 55 Control Board Status Display. ................................................................. 56 Power and Energy Display ..................................................................... 57 Failures Record ...................................................................................... 58 Control Board Maintenance ......................................................................... 59 Introducing Password ............................................................................. 59 Inputs and Outputs ................................................................................. 60 Counters ................................................................................................. 61 List of Failures ........................................................................................ 62 Events .................................................................................................... 62 Date/Hour ............................................................................................... 65 Language Selection ................................................................................ 65 Control Board Programming ................................................................... 66 Annex lll Dimensions, Connections and Mechanisation Measurements Module ................................................................................ 68 Visualisation Module .................................................................................... 76 Annex lV CAN Communications Introduction .................................................................................................. 79 Topology ...................................................................................................... 80 Wiring .......................................................................................................... 81 Wiring Diagrams .......................................................................................... 83 Annex V Telesignal Communication Option by Digital Outputs ................................................... 86 Introduction ............................................................................................. 86 Telesignal Components .......................................................................... 86 Telesignal Programming ......................................................................... 88 Wiring of the Telesignal Option ............................................................... 89 Annex VI CCrs Communication Option via Modem ............................................................. 96 Introduction ............................................................................................. 96 CCrs Installation ..................................................................................... 96

Contents

Contents Page No. DSE Model 8610 and 8620 AMF Controller Installation ................................................................................................... 98 Terminal Description ............................................................................... 98 Analogue Sensors ................................................................................ 101 Magnetic Pick-up, CAN and Expansion ............................................... 102 V1 Load switching and Generator Voltage Sensing ............................. 104 V2 Mains Voltage Sensing (DSE8620 Only) ........................................ 105 Generator Current Transformers .......................................................... 106 Mains Current Transformers (DSE 8620 Only) .................................... 107 Configurable Digital Inputs ................................................................... 108 PC Configuration Interface Connector ................................................. 109 RS485 Connector ................................................................................. 110 RS232 Connector ................................................................................. 110 Description of Controls .............................................................................. 111 DSE 8610 Automatic Mains Failure (AMF) Control Module below: ...... 111 Viewing the Instrument Pages .............................................................. 115 Viewing The Event Log ........................................................................ 124 User Configurable Indicators ................................................................ 125 Operation ................................................................................................... 126 Control .................................................................................................. 126 Control Push- Buttons (DSE 8610 Only) .............................................. 127 Dummy Load/ Load Shedding Control ................................................. 131 Stop Mode ............................................................................................ 132 Automatic Operation (DSE 8620 Only) ................................................ 133 Manual Operation ................................................................................. 137 Test Operation (DSE 8620 Only) .......................................................... 139 Protections ................................................................................................ 141 Protections Disabled ............................................................................ 141 Indications ............................................................................................ 144 Warnings .............................................................................................. 145 High Current Warning Alarm ................................................................ 147 Shutdowns ............................................................................................ 148 Electrical Trips ...................................................................................... 150 High Current Shutdown / Electrical Trip Alarm ..................................... 152 Earth Fault Shutdown / Electrical Trip Alarm ........................................ 154 Short Circuit Alarm ............................................................................... 155 Rocof/Vector Shift..................................................... (DSE 8620 Only) 156 Scheduler .................................................................................................. 157 Stop Mode ............................................................................................ 157 Manual Mode ........................................................................................ 157 Auto Mode ............................................................................................ 157 Synchroscope Operation ........................................................................... 158 Commissioning .......................................................................................... 159 Commissioning Screens ....................................................................... 159 Front Control Configuration ....................................................................... 160 Accessing The Main Front Panel Configuration Editor ......................... 160 Adjustable Parameters ......................................................................... 163 Accessing The â&#x20AC;&#x2DC;runningâ&#x20AC;&#x2122; Configuration Editor ...................................... 166 Fault Finding .............................................................................................. 169 DSE Model 8660 ATS and Mains Controller Introduction ................................................................................................ 171 Specifications ............................................................................................ 172 Part Numbering ....................................................................................172

iii

Contents

Contents Page No. Installation ................................................................................................. 173 Terminal Description ............................................................................. 173 Load Current T ....................................................................ransformer 180 Typical Arrangement of Dsenet® ......................................................... 185 Description of Controls .............................................................................. 186 DSE8660 AMF Control Module ............................................................ 186 Quickstart Guide ................................................................................... 187 Viewing the Instrument pages .............................................................. 190 Viewing the Event Log ............................................................................... 193 User Configurable Indicators ..................................................................... 194 Controls ..................................................................................................... 196 Operation ................................................................................................... 198 Alternative Configurations .................................................................... 198 Stop Mode ............................................................................................ 198 Automatic mode ................................................................................... 198 Manual Mode ........................................................................................ 200 Test Mode ............................................................................................. 201 Protections ................................................................................................ 202 Indications ............................................................................................ 202 Warnings .............................................................................................. 204 Electrical Trips ...................................................................................... 205 Scheduler ............................................................................................. 205 Front Panel Configuration .................................................................... 206 Accessing The Main Front Panel Configuration Editor ......................... 207 Accessing the ‘Running’ Configuration Editor ...................................... 211 Commissioning .......................................................................................... 213 Pre-Commissioning .............................................................................. 213 Fault Finding .............................................................................................. 214

KS1 Panel Description and Main Features Control and protection controller is presented in a panel box of 72x72x75mm. It is manufactured according to DIN Title 43700 in NORYL UL 94 V-0 Self-extinguishing black colour.

Programming by micro-switches of the parameters: a

Overspeed programming and activation

b Reading of frequency by generator or pick-up Offers the possibility to start the engine in MANUAL or AUTOMATIC mode (by means of a free-voltage contact) and protect it against possible breakdowns. The management is made through an electronic circuit based on a microcontroller and located inside the controller. In the front part we can find the ON/OFF switch, a RESET button, a key for selecting MANUAL; STOP or AUTOMATIC mode and 14 leds. In the back side we can find 18 switchable connection terminals divided in two blocks, 6 programming micro-switches and one port RJ11 for programming and searching the alarm recordings and hour-counter

Pre-heating time

d Cooling time.

Action after fuel reserve alarm.

Engine running detection through D+.

Port RJ11, which allows: a

Advanced programming of the controller.

b Internal tour-counter reading. Main features are described as follows: c 1

Power supply voltage 12/24V.

Free-voltage contact start (LT).

Engine Protections:

Alarm history files.

d PC communication.

Fuel reserve

b Battery charger failure c

High engine coolant temperature

d Low oil pressure 4

Overfrequency (overspeed): a

By generator

b By pick-up 5

Auxiliary Input with alarm led.

All outputs are short-circuit sensitive.

â&#x20AC;&#x153;Quick connectionâ&#x20AC;? terminals.

9813/2550-1

KS1 Panel Front Panel Components

Front Panel Components Controller works as a diesel engine protection with possibility to carry out a start manoeuvre. In the front part, we can see the following components:

3 P033010

Fig 1. 1

Switch OFF/ON. It allows to connect and disconnect the controller.

Mode Selection Key (Man Stop Aut). In man position, the control panel will give the order to start the engine (1 attempt to start). In stop position, the controller will remain in automatic mode and will do as follows: if free voltage contact closes, the controller will start the genset. If the contact opens, the genset will stop.

Reset push button. It allows to restart the connection of the controller.

9813/2550-1

KS1 Panel Front Panel Components 4

Fuel reserve led (yellow). Indicates low fuel level in the tank This led remain lit during the time that we have this alarm condition.

Battery charger failure led (D+) (yellow). Indicates that the battery charger generator is not charging the battery. This led remains lit during the time that we have this alarm condition.

Auxillary alarm led (AUX) (yellow). Indicates that the alarm condition established in the auxiliary input of the controller has been detected. This led remains lit during the time that we have this alarm condition.

Pre-heating Led (yellow). This led starts blinking in 1 second intervals approx. during the pre-heating cycle carried out before every attempt to start the engine.

Cooling Stop Led (Cool Stop) (yellow). The led starts blinking in 1 second intervals approx. when COOLING STOP Led (COOL STOP) (yellow). The led starts blinking in 1 second intervals approx. when the controller orders a â&#x20AC;&#x2DC;stop cycleâ&#x20AC;&#x2122; and it never stops until this cycle comes to an end.

Contact Led of activated LT contactor (green). This signal activates when we close the free-voltage contact and it stops when the we open this contact.

Engine running Led (M) (green). Indicates that the engine is working. Detection can be done by reading the D+ or by reading the frequency. The latter can be done by generator or by means of the pick-up.

Emergency Stop Led (red). This Led lights when we push the emergency stop button. After the alarm condition, it will only switch off once we put the emergency stop in its position and resetting the controller.

Over speed Led (red). This Led becomes active depending on two conditions: During the overspeed programming to indicate that the programming was successful (see section 3.2) and also when the over speed protection device trips. In the latter, the controller starts a programmable stop cycle and the optical warning will last until we reset the controller.

Low Oil Pressure Led (BPA) (red). Indicates that the engine pressure switch has detected an anomaly. This protection activates a programmable stop cycle. This Led will remain lit until this alarm is remain reset.

High Oil Temperature Led. Indicates that the engine pressure switch has detected an anomaly. This protection activates a programmable stop cycle. This led will remain lit until this alarm condition is reset.

Engine failure Led (red). Indicates that the engine stops without any order from the controller.

Fail to start Led (red). Indicates that the controller completed 5 attempts to start the engine but the gunset did not start.

9813/2550-1

KS1 Panel Front Panel Components 17

Power supply (ON) (green). This optical signal indicates that the controller is ON.

9813/2550-1

KS1 Panel Backside Components

Backside Components In the back side we will find the connection terminals, the 6 programming micro-switches and one port RJ11 for programming and alarm records and partial and total hour counter.

Connection Terminals

This Terminal is connected to the battery negative.

Alternator Voltage Input 220V (GEN) This input is used to carry out the reading of frequency by generator. To achieve this, one of the phases of the generator is connected to this terminal while the neutral is connected to the GP terminal. Reading is always made between phase and neutral, never between the phases. The usual voltage for this input is 220V (effective). It can reach a maximum value of 280V (effective).

Alarm Output (AL)

Battery Negative (-BAT)

Deexcitación Stop (DS) This output activates when the genset is running and disables when the control panel orders to stop. It is necessary to set an external relay with the corresponding diodes for the inductive current. Maximum intensity permitted by this output is 0,5A.

This output activates when any anomaly is detected in the proper working of the genset or there are any parameter out of the established ranks. It is necessary to put a external relay with the corresponding diodes for the inductive current. Maximum intensity permitted by this output is 0,5A. 5

Excitation Stop (ES) When there is an order to stop the genset, this output activates for 10 seconds. After this period of time, if it is detected that the genset does not stop, this output will keep being active and ordering the genset to stop for several times with the same time period until the genset stops. It is necessary to set an external relay with the corresponding diodes for the inductive current. Maximum intensity permitted by this output is 0,5A.

Terminal D+ (Ed+) In This Output, The D+ Terminal Of The Battery Charger Alternator Is Connected So That It Starts Charging The Battery. On The Other Hand, The Controller Reads The Battery Charger Voltage In Order To Detect Any Failure In The Charge Alternator Or Detect If The Engine Is Running.

Start Output (ARR) When there is an order to start the engine, this output activates for 5 seconds in order to supply the power to the engine starter. After this time, if it detects that the engine is running, the output goes out. It is necessary to set an external relay with the corresponding diodes for the inductive current. Maximum intensity permitted by this output is 0,5A.

Contactor Activation Input (Cont) This Output Activates Once That The Preheating Time Is Over (20 Sg) After The Controller Has Already Detected “Engine Running”. This Is Used To Heat The Genset With No Load Before Activating The Load Contactor. It Is Necessary To Put A External Relay With The Corresponding Diodes For The Inductive Current. Maximum Intensity Permitted By This Output Is 0,5a.

This Terminal is connected to the battery positive, in either 12V or 24V batteries.

Pre-heating Input (PR) This Output Activates Before Every Start Attempt During The Previously Established Period According To The Micro-switch Position (See Section 3.2) In Order To Preheat The Engine. It Is Necessary To Put A External Relay With The Corresponding Diodes For The Inductive Current. Maximum Intensity Permitted By This Output Is 0,5a.

Battery Positive 12/24V (Vpower)

9813/2550-1

Pick-up Input (Pick-Up) This input is used to carry out the reading of the frequency pick-up. To achieve this, we must connect

KS1 Panel Backside Components to this terminal one cable with the signal supplied by ten magnetic Pick-up. The other cable will be connected to the GP terminal of the Control Panel. These inputs have no polarity. 12

It can only be used one out of two ways of reading of frequency. Never both of them used simultaneously. The selection between both methods of reading is made by means of the microcircuit “2” in the back part of the controller as stated in the section 3.2 of this manual. Note: It is very important to connect only one of the two different frequency reading inputs. If the alternator phase and neutral to the generator input in the control panel, it will not be possible to connect the Pick-up cables to the corresponding input under no circumstances and vice versa.

Through the micro-switches which are located in the upper part of the controller we can programme different parameters described as follows: 1

Water Temperature Input (HWTI)

Low Oil Pressure Input (LOPI)

This process described above is valid for genset frequency detection as well as Pick-up detection. 2

Fuel Reserve Input (FRI)

Auxiliary Input (AUXI) It is a digital input which activates when low level. It can be connected to any type of sensor which closes a contact when activates. It is equipped with optical signal by means of an AUXILIARY ALARM in yellow colour.

Frequency Reading By Generator Or Pick-up (G/P). By means of this micro-switch we can choose the detection to be done by using the generator or pickup. For reading by means of the generator it is necessary to set the micro-switch “2” in “ON” position. To select the reading by Pick-up, it is necessary to switch it off.

It is a digital input which activates when low level. It is connected to the fuel tank depth gauge and activates the fuel reserve alarm. Action after detecting the alarm is programmable (i.e. 3.2). 16

Overspeed Activation And Programming (OS) To establish the frequency value when over speed protection should activate, it is necessary to start the genset and wait the genset to be stable. Once the genset is working at nominal frequency, we must change the switch “1” to “ON” position. Afterwards, over speed led will light for one second approx. to indicate that the programming of this parameter has been successful. From this moment, over speed detection is active. To disable this protection, we must switch it off.

It is a digital input which activates when low level. It is connected to the engine oil pressure and activates the low oil pressure alarm. 15

Emergency If this input is active, an immediate genset stop will happen. This terminal is connected to a negative through an emergency push button with a NC (normally closed) contact. In order to activate this input it is necessary to open this contact. Therefore, there is no presence of a negative in the control panel input.Stop Input (EMI)

Micro-switches

It is a digital input which activates when low level. It is connected to the coolant temperature thermostat and activates the water temperature alarm. 14

External Start Input (ILT) It is a digital input which activates when low level. It is connected to a free- voltage contact (LT) which orders the starting sequence of the genset when the controller is operating in Automatic Mode (see section 4.2)

Alternator and Pick-up Voltage Common Input (GP) This input is common to connect the neutral of the generator when the reading of frequency is made through generator and one of the signal cables of the Pick-up if the reading is made by means of this type of sensor.

Note: It is very important to connect only one of the two different frequency reading inputs. If the alternator phase and neutral to the generator input in the control panel, it will not be possible to connect the Pick-up cables to the corresponding input under no circumstances and vice versa.

9813/2550-1

KS1 Panel Backside Components 3

Fuel Reserve (Fr). Alarm / Stop It allows to select the action after detecting the fuel reserve alarm. By means of the micro-switch “3” set in “ON” position, when the alarm is detected, the corresponding optical led activates and initiates a programmable stop cycle. In “OFF” position, this alarm is indicated only by optical signal

Pre- Heating (PR) Micro-switch “4” allows to select whether we want to programme a pre-heating time of 15 seconds in the ON position or 5 seconds when the position is OFF.

Cooling (ENF) Micro-switch “5” allows to select if we want to programme a cooling time for 60 seconds in the “ON” position or 5 seconds in “OFF” position.

Engine Running Detection By D+ (LD+) Micro-switch “6” is in “ON” position, we are selecting the “engine running” detection by reading the D+ (Battery-charger alternator). In “OFF” position, detection will be made only by the reading of the frequency (Generator or Pick-up).

Note: Engine running detection is always made by Means of frequency reading, either by generator or Pick-up. Activating this micro-switch, we add the detection by D+. in this case, “engine running” detection is made simultaneously by the reading of frequency and D+.

Port RJ11 It allows the programming of different parameters, also the reading of the tour-counter (partial and total) and the alarm recordings through the PC.

9813/2550-1

KS1 Panel Operation Modes

Operation Modes Recommendations

select MANUAL mode. By turning the key to the right in “AUT” position, AUTOMATIC mode is selected.

In order to assure the excellent working of the controller we enumerate the following recommendations:

– Stop Mode (STOP) By selecting this operation mode, the controller orders the stop of the genset and holds for a mode change.

– Before switching the controller on, be sure that the power supply terminals are properly connected and the mode selection key is set in “STOP” position. – The controller detects “engine running” in two different ways: by reading the frequency or by reading the battery charger alternator voltage (D+). By default, the controller always detects “engine running” by reading the frequency. If we want to detect it by means of the reading of D+ voltage it is necessary to turn the micro-switch “6” in the suitable position (see section 3.2).

Note: Under no circumstances we can stop the genset by switching the controller off or by pushing the RESET button. We can only stop the engine by turning the key to STOP position. – Modo manual (MAN) When selecting the MANUAL mode the controller orders immediate start of the engine. It carries out a warm up cycle during the time determined according to the position of the micro-switch “4”. (i.e. section 3.2).

– Detection of “engine running” by means of frequency can be done in two different ways. By generator or by Pick-up. They can nor be used simultaneously. Selection is made by means of the micro-switch “2” as stated in section 3.2.

Engine protections are active anytime. Load connection (genset contactor closing), is carried out automatically after 20 seconds in order to stabilize the genset. From that moment on, the contactor remain the same position until the stop of the genset or any associated alarm.

– If the Pick-up is set in the corresponding terminals, we must be sure that the terminals corresponding to the generator are disconnected and vice versa. Important: They can not be connected to the controller terminals the generator and the Pickup at the same time under no circumstances. – May sure that the cable which activates the genset stop is connected to the right terminal in the controller. If the genset stop is produced by excitation it must be connected to the PE terminal. In case of de-excitation it must be connected to the PD terminal.

In case the genset stops, it is necessary to activate STOP mode before attempting to start the genset again in MANUAL mode. – Automatic Mode (AUT) In this operation mode, the start is subordinated to the closing of the free-voltage contact. When this contact is closed, the controller orders 5 attempts to start in sequence as long as there is no “engine running” detection. Every attempt is 5 seconds long and the time inbetween attempts is 10 seconds.

Operation Modes The starting of the genset is made by setting the switch the OFF/ON switch (in the front of the controller) in ON position. The first action carried out by the controller is an internal diagnose and lamp checking lighting all the leds in the front panel. Afterwards, the controller remains on hold, as long as the mode operation key is in STOP position. Controller M6 can work in three different ways which can be selected by means of the lock in the front panel. With the key is on “STOP” position, we are selecting “STOP” mode. By turning the key to the left in “MAN” position, we

When the free-voltage opens, the controller orders to stop and holds before the contact closes again or wating for a change of operation mode. Note: If the controller disconnects, resets, or fails power supply, once it is restored, if it is in MANUAL or AUTOMATIC mode with the free-voltage contact closed the genset will start.

9813/2550-1

KS1 Panel Connection Diagram

Connection Diagram KS1

P033010-01

Fig 2.

P033010-02

Fig 3.

9813/2550-1

KS1 Panel Technical Features

Technical Features DESCRIPTION

MIN.

Hole dimension on front panel for assembly (acc. DIN 43700)

TIP.

MAX.

72 x 72

Depth for assembling

UN. mm

110

Power supply range

Operation temperature range

-40

Consumption without any activated input/output

Intensity of any output (transistor)

500

D+ output capacity (transistor)

500

280

Voltage range between the inputs GEN and GP (Phase and Neutral)

220

Variables programmed by defect

Timer (s)

Pre-heating time

Cooling time

Heating time (input contactor)

Maximum duration of starting intent

Time among intents

Maximum number of intents

Stopped time (for excitation)

BPA (Low Oil Pressure) checkup retard

ATA (High Coolant Temperature)

Aux checkup retard

All the outputs must be equipped with devices for the erasing of inductive current (diodes, stickers, RC filters, etc). The manoeuvre wired will stay at an enough distance of high electric fields: at least half meter of current lines up to 600 A and 1 meter to current lines of more than 600 A.

9813/2550-1

KS1 Panel Technical Features

Most Outstanding Advantages – Small size – Power size – Keystart – Short-circuit sensitive outputs – Pre-heating output – Alarm output – PC connection for it consults of historical of alarms and programming – Programming by means of micro-switches (Fuel Reserve, Pre-heating, Cooling, Generator or Pick-up, Over speed, Engine running by D+) – Emergency stop input – Free auxiliary input – Over speed protection

9813/2550-1

CP1 and CP2 Digital Control Panels Introduction Note: The following Digital Control Panel Information is common to both CP1 and CP2 panels except where specified as CP1 or CP2.

The Panel provides the following readings of the Electric Mains supply:

Configurable Inputs; The panel has 5 inputs that can be programmed to carry out the following functions: – Start disabling. – External start.

– Phase to neutral voltage.

– Test.

– Phase to phase voltage.

– Manual override.

– Phase amperage.

– 3 programmable alarms.

– Frequency.

– Mains contactor confirmation (CP2 only).

– Real, apparent and reactive powers.

– Generator Set contactor confirmation (CP2 only).

– Power factor and cos phî. – Energy (KwH) and historical power (day, month, year) with programming timer option.

The panel provides the following Engine features information: Engine alarm inputs:

Engine Statistics: – Number of working hours. – Number of starts.

The panel controls the following functions of the engine:

– Fuel reserve.

– Pre-heating or Glow Plug.

– Oil pressure.

– Stop.

– Coolant temperature.

– Start.

– Coolant level.

– Coolant heater.

– Emergency stop. (Stop button).

– Fuel Transfer pump. – Alternator excitation.

Analog Engine Inputs – Fuel level. – Oil Pressure. – Coolant Temperature. – Configurable input (i.e. Oil temperature). – Battery charge alternator voltage.

9803/9985-1

CP1 and CP2 Digital Control Panels Introduction

Password The stored user access password is 1111. This allows access to the main menu. User access (password: 1111). Maintenance access (password 1911) - Dealer only. To change the user password, use the (+) or (-) buttons and accept (v). Enter the new password at the position shown. K Fig 1. ( T 13) A

Old password

New password

T038430

Fig 1.

9803/9985-1

CP1 and CP2 Digital Control Panels Control Panel Front Views

Control Panel Front Views The panel has a backlit display and different LEDs to indicate the device status. Different push buttons allow the user to command and program the panel.

CP1

START

STOP

DIESEL TRANS

RESET

AUTO

a Aux.1

Aux.2

e T037950

Fig 2. CP1 1

Backlit display (4 lines of 20 digits).

CONTACTORS status LEDs.

Note: The display turns off the backlighting after 10 minutes if no pulse from the keyboard is detected. 2

Control board push buttons. a

Operating mode buttons.

b Command buttons. c 3

Display buttons.

Data LEDs d ENGINE status LEDs. e

ALARMS LEDs.

9803/9985-1

CP1 and CP2 Digital Control Panels Control Panel Front Views

CP2

START

STOP

DIESEL TRANS

RESET

g LOAD

MAINS

AUTO

TEST

MAN

GEN

Aux.1

Aux.2

f T038220

Fig 3. CP2 1

Backlit display (4 lines of 20 digits).

Note: The display turns off the backlighting after 10 minutes if no pulse from the keyboard is detected.

ENGINE status LEDs.

ALARMS LEDs.

g Electric power status LEDs 2

Control board push buttons. h Contactors status LEDs a

Operating mode buttons.

b Command buttons. c

Display buttons.

d Contactors buttons 3

Data LEDs

9803/9985-1

CP1 and CP2 Digital Control Panels Control Panel Push Buttons

Control Panel Push Buttons Operating Mode Buttons Automatic mode: The control panel monitors the status of the generating set and controls its working process and the programmable inputs.

LED on: Automatic mode running. LED flashing: Automatic mode blocked.

Manual mode: The user controls the device.

LED off: Manual mode running.

Test mode button (CP2 Only). The device starts the engine and monitors and controls its working process.

Block mode button (CP2 Only). The device controls the installation status, but disables every possibility of engine starting.

Manual mode button (CP2 Only). The user controls the device.

Command buttons

Stop engine push button (manual mode only).

Start engine push button (manual mode only).

Press once, the engine stops and a cooling phase begins.

One press will start the engine.

Press twice, the engine stops immediately.

LED ON: Engine starting

LED ON: The engine is in stopping phase (with or without cooling-down)

9803/9985-1

CP1 and CP2 Digital Control Panels Control Panel Push Buttons

Contactors Buttons (CP2 only)

Reset push button. Allows the user to acknowledge and clear the alarm condition LED flashing: There are alarms to check.

Mains contactor (CP2 only). Switches to mains contactor (manual mode only).

LED on: Active alarms. Transfer Fuel Pump push button. In manual mode, this button activates the transfer pump if the fuel level is under the programmed levels.

Generator Set contactor (CP2 only). Switches to generator set contactor (manual mode only).

LED flashing: There are alarms to check up. LED on: Alarms active.

Display Buttons

T038010

Fig 4. Confirmation button: Allows access to menu, validates and store the entered data. Cancellation button: Go back in the menu and cancels the entered data. Up button: Moves along the selection displays and maintenance menus, also increases the programmed values. Down button: Moves back in the selection display and maintenance menus, it also reduces the programmed values.

9803/9985-1

CP1 and CP2 Digital Control Panels Data LED’s

Data LED’s Engine Status LED’s Table 1. Engine started

Alarm LED’s K Alarms ( T 26) Table 2. Fuel Storage

Pre-heating Battery Levels Engine starting

High Temperature Battery charge alternator status

Starting Failure

Overspeed

Low Oil Pressure

Aux 1 (Free to program)

Aux 2 (Free to program)

9803/9985-1

CP1 and CP2 Digital Control Panels Data LEDâ&#x20AC;&#x2122;s

Electric Power Status LEDâ&#x20AC;&#x2122;s K Alarms ( T 26) Table 3. Mains power status

On: Activated without errors. Flashing: status with errors. Off: Not activated.

Engine status

On: Activated without errors. Flashing: status with errors. Off: Not activated.

Generator Set power status

On: Activated without errors. Flashing: status with errors. Off: Not activated.

9803/9985-1

CP1 and CP2 Digital Control Panels Starting and Stopping - Manual Mode

Starting and Stopping - Manual Mode Note: Before initiating the stop cycle, it is advisable that the main generator set circuit breaker be switched OFF.

Stopping

Starting

Note: Before initiating the stop cycle, it is advisable that the main generator set circuit breaker be switched OFF. The generator set can be stopped in two ways:

T038020

Press STOP button once. The generator set stops with a cooling down phase.

Press STOP button twice. The generator set stops with no cooling down phase (not recommended).

Fig 5. When START button is pressed, the starting cycle will be initiated, and the START LED will be on. At the same time, if the engine has glow plugs, the PR output will be activated, and the appropriate LED will be on during the programmed period of time.

Sequence Pressing the STOP button once, the stop cycle will begin with the engine cooling process. The STOP button will light.

If the generator fails to start at the first crank, the generator will wait for 5 seconds before attempting another start. It is not necessary to press `Start' again. The generator will attempt to start 4 times. If the machine is still not running, the controller will trigger the start failure alarm. T038030

To stop the start cycle, just press the stop button.

Fig 6.

Note: Readings about the engine condition are shown on the display, and details about the start operating process can be seen. The sequence is as follows:

Note: Readings about the engine condition are shown on the display, and details about the stop operating process can be seen. The sequence is as follows:

– Generator Set Stop – Generator Set Starting – Generator Set Started

– Generator Set Stabilised

– Generator Set Cooling

– Generator Set Loading

– Generator Set Stopping

Note: The starting process in an automatic system by means of timer, ATS signal, etc. works in the same way as a starting cycle in manual mode.

Once the cooling time is over (20 seconds by default), the unit will stop.

– Generator Set Stopped

9803/9985-1

CP1 and CP2 Digital Control Panels Starting and Stopping - Automatic Mode

Starting and Stopping - Automatic Mode

T038040

Fig 7. In automatic mode, the control panel constantly controls the generator set operation. In some situations, that can be programmed to supply power, the controller starts the generator set activating the generator set contactor. The generator set can be programmed to start with the activation of contactors from the following signals: – External start – Start controlled by timer. (if it is included in programming timer) – Forced start – Maximum mains voltage alarm (CP2 only). – Minimum mains voltage alarm (CP2 only). – Maximum mains power supply frequency alarm (CP2 only). – Minimum mains power supply frequency alarm (CP2 only). – Mains sequence alarm (CP2 only). – Mains power failure alarm (CP2 only). – Mains contactor failure alarm (CP2 only). The generator set can be programmed to start without the activation of contactors from the following signals: – Engine test. Also, automatic mode allows the management of starts using external devices, (PC, modem, or visualization modules or commutation devices). The generator set stops with cooling down cycle after the deactivation of the command which automatically started the generator set.

9803/9985-1

CP1 and CP2 Digital Control Panels Operational Modes

Operational Modes Test Mode (CP2 only)

Block Mode (CP2 only)

T038240

T038230

Fig 8.

Fig 9.

In Test mode, the device commands the starting of the generator set following the procedure explained in Engine Starting. The controller unit does not activate the generator set contactor, as long as the generator set is not started under mains alarms or mains contactor failure alarms.

The device blocks the generating set disabling every possibility of starting under any conditions.

In test mode, the device does not control the functions related to the programmable inputs, except the ones associated with the alarms.

Block Mode (CP1 only) The generator may start automatically in manual mode if an external signal is received. To block auto-start, select manual mode then press and hold AUTO for 5 seconds. To remove the blocking function, press and hold AUTO for 5 seconds.

5 seconds

Lock

5 seconds

Unlock

9803/9985-1

CP1 and CP2 Digital Control Panels Operational Modes

Activation of Contactors (CP2 only) Push MAINS button K Fig 10. ( T 23)

activate

mains

contactor.

T038370

Fig 10. Push GEN button to activate generator set contactor. K Fig 11. ( T 23)

T038380

Fig 11. Activation of the generator set contactor is possible only if the engine is running and produces a stabilized electric signal. Activation of the generator set contactor deactivates the mains contactor and vice versa; there is a waiting time of one second (not programmable) between the contactors switching.

Linking Generators and Transfer Panels Generators and transfer panels can be extended with additional equipment by use of the CANBUS network. A CANBUS system must have 2 terminating resistors (120 ohms) activated to ensure communication. Every JCB control panel has a switch to enable a terminating resistor. Therefore on any network 2, and only 2, resistors must be activated.

9803/9985-1

CP1 and CP2 Digital Control Panels Maintenance

Maintenance Working Counters

power values along the day are added to the monthly energy values. The daily counter then starts from 0.

The CP1 and CP2 controllers record a number of stored values regarding the control board functions. The counters of the device are:

– Monthly counter of power. The monthly counter of power registers the quantity of power produced by the generator set from the fist day of the current month up to the day before the moment of checking. With the change of month, the stored power values are added to the annual power counter. The monthly counter then starts from 0.

– Total working hours counter. The device records the number of working hours of the generator set engine. This counter can not be reset.

– Annual counter of power

– Partial working hours counter

The annual counter of power registers the quantity of power produced by the generator set from 1st January up to the month before to the moment of checking. With the change of year, the stored power values are reset and the counter starts from 0.

The device records the number of working hours of the generator set engine. This counter can be reset and it starts from 0. – Succeeded starts counter. The device records the number of obtained starts. This counter can be reset and it starts from 0.

The user can see the counters readings by accessing from the menu Main - 3.Counters The partial counters can be reset to 0 by selecting with the UP/DOWN buttons and pressing RESET for 5 seconds.

– Failed starts counter. The device records the number of failed starts. This counter can be reset and it starts from 0.

Maintenance Counters CP1 and CP2 Display

– Total counter of power. The device records the total amount of power produced by the generator set (MWh). This counter can not be reset.

The CP1 and CP2 controllers have two maintenance counters: 1

Hours run.

Days till maintenance due.

– Partial counter of power. The device records the total amount of power produced by the generator set (MWh). This counter can be reset and it starts from 0.

When either of these counters reach their preprogrammed limit, an audible alarm and message display will be activated.

– Daily counter of power. The daily counter of power registers the quantity of power produced by the generator set from the 00:00H. of the present day up to the moment of checking. With the change of the day, the stored

The maintenance password is required to reset these counters.

Programming The maintenance meter is programmed from Meters Menu Mant.#1. By pushing the tick button you have access to the time value setup that should have a difference of 0 hours.

9803/9985-1

CP1 and CP2 Digital Control Panels Maintenance Display The remaining time before the maintenance alarm switches on is displayed on the Meters Menu - >Mant.#1 in hours and minutes.

Note: The existence of analogous modules with the same identifier is not allowed. If the visualization module detects another similar module with the same identifier, the message ‘ID. FAILURE DISPLAY’ is displayed.

Cancellation

Note: When the module identifier is changed, it is automatically reset. Never change the identifier of the measure group with the generator set working.

To cancel the on-going maintenance meter you should program on the Meter Menu Mant.#1 pushing the tick button and changing the value to 0.

Identifier Assignment

Fault History

As standard, all electronic modules have a pre-set identification of ‘0’. When connecting multiple modules, each unit must be assigned an individual identification number in accordance with the start-up sequence

The CP1 and CP2 controllers register the alarms and save the status of the control board at the moment of the detection. The CP1 and CP2 controllers store the last 100 detected failures, including the date and hour of the moment in which the failure was produced.

Equipment List The CP1 and CP2 controllers allow identification and display of all the electronic devices connected to the controller. In order to view these parameters we have to go to Parameters Menu -> equipment list. This option menu shows all the electronic devices (PHR6 and PHG6) and display modules (CP1, CP2 and ATP1) currently connected, marked with an (*) the module from which it is displaying the equipment list. Information of the following equipment is specified: – The electronic module model – The electronic module identifier (from 0 to 14) – The firmware version – For the display modules CP1, CP2 and ATP1 the associated measures group is indicated between bracket s. For display modules CP1 and CP2 the display module m aster has to has the same identifier as the associated measured group. For repetitive display modules, the module has to have different identifier from the master display and has to be associated with the same measure module. The display of the visualization modules of the ATS panels must have the same identification as the measurements linked module in the ATS and the measurements module identification linked to the manual control panel.

9803/9985-1

CP1 and CP2 Digital Control Panels Alarms

Alarms Engine Alarms Description

Table 4. LED in the front panel

Type

Action

High coolant temperature

LED flashes

Alarm

Immediate engine stop with no cooling

Low oil pressure

LED flashes

Alarm

Immediate engine stop with no cooling

Alarm

Immediate engine stop with no cooling

Warning

Engine does not stop

Emergency stop Battery charge alternator failure (engine running)

LED off

Start failure

LED flashes

Low coolant level

LED flashes

Alarm

Immediate engine stop with no cooling

Fuel storage

LED flashes

Warning

Engine does not stop

Overspeed

LED on

Alarm

Immediate engine stop with no cooling

Loss of speed

Alarm

Engine stop with cooling

Low battery voltage

Warning

No stop

High coolant temperature by sensor

LED on

Warning

Engine does not stop

Low oil pressure by sensor

LED on

Warning

Engine does not stop

9803/9985-1

CP1 and CP2 Digital Control Panels Alarms Description

LED in the front panel

Low fuel level by sensor

LED on

Type

Action

Warning

Engine does not stop

Low engine temperature

Warning

Engine does not stop

Generator Set voltage drops

Alarm

Engine stop with cooling

Unexpected shutdown Stop failure

Generator Set Alarms Table 5. Type

Description

Action

Overload

Alarm

Engine stop with cooling

Generator Set voltage asymmetry

Alarm

Engine stop with cooling

Maximum voltage of the generator set

Alarm

Immediate engine stop with no cooling

Maximum generator set frequency

Alarm

Immediate engine stop with no cooling

Erroneous phase sequence of the generator set

Alarm

Engine stop with cooling

Inverse power

Alarm

Engine stop with cooling

Short circuit

Alarm

Engine stop with cooling

Minimum generator set voltage

Alarm

Engine stop with cooling

Minimum generator set frequency

Alarm

Engine stop with cooling

Mains Alarms (CP2 only) Table 6. Description

Action

Maximum mains voltage

Possible failure checked. The engine is started.

Minimum mains voltage

Possible failure checked. The engine is started.

Maximum mains power supply frequency

Possible failure checked. The engine is started.

Minimum mains power supply frequency

Possible failure checked. The engine is started.

Mains phase sequence failure

Possible failure checked. The engine is started.

Mains power failure

Possible failure checked. The engine is started.

Mains contactor switching failure(MC)

Possible failure checked. The engine is started.

Generator Set contactor switching failure (GC)

Check if it is failure and engine stop with cooling

9803/9985-1

CP1 and CP2 Digital Control Panels Alarms

Programmable Alarms and Inputs All alarms except the non-programmable can be configured as follows: To be carried out:

The low oil pressure alarm of the CP1 and CP2 is associated with the specific low oil pressure digital input (LOP).The status of such input must be validated during a stabilisation time (Times table parameter 16) before the low oil pressure alarm triggers. It can be configured as normally open or normally closed (Regulations table parameter 6).

– Never – Always

The low oil pressure alarm is configured (Alarms table parameter 4) to be detected from the engine started condition.

– During the engine start – From the started engine condition – From the engine nominal condition

A stabilisation time can be associated with the low oil pressure alarm (Alarms table parameter 5) to delay the moment in which the alarm conditions are verified.

To carry out one of the following actions: – No actions to be performed (warning)

This alarm is configured (Alarms table parameter 6) to carry out the immediate engine stop.

– Stop with engine cooling – Immediate engine stop Each alarm condition will be highlighted by default.

Emergency Stop (Not programmable) For Settings The emergency stop alarm of the CP1 and CP2 is associated with the specific emergency stop digital input (EMS).

High Coolant Temperature

The high coolant temperature alarm of the CP1 and CP2 is associated to the specific high coolant temperature digital input (HTC). The status of such input must be validated during a stabilisation time (Times table parameter 17) before the high coolant temperature alarm triggers. It can be configured as normally open or normally closed (Regulations table parameter 7). The high coolant temperature alarm can be configured (Alarms table parameter 1) to be detected ‘Always’.

It can be configured as normally open or normally closed (Regulations table parameter11). When activated, the emergency stop signals the measurement module to cut power to ‘starting’, ‘preheating’ and ‘engine run’ systems. The engine can not be restarted until the emergency stop button is reset and the alarm is acknowledged on the panel. The emergency stop alarm always stops the engine without cooling. No delay timing can be associated with that action, as it is immediately executed after the emergency stop input is detected (EMS).

A stabilisation time can be associated with the high coolant temperature alarm (Alarms table parameter 2) to delay the moment in which the alarm conditions are verified.

Battery Charge Alternator Failure

This alarm has been configured (Alarms table parameter 3) to carry out: the immediate engine stop. Low Oil Pressure

The battery charge alternator failure alarm of the CP1 and CP2 is associated with the battery charge alternator voltage analog input (DI). The voltage value of such input must exceed the voltage threshold of the engine started

9803/9985-1

CP1 and CP2 Digital Control Panels Alarms detection (Thresholds table parameter 21); if not, the battery charge alternator failure alarm is triggered.

This alarm is configured (Alarms table parameter 18) to carry out the following action: Immediate engine stop if the engine is not already stopped.

The battery charge alternator alarm is configured (Alarms table parameter 10) to be detected from the engine started condition. A stabilisation time can be associated with the battery charge alternator low alarm (Alarms table 11). During this time the obtained voltage values must be kept under the started engine detection threshold (through the DI input) as a condition for the battery charge alternator failure alarm to be triggered. This alarm has been initially configured (Alarms table parameter 12) to be inactive. (warning)

Fuel Reserve

The fuel reserve alarm of the CP1 and CP2 is associated with the specific fuel reserve digital input (FR) The status of this input must be validated during a stabilisation time (Times table parameter 15) before triggering the fuel reserve alarm. It can be configured as normally open or normally closed (Regulations table parameter 5). The low coolant level alarm is configured (Alarms table parameter 19) to be detected Always.

Starting Failure

The starting failure alarm of the CP1 and CP2 is triggered if all the starting attempts (Times table parameter 1), consecutive and non effective, during the engine starting cycle are effected. Between each start attempt there is a programmable waiting time (Times table parameter 2). Once the alarm is produced, the user must check it before trying to start the engine again

A stabilisation time (Alarms table parameter 20) can be associated to the fuel reserve alarm to delay the moment in which the alarm condition is verified. This alarm is configured (Alarms table parameter 21) to carry out the following action: No actions to be performed (warning) Overspeed

Low Coolant Level

The low coolant level alarm of the CP1 and CP2 is associated with the specific low coolant level digital input (NA). The status of this input must be validated during a stabilisation time (Times parameter 18) before triggering the low coolant level alarm. It can be configured as normally open or normally closed (Regulations table parameter 8). The low coolant level alarm is configured (Alarms table parameter 16) to be detected Always. A stabilisation time (Alarms table parameter 17) can be associated with the low coolant level alarm to delay the moment in which the alarm condition is verified.

The overspeed alarm of the CP1 and CP2 is associated with the rotation speed of the engine ring gear. This measurement is done through the pick up input of the measurement module. The alarm functions depend on the parameter that determines the number of teeth of the engine ring gear (Thresholds table parameter 24) would not be zero. The overspeed alarm is configured (Alarms table parameter 22) to be detected: - From the engine nominal condition. A stabilisation time can be associated with the overspeed alarm (Alarms table parameter 23). The rotation speed of the ring gear during this time must be over the maximum limits of the rotation speed (Thresholds table parameter 11).

9803/9985-1

CP1 and CP2 Digital Control Panels Alarms This alarm is configured (Alarms table parameter 24) to carry out the following action: Immediate engine stop. Underspeed

A stabilisation time can be associated with the overload alarm (Alarms table parameter 29). During this time the amperage values must be kept over the maximum programmed limits (Thresholds table parameter 7). This alarm is configured (Alarms table parameter 30) to carry out the following action: Stop with engine cooling.

The underspeed alarm of the CP1 and CP2 is associated with the rotation speed of the engine ring gear. This measurement is done through the pick up input of the measurement module. The alarm functions depend on the parameter that determines the number of teeth of the engine ring gear (Thresholds table parameter 24) would not be zero. The underspeed alarm is configured (Alarms table parameter 25) to be detected: - From the engine nominal condition. A stabilisation time can be associated with the underspeed alarm (Alarms table parameter 26). During this time it must be kept under the programmed minimum limits (Thresholds table parameter 12). This alarm is configured (Alarms table parameter 27) to carry out the following action: Stop with engine cooling.

The generator set voltage asymmetry alarm of the CP1 and CP2 controls that the difference found between any pair of real voltage values among generating set voltage phases (VG12, VG23 or VG31, must be over the maximum asymmetry programmed limits ( Thresholds table parameter 4). The voltage asymmetry alarm is activated only when the device is configured for the measurement of three-phase with neutral or three-phase without neutral voltage values. The voltage asymmetry alarm is configured (Alarms table parameter 31) to be detected: From the engine nominal condition. A stabilisation time can be associated with the voltage asymmetry alarm (Alarms table parameter 32). During this time, the difference between any pair of voltage values of the generator set phases (V12, V23 or V31) must be over the maximum asymmetry programmed limits (Thresholds table parameter 4).

Overload

The overload alarm of the CP1 and CP2 is associated with the effective amperage value in any of the phases. The value must be superior to the maximum programmed overload limit (Thresholds table parameter 7) but under the maximum limit of short-circuit (Thresholds table parameter 8). The phases that are checked to detect the overload alarm are selected depending on the configuration of the installation phases (Thresholds table parameter 1): â&#x20AC;&#x201C; Single-phase configuration, phase 1 is tested. â&#x20AC;&#x201C; Three-phase configuration with neutral or threephase without neutral, phase 1, 2 and 3 are tested. The overload alarm is configured (Alarms table parameter 28) to be detected: From the engine nominal condition.

Generator Set Voltage Asymmetry

This alarm is configured (Alarms table parameter 33) to carry out the following action: Stop with engine cooling.

Maximum Generator Set Voltage

The maximum generator set voltage alarm of the CP1 and CP2 is associated with the fact that the real voltage value obtained from any pair of phases of the generator set (V12, V23 or V31) is over the maximum programmed voltage limits (Thresholds table parameter 2). The phases that are checked to detect the maximum generator set voltage alarm are selected depending on the

9803/9985-1

CP1 and CP2 Digital Control Panels Alarms configuration of the phases in the installation (Thresholds table parameter 1):

Incorrect Phase Sequence of the Generator Set

â&#x20AC;&#x201C; Single-phase configuration, V1N voltage is tested. â&#x20AC;&#x201C; Three-phase configuration with neutral or threephase without neutral, V12, V23, V13 voltages is tested. The maximum generator set voltage alarm is configured (Alarms table parameter 34) to be detected: From the engine nominal condition. A stabilisation time can be associated with the maximum generator set voltage alarm (Alarms table parameter 35). During this time, the voltage values obtained between generator set phases (V12, V23 or V31) must be over the maximum programmed limits. (Thresholds table parameter 2). This alarm can be configured (Alarms table parameter 36) to carry out the following action: Immediate engine stop.

The incorrect phase sequence alarm is activated only when the device is configured to work with three phase with neutral or three-phase without neutral. The incorrect phase sequence alarm is configured (Alarms table parameter 40) to be detected: From the engine nominal condition. A stabilisation time can be associated with the incorrect phase sequence alarm (Alarms table parameter 41). During this time an incorrect order in the maximum voltage values of the generator set must be detected. This alarm is configured (Alarms table parameter 42) to carry out the following action: Stop with engine cooling.

Maximum Generator Set Frequency

The maximum generator set frequency alarm of the CP1 and CP2 is associated with the fact that the frequency generated by the generator set surpasses the maximum programmed frequency limits. (Thresholds table parameter 5). The first-phase is used to measure the generator set frequency. If no signal is detected, the measure is taken in the second-phase. In the same way, if no signal is detected, the measure is taken in the third-phase. The maximum generator set frequency alarm is configured (Alarms table parameter 37) to be detected: From the engine nominal condition. A stabilisation time can be associated with the maximum generator set frequency alarm (Alarms table parameter 38). During this time, the generator set frequency values obtained must be kept over the maximum programmed limits. (Thresholds table parameter 5). This alarm is configured (Alarms table parameter 39) to carry out the following action: Immediate engine stop.

The incorrect phase sequence of the generator set alarm of the CP1 and CP2 is associated with the fact that the maximum values of the generator set signal phases are in order (phase 1, phase 2 and phase 3 in this order).

Inverse Power

The inverse power alarm of the CP1 and CP2 is activated when the power obtained (mains or generator set) is negative and exceeds the resultant value after calculating the programmed factor in a hundred per cent (Thresholds table parameter 10) of the nominal power. (Thresholds table parameter 9). Sometimes, the inverse power alarms can be triggered due to incorrect wiring of the current transformers. The inverse power alarm is configured (Alarms table parameter 43) to be detected: From the engine nominal condition. A stabilisation time can be associated to the inverse power alarm (Alarms table parameter 44). During this time the power could be out the programmed limits. This alarm is configured (Alarms table parameter 45) to carry out the following action: Stop with engine cooling.

9803/9985-1

CP1 and CP2 Digital Control Panels Alarms pressure readings are under the programmed limits (Thresholds table parameter 26).

Low Battery Voltage

The low battery voltage alarm of the CP1 and CP2 is triggered when the voltage obtained is lower than the programmed limits (Thresholds table parameter 17). The low battery voltage alarm is configured (Alarms table parameter 46) to be detected: Always. A stabilisation time can be associated to the low battery voltage alarm (Alarms table parameter 47). During this time, the voltage value detected must be under the programmed limits. (Thresholds table parameter 17).

The low oil pressure by sensor alarm is configured (Alarms table parameter 52) to be detected: From the started engine condition. A stabilisation time can be associated to the low oil pressure by sensor alarm (Alarms table parameter 53). During this time the pressure values must be detected under the programmed limits. (Thresholds table parameter 26). This alarm has been initially configured (Alarms table parameter 54) to be inactive. (warning). Low Fuel Level by Sensor

This alarm has been initially configured (Alarms table parameter 48) to be inactive. (warning). High Coolant Temperature by Sensor

The high coolant temperature by sensor alarm is associated with the coolant temperature analog input (T). The high coolant temperature by sensor alarm triggers when a temperature reading is above the programmed limits. (Thresholds table parameter 27). The high coolant temperature by sensor alarm is configured (Alarms table parameter 49) to be detected: Always. A stabilisation time can be associated to the high coolant temperature by sensor alarm (Alarms table parameter 50). During this time, the coolant temperature value detected must be over the programmed limits. (Thresholds table parameter 27).

The low fuel level by sensor alarm of the CP1 and CP2 is associated with the fuel level analog input (NC = FL). The low fuel level by sensor alarm triggers when the fuel level is under the programmed limits. (Thresholds table parameter 25). The low fuel level by sensor alarm is configured (Alarms table parameter 55) to be detected: Always. A stabilisation time can be associated with the low fuel level by sensor alarm (Alarms table parameter 56). During this time the fuel level values must be detected under the programmed limits (Thresholds table parameter 25). This alarm has been initially configured (Alarms table parameter 57) to be inactive. (warning). Short Circuit

This alarm has been initially configured (Alarms table parameter 51) to be inactive. (warning). The short circuit alarm of the CP1 and CP2 is associated with real amperage value when any of the phases are over the maximum short circuit programmed limits (Thresholds table parameter 8).

Low Oil Pressure by Sensor

The low oil pressure by sensor alarm of the CP1 and CP2 is associated with the oil pressure analog input (T). The low oil pressure by sensor alarm triggers when the

The phases that are checked to detect short circuit alarm are selected depending on the configuration of the phases in the installation (Thresholds table parameter 1):

9803/9985-1

CP1 and CP2 Digital Control Panels Alarms – Single-phase configuration, phase 1 is tested. – Three-phase configuration with neutral or threephase without neutral, phase 1, 2 and 3 are tested. The short circuit alarm is configured (Alarms table parameter 58) to be detected: From the engine nominal condition. This alarm is configured (Alarms table parameter 60) to carry out the following action: Stop with engine cooling.

Minimum Generator Set Frequency

The minimum generator set frequency alarm of the CP1 and CP2 is associated with the fact that the frequency generated by the generator set is under the minimum programmed frequency limits. (Thresholds table parameter 6). The first-phase is used to measure the generator set frequency. If no signal is detected, the measure is taken in the second-phase. In the same way, if no signal is detected, the measure is taken in the third-phase.

Minimum Generator Set Voltage

The minimum generator set voltage alarm of the CP1 and CP2 is associated to the fact that real voltage value obtained from any pair of phases of the generator set ((V12, V23 or V31) is under the minimum programmed voltage limits (Thresholds table parameter 3). The phases that are checked to detect the minimum generator set voltage alarm are selected depending on the configuration of the phases in the installation (Thresholds table parameter 1): – Single-phase configuration, V1N voltage is tested.

The minimum generator set frequency alarm is configured (Alarms table parameter 64) to be detected: From the engine nominal condition. A stabilisation time can be associated to the minimum generator set frequency alarm (Alarms table parameter 65). During this time, the generator set frequency values obtained must be kept under the minimum programmed limits (Thresholds table parameter 6). This alarm is configured (Alarms table parameter 66) to carry out the following action: Stop with engine cooling.

– Three-phase configuration with neutral or threephase without neutral, V12, V23, V13 voltages are tested. The minimum generator set voltage alarm is configured (Alarms table parameter 61) to be detected: From the engine nominal condition . A stabilisation time can be associated to the minimum generator set voltage alarm (Alarms table parameter 62). During this time, the voltage values obtained between generator set phases (V12, V23, V13) must be under the minimum programmed limits. (Thresholds table parameter 3).

Unexpected Shutdown

The unexpected shutdown of the CP1 and CP2 triggers when the controller, while the engine is running, does not detect all the engine starting conditions. (Regulations table parameters 19 to 22).

Stop Failure

This alarm is configured (Alarms table parameter 63) to carry out the following action: Stop with engine cooling. 31 The stop failure alarm of the CP1 and CP2 is raised if 15 seconds after the engine stop attempt it has not detected all conditions of the engine (Regulations table parameters19 to 22).

9803/9985-1

CP1 and CP2 Digital Control Panels Alarms In case the stop failure alarm is disconnected (Alarms table parameter 70), the device will consider the engine as stopped after waiting the stop conditions for a maximum time of 15 seconds.

This alarm is configured (Alarms table parameter 78) to carry out the following action: Stop with engine cooling. Programmable Alarm 1

To detect the stop of the engine, all the stopping conditions must be detected during a programmed time (Alarms table parameter 71). Low Engine Temperature

The low engine temperature alarm of the CP1 and CP2 is associated with the analog coolant temperature input (T). The low engine temperature alarm triggers when a temperature value is under the programmed limits. (Thresholds table parameter 28). The low engine temperature alarm is configured (Alarms table parameter 73) to be detected: Never. A stabilisation time can be associated to the low engine temperature alarm (Alarms table parameter 74). During this time, the coolant temperature values must be detected under the programmed limits. (Thresholds table parameter 28). The low engine temperature alarm, once activated, can set up the controller to do not switch on the generator set change over until the engine exceeds the low temperature limits (Thresholds table parameter 28).

The programmable alarm 1 of the CP1 and CP2 is activated by associating one of the general digital inputs (ENT1, ENT2, ENT3, ENT4 or ENT5) to the working mode of the programmable alarms. (Programming table parameter 13). The status of such input must be validated during a stabilisation time (Times table parameter 19, 20, 22, 23 or 24) before triggering the programmable alarm 1 alarm. The programmable alarm 1 is configured (Alarms table parameter 79) to be detected: Never. A delay time (Alarms table parameter 80) can be associated to the programmable alarm 1 in order to restrain the moment in which the alarm conditions are checked. This alarm has been initially configured (Alarms table parameter 81) to be inactive. (warning). A programmable text can be associated with the programmable alarm 1 and will appear on the visualization module display when the alarm is triggered. Programmable Alarm 2

Generator Set Signal Failure

The generator set signal failure alarm of the CP1 and CP2 is triggered if, while the engine is running, no voltage is detected in any of the phases. The generator set signal failure alarm is configured (Alarms table parameter 76) to be detected: From the engine nominal condition. A stabilisation time can be associated with the generator set signal failure alarm (Alarms table parameter 77). During this time no voltage must be detected before the pre-set time expires to activate the alarm.

The programmable alarm 2 of the CP1 and CP2 is activated by associating one of the general digital inputs (ENT1, ENT2, ENT3, ENT4 or ENT5) to the working mode of the programmable alarms. (Programming table parameter 14). The status of such input must be validated during a stabilisation time (Times table parameter 19, 20, 22, 23 or 24) before triggering the programmable alarm 2 alarm. The programmable alarm 2 is configured (Alarms table parameter 82) to be detected: Never.

9803/9985-1

CP1 and CP2 Digital Control Panels Alarms A delay time (Alarms table parameter 83) can be associated to the programmable alarm 2 in order to restrain the moment in which the alarm conditions are checked. This alarm has been initially configured (Alarms table parameter 84) to be inactive. (warning). A programmable text can be associated with the programmable alarm 2 and will appear on the visualization module display when the alarm is triggered. Programmable Alarm 3

The programmable alarm 3 of the CP1 and CP2 is activated by associating one of the general digital inputs (ENT1, ENT2, ENT3, ENT4 o ENT5) to the working mode of the programmable alarms. (Programming table parameter 15). The status of such input must be validated during a stabilisation time (Times table parameter 19, 20, 22, 23 or 24) before triggering the programmable alarm 3. The programmable alarm 3 is configured (Alarms table parameter 85) to be detected: Never. A delay time (Alarms table parameter 86) can be associated to the programmable alarm 3 in order to restrain the moment in which the alarm conditions are checked. This alarm has been initially configured (Alarms table parameter 87) to be inactive. (warning). A programmable text can be associated with the programmable alarm 3 and will appear on the visualization module display when the alarm is triggered. For Settings

9803/9985-1

CP1 and CP2 Digital Control Panels Transfer Fuel Pump (Optional)

Transfer Fuel Pump (Optional) Once the transfer pump option is activated, its operation modes are as follows: 1

Inhibited mode. No transfer fuel pump functions can be activated.

Manual mode: The transfer pump is operated by pressing the diesel transfer button, provided that the fuel level is under the maximum threshold parameters.

Automatic mode: The transfer pump operates according to the maximum and minimum activation fuel levels set.

Control board mode: The transfer pump operation is carried out as follows: a

When the controller is in automatic or test mode, the transfer pump is operated automatically.

b When the controller is manual mode, the transfer pump operation is carried out in manual mode. c

When the controller is in a blocked-mode, the transfer pump operation is inhibited.

Gauging system for the fuel tank: For an accurate fuel level measurement (needed for the fuel pump and fuel level alarm functions) a calibration of the tank level sender must be done, by having access to both the minimum and maximum parameters of the level sender (Measurements table parameters 12 and 13). To adjust the minimum fuel level of the tank , the parameter 12 of the measurement table must be recorded (press green button twice) with the level sender in its minimum position. To adjust the maximum fuel level of the tank, the parameter 13 of the measurement table must be recorded (press green button twice) with the level sender in its maximum position.

9803/9985-1

CP1 and CP2 Digital Control Panels Inputs and Outputs

Inputs and Outputs The digital inputs, with specific functions as well as the programmable ones, have a stabilisation time (Times table parameters 15 to 24) which requires the values of the inputs to be stable for a period of time.

Likewise, all the inputs of the control board can be configured to be active or not active; with contact closed to earth (Regulations table parameters 5 to 15). The status of the inputs and outputs can be visualized from the menu MAIN > 1. Inputs/Outputs. From this screen, the status of the digital inputs and outputs are displayed.

N P U T

IN:

OUT:

Table 7. S / O U T

P U T

M S 3

P I

X N A B R

C P R 4

B g

6 3

3 1

M A

Key to screen content K Table 7. ( T 37) A

Input/output index

Input

Output

The following characters show the detection of the active input: IN 1.

R: Fuel Reserve (FR).

IN 2.

B: Low oil pressure. (LOP)

IN 3.

IN 4.

N: Coolant level.(CL)

IN 5.

X: "Programmable input 4. (default value, external start). (ES)

IN 6.

I: "Programmable input 5. (default value, start disabling). (SD)

High temperature. (HCT)

IN 7.

P: Emergency stop. (EMS)

IN 8.

1: Programmable input 1.

IN 9.

2: Programmable input 2.

IN 10.

3: Programmable input 3.

IN 11.

S: Stop button.

IN 12.

M: Start key.

The following characters show the detection of the active output: OUT 1.

A: Active alarm.(AL)

OUT 2.

M: Engine started.(SE)

OUT 3.

1: Programmable output 1. (OUT1)

OUT 4.

+: Battery charge alternator (D+)

9803/9985-1

CP1 and CP2 Digital Control Panels Inputs and Outputs

Digital Inputs

OUT 5.

2: Programmable output 2. (OUT2)

OUT 6.

3: Programmable output 3. . (OUT3)

OUT 7.

OUT 8.

g: Generating set contactor. (GCC, GCNC, GCNO)

OUT 9.

B: Fuel transfer/pre-heating. (FPC, FPNA)

Mains contactor.(MCC, MCNC, MCNO)

OUT 10. 4:

Programmable output 4.

OUT 11. R:

Pre-heating/excitation stop. (PH)

OUT 12. P:

De-excitation stop/excitation stop. (START)

OUT 13. C:

Controller fitting.

Preset Inputs The measures module has 5 digital inputs, whose operation is already pre-set. Fixed inputs show the following situations: High temperature (HCT).

Digital signal reporting to the controller that the temperature switch of the engine has detected a failure and activates an alarm due to the engine high temperature (Alarm table parameters 1 to 3). Low Oil Pressure (LOP)

T038010

Fig 12. Press UP/DOWN buttons to gain access to the analog inputs readings. A N A L O G S

Digital signal reporting to the controller that the engine pressure switch has detected a failure and activates an alarm due to the low oil pressure (Alarm table parameters 4 to 6). Coolant Level (CL)

I N P U T S

F L

0 . 0

P A

0 . 0

E T

0 . 0

A A

0 . 0

D T

0 . 0 V

V B

0 . 0 V

The value of the resistive analog inputs is found in Ohms and the value of the voltage analog inputs is given in Volts. The inputs that can be seen are:

Digital signal reporting to the controller that an alarm triggered due to low coolant level (Alarms table parameters 16 to 18). Emergency Stop (EMS)

FL: Fuel level. OP: Oil pressure. ET: Engine temperature. AA: Analog Auxiliary. DT: Dynamo voltage. BV: Battery voltage.

Digital signal reporting to the controller that an immediate stop without cooling must be done.

9803/9985-1

CP1 and CP2 Digital Control Panels Inputs and Outputs This function only works when the CP1 and CP2 function in automatic mode.

Fuel Reserve (FR)

Digital signal reporting to the controller that an alarm has been generated due to a failure in the fuel reserve. (Alarm table parameters 19 to 21).

The input configured as start disabling signal (Programming table parameter 9) does not allow the starting of the generator set under any condition, excepting manual override starting (Programming table parameter 12) configured as a high priority option. (Regulations table parameter 25).

Programmable Inputs

External Start Signal (ES + INP5)

The CP1 and CP2 measurements module has 5 digital inputs whose operation can be programmed. The programmable inputs can be configured to take the following behaviour: Rate Notice Signal (EJP1) - France Only

This function only works when the CP1 and CP2 function in automatic mode. The input configured as external start (Programming table parameter 10) forces the starting of the generator set if it is working in automatic mode, provided that no of the following start disabling conditions are present:

This function only works when the CP1 and ATP1 function in automatic mode.The input configured as rate notice (Programming table parameter 7) starts the generator set after activating the relating input and once a programmed time is over.

â&#x20AC;&#x201C; The device does not control the start disabling (SD) input or it is not activated. â&#x20AC;&#x201C; The device status is not blocked by the programming timer. Test Signal (TEST)

(Times table parameter 9). The rate notification is considered finished when the EJP1 input is deactivated and a stop with engine cooling is produced. Rate Notice Signal (EJP2) - France Only

This function only works when the CP1 and CP2 function in automatic mode.

The input configured as test (Programming table parameter 11) allows the checking of the generator set without interfering in the mains. Manual Override (IMFOR)

The input configured as rate change notice signal (Programming table parameter 8) activates the generator set contactor, provided no abnormal situation is detected in the generator set. Start Disabling Signal (SD + INP4)

This function only works when the CP1 and CP2 function in automatic mode. The input configured as override (Programming table parameter 12) meets the fire safety regulations and

9803/9985-1

CP1 and CP2 Digital Control Panels Inputs and Outputs accordingly the generator set working can not be interrupted under any condition except overspeed and emergency stop (be it alarm, external disabling input or programmed blocking). Three manual override working modes can be configured (Regulations table parameter 25): – 0: Manual override disabling. The manual override process is not managed, despite of having an associated programmable input. – 1: Starting due to mains power failure. When the manual override input is activated, there is a time in which the generator set is expected to start due to any programmed condition (mains signal alarms mains contactor failure, external start...). In automatic mode, to stop the functions of the device, it is not enough the mains voltage alarm disappears but must be deactivated the manual override input. – 2: Manual override starting. The generator set starts immediately when the manual override input is activated, without awaiting for any other starting condition. To stop the device, it is necessary to change to manual mode and stop the controller.

Analog Inputs The CP1 and CP2 has 5 analog inputs to measure several engine working values. Such analog inputs will portray the engine working process and display its condition, activating alarms if required. The alarms caused by the analog inputs do not stop the engine, they are only a warning. By default, the alarms raised by analog inputs do not stop the controller (engine warnings), but can be configured to produce a stop, with or without cooling. The CP1 and CP2 controller carries out a continuous check of the installed analog sensors, showing in the visualization module display the value of the readings made.

When the fuel pump (BT) relay from the measurement module is programmed to control the functions of the fuel transfer pump, it will start the pump to transfer fuel to the tank if the fuel level is detected under the minimum limits (Thresholds table parameter 18). The fuel pump is deactivated when the fuel level is detected over the programmable threshold (Thresholds table parameter 19). Working the fuel pump in manual mode, the threshold disables the activation of the fuel transfer pump except in case of the user intervention.

Pick-up Input (PCK1, PCK2) The pick-up input from the measurement module measures the rotation speed of the engine in revolutions per minute (rpm). To activate the pick up calculation through the engine ring gear, the number of teeth of the gear must be introduced (Thresholds table parameter 24). In case the number of teeth is ‘0’ the controller is configured to not activate the pick up and the rotation speed will be calculated through the generator set frequency as per the equivalence-ratio 50Hz/1500 rpm or 60Hz/1800 rpm. (Regulations table parameter 26). The CP1 and CP2 device can be configured to trigger an overspeed alarm (Alarms table parameters 22 to 24) as well as an underspeed alarm (Alarms table parameters 25 to 27) taking into account the mechanical speed given by the pick up.

Digital Programmed Outputs The CP1 and CP2 device has 8 outputs of specific functions (2 outputs to relay, 3 power outputs and 3 digital outputs). The working mode of those outputs is pre-established, though they can be configured. Pre-heating Output (Power Output)

Fuel Level The analog fuel level input indicates the amount of fuel left in the tank. To fit its working mode, the maximum fuel level in the tank must be set (Measurements table parameter 13), and the same with the minimum fuel level. (Measurements table parameter 12). In the same way, a minimum fuel-in tank threshold (Thresholds table parameter 25) can be fixed, and it will raise an engine warning (Alarms table parameter 55 to 57) when the fuel level is detected under such limits.

The pre-heating output (PR) is connected to a high voltage short-circuitable driver (70A) in charge of regulating the glow plug heating procedure of the engine during the starting cycle. The activation time of the pre-heating output is configurable (Times table parameter 4). The pre-heating

9803/9985-1

CP1 and CP2 Digital Control Panels Inputs and Outputs output can be also used to control the stop by excitation of engines with this kind of stop configuration (Regulations table parameter 18).

starting pulse (alternator mode) of a programmable time (Times table parameter 8) or to keep the alternator continuously excited (dynamo mode). generator set contactor output. (Relay output)

Engine Starting Output (Power Output)

The engine starting output (ARR) is connected to a high voltage short-circuitable driver (70A) which activates the starting of the engine. The activation of the engine starting remains until any programmed starting condition is detected (Regulations table parameters 19 to 22) during a maximum programmable time (Times table parameter 5).

The generator set contactor output (GC) controls the connection of the installation to the generator set. Alarm output (AL). (Digital output)

Engine Stop Output (Power Output)

The engine stop output (PC) is connected to a high voltage short-circuitable driver (70A) which controls the stopping of the engine.

The alarm output (AL) is in charge of communicating the different status of the CP1and CP2 device. The AL output is activated simultaneously with the flashing of the LED of the Reset button and the buzzer from the display module of the CP1and CP2 . This input monitors the following status of the CP1and CP2 controller: â&#x20AC;&#x201C; External start of the control board

De-excitation stop: The engine stop output configured as stop by de-excitation is activated 500ms after the preheating output is disabled and it is deactivated when the stopping of the engine is requested. Fuel Pump/Pre-heating Output (Relay Output)

The alarm output of the device (AL) is activated for 5 seconds if the control board detects a start signal from a programmable input, associated with the AE mode. â&#x20AC;&#x201C; Control board failures

The fuel pump/pre-heating (BT) output can be configured (Regulations table parameter 4) to control the filling of the generator set fuel tank with the fuel pump or the preheating process of the engine. Battery charge alternator excitation output (D+). (Digital output)

The CP1and CP2 device is activated for a maximum programmable time (Times table parameter 14) if an active failure or a failure waiting to be acknowledged by the user is detected. If the user presses the Reset button once, the AL output is deactivated. The failures that activate the AL output are suitable to the alarms which induce the engine stop as well as the warnings which do not stop the engine, except the ones raised by the quality of the mains signal.

The D+ output is in charge of exciting the battery charge alternator during the starting process. This output can be configured (Regulations table parameter 3) to produce a

9803/9985-1

CP1 and CP2 Digital Control Panels Inputs and Outputs Possible alarm configurations:

Engine started output (SE). (Digital output)

– Emergency stop – Low oil pressure – Battery charge alternator alarm

The engine started output (MA) is activated whatever engine started condition is detected and remains activated while the engine continues running. The engine started output (MA) deactivates when the engine stopping cycle starts. This process includes the cooling of the engine (Times table parameter 11) during the stopping cycle.

Programmable Outputs The CP1 and CP2 device has 3 programmable outputs whose working mode can be configured to indicate different controller status. (Programming table parameters 1 to 3).

– High coolant temperature – Programmable alarm 1 – Programmable alarm 2 – Programmable alarm 3 Output programmed by function The programmable outputs configured as programmed by function are configured to allow a function associated to an already used output. Possible functions of configurations: – Heater

The possible configurations are: Inhibited output The programmable outputs configured as inhibited output do not follow any action or status, they remain constantly deactivated.

The output can function to activate the heater (glow plug) if the BT relay is programmed to control the fuel pump.

Output programmed by input status. The programmable outputs (associated to a programmable input) configured as programmed by input status are activated when an associated input is detected. Possible input configurations: – Fuel level input – Coolant level input – Programmable input 1 – Programmable input 2 – Programmable input 3 – Programmable input 4 – Programmable input 5 Output programmed by alarm. The programmable outputs configured as programmed by alarm are activated when the device detects any activated alarm, associated to programmable outputs or that has not been yet checked by the user.

9803/9985-1

Annex I Parameters Tables The CP1 and CP2 device allows 3 levels of access to the configuration. To modify any parameter of the CP1 and CP2, a validation is required, by means of a password introduction. The 3 access levels are: 1

Maintenance access. Allows the setting of the level 1 and 2 parameters. (default password:1911)

Supervisor access. Allows the setting of the level 1, 2 and 3 parameters. (value resting use, manufacturer only)

User access. Allows the setting of the level 1 parameters. (default password: 1111) Table 8. TIMES

Parameter

Psw

Number of starts

Description

Default Value

Range

1..10

Time between starting. Time between one starting 5’’ attempt and another. All the outputs are deactivated

3’’..15’’

Starting delay. Range of time between mains failure and engine starting

0’’

0’’..1800’’

Glow plug pre-heating time

0’’

0’’..180’’

Starting time. Maximum waiting time before 5’’ detecting the starting condition. During this time the starting output is active.

Activation of load time. Range of time from the detection of the engine starting condition to the generator set contactor activation.

3’’

1’’..600’’

Nominal condition time. Range of time from the detection of the engine starting condition to the quality validation of the generated signal.

2”

2”..15”

D+ activation time. After this time . the DI voltage value will be checked and the D+ output will be activated in acordance with the PR regulations Parameter 3, until the engine stops.

3’’

1’’..10’’

EJP1 delay (Rate change notice - France only)

1”

1”..1800”

Cooling time

120’’

2’’..1800’’

Fuel stop solenoid activation time

10’’

1’’..30’’

15” Maximum time for alarm activation. The alarm output will be activated (together with the flashing of the reset button and the buzzer on the display) when corresponds within this limited time

0-Undefined 1”..1800”

Filtered from FR input

0.0’’..5.0’’

1.0’’

1’’..30’’

Filtered from LOP input

1.0’’

0.0’’..5.0’’

Filtered from HCT input

1.0’’

0.0’’..5.0’’

9803/9985-1

Annex I Parameters Tables TIMES Parameter

Psw

Description

Default Value

Range

Filtered from CL input

1.0’’

0.0’’..5.0’’

Filtered from INT4 input

1.0’’

0.0’’..5.0’’

Filtered from INT5 input

1.0’’

0.0’’..5.0’’

Filtered from INT1 input

1.0’’

0.0’’..5.0’’

Filtered from INT2 input

1.0’’

0.0’’..5.0’’

Filtered from INT3 input

1.0’’

0.0’’..5.0’’

Table 9. MEASUREMENTS Parameter

Psw

Description

Conversion factor of the amperage 100 transformers. Common factor to the real intensity values IR,IS,IT

Default Value

Regulation voltage zero. Voltage readings reboot. Push green button twice to reset.

Fuel level regulation EMPTY

Set level sender to minimum and push green button twice.

Fuel level regulation FULL

Set level sender to minimum and push green button twice.

8 10

Range

Table 10. REGULATIONS Parameter

Psw

Description

Default Value Range 0-Off

Transfer Fuel Pump working mode

1-Manual 2-Automatic 3-Control board

Starting mode by default

0-Locked 1-Manual 2-Automatic 3-Test

D+ deactivation

0-Alternator 1-Dynamo

9803/9985-1

Annex I Parameters Tables REGULATIONS 4

BT relay output configuration

1-Transfer pump

Pre-heater or fuel transfer pump 5

FR input configuration

0-Inhibited 2- Heater

0-OFF 1-Normally open. 2- Normally closed.

LOP input configuration

HCT input configuration

CL input configuration

INT4 input configuration

INT5 input configuration

EMS input configuration

INT1 input configuration

INT2 input configuration

INT3 input configuration

EMER/CS input configuration

Input associated to the LED AUX1 from the visualization module

0-No programmed 1-FR 2-LOP 3-HCT 4-CL 5- INT4 6- INT5 7-EMS 8-INT1 9-INT2 10-INT3

Input associated to the LED AUX2 from the visualization module

9803/9985-1

Annex I Parameters Tables REGULATIONS 18

Pre-heating and programmed stop inputs configuration

0- Fuel de-activation solenoid and Preheating. 1- Fuel activation solenoid and Preheating. 2- Fuel de-activation solenoid and Fuel activation solenoid.

Phase voltage with Start condition

0-Not checked 1-Stabilized 2- Pre-start 3- Stabilized and Pre-start

Alternator voltage as starting condition

PICK-UP input as starting condition

LOP input as starting condition

Voltage transformer

0-Not installed 1-Transformer 400/ 600

Amperage measurement location.

0- Output line 1-Generator set control panel

Manual override working mode

0-Not allowed 1- Starting due to Mains failure 2- Starting due to manual override.

Rotation speed of the engine ring gear related with generator set voltage frequency

0-50Hz/1500rpm

60Hz/1800rpm 1-50Hz/3000rpm 27

Temperature readings

Pressure readings

0-Centigrade 1-Fahrenheit 0-Bar 1-Psi

9803/9985-1

Annex I Parameters Tables REGULATIONS 29

Type of analogical sensors

0-VDO 1-SCANIA EMS 2 - YANMAR

Type of control board selection Note: Not used on CP1.

0: Manual 1: Automatic

Note: After the modification of the parameter 30, you should restart the control board, disconnecting its feed to allow the upgrade in its operation mode.

9803/9985-1

Annex I Parameters Tables Table 11. THRESHOLDS Parameter

Psw

Description

Default Value

Range 0- Three-phase without neutral

Three-phase, bi-phase or single-phase without neutral, delta or delta without neutral.

1-Three-phase 1

2-Bi-phase 3- single-phase 4- Delta 5- Delta without neutral

Maximum Generator Set Voltage

440V

Minimum Generator Set Voltage

360V

Maximum Generator Set asymmetry value

80V

Maximum Generator Set Frequency

58Hz

Minimum Generator Set Frequency

45Hz

Maximum Generator Current

1000 A

Short-circuit detection

3000 A

Generator Set Nominal power

200 kW

Maximum Inverse Power

10%

Maximum PICK UP speed

1740 rpm

Minimum PICK UP speed

1350 rpm

Minimum battery voltage

8V (16V)

Aug-23

Transfer Fuel Pump: minimum fuel level

30%

15%-40%

0-20%

Transfer Fuel Pump: maximum fuel level

80%

70%-90%

Starting voltage in generator set signal

40V

30-100

Starting voltage in alternator signal

8V (21V)

Jun-23

Starting speed (PICK UP)

1000 rpm

300-1000

Teeth of the engine ring gear

0-300

Fuel reserve level

10%

0..30

Low oil pressure threshold

1.2 bar

0.5-3

High water temperature pressure threshold

98ºC

80-105

Low engine temperature by sensor

OFF

OFF(0ºC)-40ºC

Minimum heating temperature

25ºC

5 - 30 ºC

Maximum heating temperature

35ºC

10 - 40 ºC

9803/9985-1

Annex I Parameters Tables Table 12. ALARMS Parameter

Psw

Description

Default Value

Range

High coolant temperature 1

Alarm 0 management

0-Not checked 1-Always checked 2-During starting 3-From starting condition (stabilized) 4- From nominal condition (Running)

Alarm 0 delay

0’’

0”…5”

Alarm 0 mode

0-Not stop the engine 1-Stop the engine 2-Stop with cooling

Low oil pressure 4

Alarm 1 management

0..4

Alarm 1 delay

15’’

0”…30”

Alarm 1 mode

0..2

Battery alternator charge failure 10

Alarm 3 management

0..4

Alarm 3 filter

5’’

0”…30”

Alarm 3 mode

0..2

Low Coolant Level 16

Alarm 5 management

0..4

Alarm 5 delay

5’’

0”…30”

Alarm 5 mode

0..2

Alarm 6 management

0..4

Alarm 6 delay

5’’

0”…30”

Alarm 6 mode

0..2

Alarm 7 management

0..4

Alarm 7 filter

5’’

0”…30”

Alarm 7 mode

0..2

Alarm 8 management

0..4

Alarm 8 filter

15”

0”…30”

Alarm 8 mode

0..2

Alarm 9 management

0..4

Fuel Reserve

Overspeed

Underspeed

Overload 28

9803/9985-1

Annex I Parameters Tables ALARMS 29

Alarm 9 filter

0”…30”

Alarm 9 mode

0..2

Alarm 10 management

0..4

Alarm 10 filter

0”…30”

Alarm 10 mode

0..2

Asymmetry

Maximum Generator Set Voltage 34

Alarm 11 management

0..4

Alarm 11 filter

5’’

0”…30”

Alarm 11 mode

0..2

Maximum Generator Set Frequency 37

Alarm 12 management

0..4

Alarm 12 filter

1’’

0”…30”

Alarm 12 mode

0..2

Erroneous Phase sequence 40

Alarm 13 management

0..4

Alarm 13 filter

5’’

0”…30”

Alarm 13 mode

0..2

Inverse power 43

Alarm 14 management

0..4

Alarm 14 filter

0”…30”

Alarm 14 mode

0..2

Low battery voltage 46

Alarm 15 management

0..4

Alarm 15 filter

0”…30”

Alarm 15 mode

0..2

High coolant temperature (by sensor) 49

Alarm 16 management

0..4

Alarm 16 filter

5’’

0”…30”

Alarm 16 mode

0..2

Low oil pressure (by sensor) 52

Alarm 17 management

0..4

Alarm 17 filter

5’’

0”…30”

Alarm 17 mode

0..2

Low fuel level (by sensor) 55

Alarm 18 management

0..4

Alarm 18 filter

5’’

0”…30”

Alarm 18 mode

0..2

9803/9985-1

Annex I Parameters Tables ALARMS Short-circuit 58

Alarm 19 management

Alarm 19 filter

Alarm 19 mode

0..4 0..2

Minimum Generator set Voltage 61

Alarm 20 management

0..4

Alarm 20 filter

15’’

0”…30”

Alarm 20 mode

0..2

Minimum Generator Set Frequency 64

Alarm 21 management

0..4

Alarm 21 filter

15’’

0”…30”

Alarm 21 mode

0..2

Stop Failure 70

Alarm 23 management

0..1

Alarm 23 filter

5’’

0”…30”

Engine Low Temperature 73

Alarm 24 management

0..4

Alarm 24 filter

15’’

0”…30”

Alarm 24 mode

0-No condensor CG 1-condensor CG

Generator Set voltage drops 76

Alarm 25 management

0..4

Alarm 25 filter

30’’

0”…30”

Alarm 25 mode

0..2

Programmable alarm 1 79

Alarm 26 management

0..4

Alarm 26 delay

0’

0”…30”

Alarm 26 mode

0..2

Programmable Alarm 2 82

Alarm 27 management

0..4

Alarm 27 delay

0’

0”…30”

Alarm 27 mode

0..2

Programmable Alarm 3 85

Alarm 28 management

0..4

Alarm 28 delay

0’

0”…30”

Alarm 28 mode

0..2

9803/9985-1

Annex I Parameters Tables Table 13. PROGRAMMING (I/O) Parameter

Psw

Description

Default Value

Range

Programmable Output Mode 1

0-No programmed 1-FR input 2-LOP alarm 3- HCT alarm 4- CL input 5- INT4 input 6- INT5 input 7- EMS alarm 8- INT1 input 9- INT2 input 10- INT3 input 11-Coolant Heater 12-Blocked Mode 13-Manual Model

Programmable Output Mode 2

Programmable Output Mode 3

Programmable Output Mode 4

14-Auto Mode 15-Test Mode 16-Alternator Alarm 17-Prg Alarm 1 18- Prg Alarm 2 19- Prg Alarm 3

9803/9985-1

Annex I Parameters Tables PROGRAMMING (I/O) 7

Input associated to EJP1 Mode

Input associated to EJP2 Mode

Input associated to IA Mode

Input associated to AE Mode

Input associated to TEST Mode

Input associated to MFOR Mode

Input associated to AL1 Mode

Input associated to AL2 Mode

Input associated to AL3 Mode

Input associated to S1 Mode

Input associated to S2 Mode

0-No programmed 5- INT4 6- ENT5 8-ENT1 9-ENT2 10-ENT3

Table 14. PARAMETERS SET SELECTOR CHART Parameter

Psw

Description

Default Value

Range

Signal Type set 1

0- Three phase without neutral 1- Three phase 2- Bi-phase 3- Single phase 4- Delta w/ neutral 5- Delta without neutral 6- Bi-phase selector

Generator Set Maximum Voltage Set 1

440V

Generator Set Minimum Voltage Set 1

360V

Generator Maximum Current Set 1

1000A

Short-circuit detection Set 1

3000A

Generator Set Minimum Frequency Set 1 58Hz

Generator Set Maximum Frequency Set 1 45Hz

9803/9985-1

Annex I Parameters Tables PARAMETERS SET SELECTOR CHART 0- Three phase without neutral 1- Three phase 2- Bi-phase 3- Single phase 4- Delta w/ neutral 8

Signal Type set 2

5- Delta without neutral 6- Bi-phase selector

Generator Set Maximum Tension Set 2

440V

Generator Set Minimum Tension Set 2

360V

Generator Maximum Current Set 2

1000 A

Short-circuit detection Set 2

3000 A

Generator Set Minimum Frequency Set 2 58Hz

Generator Set Maximum Frequency Set 2 45Hz

9803/9985-1

Annex Il Device Display Figures and Readings

Annex Il Device Display Figures and Readings Status of the Device

ENGINE

The CP1 and CP2 status can be read in the display and allows the user to gain access to the different figures and readings by means of the UP/DOWN buttons.

Generator Figures Displayed 1

Voltage readings between the different phases, and neutral phase and the amperage per phase and frequency. GENERATOR:

1500 RPM

100 H

75%

24V

700c

24V

6-7 BAR

Note: The engine must be provided with the appropriate VDO sensors, in order to visualize the temperature and the oil pressure.

50.0Hz

V1N

230V

V2N

230V

V 3N

230V

Voltage readings between phases and the amperage reading in each phase and frequency. GENERATOR:

50.0Hz

V 1 2N

400 V

V 2 3N

400 V

V 31N

400 V

.- V., A., FL, RPM., P. readings, The voltage and amperage readings are displayed alternatively. FL fuel level, RPM engine speed. P actual power output (kW).

GENERATOR: V1N

230 V

75%

0 kW

50.0Hz I1 RPM

0A 1500

Engine Status Display 4

4. - RPM., H., FL, DT, ET, BV,OP, readings. Readings displayed: RPM engine speed, H working hours, FL fuel level, DT battery charging alternator output voltage, ET engine temperature, BV battery voltage, OP oil pressure.

9803/9985-1

Annex Il Device Display Figures and Readings

Control Board Status Display. 5

Status of the programmable alarms.

A Programmable inputs status

GENS s I T I NH

CP1 + CP2

ET : STOP AE CKG CKM F JP1 JP2 I B I TED START

K C072900

Fig 13. Key A

Programmable Inputs Status

CP1 and CP2

IA:

Start inhibition

AE:

External starting

CKG:

Generator Set Contactor Confirmation

CKM:

Mains contactor Confirmation

Loaded activation Relay

Test function

Forced Star function

JP2:

ESP1 function

JP2:

ESP2 function

9803/9985-1

Annex Il Device Display Figures and Readings

Power and Energy Display 6

Actual power values and cos. phÃ®. per phase. POWER :

1.00 L

30 kW

FP1

1.00 L

30 kVA

FP2

1.00 L

0 kVA R

FP3

1.00 L

Key FP

Total power factor

FP1

Phase 1 power factor

FP2

Phase 2 power factor

FP3

Phase 3 power factor

Total consumed power values (day, month, year) ENERGY :

30kW h

10 kWh

100 MWh

17 :56:23

1000 MWh

4/12/06 L

Key D

Accumulated daily power

Accumulated monthly power

Accumulated annual power

9803/9985-1

Annex Il Device Display Figures and Readings

Failures Record

A L A R M

E N

M I N . V O L T S G E

1 / 3 G E N S E T

E: Alarm. A: Warning.

N: Number of failure in the record.

N: To be checked.

N: Nâ&#x20AC;? of position in the total record of failures. C072910

Fig 14. Key E

Alarm

Warning

To be checked

N (1)

Number of failures in the record

N (3)

No. of position in the total record of failures

9803/9985-1

Annex Il Device Display Control Board Maintenance

Control Board Maintenance Introducing Password Switch on the control panel, select â&#x20AC;&#x153; Menu â&#x20AC;&#x153; and accept (V). Use the (+) and (-) buttons to introduce the password. Select the first number and accept it. Use the same procedure for the 4 numbers.

* * 4 5 6

* . . .

* F E D

* a v a

* u e t

* M E N U * * * * * * * l t H i s t o r y n t a / H o u r C072930

Fig 16. ********

********

Password

* * * * * * * M E N U 7 . L a n g u a ge 8 . P a s s w o r d

0000

* * * * * * *

Main Menu Display C072940

Push (+)(-) buttons and accept (v) to navigate on each menu. 1

Inputs / Outputs

Parameters (only with authorized code)

Counters

Fault History

Events (only with programming clock option)

Date/ Hour

Language

Password

* * 1 2 3

* . . .

* I P C

* n a o

* p r u

* M E u t s / a m e t n t e r

Fig 17.

N U * * * * * * * o u t p u t s e r s s C072920

Fig 15.

9803/9985-1

Annex Il Device Display Control Board Maintenance

Inputs and Outputs *

I N P U T S / O U T P U T S

3 2 1 0 9 8 7 6 5 4 3 2 1 I N : O U T :

R: Fuel level B: Low temperature pressure A: High temperature N: Coolant level X: Programmable input 4.

M S 3 2 1 P I X N A B R C P R 4 B g r 3 2 + 1 M A

: Programmable input 5.

P: Emergency stop. 1: Programmable input 2: Programmable input 3: Programmable input S: Stop button. M:

1. 1. 1.

Key start.

A: Active alarm M: Engine started 1:Programmable output 1. +: D+ 2: Programmable output 2. 3: Programmable output 3. r: Mains contactor g: Generating set contactor. B: Fuel transfer/Heating 4: Programmable output 4. R: PR/PD P: PD/PE C: Controller fitting.

C072950

Fig 18.

N C T M D I

A N A 0 0 0

L . . .

O G 0 0 0 V

I N P A V

P U T S A 0 . 0 A 0 . 0 B 0 . 0 V

FL: Fuel level OP: Oil pressure ET: Engine Temperature AA: Auxiliary analog DI: Dinamo Voltage BV: Battery Voltage C072960

Fig 19.

9803/9985-1

Annex Il Device Display Control Board Maintenance

Counters * * * T B N

* C o t a l i a s e o r m a

O U N T E R S * * h o u r s 0 1 : 0 0 : d h o u r s 0 0 : 1 0 : l s t a r t u p s 1

* * * F T A

* C O U N T E R S a i l t o s t a r t o t a l t p r e s e n t

* * * * C O U N T E R S D a y M o n t h Y e ar

* * * u p s 5 0 k W 1 0 k W * * * * 2 0 k Wh 5 0 MWh

1 0 0 M W h C072970

Fig 20.

* * * M M R

* C a i n t a i n t e n t a

O U N T E R S * * . # 1 ! 0 : . # 1 1 5 0 : l 1 :

* 0 0 0

* 0 0 4

C072980

Fig 21. Partial counters can be reset by pushing the RESET button for 5 seconds

9803/9985-1

Annex Il Device Display Control Board Maintenance

List of Failures When the events menu is selected, it is possible to view the recorded list of past events and what the operating conditions were at that moment of occurrence.

* L 1 2 3

I . . .

S M M M

T O F A I N S A I N S A I N S

F M M M

A A I A

I L U R E X V O L N V O L X F R E

S * T A G E T A G E Q U E N C072990

Fig 22.

Events * * 5 6 7

The programming of events in the control panel is determined by the activation of the programming timer. The programming of events is carried out from the fifth option in the maintenance menu. K Fig 23. ( T 62)

* . . .

* E D L

* v a a

* e t n

* M E N U n t s e / T i m e g u a g e

* * * * * * *

C073000

Fig 23. Events are programmed to be repeated one day per week. To go into each menu we have to use the (+)(-) buttons and accept (v).

* * * M T W

* o u e

* E V E N T S n d a y e s d a y d n e s d a y

* * * * *

C073010

Fig 24.

9803/9985-1

Annex Il Device Display Control Board Maintenance

* * * T F S

* h r a

* E V E N T S r u s d a y i d a y t u r d a y

* * * * *

* * * * * E V E N T S S u n d a y

* * * * *

C073020

Fig 25.

9803/9985-1

Annex Il Device Display Control Board Maintenance

Start time

Finish Time

Type of event

* * * B A T

* L R E

* O Q R F S T

L 1 1 2

u 0 5 0

n : : :

e 0 5 0

s * 0 . . 1 0 . . 1 0 . . 2

* 1 7 2

* : : :

* 0 0 0

* 0 0 0 C073030

Fig 26. The possible events to be programmed are (in order of priority ): – Locked (BLOQ): Blocks the generator set start up and also the counter functions. – Forced Start (ARRF): Starts the generator set and activates the contactor.

* * * B -

* L -

* O Q - - -

Mo 2 0 0

n 2 0 0

d : : :

a 0 0 0

y * 0 . . 2 0 . . 0 0 . . 0

* 3 0 0

* : : :

* 5 0 0

* 9 0 0

* * * B -

* L -

* O Q - - -

T u 0 0 0

e 0 0 0

s : : :

d 0 0 0

a 0 0 0

y * * . . 0 3 . . 0 0 . . 0 0

* : : :

* 0 0 0

C073040

– Test (TEST):

Fig 27.

Starts the generator set without activation of the contactor; in case of external start. – Free (----): No events are programmed for this range; the start and finish time have no effect. This programming-timer option can program 5 different events for one day. For each event there is an activation range indicating the time and exact minute when the event starts and finishes; the starting time must be always previous to the finishing time. Starting and finishing times are included between 00:00h and 23:59h. Select day and accept (V), condition (v), start hour (V), start minutes (V), stop hour (V), stop minutes (V). To select program 2-3-4-5 use (+)(-) and repeat the before/previous process. To programme an event for two consecutive days in the week (i.e from Monday 22:00h to Tuesday 03:00h), the event must be programmed to finish at Monday 23:59 and the same event starting at Tuesday 00:00h.

9803/9985-1

Annex Il Device Display Control Board Maintenance

Date/Hour

* * *

D A T A

H o u r : D a t a :

H O U R

1 1 : 0 0 : 5 5 1 0 / 1 2 / 0 6

* * *

D C073050

Fig 28. Select date and accept (V), condition (v), start hour (V), minutes (V), stop hour (V), stop minutes (V). To select

program 2-3-4-5 use (+)(-) and repeat the before/previous process.

Language Selection

* * 0 1 2 * * 1 2 3

* . F r a . E n g . I t a

L n l l

A c i i

* . S p a . F r a . E n g N a s a

L n n l

A i c i

G U A J E i s h n

N s a s

G U A G E h i s h

* * *

C073060

Fig 29. To go into each menu we have to use the (+)(-) buttons and accept (v).

9803/9985-1

Annex Il Device Display Control Board Maintenance

Control Board Programming * * 1 2 3

* . . .

* P A M e a s T i m e R e g u

R A M E T E R S u r e m e n t S s l a t i o n s

* * * *

* * 4 5 6

* . . .

* P A T h r e A l a r P r o g

R s m r

* * * *

A M E T E R S h o l d s s a m a t i o n

I / O

* * * * P A R A M E T E R S * * * * 7 . T e x t s 8 . I d e n t i f i c a t o r

Nâ&#x20AC;? Parameter

* * * P P P

* 0 0 0

M 1 2 3

E . . .

A . . .

S . . .

U . . .

R . . .

E . . .

M . . .

E . . .

N . . .

T . . .

S * * * * . 4 . 5 . 0

Value C073070

Fig 30. To go into each menu we have to use the (+),(-) buttons and accept (v).

The access of the main menu is restricted to, at least, a password of the maintenance level.

Texts

* * 1 2 3

* . . .

* P R O G P R O G P R O G

T R R R

E A A A

X M M M

T M M M

S * * * * A B L E 1 A B L E 2 A B L E 3

* * * * T E X T S 4 . D I S P L A Y

* * * *

C073080.

Fig 31. We can assign a text to the programmable inputs, maximum 15 characters. The device has an A-Z alphabet and 0-9 numbers.

9803/9985-1

Annex Il Device Display Control Board Maintenance Personalization of the Programmable Alarms Text It is possible to personalise the alarm text.

9803/9985-1

Annex lll Dimensions, Connections and Mechanisation Measurements Module

D O

G H C073090

Fig 32. Measurements Module Connections

9803/9985-1

Annex lll Dimensions, Connections and Mechanisation Measurements Module Key K Fig 32. ( T 68) A

Digital Outputs CS

Fuel Solenoid F

LOP

Low Oil Pressure

Fuel Reserve

CAN bus

EMER

Emergency Stop

Pre-heating

CANH

CAN High

START

Start Signal

CANL

CAN Low

+BAT

+12/24V

Digital Outputs Out1

Digital output 1

Out2

Digital output 2

Out3

Digital output 3

Alarm (+12V if alarm is active)

D+

Charge Alternator Excitation

Engine Started (+12V if engine started)

Analog Inputs GND

Key K Fig 32. ( T 68)

Ground Output (used for engines which require a separate ground signal).

Charge Alternator Voltage

AnC

Programmable Analogue Input

Coolant Temperature

Oil Pressure

Fuel Level

Pick-up

PCK2

Pick-up 2

PCK1

Pick-up 1

Digital Inputs INT3

Digital Programmable Input 3

INT2

Digital Programmable Input 2

INT1

Digital Programmable Input 1

EMS

Emergency Stop

INT5

Digital Programmable Input 5 (ground to inhibit starting in Auto mode)

INT4

Digital Programmable Input 4 (if wired for Auto-start, ground input to start)

Coolant Level

HCT

High Coolant Temperatures

Feeding MAN

Connection for ON/OFF Switch from panel

-BAT

Negative Battery Supply

8-36V

Positive Battery Supply

Generator Set Voltage GVN

Generator Neutral Voltage Monitoring

GV1

Generator Phase 1 Voltage Monitoring

GV2

Generator Phase 2 Voltage Monitoring

GV3

Generator Phase 3 Voltage Monitoring

Mains Voltage MVN

Mains Neutral Voltage Monitoring

MV1

Mains Phase 1 Voltage Monitoring

MV2

Mains Phase 2 Voltage Monitoring

MV3

Mains Phase 3 Voltage Monitoring

Amperage ILN

Neutral Current Monitoring

IL1

Phase 1 Current Monitoring

IL2

Phase 2 Current Monitoring

IL3

Phase 3 Current Monitoring

Relay Output (Voltage Free) MCNO

Mains Contactor, Normally Open

MCNC

Mains Contactor, Normally Closed

MCC

Mains Contactor, Common Note: Mains contactor normally wired as Normally Closed.

9803/9985-1

GCNO

Generator Contactor, Normally Open

GCNC

Generator Contactor, Normally Closed

Annex lll Dimensions, Connections and Mechanisation Measurements Module Key K Fig 32. ( T 68) GCC

Generator Contactor, Common Note: Generator contactor normally wired as Normally Open.

FPNO

Fuel Pump Relay, Normally Open

FPC

Fuel Pump Relay, Common

C073100

Fig 33. Measurements Module Connections Section 1

ON/OFF Switch

C C073110

Fig 34. Measurements Module Connections Section 2 Key K Fig 34. ( T 70) A

Battery

ON/OFF Switch

CANBUS

It is advisable to use a cable of section 1 mm2.

9803/9985-1

Annex lll Dimensions, Connections and Mechanisation Measurements Module

C C073120

Fig 35. Measurements Module Connections Section 3 Key K Fig 35. ( T 71) A

Mains Contactor

Generator Set Contactor

Fuel Pump Contactor or Pre-heating Activation

9803/9985-1

Annex lll Dimensions, Connections and Mechanisation Measurements Module

B C073130

Fig 36. Measurements Module Connections Section 4 Key A

Emergency Stop

Power Outputs Max 40A

Battery

9803/9985-1

Annex lll Dimensions, Connections and Mechanisation Measurements Module

C073140

Fig 37. Measurements Module Connections Section 5

9803/9985-1

Annex lll Dimensions, Connections and Mechanisation Measurements Module

SIGNAL

DESCRIPTION

Table 15. TYPE

CHARACTERISTICS

8Â±36V

Battery positive

Feeding

Feeding device voltage from 8 to 36 V

-BAT

Battery negative

Feeding

Negative device feeding

MAN

Manual

Input

Digital input of starting PNP

CANL

CANL line CAN bus

Bus

CAN communication

CANH

CANH line CAN bus

Bus

CAN communication

Fuel reserve

Input

NPN digital input

LOP

Low oil pressure

Input

NPN digital input

HCT

High coolant temperature

Input

NPN digital input

Coolant level

Input

NPN digital input

External start

Input

NPN digital input

Inhibited starting

Input

NPN digital input

EMS

Emergency stop

Input

NPN digital input

INT1

Input 1

Input

NPN digital input

INT2

Input 2

Input

NPN digital input

INT3

Input 3

Input

NPN digital input

PCK1

Pick-up

Input

High speed digital input PICK-UP

PCK2

Pick-up

Input

High speed digital input PICK-UP

Fuel level

Input

Digital input of resistive sensor

Pressure

Input

Digital input of resistive VDO sensor

Temperature

Input

Digital input of resistive VDO sensor

AnC

Analog auxiliary input (ex. Oil Input Temperature)

Digital input of resistive VDO sensor

Alternator voltage

Input

Analog voltage input 0-40V

GND

VDO sensors

Input

Negative to 2 terminals sensors type

D+

Alternator excitation

Output

PNP digital input

Alarm

Output

PNP digital input

Started engine

Output

PNP digital input

OUT1

Output 1

Output

PNP digital input

OUT2

Output 2

Output

PNP digital input

OUT3

Output 3

Output

PNP digital input

EMER

Emergency button (SETA)

Output

NPN digital input

Configurable stop

Output

Power PNP digital input

Pre-heating

Output

Power PNP digital input

START

Starting

Output

Power PNP digital input

OUT4

Output 4

Output

Power PNP digital input

+BAT

Battery positive

Feeding

Digital inputs feeding voltage

FPC

Fuel pump

Output

Fuel pump relay, C contact

9803/9985-1

Annex lll Dimensions, Connections and Mechanisation Measurements Module

SIGNAL

DESCRIPTION

TYPE

CHARACTERISTICS

FPNA

Fuel pump

Output

Fuel pump relay, NA contact

GCC

Generator Set contactor

Output

Generator Set contactor relay, C contact

GCNC

Generator Set contactor

Output

Generator Set contactor relay, NC contact

GCNO

Generator Set contactor

Output

Generator Set contactor relay, NO contact

MCC

Mains contactor

Output

Mains contactor relay, C contact

MCNC

Mains contactor

Output

Mains contactor relay, NC contact

MCNO

Mains contactor

Output

Mains contactor relay, NO contact

IL3

Phase 3 amperage

Input

Amperage measurement analog input

IL2

Phase 2 amperage

Input

Amperage measurement analog input

IL1

Phase 1 amperage

Input

Amperage measurement analog input

ILN

Shared amperage

Input

Amperage measurement analog input

MV3

Phase 3 mains voltage

Input

Voltage measurement analog input

MV2

Phase 2mains voltage

Input

Voltage measurement analog input

MV1

Phase 1mains voltage

Input

Voltage measurement analog input

MVN

Neutral mains voltage

Input

Voltage measurement analog input

GV3

Phase 3 generator set voltage Input

Voltage measurement analog input

GV2

Phase 2 generator set voltage Input

Voltage measurement analog input

GV1

Phase 1 generator set voltage Input

Voltage measurement analog input

GVN

Neutral generator set voltage Input

Voltage measurement analog input

9803/9985-1

Annex lll Dimensions, Connections and Mechanisation Visualisation Module

Visualisation Module

FEEDING

CANBUS

8-36V

-BAT

8-36V

-BAT

CANH CANL CANH

MAN AUTO CANL

BAT CAN BUS

B C07315

Fig 38. Visualisation Module Connections 1 It is advisable to use a cable of section 1 mm2.

9803/9985-1

Annex lll Dimensions, Connections and Mechanisation Visualisation Module SIGNAL

DESCRIPTION

TYPE

CHARACTERISTICS

8 divided by 36V

Battery positive

Feeding

Feeding device voltage from 8 to 36 V

-BAT

Battery negative

Feeding

Negative device feeding

MAN

Manual

Input

Digital input PNP

AUTO

Automatic

Input

Digital input PNP

CANL

CANL line bus CAB

Bus

CAN communication

CANH

CANL line bus CAB

Bus

CAN communication

Symbol

Parameter

Table 16. Electric Characteristics Conditions Min

Usual

Max

Unit

Feeding (terminals 8 divided by 36V, –BAT, +BAT) 8divided by 36V

Power supply voltage of the unit

VDC

+BAT

Power supply voltage of the outputs

VDC

IBAT

Feeding force

8divided by 36V=12V

100

IBAT

Feeding force

8divided by 36V=24V

PBAT

Power consumption

1,2

+40

CAN Bus (terminals CANL, CANH) VIN

CANH y CANL input voltage

-27

DRCAN

Transmission speed

LCAN

Bus length

500

Nodes

Number of nodes on the bus

nodes

Kbps

Digital inputs PNP (terminals MAN) VIN

Voltage input

VIL

Low level voltage input

-0,7

VIH

High level voltage input

IIL

Low level power supply voltage

VIN = 0V

100

IIH

High level power supply voltage

VIN = 12V

"0,8

Digital inputs NPN (terminals FR, LOP, HCT, CL, ES, IS, EMS, INP1, INP2, INP3, SETA) VIN

Low level voltage input

-0,7

VIL

High level voltage input

VIH

Low level power supply voltage

IIL

High level power supply voltage

VIN = 0V

2,5

"mA

IIH

Low level voltage input

VIN = 24V

100

VAC

VIN=12VAC

2,6

High speed digital inputs (terminals PCK)

VIN

Input voltage

IIN

Input power supply

9803/9985-1

Annex lll Dimensions, Connections and Mechanisation Visualisation Module Symbol

Parameter

Conditions

FIN

Input frequency

VIN=12VAC

Min

Usual

Max

3600

Unit Hz

Analog inputs (terminals FL, P, T, AnC=TC, DI, GND) VI

Voltage input

RNC

Fuel level resistance

400

Pressure resistance

200

Coolant temperature resistance

4000

RTC

Oil temperature resistance

4000

Ω Ω Ω Ω

Alternator voltage

PNP outputs (terminals D+, AL,SE, OUT1, OUT2, OUT3) VO

Output voltage

Output amperage

RD+

D+ output resistance

+BAT

V 1

+BAT

Power PNP outputs (terminals CS, PH, START, OUT4) VO

Output voltage

Output power supply

T=¥

Output power supply

T = 1s

250

VAC

AAC

Relay outputs (terminals MRNA, MRNC, MRC, GCNA, GCNC, GCC, BTNA, FPC) VO

Relay contactors maximum voltage

Relay contactors power

cosj = 0

Amperage values analog inputs (terminals ILN, IL1, IL2, IL3) IIN

Input feeding power

RIN

Input resistance

"0,05

Voltage measurements analog inputs (terminals MVN, MV1, MV2, MV3, GNV, GV1, GV2, GV3)

VIN-FF

Phase to phase voltage input

600

VAC

VIN-FN

Phase to neutral voltage input

350

VAC

RIN

Input resistance

9803/9985-1

MΩ

Annex lV CAN Communications Introduction The CAN bus is a powerful and reliable industrial bus that ensures the efficient communication between the devices in the environments full of electric disturbances. The devices provided with CAN controller can be integrated into an industrial system of control and automation. The most important characteristics of a control system with CAN bus communication are the following: – It is possible to connect up to 110 devices in a single CAN network. – Each network can reach a length of 1000 metres, easily extended (up to 2000 meters) with the use of bridges or repeaters. – CAN bus transmission speed 50 Kbits/s (for 1000 meters bus: 10 ms of data updating). – Direct access to the CAN bus from a PC by means of a USB Can. The Can bus is prepared to work in extreme conditions of noise and interferences and at the same time, the failure checking mechanisms guarantee that the frames affected by the disturbance can be detected. The CAN bus is designed to continue the communication even if: – Any of the two bus wires cuts. – Any cable is short-circuited to earth. – Any cable is short-circuited to feeding.

9803/9985-1

Annex lV CAN Communications Topology

Topology

E C073160

Fig 39. The Can network uses a bus topology in which each node has an input and an output connection, The endpoint nodes of the bus must have a 120ÎŠ terminator: this terminator is activated by means of a switch in each module (ON: enabled terminator, 1: disabled terminator). In each case, the impedance found between the CANH and CANL must be, approximately, 60ÎŠ. To do so, in each network endpoint a resistance value must be defined to guarantee such impedance value from every connected device. Note: The impedance measurement must be obtained when all the equipment is not working or they have not physical access from the network. For more information it is recommended to consult the ISO11898 standards and the different applications notes.

9803/9985-1

Annex lV CAN Communications Wiring

Wiring The can network needs a wiring depending of the distance, the speed transmission, and the number of nodes connected to the bus.

Bus length

Table 17. Wire characteristics according to distance Wire characteristics Length/resistance

Diameter

0 m..40 m

70 mΩ/m

0,25 mm2..0,34 mm2, AWG23,AWG22

40 m..300 m

<60 mΩ/m

0,34 mm2..0,6 mm2, AWG22,AWG20

300 m..600 m

<40 mΩ/m

0,5 mm2..0,6 mm2, AWG20

600 m..1 Km

<26 mΩ/m

0,75 mm2..0,8 mm2, AWG18

Bus length

Table 18. Wire characteristics according to number of nodes Number of nodes 32

100 m

0,25 mm2

250 m

0,34 mm

500 m

0,75 mm2

1.00 mm2

Wire resistance

<21Ω

<18.5Ω

<16Ω

0,5 mm

100 2

0,25 mm2 0,5 mm2

In order to connect the different nodes of the network a twisted pair of wires without shielding may be used. As an exception, the connection between the measurement and the visualization module can be done using a wiring not twisted. In very noisy environments affected by high electromagnetic interference (EMI), a twisted shielded wire with the shield connected to earth can be used. Other technique to improve the immunity against the electromagnetic interference consists in substituting the CAN terminator of the node for 2 resistances of 62Ω and installing a de coupling capacitor between the resistances CAN and the battery negative.

9803/9985-1

Annex lV CAN Communications Wiring

C073170

Fig 40. Key A

Bus Line

Protection technique against electromagnetic interferences: De coupling capacitor. K Fig 40. ( T 82)

9803/9985-1

Annex lV CAN Communications Wiring Diagrams

Wiring Diagrams Key K Fig 41. ( T 83)

A 120

MEASUREMENTS H L

Measurements

Display

1 O

H L

120

H L

O 1

DISPLAY

B C073180

Fig 41. Manual/AMF Device

A C

MANUAL MEASUREMENTS

H L

120

ON 1 O

H L

COMMUTATION MEASUREMENTS 120

H L

H L DISPLAY

1 O

H L

120

H L

1 O

H L DISPLAY

ON 1 O C073190

Fig 42. Manual plus Transfer Switch Key K Fig 42. ( T 83) A

Manual

Commutation

Measurements

Display

9803/9985-1

Annex lV CAN Communications Wiring Diagrams

MEASUREMENTS H L

H L

120

CCrs

O 1

120

ON 1 O

H L

120

ON 1 O

DISPLAY

B C073200

Fig 43. Manual/AMF Device plus CCrs Option

MEASUREMENTS H L

H L

120

USBCan

120

ON 1 O

O1 L

120

H L

H L DISPLAY

ON 1 O

C073210

Fig 44. Manual/AMF Device plus CCrs Option Key K Fig 43. ( T 84) K Fig 44. ( T 84) A

Measurements

Display

9803/9985-1

Annex lV CAN Communications Wiring Diagrams

MANUAL

C MEASUREMENTS H L

H L

120

ON 1 O

120

DISPLAY

COMMUTATION

MEASUREMENTS

120

H L

ON 1 O

120

ON 1 O

DISPLAY

CCrs

120

H L 1 O C073220

Fig 45. Manual plus Transfer Switch Device plus CCrs Key K Fig 45. ( T 85) A

Manual

Commutation

Measurements

Display

9803/9985-1

Annex V Telesignal Communication Option by Digital Outputs Introduction The range of CP1 and CP2 controllers allow the monitoring of the devices status by means of a number of relay outputs. The Telesignal option is connected to the range of JCB digital devices through a CAN communication cable. The configuration software of the control boards, configured in local mode (USB can) or remote (CCrs), allows the adjustment of its functions. The Telesignal option is connected to the control board with a twisted pair with or without shielding, depending on the installation environment and it can even be of 1 Km length. The CP1 and CP2 device allows the installation of 4 optional Telesignal equipments simultaneously.

Telesignal Components – Feeding and communication terminal plate – Terminal plate of digital outputs to relay 4 contact outputs NC/NO or 8 contact outputs NO – 1 feeding led – 12 LEDs to visualize the output status. – Activation Microswitch, CAN terminator. – Microswitch of 2 switches to fix the number of modules (maximum 4) SWITCH

9803/9985-1

Annex V Telesignal Communication Option by Digital Outputs

D C

O C073230

Fig 46. Telesignal Module

9803/9985-1

Annex V Telesignal Communication Option by Digital Outputs

Telesignal Programming The Telesignal option allows the output programming in order to monitor the status of the CP1 and CP2 device. The ‘Configurator’ application is used to programming the Telesignal option. This application only detects and programs the Telesignal with the 0 identification. If 2 or more Telesignal would be necessary in one installation, see the following procedure: 1

Switch off all the Telesignal modules.

Switch on the only one Telesignal with the 0 identification. Configure it with the Telesignal application.

Switch off the Telesignal module when it is already configured and modify/change the identification (1,2 or 3)

Repeat the process with all the Telesignal modules.

To Program an Output 1

Select the item referring the chosen output.

Select the file where the activation conditions we want to apply to the selected output can be found.

Select the desired condition.

Repeat the process with all the conditions needed.

By pressing the ‘General Alarm’ button all the possible alarm conditions to activate the output are selected.

Working Mode The outputs of the Telesignal option can be programmed to be activated depending on: – Any alarms of the control board, active or waiting to be checked. – Any activated input of the control board. – Any activated output of the control board. – Control mode (Automatic or Manual). Each output of the Telesignal device is activated if, at least, one of the programmed activation conditions is raised.

9803/9985-1

Annex V Telesignal Communication Option by Digital Outputs

Wiring of the Telesignal Option Table 19. TYPE

SIGNAL

DESCRIPTIĂ&#x201C;N

8divided by 36V

Battery positive

Feeding

CHARACTERISTICS Control board Feeding voltage from 8 to 36V

-BAT

Battery negative

Feeding

Control board negative feeding

8divided by 36V

Battery positive

Feeding

Control board Feeding voltage from 8 to 36V

-BAT

Battery negative

Feeding

Control board negative feeding

CANL

CANL line CAN bus

Bus

CAN communication

CANH

CANH line CAN bus

Bus

CAN communication

CANL

CANL line CAN bus

Bus

CAN communication

CANH

CANH line CAN bus

Bus

CAN communication

Common relay output 1

Digital output

Voltage free contact 8 A 250 VAC

NC1

Normally-closed contact relay output 1

Digital output

Voltage free contact 8 A 250 VAC

NO1

Normally-open contact relay output 1

Digital output

Voltage free contact 8 A 250 VAC

Common relay output 1

Digital output

Voltage free contact 8 A 250 VAC

NC2

Normally-closed contact relay output 2

Digital output

Voltage free contact 8 A 250 VAC

NO2

Normally-open contact relay output 2

Digital output

Voltage free contact 8 A 250 VAC

Common relay output 2

Digital output

Voltage free contact 8 A 250 VAC

NC3

Normally-closed contact relay output 3

Digital output

Voltage free contact 8 A 250 VAC

NO3

Normally-open contact relay output 3

Digital output

Voltage free contact 8 A 250 VAC

Common relay output 3

Digital output

Voltage free contact 8 A 250 VAC

NC4

Normally-closed contact relay output 4

Digital output

Voltage free contact 8 A 250 VAC

NO4

Normally-open contact relay output 5

Digital output

Voltage free contact 8 A 250 VAC

Common relay output 3

Digital output

Voltage free contact 8 A 250 VAC

NC5

Normally-closed contact relay output 4

Digital output

Voltage free contact 8 A 250 VAC

Common relay output 3

Digital output

Voltage free contact 8 A 250 VAC

NC6

Normally-closed contact relay output 4

Digital output

Voltage free contact 8 A 250 VAC

Common relay output 3

Digital output

Voltage free contact 8 A 250 VAC

NC7

Normally-closed contact relay output 4

Digital output

Voltage free contact 8 A 250 VAC

Common relay output 3

Digital output

Voltage free contact 8 A 250 VAC

NC9

Normally-closed contact relay output 4

Digital output

Voltage free contact 8 A 250 VAC

Common relay output 3

Digital output

Voltage free contact 8 A 250 VAC

NC9

Normally-closed contact relay output 4

Digital output

Voltage free contact 8 A 250 VAC

C10

Common relay output 3

Digital output

Voltage free contact 8 A 250 VAC

NC10

Normally-closed contact relay output 4

Digital output

Voltage free contact 8 A 250 VAC

C11

Common relay output 3

Digital output

Voltage free contact 8 A 250 VAC

NC11

Normally-closed contact relay output 4

Digital output

Voltage free contact 8 A 250 VAC

9803/9985-1

Annex V Telesignal Communication Option by Digital Outputs SIGNAL

DESCRIPTIĂ&#x201C;N

TYPE

CHARACTERISTICS

C12

Common relay output 3

Digital output

Voltage free contact 8 A 250 VAC

NC12

Normally-closed contact relay output 4

Digital output

Voltage free contact 8 A 250 VAC

The CAN network of the control board has a BUS based topology. The different devices are consecutively connected, using the CP1 and CP2 input and output terminals to link the modules.

The terminating resistors will be connected to the network terminal nodes, using the appropriate microswitch. The maximum distance between the terminal nodes of the network is 1000m

Dimensions and Connections

C073240

Fig 47. Telesignal Module 1 Connections Key A

Feed

CAN bus

Relay Outputs 250 V AC

9803/9985-1

Annex V Telesignal Communication Option by Digital Outputs

8-36V

-BAT

8-36V

CANH CANL CANH

-BAT CANL

BAT CAN BUS

B C073250

Fig 48. Telesignal Module 2 Connections Key A

Battery

CAN bus

To feed the plates it is advisable to use 1 mm2 diameter cable

9803/9985-1

Annex V Telesignal Communication Option by Digital Outputs

C4 NC4 NO4

C2 NC2 NO2 C1 NC1 NO1

C3 NC3 NO3

C6 NO6 C5 NO5

C8 NO8 C7 NO7

C10 NO10

C9 NO9

C12 NO12 C11 NO11

C073260

Fig 49. Telesignal Module 3 Connections Key A

Relay Outputs 20 V AC 8A Table 20. Wiring TYPE

SIGNAL

DESCRIPTION

CHARACTERISTICS

8divided by 36V

Battery positive

Feeding

Control board feeding voltage from 8 to 36V

-BAT

Battery negative

Feeding

Feeding control board negative

CANL

CANL line CAN bus

Bus

CAN communication

CANH

CANH line CAN bus

Bus

CAN communication

Relay 1

Output

Relay 1, contact C

NC1

Relay 1

Output

Relay 1, contact NC

NO1

Relay 1

Output

Relay 1, contact NO

Relay 2

Output

Relay 2, contact C

NC2

Relay 2

Output

Relay 2, contact NC

NO2

Relay 2

Output

Relay 2, contact NO

Relay 3

Output

Relay 3, contact C

NC3

Relay 3

Output

Relay 3, contact NC

NO3

Relay 3

Output

Relay 3, contact NO

9803/9985-1

Annex V Telesignal Communication Option by Digital Outputs SIGNAL

DESCRIPTION

TYPE

CHARACTERISTICS

Relay 4

Output

Relay 4, contact C

NC4

Relay 4

Output

Relay 4, contact NC

NO4

Relay 4

Output

Relay 4, contact NO

Relay 5

Output

Relay 5, contact C

NO5

Relay 5

Output

Relay 5, contact NO

Relay 6

Output

Relay 6, contact C

NO6

Relay 6

Output

Relay 6, contact NO

Relay 7

Output

Relay 7, contact C

NO7

Relay 7

Output

Relay 7, contact NO

Relay 8

Output

Relay 8, contact C

NO8

Relay 8

Output

Relay 8, contact NO

Relay 9

Output

Relay 9, contact C

NO9

Relay 9

Output

Relay 9, contact NO

C10

Relay 10

Output

Relay 10, contact C

NO10

Relay 10

Output

Relay 10, contact NO

C11

Relay 11

Output

Relay 11, contact C

NO11

Relay 11

Output

Relay 11, contact NO

C12

Relay 12

Output

Relay 12, contact C

NO12

Relay 12

Output

Relay 12, contact NO

9803/9985-1

Annex V Telesignal Communication Option by Digital Outputs Electrical Characteristics

Symbol

Parameter

Conditions

Minimum Usual

Maximum Unit

Feeding (terminals 8 divided by 36V â&#x20AC;&#x201C;BAT)" 8 divided by36V

Power supply voltage of the unit

VDC

IBAT

Feeding force

8 divided by 36V=12V

IBAT

Feeding force

8 divided by 36V=24V

PBAT

Power consumption

CAN Bus (CANL, CANH terminals) VIN

CANH y CANL input voltage

-27

+40

DRCAN

Transmission speed

LCAN

Bus length

250

Nodes

Number of nodes on the bus

nodes

V Kbps

Relay outputs (Terminals C1, NC1, NO1, C2, NC2, NO2, C3, NC3, NO3, C4, NC4, NO4, C5, NO5, C6, NO6, C7, NO7, C8, NO8, C9, NO9, C10, NO10, C11, NO11, C12, NO12)

Relay contactors maximum voltage

Relay contactors power

cos = 0

9803/9985-1

250

VAC

Annex V Telesignal Communication Option by Digital Outputs

Page left intentionally blank

9803/9985-1

Annex VI CCrs Communication Option via Modem Introduction

Communicating with the Control Board

The range of CP1, CP2 and ATP1 controllers allow a remote monitoring and supervision function thanks to the CCrs option. This option allows provision of a connection between the control board and the monitorization and configuration software, by means of a modem or GPRS .

The PC software of the control board automatically detects (when starting) if a local connection of communications (USB Can option) is available or if it detects a remote connection via modem. In case a remote connection is found, a dialogue box will appear for you to enter the required parameters to establish the communication.

CCrs Installation System Requirements The CCrs option needs the following elements to obtain a remote connection: A PC that fulfils the following requirements to execute the monitorization and configuration software: – Pentium III 1.3 GHz – Microsoft Windows XP with Microsoft .Net Framework – 512 Mb RAM – 50 Mb free in the hard disk – Modem 14400 or superior (line modem or GPRS) Modem and serial cable to connect to the CCrs. C073270

Optional: a null modem type cable and CCrs configuration software.

Fig 50. Remote Communication Parameter Box Communication parameters required: – Telephone number of the control board. – PIN: Pin of the SIM if required – Password: Control board password, at least user level password. – Kind of modem: Line or GSM/GPRS. – Locate option. The introduced parameters can be stored for the next use (except the control board password). In the same way, a kind of ‘waiting connection’ can be made, capable of allowing the connection between the control boards and the PC software in case any event occurs in the registration moment.

Annex VI CCrs Communication Option via Modem Once the dialing data are introduced, the software of the PC tries to establish the connection with the control board.

As soon as the connection with the control board is confirmed, the monitorization or configuration software of the control board starts running.

C073280

Fig 51.

DSE Model 8610 and 8620 AMF Controller Installation

DSE Model 8610 and 8620 AMF Controller Installation The DSE8xxx 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.

Terminal Description To aid user connection, icons are used on the rear of the module to help identify terminal functions. An example of this is shown below. Note: Availability of some terminals depends upon module version. Full details are given in the section entitled Terminal Description elsewhere in this manual.

P033120-26

Fig 1. Terminals 1-13

Ethernet

Terminals 15-19

Serial and part number label

Terminals 22-36

Terminals 39-46

Terminals 47-50

Terminals 51-57

Terminals 60-68

USB

USB (B) PC configuration connection

9813/2550-1

DSE Model 8610 and 8620 AMF Controller Installation DC Supply, Fuel and Start Outputs, Outputs E-J Icon

Pin No. Description

Cable Size

DC Plant Supply Input

2.5mm²

(Negative)

AWG 13

DC Plant Supply Input

2.5 mm²

(Positive)

AWG 13

Emergency Stop Input

2.5 mm²

AWG 13

Output relay A (FUEL)

Output relay B (START)

2.5 mm² AWG 13 2.5 mm² AWG 13

Charge fail/ excite

Functional Earth

2.5 mm²

Notes

(Recommended Maximum Fuse 15A antisurge) Supplies the module (2A antisurge requirement) and Output relays E K

Plant Supply Positive. In addition, 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.

AWG 13

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

2.5 mm²

Connect to a good clean earth point.

AWG 13

9813/2550-1

DSE Model 8610 and 8620 AMF Controller Installation Icon

Pin No. Description

Cable Size

Notes

1.0mm²

Plant Supply Positive from terminal 2. 3 Amp rated.

Output relay E

AWG 18

Output relay F

Output relay G

1.0mm²

Plant Supply Positive from terminal 2. 3 Amp rated.

AWG 18 1.0mm²

Plant Supply Positive from terminal 2. 3 Amp rated.

AWG 18

Output relay H

1.0mm²

Plant Supply Positive from terminal 2. 3 Amp rated.

AWG 18

Output relay I

1.0mm²

Plant Supply Positive from terminal 2. 3 Amp rated.

AWG 18

Output relay J

1.0mm²

Plant Supply Positive from terminal 2. 3 Amp rated.

AWG 18

Note: Terminal 14 is not fitted to the DSE 8610 and 8620 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.

100

9813/2550-1

100

DSE Model 8610 and 8620 AMF Controller Installation

Analogue Sensors Icon

Pin No.

Description

Cable Size

Notes

Senser Common Return

0.5mm²

Return feed for sensors

AWG 20 16

Oil Pressure Input

0.5mm²

Connect to Oil pressure sensor

AWG 20 17

Coolant Temperature Input 0.5mm²

Fuel Level Input

Connect to Coolant Temperature sensor

AWG 20 0.5mm²

Connect to Fuel Level sensor

AWG 20 19

Flexible sensor

0.5mm²

Connect to additional sensor (user configurable)

AWG 20 Note: Terminals 20 and 21 are not fitted to the 8600 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 SEPARATE earth connection from the system earth star point, to terminal 15 directly, and not use this earth for other connections. 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.

101

9813/2550-1

101

DSE Model 8610 and 8620 AMF Controller Installation

Magnetic Pick-up, CAN and Expansion Pin No.

Description

Cable Size

Notes

Magnetic pick-up Positive

0.5mm²

Connect to Magnetic Pick-up device

AWG 20 23

Magnetic pick-up Negative

0.5mm²

Connect to Magnetic Pick-up device

AWG 20 24

Magnetic Doesn’t screen

CAN port H

Connect to ground at one end only 0.5mm²

Use only 120W CAN approved cable

AWG 20 26

CAN port L

0.5mm²

Use only 120W CAN approved cable

AWG 20 27

CAN port Common

0.5mm²

DSENet expansion +

0.5mm²

Use only 120W CAN approved cable

AWG 20 Use only 120W RS485 approved cable

AWG 20 29

DSENet expansion -

0.5mm²

Use only 120W RS485 approved cable

AWG 20 30

DSENet expansion SCR

0.5mm²

Use only 120W RS485 approved cable

AWG 20

102

Multiset Comms (MSC) Link 0.5mm² H AWG 20

Use only 120W RS485 approved cable

Multiset Comms (MSC) Link 0.5mm² L AWG 20

Use only 120W RS485 approved cable

Multiset Comms (MSC) Link 0.5mm² SCR AWG 20

Use only 120W RS485 approved cable

9813/2550-1

102

DSE Model 8610 and 8620 AMF Controller Installation Pin No.

Description

Cable Size

Analogue Governor Output B

0.5mm²

Notes

AWG 20 35

Analogue Governor Output A

0.5mm² AWG 20

Analogue AVR Output B

Analogue AVR Output A

0.5mm² AWG 20 0.5mm² AWG 20

Note: Terminal 36 is not fitted to the DSE 8610 and 8620 controller Note: Screened cable must be used for connecting the Magnetic Pick-up, ensuring that the screen is earthed at one end ONLY. Note: Screened 120W impedance cable specified for use with CAN must be used for the CAN link and the Multiset comms (MSC) link. DSE stock and supply Belden cable 9841 which is a high quality 120W 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 8600 series controller on the CAN link. Refer to Electronic Engines and DSE Wiring for further information. Part No. 057-004.

103

9813/2550-1

103

DSE Model 8610 and 8620 AMF Controller Installation

V1 Load switching and Generator Voltage Sensing Pin No.

Description

Cable Size

Notes

Output relay C

1.0mm

Normally configured to control load switching device

AWG 18

(Recommend 10A fuse)

Output relay C

1.0mm

Normally configured to control load switching device

AWG 18 41

Output relay D

1.0mm

Normally configured to control load switching device

AWG 18

(Recommend 10A fuse)

1.0mm

Normally configured to control load switching device

AWG 18 43

Generator L1 (U) voltage

1.0mm²

Connect to generator L1 (U) output (AC)

monitoring

AWG 18

(Recommend 2A fuse)

Generator L2 (V) voltage

1.0mm²

Connect to generator L2 (V) output (AC)

monitoring input

AWG 18

(Recommend 2A fuse)

Generator L3 (W) voltage 1.0mm²

Connect to generator L3 (W) output (AC)

monitoring input

AWG 18

(Recommend 2A fuse)

Generator Neutral (N) input

1.0mm²

Connect to generator Neutral terminal (AC)

AWG 18 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.

104

9813/2550-1

104

DSE Model 8610 and 8620 AMF Controller Installation

V2 Mains Voltage Sensing (DSE8620 Only) Icon

Pin No.

Description

Cable Size

Notes

Mains L1 (R) voltage monitoring

1.0mm²

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

Mains L2 (R) voltage monitoring

1.0mm²

AWG 18 Connect to Mains L1 (S) incoming supply (AC) (Recommend 2A fuse)

AWG 18 49

Mains L3 (T) voltage monitoring

1.0mm²

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

AWG 18 50

Mains Neutral (N) input

1.0mm²

Connect to Mains N incoming supply (AC)

AWG 18

105

9813/2550-1

105

DSE Model 8610 and 8620 AMF Controller Installation

Generator Current Transformers Note: The DSE 8610 and 8620 module has a burden of 0.5VA on the CT. Ensure the CT is rated for the burden of Icon

the DSE 8610 and 8620 controller, the cable length being used and any other equipment sharing the CT. If in doubt, consult your CT supplier.

Pin No.

Description

Cable Size Notes

CT Secondary for Gen L1

2.5mm²

Connect to s1 secondary of L1 monitoring CT

AWG 13 52

CT Secondary for Gen L2

2.5mm²

Connect to s1 secondary of L2 monitoring CT

AWG 13 53

CT Secondary for Gen L3

2.5mm²

Connect to s1 secondary of L3 monitoring CT

AWG 13 Connection to terminals 54 & 55

Icon

The function of terminals 54 and 55 change position depending upon wiring topology as follows:

Topology

Pin No.

Description

No earth fault measuring

Do not connect

Connect to s2 of the CTs connected to 2.5mm² L1,L2,L3,N AWG 13

Connect to s1 of the CT on the neutral 2.5mm² conductor AWG 13

Un-restricted earth fault measuring 54 (Earth fault CT is fitted in the neutral to earth link) 55

Connect to s1 of the CT on the neutral 2.5mm² to earth conductor. AWG 13

Restricted earth fault measuring

Cable Size

Connect to s2 of the CT on the neutral 2.5mm² AWG 13 to earth link. Also connect to the s2 of CTs connected to L1, L2, L3.

106

9813/2550-1

106

DSE Model 8610 and 8620 AMF Controller Installation

Mains Current Transformers (DSE 8620 Only) Icon

Pin Description No.

Cable Size

Notes

CT Secondary for Mains L1

2.5mm²

Connect to s1 secondary of L1 monitoring CT

CT Secondary for Mains L2

AWG 13 2.5mm²

Connect to s1 secondary of L2 monitoring CT

AWG 13

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

To Load

To Supply

CT labelled as p2, l or L

Note: Terminals 56 to 59 are not fitted to the 8610 series controller.

CT Connections 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 (I1, I2, I3) 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 DSE8600 series modules.

P033120-20

Fig 2. 1

107

CT labelled as p1, k or K

9813/2550-1

107

DSE Model 8610 and 8620 AMF Controller Installation

Configurable Digital Inputs Icon

Pin No.

Description

Cable Size

Notes

Configurable digital input A

0.5mm²

Switch to negative

AWG 20 61

Configurable digital input B

0.5mm²

Switch to negative

AWG 20 62

Configurable digital input C

Configurable digital input D

0.5mm²

Switch to negative

AWG 20 0.5mm²

Switch to negative

AWG 20 64

Configurable digital input E

0.5mm²

Switch to negative

AWG 20 65

Configurable digital input F

0.5mm²

Switch to negative

AWG 20 66

Configurable digital input G

Configurable digital input H

0.5mm²

Switch to negative

AWG 20 0.5mm²

Switch to negative

AWG 20 68

Configurable digital input I

0.5mm²

Switch to negative

AWG 20 69

Configurable digital input J

0.5mm²

Switch to negative

AWG 20 70

Configurable digital input K

0.5mm²

Switch to negative

AWG 20 Note: See the software manual for full range of configurable outputs available.See the software manual for full range of configurable outputs available.

108

9813/2550-1

108

DSE Model 8610 and 8620 AMF Controller Installation

PC Configuration Interface Connector Icon

Description

Cable Size

Socket for connection to PC software

0.5mmÂ˛ AWG 20

This is a standard USB type A to type B connector.

Note: The USB connection cable between the PC and the 8600 series module must not be extended beyond 5m (yards). For distances over 5m, it is possible to use a third party USB extender. Typically, they extend USB up to 50m (yards). The supply and support of this type of equipment is outside the scope of Deep Sea Electronics PLC.

109

9813/2550-1

109

DSE Model 8610 and 8620 AMF Controller Installation

RS485 Connector

Pin No.

Notes

Request to send

Pin No.

Notes

Clear to send

Two core screened twisted pair cable.

Ring Indicator

2 3

120W impedance suitable for RS485 use. Recommended cable type - Belden 9841 Max distance 1200m (1.2km) when using Belden 9841 or direct equivalent.

Fig 4.

Fig 3.

RS232 Connector Pin No.

Notes

Received Line Signal Detector (Data Carrier Detect)

Received Data

Transmit Data

Data Terminal Ready

Signal Ground

Data Set Ready

110

9813/2550-1

110

DSE Model 8610 and 8620 AMF Controller Description of Controls

Description of Controls The following section details the function and meaning of the various controls on the module.

DSE 8610 Automatic Mains Failure (AMF) Control Module below:

Fig 5.

111

9813/2550-1

111

DSE Model 8610 and 8620 AMF Controller Description of Controls

P033120-62

DSE 8620 Automatic Mains Failure (AMF) Control Module below:

112

9813/2550-1

112

DSE Model 8610 and 8620 AMF Controller Description of Controls

P033120-63

113

9813/2550-1

113

DSE Model 8610 and 8620 AMF Controller Description of Controls

Fig 6.

114

9813/2550-1

114

DSE Model 8610 and 8620 AMF Controller Description of Controls

Viewing the Instrument Pages It is possible to scroll to display the different pages of information by repeatedly operating the next / previous page buttons

Example Status

Engine

Generator

And so on until the last page is reached. A Further press of the scroll right button returns the display to the Status page.

If no buttons are pressed upon entering an instrumentation page, the instruments will be displayed automatically subject to the setting of the LCD Scroll Timer. The LCD Page and LCD Scroll timers are configurable using the DSE Configuration Suite Software or by using the Front Panel Editor. The screenshot shows the factory settings for the timers, taken from the DSE Configuration SuiteSoftware.

Autoscroll

Alternatively, to scroll manually through all instruments on the currently selected page, press the scroll buttons. The ‘autoscroll’ is disabled.

When scrolling manually, the display will automatically return to the Status page if no buttons are pressed for the duration of the configurable LCD Page Timer.

To re-enable ‘auto scroll’ press the scroll buttons to scroll to the ‘title’ of the instrumentation page (i.e. Engine). A short time later (the duration of the LCD Scroll Timer), the instrumentation display will begin to auto scroll.

If an alarm becomes active while viewing the status page, the display shows the Alarms page to draw the operator’s attention to the alarm condition.

115

9813/2550-1

115

DSE Model 8610 and 8620 AMF Controller Description of Controls Status This is the ‘home’ page, the page that is displayed when no other page has been selected, and the page that is automatically displayed after a period of inactivity (LCD Page Timer) of the module control buttons. This page will change with the action of the controller , when on gen generator parameters will be seen and when changing to mains the mains parameters will be shown.

Factory setting of Status screen showing engine stopped...

‘Stop Mode’ etc is displayed on the Home Page

With a summary of the instrumentation shown when the engine is running.

Other pages can be configured to be shown, automatically scrolling when the set is running.

Note: The following sections detail instrumentation pages, accessible using the scroll left and right buttons, regardless of what pages are configured to be displayed on the ‘status’ screen.

...and engine running The contents of this display may vary depending upon configuration by the generator manufacturer / supplier. The display above is achieved with the factory settings, shown below in the DSE Configuration suite software:

116

9813/2550-1

116

DSE Model 8610 and 8620 AMF Controller Description of Controls Engine Contains instrumentation gathered about the engine itself, some of which may be obtained using the CAN or other electronic engine link.

The tick icon denotes that manual fuel pump control is enabled in this system. Press and hold to start the fuel transfer pump, release to stop the pump. This is detailed further in the section entitled ‘operation’ elsewhere in this document.

– Engine Speed – Oil Pressure – Coolant Temperature – Engine Battery Volts – Run Time – Oil Temperature* – Coolant Pressure*

Generator

– Inlet Temperature* – Exhaust Temperature*

Contains electrical values of the generator (alternator), measured or derived from the module’s voltage and current inputs.

– Fuel Temperature* – Fuel Consumption* – Fuel Used*

– Generator Voltage (ph-N)

– Fuel Level*

– Generator Voltage (ph-ph)

– Auxiliary Sensors (if fitted and configured)

– Generator Frequency

– Engine Maintenance Due (if configured)

– Generator Current

– Engine ECU Link*

– Generator Earth Current

*When connected to suitably configured and compatible engine ECU. For details of supported engines see ‘Electronic Engines and DSE wiring’ (DSE Part number 057-004). – Tier 4 engine information will also be available if used with a Tier 4 suitable engine / ECU. Depending upon configuration and instrument function, some of the instrumentation items may include a tick icon beside them. This denotes a further function is available, detailed in the ‘operation’ section of this document.

– Generator Load% – Generator Load (kW) – Generator Load (kVA) – Generator Power Factor – Generator Power Factor Average – Generator Load (kVAr) – Generator Load (kWh, kVAh, kVArh) – Generator Phase Sequence – Generator config (Nominals) – Generator Active Config – Synchroscope display

117

9813/2550-1

117

DSE Model 8610 and 8620 AMF Controller Description of Controls Mains – Mains Voltage (ph-N) – Mains Voltage (ph-ph) – Mains Frequency – Mains Current – Mains Load (kW) – Mains Load Total (kW) – Mains Load (kVA) – Mains Load Total (kVA) – Mains Power Factor – Mains Power Factor Average – Mains Load (kVAr) – Mains Load (kWh, kVAh, kVArh) – Mains Phase Sequence – Mains config (Nominals) – Mains Active Config

118

9813/2550-1

118

DSE Model 8610 and 8620 AMF Controller Description of Controls RS232 Serial Port

Press down to view the modem status....

This section is included to give information about the RS232 serial port and external modem (if connected). The items displayed on this page will change depending upon configuration of the module. You are referred to your system supplier for further details. Note: Factory Default settings are for the RS232 port to be enabled with no modem connected, operating at 19200 baud, mod bus slave address 10. Example 1 – Module connected to an RS232 telephone modem.

Example 1 continued – Modem diagnostics Modem diagnostic screens are included; press down when viewing the RS232 Serial Port instrument to cycle the available screens. If you are experiencing modem communication problems, this information will aid troubleshooting.

When the DSE8610 series module is power up, it will send ‘initialisation strings’ to the connected modem. It is important therefore that the modem is already powered, or is powered up at the same time as the DSE86xx series module. At regular intervals after power up, the modem is reset, and re initialised, to ensure the modem does not ‘hang up’. If the DSE8610 series module does not correctly communicate with the modem, “Modem initialising’ appears on the Serial Port instrument screen as shown overleaf. If the module is set for “incoming calls” or for “incoming and outgoing calls”, then if the modem is dialled, it will answer after two rings (using the factory setting ‘initialisation strings)’. Once the call is established, all data is passed from the dialling PC and the DSE8610 series module. If the module is set for “outgoing calls” or for “incoming and outgoing calls”, then the module will dial out whenever an alarm is generated. Note that not all alarms will generate a dial out; this is dependant upon module configuration of the event log. Any item configured to appear in the event log will cause a dial out. Modem - Indicates that a modem is configured. Shows ‘RS232’ if no modem is configured.

119

DTR - Shows the state of the modem communication lines. These can help diagnose connection problems. Example: RTS A dark background shows the line is active. RTS a grey background shows that the line is toggling high and low. Line

Description

RTS

Request To Send

Flow control

CTS

Clear To Send

Flow control

DSR

Data Set Ready

Ready to communicate

DTR

Data Terminal Ready

Ready to communicate

DCD

Data Carrier Detect

Modem is connected

9813/2550-1

119

DSE Model 8610 and 8620 AMF Controller Description of Controls

Example 3 – Modem status of a GSM modem

(Tx: AT+IPR= 9600) = Shows the last command sent to the modem and the result of the command. Modem Setup Sequence

Currently connected GSM operator and signal strength

If the Modem and DSE8600 series communicate successfully:

In case of communication failure between the modem and DSE8600 series module, the modem is automatically reset and initialisation is attempted once more:

In the case of a module that is unable to communicate with the modem, the display will continuously cycle between ‘Modem Reset’ and ‘Modem Initialising’ as the module resets the modem and attempts to communicate with it again, this will continue until correct communication is established with the modem. In this instance, you should check connections and verify the modem operation.

Many GSM modems are fitted with a status LED to show operator cell status and ringing indicator. These can be a useful troubleshooting tool. In the case of GSM connection problems, try calling the DATA number of the SIMCARD with an ordinary telephone. There should be two rings, followed by the modem answering the call and then ‘squealing’. If this does not happen, you should check all modem connections and double check with the SIM provider that it is a DATA SIM and can operate as a data modem. DATA is NOT the same as FAX or GPRS and is often called Circuit Switched Data (CSD) by the SIM provider. Note: n the case of GSM modems, it is important that a DATA ENABLED SIM is used. This is often a different number than the ‘voice number’ and is often called Circuit Switched Data (CSD) by the SIM provider. If the GSM modem is not purchased from DSE, ensure that it has been correctly set to operate at 9600 baud. You may need to install a terminal program on your PC and consult your modem supplier to do this. GSM modems purchased from DSE are already configured to work with the DSE86xx series module.

Example 2 – Module connected to a modem.

120

9813/2550-1

120

DSE Model 8610 and 8620 AMF Controller Description of Controls RS485 Serial Port This section is included to give information about the currently selected serial port and external modem (if connected). The items displayed on this page will change depending upon configuration of the module. You are referred to your system supplier for further details. Note: Factory Default settings are for the RS485 port to operating at 19200 baud, mod bus slave address 10. Module RS485 port configured for connection to a mod bus master

master PLC requests data from the DSE86xx mod bus slave once per second, the timeout should be set to at least 2 seconds. The DSE Modbus Gen common document containing register mappings inside the DSE module is available upon request from support@deepseaplc.com. Email your request along with the serial number of your DSE module to ensure the correct information is sent to you. Typical requests (using Pseudo code) BatteryVoltage=ReadRegister(10,0405,1): reads register (hex) 0405 as a single register (battery volts) from slave address 10. WriteRegister(10,1008,2,35701, 65535-35701): Puts the module into AUTO mode by writing to (hex) register 1008, the values 35701 (auto mode) and register 1009 the value 65535-35701 (the bitwise opposite of auto mode)

DSE86xx series modules operate as a mod bus RTU slave device. In a mod bus system, there can be only one Master, typically a PLC, HMI system or PC SCADA system. This master requests for information from the mod bus slave (DSE86xx series module) and may (in control systems) also send request to change operating modes etc. Unless the Master makes a request, the slave is ‘quiet’ on the data link. The factory settings are for the module to communicate at 19200 baud, mod bus slave address 10. To use the RS485 port, ensure that ‘port usage’ is correctly set using the DSE Configuration Suite Software.

Shutdown=(ReadRegister(10,0306,1) >> 12) & 1): reads (hex) 0306 and looks at bit 13 (shutdown alarm present) Warning=(ReadRegister(10,0306,1) >> 11) & 1): reads (hex) 0306 and looks at bit 12 (Warning alarm present) ElectricalTrip=(ReadRegister(10,0306,1) >> 10) & 1): reads (hex) 0306 and looks at bit 11 (Electrical Trip alarm present) ControlMode=ReadRegister(10,0304,2); register 0304 (control mode).

reads

(hex)

Required settings are shown below:

‘Master inactivity timeout should be set to at least twice the value of the system scan time. For example if a mod bus

121

9813/2550-1

121

DSE Model 8610 and 8620 AMF Controller Description of Controls About Contains important information about the module and the firmware versions. This information may be asked for when contacting DSE Technical Support Department for advice. – Module Type (i.e. 8620) – Application Version – The version of the module’s main firmware file – Updatable using the Firmware Update Wizard in the DSE Configuration Suite Software

(E8.A4.C1.0.C2) = Unique setting for each module

– USB ID – unique identifier for PC USB connection – Analogue Measurements software version – Firmware Update Boot loader software version Ethernet Pages Update Network settings using DSE Configuration Suite Software+ 1 Power cycle off/on before the editor pages are updated.

Pages available in the “ABOUT” screen to confirm Network settings. Data Logging Pages The DSE data logging pages show information depending on the configuration in the module. (Internal memory) - Location of stored data. Internal module memory or external USB memory. (Logging Active) - If data logging is active or inactive Inserting a USB drive to the host USB will display the following change to the page.

122

9813/2550-1

122

DSE Model 8610 and 8620 AMF Controller Description of Controls Memory space remaining, this depends what size memory drive is fitted (Max 16Gb) or allocated internal (2Mb) memory left available.

Can Error Messages Note: Removal of the USB drive should only be carried out using the following method

When connected to a suitable CAN engine the 8620 series controller displays alarm status messages from the ECU.

Press and hold the tick button until “Ok to remove USB drive” is displayed.

Type of alarm that is triggered in the DSE module (i.e. Warning or Shutdown)

Press to access the list of current active Engine DTCs (Diagnostic Trouble Codes). It is now safe to remove the USB drive. The code interpreted by the module shows on the display as a text message. Additionally, the manufacturer’s code is shown.

This ensures the logging data file will save to memory complete and will not become corrupt.

Press down to view the next page

Note: For details on these code meanings, refer to the ECU instructions provided by the engine manufacturer, or contact the engine manufacturer for further assistance.

Remaining time available for logging information. XXXX hours XX minutes

Note: For further details on connection to electronic engines please refer to Electronic engines and DSE wiring. Part No. 057-004

Press down to view the next page

123

9813/2550-1

123

DSE Model 8610 and 8620 AMF Controller Description of Controls

Viewing The Event Log

repeatedly press the next page button until the LCD screen displays the Event log

The DSE8600 series modules maintain a log of past alarms and/or selected status changes. The log size has been increased in the module over past module updates and is always subject to change. At the time of writing, the 86xx series log is capable of storing the last 250 log entries.

This is event 1.

Under default factory settings, the event log only includes shutdown and electrical trip alarms logged (The event log does not contain Warning alarms); however, this is configurable by the system designer using the DSE Configuration Suite software.

Press down to view the next most recent shutdown alarm:

Continuing to press down cycles through the past alarms after which the display shows the most recent alarm and the cycle begins again. To exit the event log and return to viewing the instruments, press the next page button to select the next instrumentation page.

Press down to view the next most recent shutdown alarm:

Once the log is full, any subsequent shutdown alarms will overwrite the oldest entry in the log. Hence, the log will always contain the most recent shutdown alarms. The module logs the alarm, along with the date and time of the event (or engine running hours if configured to do so).

Continuing to press down cycles through the past

If the module is configured and connected to send SMS text

ments, press the next page button to select the next

alarms after which the display shows the most recent alarm and the cycle begins again. To exit the event log and return to viewing the instruinstrumentation page.

To view the Event log:

124

9813/2550-1

124

DSE Model 8610 and 8620 AMF Controller Description of Controls

User Configurable Indicators These LEDs can be configured by the user to indicate any one of 100+ different functions based around the following:– Indications - Monitoring of a digital input and indicating associated functioning user’s 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, Preheating, Panel Locked, Generator Available, etc.

P033120-61

Fig 7. 1

125

User configurable LED

9813/2550-1

125

DSE Model 8610 and 8620 AMF Controller Operation

Operation Control Control of the DSE 8610 and 8620 module is via push buttons mounted on the front of the module with Stop/ Reset, Manual, Test, Auto, Alarm Mute and Start functions. For normal operation, these are the only controls which need to be operated. The smaller push buttons are used to access further information such as mains voltage or to change the state of the load switching devices when in manual mode. Details of their operation are provided later in this document. The following descriptions detail the sequences followed by a module containing the standard â&#x20AC;&#x2DC;factory configurationâ&#x20AC;&#x2122;. Always refer to your configuration source for the exact sequences and timers observed by any particular module in the field.

Fig 8. Note: PLC Functionality. This control module has PLC functionality built in. This can have change the standard operation when used.(Default configuration the no PLC is set. See software manual for more information)

126

9813/2550-1

126

DSE Model 8610 and 8620 AMF Controller Operation

Control Push- Buttons (DSE 8610 Only) Stop/Reset

This push-button places the module into its Stop/reset mode. This will clear any alarm conditions for which the triggering criteria have been removed. If the engine is running and this push-button is operated, the module will automatically instruct the generator contactor/breaker to unload the generator. The fuel supply will be removed and engine will be brought to a standstill. Should a remote start signal be present while operating in the mode, a remote start will not occur.

Manual

This push-button is used to allow manual control of the generator functions. Entering this mode from another mode will initially not cause any change of operating state, but allows further push-buttons to be used to control the generator operation. For example, once in Manual mode it is possible to start the engine by using the ‘START’ push-button. If the engine is running, off-load in the Manual mode and a remote start signal becomes present, the module will automatically instruct the generator contactor/breaker device to place the generator on load. Should the remote start signal then be removed the generator will remain on load until either the ‘STOP/RESET’ or ‘AUTO’ push-buttons are operated.

Start

This push-button is used to start the engine. The module must first be placed in the ‘MANUAL’ mode of operation. The ‘START’ button should then be operated. The engine will then automatically attempt to start. Should it fail on the first attempt it will re-try until either the engine fires or the pre-set number of attempts have been made. To stop the engine the ‘STOP/ RESET’ button should be operated. It is also possible to configure the module such that the start push-button must be held to maintain engine cranking. Note: Different modes of operation are possible - Please refer to your configuration source for details.

Auto

127

This push-button places the module into its ‘Automatic’ mode. This mode allows the module to control the function of the generator automatically. The module will monitor the remote start input and once a start condition is signalled the set will be automatically started and placed on load. If the starting signal is removed, the module will automatically transfer the load from the generator and shut the set down observing the stop delay timer and cooling timer as necessary. The module will then await the next start event. For further details, please see the more detailed description of ‘Auto Operation’ earlier in this manual.

9813/2550-1

127

DSE Model 8610 and 8620 AMF Controller Operation Mute/Lamp Test

This button silences the audible alarm if it is sounding and illuminates all of the LED’s as a lamp test feature.

Transfer to generator

Allows the operator to transfer the load to the generator, Synchronising first if required. (when in Manual mode only)

Open generator (DSE 8610 Only)

Allows the operator to open the generator breaker (when in Manual mode only)

Menu navigation

Used for navigating the instrumentation, event log and configuration screens. For further details, please see the more detailed description of these items elsewhere in this manual

For (DSE 8620 Only) Test

128

This button places the module into its ‘Test’ mode. This allows an on load test of the generator. Once in Test mode the module will respond to the start button, start the engine, and run on load. For further details, please see the more detailed description of ‘Test operation’ elsewhere in this document.

9813/2550-1

128

DSE Model 8610 and 8620 AMF Controller Operation Transfer to mains

Operative in Manual Mode only ‘Normal’ breaker button control – Allows the operator to transfer the

load to the mains – If the Generator is on load and mains is available the generator will synchronise and parallel with the mains. – If the Generator & mains are in parallel, the generator power will ramp off and open the generator breaker. ‘Alternative’ breaker button control (Synchronises when necessary) – If generator is on load, transfers the load to the mains. – If mains is on load, opens the mains breaker – If generator and mains are off load, closes the mains breaker. Transfer to generator

Operative in Manual Mode only ‘Normal’ breaker button control – Allows the operator to transfer the load to the generator – If the mains is on load and the generator is available the generator will synchronise and parallel with the mains. – If the mains & generator are in parallel the generator power will ramp up and open the mains breaker. ‘Alternative’ breaker button control (Synchronises when necessary) – If mains is on load, transfers the load to the generator. – If generator and mains are off load, closes the generator breaker

Menu navigation

Used for navigating the instrumentation, event log and configuration screens. For further details, please see the more detailed description of these items elsewhere in this manual

The following description details the sequences followed by a module containing the standard ‘factory configuration’.

129

Remember that if you have purchased a completed generator set or control panel from your supplier, the

9813/2550-1

129

DSE Model 8610 and 8620 AMF Controller Operation moduleâ&#x20AC;&#x2122;s configuration will probably have been changed by them to suit their particular requirements. Always refer to your configuration source for the exact sequences and timers observed by any particular module in the field.

130

9813/2550-1

130

DSE Model 8610 and 8620 AMF Controller Operation

Dummy Load/ Load Shedding Control

Load Shedding Control

This feature may be enabled by the system designer to ensure the loading on the generator is kept to a nominal amount. If the load is low, ‘dummy loads’ (typically static load banks) can be introduced to ensure the engine is not too lightly loaded. Conversely as the load increases towards the maximum rating of the set, non-essential loads can be shed to prevent overload of the generator.

The Load Shedding Control feature (if enabled) allows for a maximum of five load shedding steps. When the generator is about to take load, the configured number of Load Shedding Control Outputs at Startup will energise. This configurable setting allows (for instance) certain loads to be removed from the generator prior to the set’s load switch being closed. This can be used to ensure the initial loading of the set is kept to a minimum, below the Load Acceptance specification of the generating set.

Dummy Load Control The dummy load control feature (if enabled) allows for a maximum of five dummy load steps. When the set is first started, all configured Dummy Load Control outputs are de-energised. Once the generator is placed onto load, the generator loading is monitored by the Dummy Load Control scheme. If the generator loading falls below the Dummy Load Control Trip setting (kW), the Dummy Load Control Trip Delay is displayed on the module display. If the generator loading remains at this low level for the duration of the timer, the first Dummy Load Control output is energised. This is used to energise external circuits to switch in (for instance) a static load bank. The generator loading has now been increased by the first dummy load. Again the generator loading is monitored. This continues until all configured Dummy Load Control outputs are energised. Should the generator loading rise above the Dummy Load Return level, the Dummy Load Return Delay begins. If the loading remains at these levels after the completion of the timer, the ‘highest’ active Dummy Load Control output is de-energised. This continues until all Dummy Load Control outputs have been de-energised. Example screen shot of Dummy Load Control setup in the DSE Configuration Suite

131

The generator is then placed on load. The Load Shedding Control scheme begins. When the load reaches the Load Shedding Trip level the Trip Delay timer will start. If the generator loading is still high when the timer expires, the first Load shedding Control output will energise. When the load has been above the trip level for the duration of the timer the ‘next’ Load shedding Control output will energise and so on until all Load Shedding Control outputs are energised. If at any time the load falls back below the Load Shedding Return level, the Return Time will start. If the load remains below the return level when the timer has expired the ‘highest’ Load Shedding Control output that has been energised will be de-energised. This process will continue until all outputs have been de-energised. When the set enters a stopping sequence for any reason the Load Shedding control outputs will de-energised at the same time as the generator load switch is signalled to open.

9813/2550-1

131

DSE Model 8610 and 8620 AMF Controller Operation

Stop Mode

When the ECU powered down (as is normal when in Stop mode), it is not possible to read the diagnostic trouble codes or instrumentation. Additionally, it is not possible to use the engine manufacturers’ configuration tools.

Stop mode is activated by pressing the stop modebutton.

– Select Stop mode on the DSE controller. – Press and hold the START mode button to power the ECU. As the controller is in STOP mode, the engine will not be started. – Engine speed is zero as detected by the Magnetic Pick-up or CANbus ECU (depending upon module variant). – Generator frequency must be zero. – Oil pressure switch must be closed to indicate low oil pressure (MPU version only)

– The ECU will remain powered 2 minutes after the Start button is released. This is also useful if the engine manufacturer’s tools need to be connected to the engine, for instance to configure the engine as the ECU needs to be powered up to perform this operation.

When the engine has stopped, it is possible to send configuration files to the module from DSE Configuration Suite PC software and to enter the Front Panel Editor to change parameters. Any latched alarms that have been cleared will be reset when STOP mode is entered. The engine will not be started when in Stop mode. If remote start signals are given, the input is ignored until Auto mode is entered. When configured to do so, When left in Stop mode for five minutes with no presses of the fascia buttons, the module enters low power mode. To ‘wake’ the module, press the stop mode button or any other fascia control button. Sleep mode configuration in the DSE Configuration Suite Software

ECU Override Note: ECU Override function is only applicable when the controller is configured for a CAN engine. Note: Depending upon system design, the ECU may be powered or unpowered when the module is in Stop mode. ECU override is only applicable if the ECU is unpowered when in Stop mode.

132

9813/2550-1

132

DSE Model 8610 and 8620 AMF Controller Operation

Automatic Operation (DSE 8620 Only) Mains Failure This mode of operation is used to ensure continuity of supply to critical loads during a mains failure condition. This is the normal mode of operation when installed on a standby generator

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

Note: If a digital input configured to panel lock is active, changing module modes will not be possible. Viewing the instruments and event logs is NOT affected by panel lock.

This mode is activated by pressing the Auto mode pushbutton. An LED indicator beside the button will illuminate to confirm this operation. Auto mode will allow the generator to operate fully automatically, starting and stopping as required with no user intervention. Should the mains (utility) supply fall outside the configurable limits for longer than the period of the mains transient delay timer, the mains (utility) available GREEN indicator LED extinguishes.

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.

To allow for short term mains supply transient conditions, the Start Delay timer is initiated. After this delay, if the preheat output option is selected then the pre-heat timer is initiated and the corresponding auxiliary output (if configured) will energise. Note: If the mains supply returns within limits during the Start Delay timer, the unit will return to a stand-by state.

Engine Running Once the engine is running, the Warm Up timer, if selected, begins, allowing the engine to stabilise before accepting the load.

After the above delays have expired the Fuel Solenoid (or enable ECU output if configured) is energised, then one second later, the Starter Motor is engaged.

After the Warm-up timer has expired then the module will transfer the load from the failed mains supply to the generator output. It will observe the following sequence. The Mains Contactor/Breaker will be instructed to open and after a short delay (transfer delay), the Generator Contactor/Breaker will be instructed to close.

The generator will then supply the requirements of the load.

133

9813/2550-1

133

DSE Model 8610 and 8620 AMF Controller Operation Note: A load transfer will not be initiated until the Oil Pressure has risen. This prevents excessive wear on the engine.

This mode is activated by pressing the Auto mode pushbutton. An LED indicator beside the button will illuminate to confirm this operation.

When the mains supply returns, the Stop delay timer is initiated. Once it has expired, the set is synchronised and paralleled with the mains supply. The system remains in this condition until expiry of the Parallel run timer. Once this has expired, the module will ramp the remaining load from the generator to mains supply. The Generator Contact/ Breaker will open and the Cooling timer is then initiated, allowing the engine a cooling down period off load before shutting down. Once the Cooling timer expires, the Fuel Solenoid is de-energised, bringing the generator to a stop.

If the remote start in island mode input activates, the Remote Start Active indicator (if configured) illuminates.

During the parallel run, the module can be configured to either run at a fixed level output, or to maintain an output in relation to the load level on the mains. For full details of these mode please refer to the manual â&#x20AC;&#x2DC;The Guide to sync and load share Pt1â&#x20AC;&#x2122;

After the above delays, the Fuel Solenoid (or enable ECU output if configured) is energised, and then one second later, the Starter Motor is engaged.

Should the mains supply fall outside limits once again the set will return on load. Note: When synchronising is enabled, the mains supply is checked before closing any load switching device. If the supply is live, synchronising will take place before any closure takes place. Note: Synchronising can be disabled if the application does not require this function. Contact your genset supplier in the first instance for further details.

To allow for false remote start signals, the Start Delay timer is initiated. After this delay, if the pre-heat output option is selected then the pre-heat timer is initiated and the corresponding auxiliary output (if configured) will energise. Note: If the Remote Start signal is removed during the Start Delay timer, the unit will return to a stand-by state.

Note: If the unit has been configured for CAN Bus, compatible ECUâ&#x20AC;&#x2122;s will receive the start command via CAN Bus. Refer to the Manual CAN and DSE Wiring. Part No. 057-004 for more information on utilising DSE modules with electronically controlled engines. The engine is cranked for a pre-set time. If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and Fail to Start fault will be displayed.

Remote Start in Island Mode This mode of operation is used to start the set in response to an external start requirement from another device. It may also be used to provide continuity of supply during expected black out events. Note: If a digital input configured to panel lock is active, changing module modes will not be possible. Viewing the instruments (Up and Down) and event log are NOT affected by panel lock. If panel lock is active the Panel lock indicator (if configured) illuminates.

When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency measured from the alternator output. Alternatively, a Magnetic Pick-up mounted on the flywheel housing can be used for speed detection (). Rising oil pressure can also be used to disconnect the starter motor; however, it cannot be used for underspeed or overspeed detection. Note: If the unit is configured for CAN Bus, speed sensing is via CAN Bus. After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine

134

9813/2550-1

134

DSE Model 8610 and 8620 AMF Controller Operation Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault.

Configuration Software manuals for full details on the feature.

Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to stabilise before accepting the load.

Remote Start on Load

Note: A load transfer will not be initiated until the Oil Pressure has risen. This prevents excessive wear on the engine. The Generator will first be instructed to synchronise with the mains supply before closing the Generator Contact/ Breaker and transferring load from mains to generator until the generator is supplying the required amount of power (adjustable using DSE Configuration Suite software).

This mode of operation is used to start the set in response to rising load levels on the mains supply (if configured). Note: If a digital input configured to panel lock is active, changing module modes will not be possible. Viewing the instruments (Up and Down) and event log are NOT affected by panel lock. If panel lock is active the Panel lock indicator (if configured) illuminates.

When the supplies have been in parallel for the duration of the parallel run time, the load will ramp off the mains supply and onto the generator. The Mains Contactor/Breaker will be instructed to open. The generator will then supply the requirements of the load.

This mode is activated by pressing the Auto mode pushbutton. An LED indicator beside the button will illuminate to confirm this operation.

When the remote start signal is removed, the Stop delay timer is initiated. Once it has expired, the set is synchronised and paralleled with the mains supply.

Should the load level on the mains supply exceed a pre-set level the module will initiate a start sequence.

The system remains in this condition until expiry of the Parallel run timer. Once this has expired, the module will ramp the remaining load from the generator to mains supply.

To allow for short duration load surges, the Start Delay timer is initiated. After this delay, if the preheat output option is selected then the pre-heat timer is initiated and the corresponding auxiliary output (if configured) will energise.

Alternative Ramping Scheme- The controller holds the power until the end of the Parallel run timer before initiating any ramping off. The Generator Contact/Breaker will open and the Cooling timer is then initiated, allowing the engine a cooling down period off load before shutting down. Once the Cooling timer expires, the Fuel Solenoid is deenergised, bringing the generator to a stop Note: Synchronising can be disabled if the application does not require this function. Contact your generating set supplier in the first instance for further details. Note: The internal â&#x20AC;&#x2DC;Schedulerâ&#x20AC;&#x2122; can be configured to operate the system in the same manner as described for the Remote start input. Please refer to the 86xx

135

Note: If the load level returns below the pre-set level during the Start Delay timer, the unit will return to a standby state. After the above delays, the Fuel Solenoid (or enable ECU output if configured) is energised, and then one second later, the Starter Motor is engaged. Note: If the unit has been configured for CAN Bus, compatible ECUâ&#x20AC;&#x2122;s will receive the start command via CAN Bus. Refer to the Manual CAN and DSE Wiring. Part No. 057-004 for more information on utilising DSE modules with electronically controlled engines. The engine is cranked for a pre-set time. 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

9813/2550-1

135

DSE Model 8610 and 8620 AMF Controller Operation start sequence will be terminated and Fail to Start fault will be displayed.

When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency measured from the alternator output. Alternatively, a Magnetic Pick-up mounted on the flywheel housing can be used for speed detection (This is selected by PC using the DSE configuration Suite software). Rising oil pressure can also be used to disconnect the starter motor; however, it cannot be used for underspeed or overspeed detection. Note: If the unit is configured for CAN Bus, speed sensing is via CAN Bus. 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.

When the remote start on load input is removed, the Stop delay timer is initiated. Once this timer has expired, the module will ramp the load from the generator to mains supply. The Generator Contact/Breaker will open and the Cooling timer is then initiated, allowing the engine a cooling down period off load before shutting down. Once the Cooling timer expires, the Fuel Solenoid is deenergised, bringing the generator to a stop. During the parallel run, the module can be configured to either run at a fixed level output, or to maintain an output in relation to the load level on the mains. Note: When synchronising is enabled, the mains supply is checked before closing any load switching device. If the supply is live, synchronising will take place before any closure takes place. Note: Synchronising can be disabled if the application does not require this function. Contact your genset supplier in the first instance for further details. Note: The load level mode of operation relies on a Current Transformer (CT) fitted to the mains feed of the system. This is then used for measurement of the mains current used in the load level calculations.

Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to stabilise before accepting the load. After the Warm-up timer has expired then the module will transfer the load from the mains supply to the generator output. It will observe the following sequence. The Generator will first be instructed to synchronise with the mains supply. Once these are matched, the Generator Contact/Breaker will be instructed to close. The load will then be ramped from the Mains to the appropriate level on the generator. The generator will then supply the requirements of the load. Note: A load transfer will not be initiated until the Oil Pressure has risen. This prevents excessive wear on the engine. Advanced Ramping Scheme - When configured the breaker closes and the Generator power is held until the end of the timer before ramping off

136

9813/2550-1

136

DSE Model 8610 and 8620 AMF Controller Operation

Manual Operation Manual mode is used to allow the operator to control the operation of the generator, and to provide fault finding and diagnostic testing of the various operations normally performed during Automatic mode operation.

detection (This is selected by PC using the 5xxx 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. Note: If the unit is configured for CAN Bus, speed sensing is via CAN Bus.

Note: If a digital input configured to panel lock is active, changing module modes will not be possible. Viewing the instruments (Up and Down) and event logs and event log is NOT affected by panel lock. If panel lock is active the Panel lock indicator (if configured) illuminates.

MANUAL, mode is selected by pressing the pushbutton. An LED besides the button will illuminate to confirm this operation. When the Start mode button is operated, the module will initiate the start sequence.

Once the engine is running, the Warm Up timer (if selected) is initiated, allowing the engine to stabilise before it can be loaded. Once the warm up timer has expired, the generator is then available to go on load and the Generator Available LED will illuminate on the front panel.

Note: There is no Start Delay in this mode of operation. If the pre-heat output option has been selected, this timer will be initiated and the auxiliary output selected energised. After the above delay, the Fuel Solenoid (or ECU output if configured) is energised, and then one second later, the Starter Motor is engaged. Note: If the unit is configured for CAN Bus, compatible ECU’s will receive the start command via CAN Bus. Refer to the Manual CAN and DSE Wiring. Part No. 057-004 for more information on utilising DSE modules with electronically controlled engines. The engine is cranked for a pre-set time. 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 will be displayed.

When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency measured from the Alternator output. Alternatively, a Magnetic Pick-up mounted on the flywheel housing can be used for speed

137

The generator will run off load unless: (DSE 8620 Only) 1

The mains supply fails,

A Remote Start on load signal is applied, or an onload run is configured in the scheduler.

The Close Generator button is pressed.

If any of the above signals are received, the generator is synchronised and paralleled with the mains supply (if available). During the parallel run, the module can be configured to either run at a fixed level output, or to maintain an output in relation to the load level on the mains. For full details of these mode please refer to the manual ‘The Guide to sync and load share Pt1’ Parallel Operation: – If the Close Generator button is pressed again while in parallel, then the module will transfer the load fully to the generators, removing the load from the mains supply. This will be achieved by ramping the load from the parallel operating level to the generator. The Mains Contactor/Breaker will then be opened. Pressing the Close Mains button will cause the module to re synchronise the generator with the mains supply and then return to parallel operation. – If the Close Mains button is pressed while in parallel, the module will open the generator load switching device, transferring the load fully to the mains supply.

9813/2550-1

137

DSE Model 8610 and 8620 AMF Controller Operation If Auto mode is selected and the mains supply is healthy, and the remote start on load signal not active, and the scheduler is not calling for a run, then the Return Delay Timer will start. Once this has expired then the module will exit parallel operation and will ramp the load back to the mains supply. It will then open the Generator Contactor/Breaker. The generator will then run off load allowing the engine a cooling period. Selecting Stop (O) de-energises the Fuel Solenoid, bringing the generator to a stop. Note: Synchronising can be disabled if the application does not require this function. Contact your genset supplier in the first instance for further details. If synchronising is disabled the system will always perform an open transition when switching the load from the mains to the generator or when returning to the mains. The parallel run stages of the sequence are not used when operating in this way. Note: When synchronising is enabled, the mains supply is checked before closing any load switching device. If the supply is live, synchronising will take place before any closure takes place.

138

9813/2550-1

138

DSE Model 8610 and 8620 AMF Controller Operation

Test Operation (DSE 8620 Only) Test operation is used to perform a full on load test sequence to allow for diagnosis of faults. Alternatively, it may also be used to provide continuity of supply during expected black out events, peak lopping or peak shaving during high tariff periods. Note: If a digital input configured to panel lock is active, changing module modes will not be possible. Viewing the instruments (Up and Down) and event log is Not affected by panel lock. If panel lock is active the Panel lock indicator (if configured) illuminates. Test mode is initiated by pressing the Test mode pushbutton. An LED besides the button will illuminate to confirm this operation. When the Start mode button is operated, the module will initiate the start sequence. Note: There is no Start Delay in this mode of operation. If the pre-heat output option has been selected, this timer will initiate and the auxiliary output selected will be energised. After the above delay, the Fuel Solenoid (or ECU output if configured) is energised, and then one second later, the Starter Motor is engaged. Note: If the unit has been configured for CAN Bus, compatible ECUâ&#x20AC;&#x2122;s will receive the start command via CAN Bus. Refer to the Manual CAN and DSE Wiring. Part No. 057-004 for more information on utilising DSE modules with electronically controlled engines. The engine is cranked for a pre-set time. 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 will be displayed.

output. Alternatively, a Magnetic Pick-up mounted on the flywheel housing can be used for speed detection (This is selected by PC using the DSE Configuration Suite software). Rising oil pressure can also be used to disconnect the starter motor; however, it cannot be used for underspeed or overspeed detection. Note: If the unit has been configured for CAN Bus speed sensing is via CAN Bus. 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 accepting the load. After the Warm-up timer has expired then the module will transfer the load from the mains supply to the generator output. It will observe the following sequence. The Generator will first be instructed to synchronise with the mains supply. Once these are matched the Generator Contact/Breaker will be instructed to close. The load will then be ramped from the Mains to the appropriate level on the generator. It will remain in this state whilst in the Test mode unless the configuration (Advanced Options-Test mode) is configured for Run Mode=Island mode. If the module has an active remote start in island mode input or the internal scheduler has been configured for island mode then the parallel run time will activate. When this expires, the load will ramp off the mains supply and onto the generator. The Mains Contactor/Breaker will be instructed to open The generator will then supply the requirements of the load. Note: A load transfer will not be initiated until the Oil Pressure has risen. This prevents excessive wear on the engine.

When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from the Alternator

139

The system will then remain in this mode of operation until a different mode is selected. It is recommended that Auto mode button is used to cancel the Test mode.

9813/2550-1

139

DSE Model 8610 and 8620 AMF Controller Operation When Auto mode button is selected the Stop delay timer is initiated. Once it has expired, the set is synchronised and paralleled with the mains supply. The system remains in this condition until expiry of the Parallel run timer. Once this has expired the module will ramp the remaining load from the generator to mains supply. The Generator Contact/ Breaker will open and the Cooling timer is then initiated, allowing the engine a cooling down period off load before shutting down. Once the Cooling timer expires the Fuel Solenoid is de-energised, bringing the generator to a stop. During the parallel run the module can be configured to either run at a fixed level output, or to maintain an output in relation to the load level on the mains. For full details of these mode please refer to the manual â&#x20AC;&#x2DC;The Guide to sync and load share Pt1â&#x20AC;&#x2122; Note: When synchronising is enabled, the mains supply is checked before closing any load switching device. If the supply is live, synchronising will take place before any closure takes place. Note: Synchronising can be disabled if the application does not require this function. Contact your genset supplier in the first instance for further details.

140

9813/2550-1

140

DSE Model 8610 and 8620 AMF Controller Protections

Protections When an alarm is present, the Audible Alarm will sound and the Common alarm LED if configured will illuminate. The audible alarm can be silenced by pressing the Mute mode button The LCD display will jump from the ‘Information page’ to display the Alarm Page

Protections Disabled User configuration is possible to prevent Shutdown / Electrical Trip alarms from stopping the engine. Under such conditions, Protections Disabled will appear on the module display to inform the operator of this status.

P033120-27

Number of present alarms. This is alarm 1 of a total of 2 present alarms

The type of alarm. E.g. Shutdown or warning

The nature of alarm, e.g. Low oil pressure

The LCD will display multiple alarms E.g. “High Engine Temperature shutdown”, “Emergency Stop” and “Low Coolant Warning”. These will automatically scroll in the order that they occurred. In the event of a warning alarm, the LCD will display the appropriate text. If a shutdown then occurs, the module will again display the appropriate text. Example:-

141

This feature is provided to assist the system designer in meeting specifications for “Warning only”, “Protections Disabled”, “Run to Destruction”, “War mode” or other similar wording. When configuring this feature in the PC software, the system designer chooses to make the feature either permanently active, or only active upon operation of an external switch. The system designer provides this switch (not DSE) so its location will vary depending upon manufacturer, however it normally takes the form of a key operated switch to prevent inadvertent activation. Depending upon configuration, a warning alarm may be generated when the switch is operated. The feature is configurable in the PC configuration software for the module. Writing a configuration to the controller that has “Protections Disabled” configured, results in a warning message appearing on the PC screen for the user to acknowledge before the controller’s configuration is changed. This prevents inadvertent activation of the feature.

9813/2550-1

141

DSE Model 8610 and 8620 AMF Controller Protections Indication/Warning Alarms Under Indication or Warning alarms: – The module operation is unaffected by the Protections Disabled feature. See sections entitled Indications and Warnings elsewhere in this document.

Shutdown/Electrical Trip Alarms Note: The EMERGENCY STOP input and shutdown alarm continues to operate even when Protections Disabled has been activated. Under Shutdown or Electrical Trip alarm conditions (excluding Emergency Stop): – The alarm is displayed on the screen as detailed in the section entitled Shutdown alarms elsewhere in this document. – The set continues to run. – The load switch maintains its current position (it is not opened if already closed) – Shutdown Blocked also appears on the LCD screen to inform the operator that the Protections Disabled feature has blocked the shutdown of the engine under the normally critical fault. – The ‘shutdown’ alarm is logged by the controllers Event Log (if configured to log shutdown alarms) and logs that the Shutdown was prevented.

142

9813/2550-1

142

DSE Model 8610 and 8620 AMF Controller Protections CAN Alarms Note: Please refer to the engine manufacturer’s documentation for Can error message information.

CAN alarms are messages sent from the CAN ECU to the DSE controller and displayed as follows in the below tables.

Display

Reason

CAN ECU Warning

The engine ECU has detected a warning alarm and has informed the DSE module of this situation. The exact error is also indicated on the module’s display and action taken depending upon the setting for the DM1 signals

ECU Shutdown

The engine ECU has detected a shutdown alarm and has informed the DSE module of this situation. The exact error is also indicated on the module’s display.

ECU Data Fail

The module is configured for CAN operation and does not detect data on the engine CAN datalink, the engine shuts down.

DM1 Signals. Messages from the CAN ECU that are configurable within the DSE module for:-

Warning, Electrical Trip, shutdown or None

Display

Reason

Amber Warning

The CAN ECU has detected a Amber warning.

Red Shutdown

The CAN ECU has detected a Red Shutdown.

Malfunction

The CAN ECU has detected a Malfunction message.

Protect

The CAN ECU has detected a Protect message

Advanced CAN alarms Allows configuration of additional can messages from the engine ECU. Display

Reason

Water in Fuel

The ECU has detected water in the fuel action taken is set by settings in advanced

After Treatment

The ECU has detected “After Treatment alarm” consult engine manufacturer for details” action taken by DSE controller is set by settings in advanced

Note: For CAN ECU error code meanings, refer to the ECU documentation provided by the engine manufacturer, or contact the engine manufacturer for further assistance.

143

9813/2550-1

143

DSE Model 8610 and 8620 AMF Controller Protections

Indications

message. However, an output or LED indicator can be configured to draw the operator’s attention to the event.

Indications are non-critical and often status conditions. They do not appear on the LCD of the module as a text

Example

– Input configured for indication. – The LCD text will not appear on the module display but can be added in the configuration to remind the system designer what the input is used for.

– As the input is configured to Indication there is no alarm generated. – LED Indicator to make LED1 illuminate when Digital Input A is active. – The Insert Card Text allows the system designer to print an insert card detailing the LED function. – Sample showing operation of the LED.

144

9813/2550-1

144

DSE Model 8610 and 8620 AMF Controller Protections

Warnings Warnings are non-critical alarm conditions and do not affect the operation of the generator system, they serve to draw the operators attention to an undesirable condition. Example

In the event of an alarm the LCD will jump to the alarms page, and scroll through all active warnings and shutdowns. By default, warning alarms are self-resetting when the fault condition is removed. However enabling ‘all warnings are latched’ will cause warning alarms to latch until reset manually. This is enabled using the 8600 series configuration suite in conjunction with a compatible PC.

Display

Reason

Auxiliary Inputs

If an auxiliary input has been configured as a warning the appropriate LCD message will be displayed and the Common Alarm Led will illuminate.

Charge Failure

The auxiliary charge alternator voltage is low as measured from the W/L terminal.

Battery Under Voltage

The DC supply has fallen below the low volts setting level for the duration of the low battery volts timer

Battery Over Voltage

The DC supply has risen above the high volts setting level for the duration of the high battery volts timer

Fail to Stop

The module has detected a condition that indicates that the engine is running when it has been instructed to stop. Note: ‘Fail to Stop’ could indicate a faulty oil pressure sensor or switch - If the engine is at rest check oil sensor wiring and configuration

Fuel Usage

Indicates the amount of fuel measured by the fuel level sensor is in excess of the Fuel Usage alarm settings. This often indicates a fuel leak or potential fuel theft.

Failed to Synchronise

if the module cannot synchronise within the time allowed by the Synchronising timer a warning is initiated. The LCD will indicate ‘Failed To Sync’ and the Common Alarm Led will illuminate

Auxiliary Inputs

Auxiliary inputs can be user configured and will display the message as written by the user.

Low Fuel Level

The level detected by the fuel level sensor is below the low fuel level setting.

Can ECU Error

The engine ECU has detected a warning alarm and has informed the DSE module of this situation. The exact error is also indicated on the module’s display.

kW Overload

The measured Total kW is above the setting of the kW overload warning alarm

Earth Fault

The measured Earth Fault Current has been in excess of the earth fault trip and has surpassed the IDMT curve of the Earth Fault alarm.

Negative Phase Sequence

Indicates ‘out of balance’ current loading of the generator. Sometimes also called Negative Sequence Current or Symmetry Fault

145

9813/2550-1

145

DSE Model 8610 and 8620 AMF Controller Protections Display

Reason

Maintenance Due

Indicates that the maintenance alarm has triggered. A visit is required by the Generator service company.

Mains Reverse Power

if the 8620 detects that the generator is exporting more than the configured limit, the LCD will indicate ‘Mains Reverse Power’ and the Common Alarm Led will flash

Loading Voltage Not Reached

Indicates that the generator voltage is not above the configured loading voltage. The generator will not take load when the alarm is present after the safety timer.

Loading Frequency Not Reached

Indicates that the generator frequency is not above the configured loading frequency. The generator will not take load when the alarm is present after the safety timer.

Protections Disabled

Shutdown and electrical trip alarms can be disabled by user configuration. In this case, Protections Disabled will appear on the module display; The alarm text is displayed but the engine will continue to run. This is ‘logged’ by the module to allow DSE Technical Staff to check if the protections have been disabled on the module at any time. This feature is available from V4 onwards.

Low Oil Pressure

The module detects that the engine oil pressure has fallen below the low oil pressure pre-alarm setting level after the Safety On timer has expired.

Engine High Temperature

The module detects that the engine coolant temperature has exceeded the high engine temperature pre-alarm setting level after the Safety On timer has expired.

Engine Low Temperature

The module detects that the engine coolant temperature has fallen below the high engine temperature pre-alarm setting level.

Overspeed

The engine speed has risen above the overspeed pre alarm setting

Underspeed

The engine speed has fallen below the underspeed pre alarm setting

Generator Over Frequency

The generator output frequency has risen above the pre-set pre-alarm setting.

Generator Under Frequency

The generator output frequency has fallen below the pre-set pre-alarm setting after the Safety On timer has expired.

Generator Over Voltage

The generator output voltage has risen above the pre-set pre-alarm setting.

Generator Under Voltage

The generator output voltage has fallen below the pre-set pre-alarm setting after the Safety On timer has expired.

Insufficent Capacity

If the generator reach full load when they are in parallel with the mains (utility). The LCD will indicate ‘Insufficient Capacity’ and the Common Alarm Led will illuminate.

Mains Failed to Close

If the mains breaker fails to close, a warning is initiated. The LCD will indicate ‘Mains Failed To Close’ and the Common Alarm Led will illuminate.

Mains Failed to Open

If the mains breaker fails to open, a warning is initiated. The LCD will indicate ‘Mains Failed To Open’ and the Common Alarm Led will illuminate.

ECU Warning

The engine ECU has detected a warning alarm and has informed the DSE module of this situation. The exact error is also indicated on the module’s display.

If the module is configured for, CAN and receives an “error” message from the engine control unit, ‘Can ECU Warning” is shown on the module’s display and a warning alarm is generated.

146

9813/2550-1

146

DSE Model 8610 and 8620 AMF Controller Protections

High Current Warning Alarm GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the preset trip a warning alarm initiates. The module shows Alarm Warning High Current. If this high current condition continues for an excess period, then the alarm escalates to a shutdown condition. For further details of the high current alarm, please see High Current Shutdown Alarm. By default, High Current Warning Alarm is self-resetting when the overcurrent condition is removed. However enabling â&#x20AC;&#x2DC;all warnings are latchedâ&#x20AC;&#x2122; will cause the alarm to latch until reset manually. This is enabled using the 8600 series configuration suite in conjunction with a compatible PC.

147

9813/2550-1

147

DSE Model 8610 and 8620 AMF Controller Protections

Shutdowns Note: Shutdown and Electrical Trip alarms can be disabled by user configuration. See the section entitled Protections Disabled elsewhere in this document. Shutdowns are latching alarms and stop the Generator. Clear the alarm and remove the fault then press Stop/ Reset to reset the module. Note: The alarm condition must be rectified before a reset will take place. If the alarm condition remains, it will not be possible to reset the unit (The exception to this is the Low Oil Pressure alarm and similar ‘active from safety on’ alarms, as the oil pressure will be low with the engine at rest).

Example

Display

Reason

Earth fault

The measured Earth Fault Current has been in excess of the earth fault trip and has surpassed the IDMT curve of the Earth Fault alarm.

Fail to Start

The engine has not fired after the preset number of start attempts

Emergency Stop

The emergency stop button has been depressed. This a fail-safe (normally closed to battery positive) input and will immediately stop the set should the signal be removed. Removal of the battery positive supply from the emergency stop input will also remove DC supply from the Fuel and Start outputs of the controller. Note: The Emergency Stop Positive signal must be present otherwise the unit will shutdown.

Low Oil Pressure

The engine oil pressure has fallen below the low oil pressure trip setting level after the Safety On timer has expired.

Engine High Temperature

The engine coolant temperature has exceeded the high engine temperature trip setting level after the Safety On timer has expired.

Fuel Usage

Indicates the amount of fuel measured by the fuel level sensor is in excess of the Fuel Usage alarm settings. This often indicates a fuel leak or potential fuel theft.

Phase Rotation

The phase rotation is measured as being different to the configured direction.

Overspeed

The engine speed has exceeded the pre-set trip 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 8000 series configuration software manual under heading ‘Overspeed Overshoot’ for details.

Underspeed

The engine speed has fallen below the pre-set trip after the Safety On timer has expired.

Generator Over Frequency

The generator output frequency has risen above the preset level

Generator Under Frequency

The generator output frequency has fallen below the preset level

Generator Over Voltage

The generator output voltage has risen above the preset level

148

9813/2550-1

148

DSE Model 8610 and 8620 AMF Controller Protections Display

Reason

Generator Under Voltage

The generator output voltage has fallen below the preset level

Oil Pressure Sensor Open Circuit

The oil pressure sensor is detected as not being present (open circuit)

Auxiliary Inputs

An active auxiliary input configured as a shutdown will cause the engine to shut down. The display shows the text as configured by the user.

Loss of Speed Signal

The speed signal from the magnetic pick-up is not being received by the DSE controller.

ECU Data Fail

The module is configured for CAN operation and does not detect data on the engine Can datalink, the engine shuts down.

ECU Shutdown

The engine ECU has detected a shutdown alarm and has informed the DSE module of this situation. The exact error is also indicated on the module’s display.

kW Overload

The measured Total kW is above the setting of the kW overload shutdown alarm

Negative Phase Sequence (DSE7000 series V2.0 or above only)

Indicates ‘out of balance’ current loading of the generator. Sometimes also called Negative Sequence Current or Symmetry Fault

Maintenance Due (DSE7000 series V2.1 or above only)

Indicates that the maintenance alarm has triggered. A visit is required by the Generator service company.

Loading Voltage Not Reached

Indicates that the generator voltage is not above the configured loading voltage after the safety timer. The generator will shutdown.

Loading Frequency Not Reached

Indicates that the generator frequency is not above the configured loading frequency after the safety timer. The generator will shutdown.

Protections Disabled

Shutdown and electrical trip alarms can be disabled by user configuration. In this case, Protections Disabled will appear on the module display; The alarm text will be displayed but the engine will continue to run. This is ‘logged’ by the module to allow DSE Technical Staff to check if the protections have been disabled on the module at any time. This feature is available from V4 onwards.

149

9813/2550-1

149

DSE Model 8610 and 8620 AMF Controller Protections

Electrical Trips

Example

Note: Shutdown and Electrical Trip alarms can be disabled by user configuration. See the section entitled Protections Disabled elsewhere in this document. Electrical trips are latching and stop the Generator but in a controlled manner. On initiation of the electrical trip condition the module will de-energise the ‘Close Generator’ Output to remove the load from the generator. Once this has occurred the module will start the Cooling timer and allow the engine to cool off-load before shutting down the engine. The alarm must be accepted and cleared, and the fault removed to reset the module.

Electrical trips are latching alarms and stop the Generator. Remove the fault then press Stop/Reset mode button to reset the module.

Display

Reason

Generator

If a generator output in excess of the high current alarm point, a warning alarm occurs. If this high current condition continues for an excess period, then the alarm escalates to either a shutdown or electrical trip condition (depending upon module configuration). For further details of the high current alarm, please see High Current Shutdown / Electrical Trip Alarm.

Auxiliary Inputs

If an auxiliary input configured as an electrical trip is active, the user configured message shows on the display.

kW Overload

The measured Total kW is above the setting of the kW overload Electrical Trip alarm

Earth Fault

The measured Earth Current is above the setting of the Earth fault alarm.

Failed to Synchronise

If the module cannot synchronise within the time allowed by the Synchronising timer a warning is initiated. The LCD will indicate ‘Failed To Sync’ and the Common Alarm Led will illuminate

Mains Reverse Power

If the module detects a mains reverse power in excess of the pre-set trip level and time delay, an electrical trip is initiated. The LCD will indicate ‘Mains Reverse Power’ and the Common Alarm Led will flash.

Negative Phase Sequence

Indicates ‘out of balance’ current loading of the generator. Sometimes also called Negative Sequence Current or Symmetry Fault

Fuel Usage

Indicates the amount of fuel used is in excess of the Fuel Usage alarm settings. This often indicates a fuel leak or potential fuel theft.

Loading Voltage Not Reached

Indicates that the generator voltage is not above the configured loading voltage after the safety timer. The generator will shutdown.

Loading Frequency Not Reached

Indicates that the generator frequency is not above the configured loading frequency after the safety timer. The generator will shutdown.

Protections Disabled

Shutdown and electrical trip alarms is disabled by user configuration. In this case, Protections Disabled will appear on the module display; The alarm text is displayed but the engine will continue to run. This is ‘logged’ by the module to allow DSE Technical Staff to check if the protections have been disabled on the module at any time. This feature is available from V4 onwards.

Generator Under Frequency

The generator output frequency has fallen below the preset level

Generator Under Voltage

The generator output voltage has fallen below the preset level

150

9813/2550-1

150

DSE Model 8610 and 8620 AMF Controller Protections Display

Reason

Insufficient Voltage

If the module is configured for Mains CT and the load levels are so high that the generator is unable to supply enough load to maintain the configured mains level, insufficient capacity will be displayed and the Common Alarm Led will flash. The generator will provide 100% of its capacity and the loading on the mains will increase.

Underspeed

The engine speed has fallen below the underspeed setting

151

9813/2550-1

151

DSE Model 8610 and 8620 AMF Controller Protections

High Current Shutdown / Electrical Trip Alarm The overcurrent alarm combines a simple warning trip level with a fully functioning IDMT curve for thermal protection.

Immediate Warning If the Immediate Warning is enabled, the DSE8600 Series controller generates a warning alarm as soon as the Trip level is reached. The alarm automatically resets once the generator loading current falls below the Trip level (unless All Warnings are latched is enabled). For further advice, consult your generator supplier.

IDMT Alarm If the IDMT Alarm is enabled, the DSE8600 Series controller begins following the IDMT ‘curve’ when the trip level is passed. If the Trip is surpassed for an excess amount of time the IDMT Alarm triggers (Shutdown or Electric trip as selected in Action). High current shutdown is a latching alarm and stops the Generator. Remove the fault then press Stop/Reset mode button to reset the module. High current electrical trip is a latching alarm and removes the generator from the load, before topping the Generator after the off load cooling timer. Remove the fault then press Stop/Reset mode button to reset the module.

IT (Trip setting)

t (time multiplier)

These settings provide for normal running of the generator up to 100% full load. If full load is surpassed, the Immediate Warning alarm is triggered, the set continues to run. The effect of an overload on the generator is that the alternator windings begin to overheat; the aim of the IDMT alarm is to prevent the windings being overload (heated) too much. The amount of time that the set can be safely overloaded is governed by how high the overload condition is. With typical settings as above, the tripping curve is followed as shown below. This allows for overload of the set to the limits of the Typical Brushless Alternator whereby 110% overload is permitted for 1 hour. If the set load reduces, the controller then follows a cooling curve. This means that a second overload condition may trip much sooner than the first as the controller knows if the windings have not cooled sufficiently.

The higher the overload, the faster the trip. The speed of the trip is dependent upon the fixed formula: T = t / ( ( IA / IT ) – 1 ) ² Factory settings for the IDMT Alarm when used on a brushless alternator are as follows (screen capture from the DSE Configuration Suite PC software:

152

9813/2550-1

152

DSE Model 8610 and 8620 AMF Controller Protections

P033120-36

Fig 9. For further details on the Thermal damage curve of your alternator, you are referred to your alternator manufacturer and generator supplier.

153

9813/2550-1

153

DSE Model 8610 and 8620 AMF Controller Protections

Earth Fault Shutdown / Electrical Trip Alarm When the module is suitably connected using the ‘Earth Fault CT’. The module measures Earth Fault and can optionally be configured to generate an alarm condition (shutdown or electrical trip) when a specified level is surpassed. If the Earth Fault alarm is enabled, the controller begins following the IDMT ‘curve’. If the Trip is surpassed for an excess amount of time the Alarm triggers (Shutdown or Electric trip as selected in Action). The higher the Earth Fault, the faster the trip. The speed of the trip is dependent upon the fixed formula:

T = K x 0.14 / ( ( I / Is)0.02 -1 ) Where: T is the tripping time in seconds (accurate to +/5% or +/- 50ms (whichever is the greater) K is the time multiplier setting I is the actual earth current measured Is is the trip setting value The settings shown in the example above are a screen capture of the DSE factory settings, taken from the DSE Configuration Suite software.

154

9813/2550-1

154

DSE Model 8610 and 8620 AMF Controller Protections

Short Circuit Alarm If the Short Circuit alarm is enabled, the DSE 8610 and 8620 controller begins following the IDMT â&#x20AC;&#x2DC;curveâ&#x20AC;&#x2122;. If the Trip is surpassed for an excess amount of time the Alarm triggers (Shutdown or Electrical trip as selected in Action). The higher the Short Circuit, the faster the trip. The speed of the trip is dependent upon the fixed formula:

155

9813/2550-1

155

DSE Model 8610 and 8620 AMF Controller Protections

Rocof/Vector Shift (DSE 8620 Only)

of DSE support.

When configured to run in parallel with the mains (utility) supply, the module monitors for ROCOF / Vector shift trips according to the module’s configuration settings. This is included within the module and will detect failure of the mains supply during parallel operation with the generator. Note: This protection operates only when in parallel with the mains supply and is disabled at all other times. Should either of these alarms operate, the module will perform either a controlled shutdown (electrical trip) of the generator or will instigate the mains failure function. This operation must be manually reset: 1

Press Stop mode button. The engine will stop if it is still running and the alarm is cleared.

Activate digital input configured to “Clear ROCOF/ Vector shift” if this has been provided.

Press Test and Selection button together and hold for 5 seconds. The ROCOF/Vector shift instrument is displayed and all ‘peak hold’ values are reset, clearing the ROCOF/Vector shift alarm.

For details on activating and configuring the ROCOF/ Vector shift protection you are referred to the DSE 8610 and 8620 software manual.

Mains Decoupling Test Mode (DSE 8620 Only) To aid the testing of the mains decoupling features in the controller, a special test mode is included. This is activated by placing the module into STOP mode and enabling the ‘test mode’ in the module’s front panel ‘running editor’, described elsewhere in this document. This allows a ‘one shot’ test of the mains decoupling protection, enabling the Test Engineer to inject the necessary test signals into the DSE control and timing the reaction from application of the signal to activation of a DSE output configured to ‘combined mains decoupling’. The actual testing of mains decoupling must be left to experienced engineers and is outside the scope

156

9813/2550-1

156

DSE Model 8610 and 8620 AMF Controller Scheduler

Scheduler DSE8600 Series contains an inbuilt exercise run scheduler, capable of automatically starting and stopping the set. Up to 16 scheduled start/stop sequences can be configured to repeat on a 7-day or 28-day cycle. Scheduled runs may be on load or off load depending upon module configuration. Example

However, if the module is moved into Auto mode during a scheduled run, the engine will be called to start. – Depending upon configuration by the system designer, an external input can be used to inhibit a scheduled run. – If the engine is running OFF LOAD in AUTO mode and a scheduled run configured to ‘On Load’ begins, the set is placed ON LOAD for the duration of the Schedule.

Screen capture from DSE Configuration Suite Software showing the configuration of the Exercise Scheduler. In this example the set will start at 09:00 on Monday and run for 5 hours, then start at 13:30 on Tuesday and run for 30 minutes.

Stop Mode – Scheduled runs will not occur when the module is in Stop/Reset mode.

Manual Mode – Scheduled runs will not occur when the module is in Manual mode. – Activation of a Scheduled Run On Load when the module is operating Off Load in Manual mode will have no effect, the set continues to run Off Load

Auto Mode – Scheduled runs will operate Only if the module is in Auto mode with no Shutdown or Electrical Trip alarm present. – If the module is in Stop or Manual mode when a scheduled run begins, the engine will not be started.

157

9813/2550-1

157

DSE Model 8610 and 8620 AMF Controller Synchroscope Operation

Synchroscope Operation Initial stage of Synchronising display will only show the difference between the Mains Supply and the Generator Output. Here the display is showing a frequency mismatch of +2.9Hz The genset frequency is too high (indicated by the arrow) and should be reduced. The voltage is +0.2 volts high, but is within the limits set for synchronising. Once the difference between the Mains and the Generator frequency has been reduced, the ‘Synchroscope’ display will become active. The moving bar will roll from one side to the other showing the phase of the two supplies. The area in the centre of the scope indicates the set limits for synchronising to occur. Synchronising will only occur when both the Frequency and the voltage differences are within acceptable limits - Indicated by ‘Tick’ marks on the top of the display. Then the moving bar display will show the phase difference. The engine speed will be automatically adjusted, altering the phase, until the moving bar enters the centre of the scope. Once the Mains and generator supplies are synchronised, the module will initiate a breaker close signal to load the generator onto the Mains. Should synchronism be broken the moving bar will pass out of the synchronising window.

Note: If the module display is showing the status page when the synchronising process begins, the module will automatically switch to the Synchroscope page. The ramp progress will also be displayed on the screen once paralleling has taken place.

158

9813/2550-1

158

DSE Model 8610 and 8620 AMF Controller Commissioning

Commissioning Commissioning Screens Commissioning screens are available to both aid the commissioning process and also to give additional

information about the synchronising and load sharing process. These screens can be enabled and disabled in the moduleâ&#x20AC;&#x2122;s display editor.

Screen 1 Average L-L Voltage and total kW Load on the set(s) and total kVAr Ramp level and % of full load kW Gov and Avr % of Drive

Screen 2 Target % and total kW Target % and total kVAr Ramp level and % of full load kW Gov and Avr % of Drive

Screen 3 Generator L1 and Mains L1 Generator Power factor and Mains Power factor Generator kW and Mains kW Generator kVAr and Mains kW

Screen 4 Mains Target and mains actual kW Mains Target and mains actual kW Power factor Ramp rate Governor Avr

Note: Some of the items may be removed from the commissioning screens if they are not applicable to the module configuration.

159

9813/2550-1

159

DSE Model 8610 and 8620 AMF Controller Front Control Configuration

Front Control Configuration This configuration mode allows the operator limited customising of the way the module operates.

Use the moduleâ&#x20AC;&#x2122;s navigation buttons to traverse the menu and make value changes to the parameters:

P033120-47

Fig 10. 1

Increase value/next time

Decrease value/next time

160

Accessing The Main Front Panel Configuration Editor

9813/2550-1

160

DSE Model 8610 and 8620 AMF Controller Front Control Configuration Ensure the engine is at rest and the module is in Stop mode by pressing the Stop/Reset button. Press the Stop/Reset and Info buttons simultaneously. If a module security PIN has been set, the PIN number request is then shown: Press Info, the first ‘#’ changes to ‘0’. Press (Up or Down) to adjust it to the correct value. Press (Right) when the first digit is correctly entered. The digit you have just entered will now show ‘#’ for security. Repeat this process for the other digits of the PIN number. You can press (Left) if you need to move back to adjust one of the previous digits.

When is pressed after editing the final PIN digit, the PIN is checked for validity. If the number is not correct, you must re-enter the PIN. If the PIN has been successfully entered (or the module PIN has not been enabled), the editor is displayed: Note: The PIN number is not set by DSE when the module leaves the factory. If the module has a PIN code set, this has been affected by your generator supplier who should be contacted if you require the code. If the code has been ‘lost’ or ‘forgotten’, the module must be returned to the DSE factory to have the module’s code removed. A charge will be made for this procedure. NB - This procedure cannot be performed away from the DSE factory.

Editing a Parameter Enter the editor as described above. Description

Icon

Press the (left) or (right) buttons to cycle to the section you wish to view/ change

Press the (up or down) buttons to select the parameter you wish to view/ change within the currently selected section.

To edit the parameter, press to enter edit mode. The parameter begins to flash to indicate that you are editing the value.

161

9813/2550-1

161

DSE Model 8610 and 8620 AMF Controller Front Control Configuration Press the (up or down) buttons to change the parameter to the required value.

Press info to save the value. The parameter ceases flashing to indicate that it has been saved.

To exit the editor at any time, press and hold the Stop/Info button.

Note: The editor automatically exits after 5 minutes of inactivity to ensure security. Note: The PIN number is automatically reset when the editor is exited (manually or automatically) to ensure security. Note: More comprehensive module configuration is possible using the 86xx series PC configuration software. Please contact us for further details.

162

9813/2550-1

162

DSE Model 8610 and 8620 AMF Controller Front Control Configuration

Adjustable Parameters Front Panel Configuration Editor. For descriptions of the parameters, you are referred to The DSE8600 series Configuration Suite Manual, DSE Part 057-119. Section

Parameters as shown on display

Values

Display

Contrast

53%

Language

English, others.

Current Date and Time

hh:mm

LCD Page Timer

Scroll Delay

Engine Pre Heat Timer

Engine Crank Duration

10s

Engine Crank Rest Time

10s

Timers

Mains

Generator

163

Engine Safety On Delay

10s

Engine Smoke Limiting

Engine Smoke Limiting Off

Engine Warm Up Time

Engine Cool Down Time

Engine Speed Overshoot Delay

Engine Failed To Stop

30s

Battery Under Voltage Warning Delay

Battery Over Voltage Warning Delay

Return Delay

30s

Generator Transient Delay

Mains Transient Delay

Mains transfer time

0.7s

Mains Under Voltage Alarm

184V

Mains Over Voltage Alarm

277V

Mains Under Frequency Alarm

45Hz

Mains over Frequency Alarm

55Hz

Mains Transient Delay

CT Primary

600A

CT Secondary

Mains KW Rating

345kW

Mains KVar Rating

258kW

Under Voltage Shutdown

184v

Under Voltage Pre-Alarm

196v

Nominal Voltage

230v

9813/2550-1

163

DSE Model 8610 and 8620 AMF Controller Front Control Configuration Section

Engine

164

Parameters as shown on display

Values

Over Voltage Pre-Alarm

265v

Over Voltage Shutdown

277v

Under Frequency Shutdown

40Hz

Under Frequency Pre-Alarm

42Hz

Nominal frequency

50Hz

Over Frequency Pre-Alarm

54Hz

Over Frequency Shutdown

57Hz

Full Load Rating

500A

kW Overload Trip

100%

Delayed Over current

Active

Delayed Over Current

100%

AC System

3 Phase 4 Wire

CT Primary

600A Power Cycle After Exit

CT Secondary

5A Power Cycle After Exit

Short Circuit Trip

200%

Earth CT Primary

500A

Earth Fault Trip

Active

Earth Fault Trip

10%

Transient Delay

Gen Reverse Power Delay

Full kW rating

345kW

Full kVAr rating

258kVAr

Load Ramp Rate

Gen Reverse Power

35kW

Insufficient Capacity Delay

Insufficient Capacity action

None

Reactive Load CTL mode

VAr fixed export

Load Parallel Power

50%

Load Power Factor

1.00pf 0 KVAr 0%

Oil Pressure Low shutdown

1.03bar

Oil Pressure Low Pre-Alarm

1.24bar

Coolant Temp High Pre-Alarm

90½C

Coolant Temp High Electrical Trip

92½C (When Enabled)

Coolant Temp High Shutdown

95½C

Start Delay Off load

Start Delay on load

Start Delay Telemetry

Pre Heat Timer

9813/2550-1

164

DSE Model 8610 and 8620 AMF Controller Front Control Configuration Section

Schedular

Parameters as shown on display

Values

Crank Duration

10s

Crank rest Time

10s

Safety On Delay

10s

Smoke Limiting

Smoke limiting off

Warm Up Time

Cool Down Time

Speed Overshoot Delay

Speed Overshoot

Fail To Stop Delay

30s

Battery Under Volts Warning

Active

Battery Under Volts Warning Delay

Charge Alternator Failure Shutdown

5s (When Enabled)

Charge Alternator Failure Shutdown

Active, Inactive. Electronic engines only when droop is enabled.

Charge Alternator Shutdown Delay

Active, Inactive

Droop%

Active, Inactive (Only Available When Schedule Is Active)

Scheduler

Weekly, Monthly (Only Available When Scheduler Is Active)

Schedule On Load

Active, Inactive (Only Available When Scheduler Is Active)

Schedule Period

Weekly, Monthly (Only Available When Scheduler Is Active)

Schedule Time & Date Selection (1-16)

Press to begin editing then or when selecting the different parameters in the scheduler.

165

9813/2550-1

165

DSE Model 8610 and 8620 AMF Controller Front Control Configuration

Accessing The ‘running’ Configuration Editor

running while the running editor is entered. Press and hold the button to enter the running editor.

The ‘running’ editor can be entered while the engine is running. All protections remain active if the engine is

Editing A Parameter

Description

Icon

Press the (left) or (right) buttons to cycle to the section you wish to view/ change

Press the (up or down) buttons to select the parameter you wish to view/ change within the currently selected section.

To edit the parameter, press Info to enter edit mode. The parameter begins to flash to indicate that you are editing the value.

Press the (up or down) buttons to change the parameter to the required value.

166

9813/2550-1

166

DSE Model 8610 and 8620 AMF Controller Front Control Configuration Press Info to save the value. The parameter ceases flashing to indicate that it has been saved.

To exit the editor at any time, press and hold the Stop/Info button.

167

9813/2550-1

167

DSE Model 8610 and 8620 AMF Controller Front Control Configuration Adjustable Parameters (Running Editor) Running Editor (Factory default settings are shown in bold italicised text) Section Parameter as shown on display Display

Contrast

Factory Setting 53%

Language

English

Load Demand priority

-1

Load Power factor

0-100% (0)

Load parallel power

0-100% (50)

Enable commissioning screens

Inactive, Active

Override starting alarms

Inactive, Active

Voltage adjust (manual mode only engine running breaker open)

0-100 % (0)

Frequency adjust (manual mode only engine running breaker 0-100 % (0) open) Enable mains decoupling test mode (Stop mode only)

168

9813/2550-1

Inactive Active

168

DSE Model 8610 and 8620 AMF Controller Fault Finding

Fault Finding Sympton

Possible Remedy

Unit is inoperative

Check the battery and wiring to the unit. Check the DC supply. Check the DC fuse.

Read/Write configuration does not operate Unit shuts down

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.

Unit locks out on Emergency Stop

If no Emergency Stop Switch is fitted, ensure that a DC positive signal is connected to the Emergency Stop input. Check emergency stop switch is functioning correctly. Check Wiring is not open circuit.

Intermittent Magnetic Pick-up sensor fault

Ensure that Magnetic pick-up screen only connects to earth at one end, if connected at both ends, this enables the screen to act as an aerial and will pick up random voltages. Check pick-up is correct distance from the flywheel teeth.

Low oil Pressure fault operates after engine has fired

Check engine oil pressure. Check oil pressure switch/sensor and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sensor is compatible with the 73x0 Module and is correctly configured.

High engine temperature fault operates after engine has fired.

Check engine temperature. Check switch/sensor and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sensor is compatible with the 8600 series module.

Shutdown fault operates

Check relevant switch and wiring of fault indicated on LCD display. Check configuration of input.

Warning fault operates

Check relevant switch and wiring of fault indicated on LCD display. Check configuration of input.

Fail to Start is activated after preset Check wiring of fuel solenoid. Check fuel. Check battery supply. Check battery supply number of attempts to start is present on the Fuel output of the module. Check the speed-sensing signal is present on the 8600 series module’s inputs. Refer to engine manual. Continuous starting of generator when in AUTO

Check that there is no signal present on the “Remote Start” input. Check configured polarity is correct.

Generator fails to start on receipt of Check Start Delay timer has timed out. Remote Start signal. Check signal is on “Remote Start” input. Confirm correct configuration of input Check that the oil pressure switch or sensor is indicating low oil pressure to the controller. Depending upon configuration, then set will not start if oil pressure is not low. Pre-heat inoperative

Check wiring to engine heater plugs. Check battery supply. Check battery supply is present on the Pre-heat output of module. Check pre-heat configuration is correct.

Starter motor inoperative

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 Positive. Ensure oil pressure switch or sensor is indicating the “low oil pressure” state to the 8610 series controller.

169

9813/2550-1

169

DSE Model 8610 and 8620 AMF Controller Fault Finding Sympton

Possible Remedy

Engine runs but generator will not take load

Check Warm up timer has timed out. Ensure generator load inhibit signal is not present on the module inputs. Check connections to the switching device. Note that the set will not take load in manual mode unless there is an active remote start on load signal.

Synchronising or load sharing is Follow the DSE “4 Steps To Synchronising” as detailed in the following section. not operating satisfactorily Incorrect reading on Engine gauges Check engine is operating correctly. Check sensor and wiring paying particular Fail to stop alarm when engine is at attention to the wiring to terminal 47 (refer to appendix). Check that sensor is rest compatible with the 8600 series module and that the module configuration is suited to the sensor. Module appears to ‘revert’ to an earlier configuration

When editing a configuration using the PC software it is vital that the configuration is first ‘read’ from the controller before editing it. This edited configuration must then be “written” back to the controller for the changes to take effect. When editing a configuration using the fascia editor, be sure to press the Accept Info button to save the change before moving to another item or exiting the fascia editor

Set will not take load

Ensure the generator available LED is lit Check that the output configuration is correct to drive the load switch device and that all connections are correct. Remember that the set will not take load in manual mode unless a remote start on load input is present or the close generator button is pressed.

Inaccurate generator Check that the CT primary, CT secondary and VT ratio settings are correct for the measurements on controller display application. Check that the CTs are wired correctly with regards to the direction of current flow (p1,p2 and s1,s2) and additionally ensure that CTs are connected to the correct phase (errors will occur if CT1 is connected to phase 2). Remember to consider the power factor. i.e. (kW = kVA x power factor) The 8600 series controller is true RMS measuring so gives more accurate display when compared with an ‘averaging’ meter such as an analogue panel meter or some lower specified digital multimeters. Accuracy of the controller is better than 1% of full scale. I.e. Gen volts full scale is 333V ph-n so accuracy is ±3.33V (1% of 333V). Note: The above fault finding is provided as a guide check-list only. As the module is configurable for a range of different features, always refer to the source of your module configuration if in doubt.

170

9813/2550-1

170

DSE Model 8660 ATS and Mains Controller Introduction This document details the installation and operation requirements of the DSE8660 modules, part of the DSEPower@ range of products.

Using a PC and the Configuration Suite software allows alteration of selected operational sequences, timers and alarms.

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

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.

The DSE8600 series is designed to provide differing levels of functionality across a common platform. This allows the generator OEM greater flexibility in the choice of controller to use for a specific application. The DSE860 module has been designed to monitor the mains (utility) supply and automatically start/stop one ore more generator sets equipped with DSE8610 controllers depending upon the status of the mains (utility) supply. Synchronising and Load Sharing features are included within the controller, along with the necessary for such a system. This provides forward sync, back sync (no break change over) and start/stop upon changing load levels. The user also has the facility to view the system operating parameters via the LCD display. The powerful ARM microprocessor contained within the module allows for incorporation of a range of complex features: – Text based languages).

LCD

display

(supporting

multiple

– True RMS Voltage, Current and Power monitoring. – Fully configurable inputs for use as alarms or a range of different functions. – R.O.C.O.F. and Vector shift for detection of mains failure when in parallel with the mains supply.

171

9813/2550-1

171

DSE Model 8660 ATS and Mains Controller Specifications

Specifications Part Numbering

P033120-55

Fig 1. At the time of this document production, there are no variants of this product.

Short Names Short Name

Description

DSE8600, DSE86xx

All modules in the DSE8600 series

172

9813/2550-1

172

DSE Model 8660 ATS and Mains Controller Installation

Installation The DSE8600 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.

Terminal Description

DC Supply, Fuel and Start Outputs Icon

Pin No.

Description

DC Plant Supply Input 2.5mmÂ˛

(Negative)

(Positive)

173

Not Connected

Cable Size

Notes

AWG 13

9813/2550-1

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

173

DSE Model 8660 ATS and Mains Controller Installation Icon

Pin No.

Description

Cable Size

Notes

Functional Earth

2.5mm²

Connect to good clean earth point

AWG 13

Output relay E

Output relay F

Output relay G

Output relay H

1.0mm²

Plant Supply Positive from terminal 2. 3 Amp rated.

AWG 18 1.0mm²

Plant Supply Positive from terminal 2. 3 Amp rated.

AWG 18 1.0mm²

Plant Supply Positive from terminal 2. 3 Amp rated.

AWG 18 1.0mm²

Plant Supply Positive from terminal 2. 3 Amp rated.

AWG 18

Output relay I

1.0mm²

Plant Supply Positive from terminal 2. 3 Amp rated.

AWG 18

Output relay J

1.0mm²

Plant Supply Positive from terminal 2. 3 Amp rated.

AWG 18

Note: Terminal 14 is not installed to the DSE8600 series controller.

174

9813/2550-1

174

DSE Model 8660 ATS and Mains Controller Installation Magnetic Pick-up, CAN and Expansion Icon

Pin No.

Description

Cable Size

Notes

Not Connected

DSENet expansion +

0.5mm²

Use only 120n RS485 approved cable

DSENet expansion-

0.5mm²

AWG 20 Use only 120n RS485 approved cable

AWG 20 30

DSENet expansion SCR

0.5mm²

Use only 120n RS485 approved cable

AWG 20 31

MultiSet Comms (MSC) Link H

0.5mm²

Use only 120n RS485 approved cable

AWG 20 32

MultiSet Comms (MSC) Link L 0.5mm²

MultiSet Comms (MSC) Link SCR

Use only 120n RS485 approved cable

AWG 20 0.5mm²

Use only 120n RS485 approved cable

AWG 20

175

Not Connected

9813/2550-1

175

DSE Model 8660 ATS and Mains Controller Installation Note: Screened 1200 impedance cable specified for use with CAN must be used for the DSENet link and the Multiset comms (MSC) link. DSE stock and supply Belden cable 9841 which is a high quality 1200 impedance cable suitable for CAN use (DSE part number 016-030)

176

9813/2550-1

176

DSE Model 8660 ATS and Mains Controller Installation Load Switching and mains Voltage Sensing (V1) Icon

Pin No.

Description

Cable Size

Notes

Output relay C

1.0mm

Normally configured to control load switching device

AWG18 (Recommend 10A fuse) 40

Output relay C

Output relay D

1.0mm

Normally configured to control load switching device

AWG18 1.0mm

Normally configured to control load switching device

AWG18 (Recommend 10A fuse) 42

Output relay D

1.0mm

Normally configured to control load switching device

AWG18 43

Mains L1 (R) voltage monitoring

1.0mm

Connect to Mains L 1 (R) incoming supply (AC) (Recommend 2A fuse)

AWG18 44

Mains L2 (S) voltage monitoring

1.0mm

Connect to Mains L 1 (S) incoming supply (AC)

AWG18 (Recommend 2A fuse) 45

Mains L3 (T) voltage monitoring

1.0mm

Connect to Mains L 1 (T) incoming supply (AC)

AWG18 (Recommend 2A fuse) 46

Mains Neutral (N) input

1.0mm

Connect to Mains N incoming supply (AC)

AWG18 Note: The above table describes connections to a three phase, four-wire system. For alternative wiring topologist, please see the ALTERNATIVE AC TOPOLOGIES section of this manual.

177

9813/2550-1

177

DSE Model 8660 ATS and Mains Controller Installation Generator Bus Voltage Sensing (V2) Icon

Pin No.

Description

Cable size

Generator Bus L 1 (U) voltage monitoring 1.0mm²

Notes Connect to Generator Bus L 1 (U) output (AC)

AWG 18 (Recommend 2A fuse) 48

Generator Bus L 1 (V) voltage monitoring 1.0mm²

Connect to Generator Bus L 1 (V) output (AC)

AWG 18 (Recommend 2A fuse) 49

Generator Bus L 1 (W) voltage monitoring 1.0mm²

Connect to Generator Bus L 1 (W) output (AC)

AWG 18 (Recommend 2A fuse) 50

Generator Bus Neutral (N) input

1.0mm²

Connect to Generator Bus Neutral terminal (AC)

AWG 18 Note: The above table describes connections to a three phase, four wire system. For alternative wiring topologist, please see the ALTERNATIVE AC TOPOLOGIES section of this manual.

178

9813/2550-1

178

DSE Model 8660 ATS and Mains Controller Installation Mains Current Transformers CT LABELLING p1, k or K is the primary of the CT that 'points' towards the MAINS 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 (I1, I2, I3) P033120-20

s2 is the secondary of the CT that should be connected with the s2 connections of all the other CTs and connected to the CT common terminal of the DSE8600 series modules.

Icon

Fig 2. 1

CT labelled as p1, k or K

To Load

To Supply

CT labelled as p2, l or L

Pin No.

Description

Cable Size

Notes

CT Secondary for Mains L1

2.5mm²

Connect to s1 secondary of L1 monitoring CT

AWG 13 52

CT Secondary for Mains L2

2.5mm²

Connect to s1 secondary of L2 monitering CT

AWG 13 53

CT Secondary for Mains L3

2.5mm²

Do Not Connect

Comon for CTs connected to 2.5mm² L1, L2, L3 (s2) AWG 13

Connect to s1 secondary of L3 monitering CT

AWG 13 Connect to s2 secondary of L1, L2, L3 monitoring CTs

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

179

9813/2550-1

179

DSE Model 8660 ATS and Mains Controller Installation

Load Current Transformer

the CT. Ensure the CT is rated for the burden of the 8600

Note: Load CT is NOT REQUIRED in a system including only one mains supply (with one 8660 controller). See section below detailing advantages of the load CT in a multiple mains (multiple 8660) system. Note: The 8600 series module has a burden of O.SVA on

Icon

series controller, the cable length 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.

Pin Description No. 56

Cable Size Notes

CT Secondary for Load CT 2.5mmÂ˛

Connect to s1 secondary of Load CT

AWG 13 57

CT Secondary for Load CT 2.5mmÂ˛

Connect to s2 secondary of Load CT

AWG 13

Note: Take care to ensure correct polarity of the CT primary as shown in the previous section. If in doubt, check with the CT supplier.

Advantages of Load CT The load CT is only required when there is more than one DSE8660 on the same system. When the load CT is installed the 8660 transfers the right amount of load to the mains before disconnecting the generator(s), preventing them from being shock loaded. Without the load CT, the 8660 does not know how much load to transfer to the mains when other 8660's are still in island mode. The 8660 would transfer a pre-determined amount of load before disconnecting the generator(s) from the mains. This would lead to there being too much load or not enough load transferred, and the generator(s) would be shock loaded as the generator(s) disconnect from the mains.

180

9813/2550-1

180

DSE Model 8660 ATS and Mains Controller Installation Configurable Digital Inputs Icon

Pin No.

Description

Cable Size Notes

Configurable digital input A

0.5mm²

Switch to negative

AWG 20 61

Configurable digital input B

Configurable digital input C

0.5mm²

Switch to negative

AWG 20 0.5mm²

Switch to negative

AWG 20 63

Configurable digital input D

0.5mm²

Switch to negative

AWG 20 64

Configurable digital input E

0.5mm²

Switch to negative

AWG 20 65

Configurable digital input F

Configurable digital input G

0.5mm²

Switch to negative

AWG 20 0.5mm²

Switch to negative

AWG 20 67

Configurable digital input H

0.5mm²

Switch to negative

AWG 20 68

Configurable digital input I

0.5mm²

Switch to negative

AWG 20 69

Configurable digital input J

Configurable digital input K

0.5mm²

Switch to negative

AWG 20 0.5mm²

Switch to negative

AWG 20

181

9813/2550-1

181

DSE Model 8660 ATS and Mains Controller Installation PC Configuration Interface Connector Icon

Description

Cable Size

Socket for connection to PC software

0.5mmÂ˛ AWG 20

This is a standard USB type A to type B connector.

Note: The USB connection cable between the PC and the DSE8600 series module must not extend beyond 5m (5yds). For distances over 5m, it is possible to use a third party USB extender. Typically, they extend USB up to 50m (yds.). The supply and support of this type of equipment is outside the scope of Deep Sea Electronics PLC.

182

9813/2550-1

182

DSE Model 8660 ATS and Mains Controller Installation Dsenet速 DSENet速 is the communication port between the host controller (DSE86xx series) and the expansion device as shown below. Further details are contained within the Specification section of this document and within the operator manual for the specific expansion module you are connecting to. Note: Screened 1200 impedance cable specified for use with CAN must be used for the DSENet速 (RS485) connection. DSE stock and supply Belden cable 9841 which is a high quality 1200 impedance cable suitable for DSENet速 use (DSE part number 016-030)

P033120-56.jpg

Fig 3.

183

9813/2550-1

183

DSE Model 8660 ATS and Mains Controller Installation Earth Systems Negative Earth The typical wiring diagrams located within this document show connections for a negative earth system (the battery negative connects to Earth) Positive Earth When using a DSE module with a Positive Earth System (the battery positive connects to Earth), the following points must be followed: â&#x20AC;&#x201C; Follow the typical wiring diagram as normal for all sections EXCEPT the earth points â&#x20AC;&#x201C; All points shown as Earth on the typical wiring diagram should connect to BATIERY NEGATIVE (not earth).

184

9813/2550-1

184

DSE Model 8660 ATS and Mains Controller Installation

Typical Arrangement of DsenetÂŽ Twenty (20) devices can be connected to the DSENetÂŽ, made up of the following devices: Device

Max number supported

DSE2130 Input Expansion

DSE2157 Output Expansion

DSE2548 LED Expansion

Note: DSE8600 series does not support the 2510/2520 display modules.

P033120-57

Fig 4.

185

9813/2550-1

185

DSE Model 8660 ATS and Mains Controller Description of Controls

Description of Controls The following section details the function and meaning of the various controls on the module.

DSE8660 AMF Control Module

Fig 5. 1

Menu navigation buttons

Main status and instrumentation display

Four configurable LEDs

Transfer to Bus (Manual mode only)

186

Start engine(s) (when in manual or test mode)

Mute Alarm/Lamp test

Select Auto mode

Select Test mode

9813/2550-1

186

DSE Model 8660 ATS and Mains Controller Description of Controls 9

Select Manual mode

Select Stop mode

Transfer to Mains (Manual mode only)

Fig 6. 1

Mains available LED. On when the Mains is within limits and able to take load

Close Mains LED. On when the Mains is OnLoad

Close Bus LED. On when the Bus is OnLoad

Bus available LED. On when the generator is within limits and able to take load.

187

Quickstart Guide This section provides a quick start guide to the module's operation.

9813/2550-1

187

DSE Model 8660 ATS and Mains Controller Description of Controls Starting the Engines(s)

P033120-59

Fig 7. 1

Ensure all DSE8610 generator controllers are in the AUTO mode. Then, select Manual mode on the DSE8660

....then press the Start button to crack the engine(s)

Note: For further details, see the section entitled 'OPERATION' elsewhere in this manual.

188

9813/2550-1

188

DSE Model 8660 ATS and Mains Controller Description of Controls Stopping the Engine(s)

P033120-60

Fig 8. 1

With the DSE8610â&#x20AC;&#x2122;s already in the AUTO mode, select Stop/Reset mode on all DSE8660â&#x20AC;&#x2122;s in the system. The generators is stopped.

Note: For further details, see the section entitled 'OPERATION' elsewhere in this manual.

189

9813/2550-1

189

DSE Model 8660 ATS and Mains Controller Description of Controls

Viewing the Instrument pages It is possible to scroll to display the different pages of information by repeatedly operating the next / previous page buttons.

Example Status

Mains

Bus

And so on until the last page is reached. A Further press of the scroll right button returns the display to the Status page.

The complete order and contents of each information page are given in the following sections Once selected the page will remain on the LCD display until the user selects a different page, or after an extended period of inactivity (LCD Page Timer), the module will revert to the status display. If no buttons are pressed upon entering an instrumentation page, the instruments are displayed automatically subject to the setting of the LCD Scroll Timer. The LCD Page and LCD Scroll timers are configurable using the DSE Configuration Suite Software or by using the Front Panel Editor.

To re-enable 'autoscroll' press the scroll buttons to scroll to the 'title' of the instrumentation page (i.e. Engine). A short time later (the duration of the LCD Scroll Timer), the instrumentation display will begin to autoscroll. When scrolling manually, the display will automatically return to the Status page if no buttons are pressed for the duration of the configurable LCD Page Timer. If an alarm becomes active while viewing the status page, the display shows the Alarms page to draw the operator's attention to the alarm condition.

The screenshot shows the factory settings for the timers, taken from the DSE Configuration Suite Software. Alternatively, to scroll manually through all instruments on the currently selected page, press the scroll buttons. The 'autoscroll' is disabled.

190

9813/2550-1

190

DSE Model 8660 ATS and Mains Controller Description of Controls Status

regardless of what pages are configured to be displayed on the 'status' screen.

This is the 'home' page, the page that is displayed when no other page has been selected, and the page that is automatically displayed after a period of inactivity (LCD Page Timer) of the module control buttons. This page is configurable using the DSE Configuration Suite Software. Factory setting of Status screen showing engine stopped ... . .. and engine running The contents of this display may vary depending upon configuration by the generator manufacturer / supplier. The display above was achieved with the factory settings, shown below in the DSE Configuration suite software:

'Stop Mode' etc is displayed on the Home Page

With a summary of the instrumentation shown when the engine is running.

Other pages can be configured to be shown, automatically scrolling when the set is running.

Note: The following sections detail instrumentation pages, accessible using the scroll left and right buttons, regardless of what pages are configured to be displayed on the 'status' screen.

Example 4 - Module RS485 port configured for connection to a modbus master. DSE86xx series modules operate as a modbus RTU slave device. In a mod bus system, there can be only one Master, typically a PLC, HMI system or PC SCADA system. This master requests for information from the modbus slave (DSE86xx series module) and may (in control systems) also send request to change operating modes etc. Unless the Master makes a request, the slave is 'quiet' on the data link. The factory settings are for the module to communicate at 19200 baud, mod bus slave address 10. To use the RS485 port, ensure that 'port usage' is correctly set using the DSE Configuration Suite Software. Required settings are shown below:

'Master inactivity timeout' should be set to at least twice the value of the system scan time. For example if a mod bus master PLC requests data from the DSE86xx modbus slave once per second, the timeout should be set to at least 2 seconds. The DSE Modbus Gencomm document containing register mappings inside the DSE module is available upon request from support@deepseaplc.com. Email your request along with the serial number of your DSE module to ensure the correct information is sent to you. Typical requests (using Pseudo code)

Configurable Status Screens

BatteryVoltage=ReadRegister(10,0405,1) : reads register (hex) 0405 as a single register (battery volts) from slave address 10.

Note: The following sections detail instrumentation pages, accessible using the scroll left and right buttons,

WriteRegister(10,1008,2,35701, 65535-35701) : Puts the module into AUTO mode by writing to (hex) register 1008,

191

9813/2550-1

191

DSE Model 8660 ATS and Mains Controller Description of Controls the values 35701 (auto mode) and register 1009 the value 65535-35701 (the bitwise opposite of auto mode) Warning=(ReadRegister(10,0306,1) >> 11) and 1) : reads (hex) 0306 and looks at bit 12 (Warning alarm present) ElectricalTrip=(ReadRegister(10,0306,1) >> 11) and 1) : reads (hex) 0306 and looks at bit 11 (Electrical Trip alarm present) ControlMode=ReadRegister(10,0304,2)reads(hex) register 0304 (control mode). About Contains important information about the module and the firmware versions. This information may be asked for when contacting DSE Technical Support Department for advice. – Module Type (i.e. 8610, 8660) – Application Version - The version of the module's main firmware file - Updatable using the Firmware Update Wizard in the DSE Configuration Suite Software. – USB ID - unique identifier for PC USB connection – Analogue Measurements software version – Firmware Update Boot loader software version

192

9813/2550-1

192

DSE Model 8660 ATS and Mains Controller Viewing the Event Log

Viewing the Event Log The DSE8600 series modules maintain a log of past alarms and/or selected status changes. The log size has been increased in the module over past module updates and is always subject to change. At the time of writing, the 86xx series log is capable of storing the last 250 log entries.

repeatedly press the next page button until the LCD screen displays the Event log

Under default factory settings, the event log only includes shutdown and electrical trip alarms logged (The event log does not contain Warning alarms), however this is configurable by the system designer using the DSE Configuration Suite software.

This is event 1.

Press down to view the next most recent shutdown alarm:

Example showing the possible configuration of the DSE8600 series event log (DSE Configuration Suite Software) This also shows the factory settings of the module (Only shutdown alarms and the mains status are logged). Once the log is full, any subsequent shutdown alarms will overwrite the oldest entry in the log. Hence, the log will always contain the most recent shutdown alarms. The module logs the alarm, along with the date and time of the event (or engine running hours if configured to do so). If the module is configured and connected to send SMS text

Press down to view the next most recent shutdown alarm: Continuing to press down cycles through the past alarms after which the display shows the most recent alarm and the cycle begins again. To exit the event log and return to viewing the instruments, press the next page button to select the next

To view the Event log:

193

instrumentation page.

9813/2550-1

193

DSE Model 8660 ATS and Mains Controller User Configurable Indicators

User Configurable Indicators These LEDs can be configured by the user to indicate anyone of 100+ different functions based around the following:-

– Indications - Monitoring of a digital input and indicating associated functioning user's equipment Such as Battery Charger On or Louver's Open, etc. – WARNINGS· Specific indication of a particular warning or condition, backed up by LCD indication – Status Indications - Indication of specific functions or sequences derived from the modules operating state - Such as, Panel Locked, Mains Available, etc.

P033120-61

Fig 9.

194

9813/2550-1

194

DSE Model 8660 ATS and Mains Controller User Configurable Indicators 1

195

User configurable LEDs

9813/2550-1

195

DSE Model 8660 ATS and Mains Controller Controls

Controls Stop/Reset

This button places the module into its Stop/Reset mode. This will clear any alarm conditions for which the triggering criteria have been removed. If the engine(s) is(are) running and the module is in Stop mode, the module will automatically instruct the changeover device to unload the generator bus (â&#x20AC;&#x2DC;Close Busâ&#x20AC;&#x2122; becomes inactive (if used)). The start request is taken away. Should a remote start be present while in this mode a remote start will not occur

Manual

This mode allows manual control of the functions. Once in Manual mode the module will respond to the start O button, sending a start request to the engine(s) over the MSC link. If the engine is running off-load in the Manual mode and a remote start signal becomes present, the module will automatically instruct the changeover device to place the generator bus on load (,Close Bus becomes active (if used)). Upon removal of the remote start signal, the generator bus remains on load until either selection of the 'Stop/reset' or 'Auto' modes. For further details, please see the more detailed description of 'Manual operation' elsewhere in this manual.

Auto

This button places the module into its 'Automatic' mode. This mode allows the module to control the function of the system automatically. The module will monitor the remote start input and mains supply status and once a start request is made, the set(s) will be automatically started and placed on load. Upon removal of the starting signal, the module will automatically transfer the load from the generator bus and shut the set(s) down observing the stop delay timer and cooling timer as necessary. The module will then await the next start event. For further details, please see the more detailed description of 'Auto operation' elsewhere in this manual.

Test

This button places the module into its 'Test' mode. This allows an on load test of the generator(s). Once in Test mode the module will respond to the start 0 button, sending a start request to the engine(s) over the MSC link, and run on load, in parallel with the mains supply. For further details, please see the more detailed description of 'Test operation' elsewhere in this manual

Start

This button is only active in TEST ~ or MANUAL @ mode. Pressing this button in manual or test mode will request the engines to start and run off load (manual) or on load (test).

196

9813/2550-1

196

DSE Model 8660 ATS and Mains Controller Controls Mute/Lamp Test

This button silences the audible alarm if it is sounding and illuminates all of the LEDs as a lamp test feature.

Close Mains

This push button is used to control the closure of the mains load switching device and has two modes of operation: 1

Synchronising is Not enabled. Pressing this button when the mains is available off load and in Manual mode, the bus load switch is opened and the mains load switch is closed. Further presses of this button will have no effect.

Synchronising is enabled. Pressing this button when the mains is available and in Manual mode, the 8660 controller, will volts match and synchronise with the Bus. The mains load switch is then closed in parallel with the Bus.

Note: This button is only active in Manual mode. Note: 1f the bus is live when the manual button is pressed, synchronising will take place before the load switch is closed. Close Bus

This push button is used to control the closure of the bus load switching device and has two modes of operation: 1

Synchronising is Not enabled. Pressing this button when the bus is off load and in Manual mode, the mains load switch is opened and the bus load switch is closed. Further presses of this button will have no effect.

Synchronising is enabled. Pressing this button when the bus is live and in Manual mode, the 8660 controller, will volts match and synchronise with the Mains. The bus load switch is then closed in parallel with the mains.

Note: This button is only active in Manual mode. Note: 1f the bus is live when the manual button is pressed, synchronising will take place before the load switch is closed. Menu navigation

Used for navigating the instrumentation, event log and configuration screens. For further details, please see the more detailed description of these items elsewhere in this manual.

197

9813/2550-1

197

DSE Model 8660 ATS and Mains Controller Operation

Operation The following description details the sequences followed by a module containing the standard 'factory configuration'. Remember that if you have purchased a completed generator set or control panel from your supplier, the module's configuration will probably have been changed by them to suit their particular requirements.

Automatic mode Note: If a digital input configured to pane/lock is active, changing module modes will not be possible. Viewing the instruments and event logs is NOT affected by panel lock. Activate auto mode by pressing the e pushbutton. An LED indicator beside the button confirms this action.

Always refer to your configuration source for the exact sequences and timers observed by any particular module in the field.

Auto mode will allow the generator to operate fully automatically, starting and stopping as required with no user intervention.

Alternative Configurations

Waiting in Auto Mode

Depending upon the configuration of your system by the generator supplier, the system may have selectable configurations (for example to select between 50Hz and 60Hz running). If this has been enabled your generator supplier will advise how this selection can be made (usually by externally operated selector switch or by selecting the required configuration file in the DSE8600 series front panel configuration editor).

If a starting request is made, the starting sequence will begin. Starting requests can be from the following sources:

Stop Mode

– Mains supply out of limits – High mains load (when the DSE8660 is configured for an automatic peak lopping system) – Activation of an auxiliary input that has been configured to remote start on load, remote start in island mode or remote start off load. – Activation of an auxiliary input that has been configured to Aux Mains Failure.

Stop mode is activated by pressing the button.

– Activation of the inbuilt exercise scheduler. – Instruction from external remote telemetry devices using the RS232 or RS485 interface.

Starting Sequence In STOP mode, the module will remove the generator bus from load (if necessary) before remove the start request from the engines. Any latched alarms (electrical trip) that have been cleared are reset when STOP mode is entered. The engine will not be started by the DSE8660 when in STOP mode. If remote start signals are given or the mains supply fails, the start request is not sent to the engines until AUTO mode is entered. If Immediate mains dropout is enabled, the mains load switch is opened and closed as appropriate, when the mains fails or becomes available to take load.

198

To allow for 'false' start requests such as mains brownouts, the start delay timer begins. There are individual start delay timers for each of the different start request types. Should all start requests be removed during the start delay timer, the unit will return to a stand-by state. If a start request is still present at the end of the start delay timer, the starting request is sent to the engine(s) over the MSC data link.

Engine Running Once the generator bus becomes available, the load is transferred. If required, the generator bus is first synchronised with the mains supply. This operation is

9813/2550-1

198

DSE Model 8660 ATS and Mains Controller Operation automatic, using the MSC data link. Load ramping takes place when appropriate, the DSE8660 controls the generator(s) bus to provide the configured power to the load and/or mains supply.

Stopping Sequence The return delay timer operates to ensure that the starting request has been permanently removed and is not just a short-term removal.

Bus Mode In this mode, the generator(s) are used to provide a fixed amount of active power (kW), this is configured into the Load parallel power parameter.

If there are no starting requests at the end of the return delay timer, the load is transferred back from the generator bus to the mains supply and the start request is removed from the engine(s).

How much reactive power is provided depends upon the kVAr/pf selection: – KVAr - The generator(s) will provide the number of KVAr configured into the Load Parallel VAr parameter. The power factor is variable in order to achieve this. – Pf - The generator(s) will product power at the power factor configured into the Load power factor parameter. The kVAr is variable in order to achieve this. Mains Mode In this mode, the generator(s) are used to provide a variable amount of active power (kW), to maintain the mains import/export levels at the configured values. This is configured into the Load parallel power parameter. How much reactive power is taken from or exported to the mains depends upon the kVAr/pf selection: – The generator(s) will be used to provide enough kVAr to keep the mains import/export VAr at the level configured into the Load Parallel VAr parameter. The mains power factor is variable in order to achieve this. – The generator(s) will be used to provide enough kVAr to keep the mains import/export at the power factor configured into the Load power factor parameter. The mains kVAr is variable in order to achieve this. As the load increases and decreases, sets may automatically start and stop, depending upon their configuration. If all start requests are removed, the stopping sequence will begin.

199

9813/2550-1

199

DSE Model 8660 ATS and Mains Controller Operation

Manual Mode

– The stop button • is pressed - The set are requested to stop

Note: If a digital input configured to pane/lock is active, changing module modes will not be possible. Viewing the instruments and event logs is NOT affected by panel lock.

– The auto button 9 is pressed. The set will observe all auto mode start requests and stopping timers before beginning the Auto mode stopping sequence.

Waiting in Manual Mode When in manual mode, the set(s) will not start automatically. To begin the starting sequence, press the button.

Engine Running In manual mode, the load is not transferred to the generator bus unless a 'loading request' is made. A loading request can come from a number of sources. – Pressing the transfer to bus ~ button – Mains supply out of limits. – Activation of an auxiliary input that has been configured to remote start on load, remote start in island mode or remote start off load. – Activation of an auxiliary input that has been configured to Aux Mains Failure. – Activation of the inbuilt exercise scheduler if configured for 'on load' runs. Parallel operation is governed by configuration. See the previous section Auto Mode: Engine Running for further details. Once bus and mains are in parallel, you can either – Press the transfer to bus ~ button. The load is ramped to the bus, the mains breaker is opened. – Press the transfer to mains button. The load is transferred to the mains. The generator bus breaker is opened. – Press the auto mode 9 button to return to automatic mode.

Stopping Sequence In manual mode, the set will continue to run until either:

200

9813/2550-1

200

DSE Model 8660 ATS and Mains Controller Operation

Test Mode Note: If a digital input configured to panel lock is active, changing module modes will not be possible. Viewing the instruments and event logs is NOT affected by panel lock. Activate test mode be pressing the ~ push button. An LED indicator beside the button confirms this action. Test mode will start the set(s) and parallel the mains to the generator bus to provide a Test on load function. Depending upon configuration this can be continuous parallel or island mode operation.

Waiting in Test Mode When in test mode, the set will not start automatically. To begin the starting sequence, press the button.

Engine Running Parallel operation is governed by configuration. See the previous section entitled Auto Mode: Engine Running for further details. In test mode, the set will continue to run on load until either: â&#x20AC;&#x201C; The stop button â&#x20AC;˘ is pressed - The generator bus breaker is opened and the set(s) are called to stop. â&#x20AC;&#x201C; The auto button e is pressed. The set(s) will observe all auto mode start requests and stopping timers before beginning the Auto mode stopping sequence.

201

9813/2550-1

201

DSE Model 8660 ATS and Mains Controller Protections

Protections When an alarm is present, the Audible Alarm will sound and the Common alarm LED if configured will illuminate The audible alarm can be silenced by pressing the Mute button The LCD display will jump from the 'Information page' to display the Alarm Page

The type of alarm. E.g. Shutdown or warning

The nature of alarm, e.g. Low oil pressure

The LCD will display multiple alarms. These will automatically scroll in the order that they occurred.

Indications Indications are non-critical and often status conditions. They do not appear on the LCD of the module as a text message. However, an output or LED indicator can be configured to draw the operator's attention to the event. Example

P033120-27

Number of present alarms. This is alarm 1 of a total of 2 present alarms

â&#x20AC;&#x201C; Input configured for indication. â&#x20AC;&#x201C; The LCD text will not appear on the module display but can be added in the configuration to remind the system designer what the input is used for.

202

9813/2550-1

202

DSE Model 8660 ATS and Mains Controller Protections – As the input is configured to Indication there is no alarm generated. – LED Indicator to make LED1 illuminate when Digital Input A is active. – The Insert Card Text allows the system designer to print an insert card detailing the LED function. – Sample showing operation of the LED.

203

9813/2550-1

203

DSE Model 8660 ATS and Mains Controller Protections

Warnings Warnings are non-critical alarm conditions and do not affect the operation of the generator system, they serve to draw the operators attention to an undesirable condition.

In the event of an alarm the LCD will jump to the alarms page, and scroll through all active warnings and shutdowns. By default, warning alarms are self-resetting when the fault condition is removed. However enabling 'all warnings are latched' will cause warning alarms to latch until reset manually. This is enabled using the 8600 series configuration suite in conjunction with a compatible PC.

Display

Reason

Battery Under Voltage

The DC supply has fallen below the low volts setting level for the duration of the low battery volts timer

Battery Over Voltage

The DC supply has risen above the high volts setting level for the duration of the high battery volts timer

Auxiliary Inputs

Auxiliary inputs can be user configured and will display the message as written by the user.

kW Overload

The measured Total kW is above the setting of the kW overload warning alarm

204

9813/2550-1

204

DSE Model 8660 ATS and Mains Controller Protections

Electrical Trips

alarm must be accepted and cleared, and the fault removed to reset the module.

Electrical trips are latching and stop the Generator but in a controlled manner. On initiation of the electrical trip condition the module will de-energise the 'Close Generator' Output to remove the load from the generator. Once this has occurred the start request is removed. The

Electrical trips are latching alarms and stop the Generator(s}. Remove the fault then press Stop/Reset CD to reset the module.

Display

Reason

Auxiliary Inputs

If an auxiliary input configured as an electrical trip is active, the appropriate message will be displayed as configured by the user.

kW Overload

The measured Total kW is above the setting of the kW overload Electrical Trip alarm

Scheduler

Manual Mode

DSE8600 Series contains an inbuilt exercise run scheduler, capable of automatically starting and stopping the set. Up to 16 scheduled start/stop sequences can be configured to repeat on a 7-day or 28-day cycle. Scheduled runs may be on load or off load depending upon module configuration.

– Scheduled runs will not occur when the module is in Manual mode. – Activation of a Scheduled Run 'On Load' when the module is operating Off Load in Manual mode will have no effect, the set continues to run Off Load

Auto Mode Example – Scheduled runs will operate Only if the module is in AUTO mode with no Shutdown or Electrical Trip alarm present. – If the module is in Stop or Manual mode when a scheduled run begins, the engine will not be started. However, if the module is moved into Auto mode during a scheduled run, the engine will be called to start. – Depending upon configuration by the system designer, an external input can be used to inhibit a scheduled run. Screen capture from DSE Configuration Suite Software showing the configuration of the Exercise Scheduler.

– If the engine is running Off Load in Auto mode and a scheduled run configured to 'On Load' begins, the set is placed On Load for the duration of the Schedule.

In this example the set will start at 09:00 on Monday and run for 5 hours, then start at 13:30 on Tuesday and run for 30 minutes.

Stop Mode – Scheduled runs will not occur when the module is in Stop/Reset mode.

205

9813/2550-1

205

DSE Model 8660 ATS and Mains Controller Protections

Front Panel Configuration

Use the module's navigation buttons to traverse the menu and make value changes to the parameters:

This configuration mode allows the operator limited customising of the way the module operates.

P033120-47

Fig 10. 1

Increase value/next time

Decrease value/next time

206

9813/2550-1

206

DSE Model 8660 ATS and Mains Controller Protections

Accessing The Main Front Panel Configuration Editor

Repeat this process for the other digits of the PIN number. You can press (left) if you need to move back to adjust one of the previous digits. When is pressed after editing the final PIN digit, the PIN is checked for validity. If the number is not correct, you must re-enter the PIN. If the PIN has been successfully entered (or the module PIN has not been enabled), the editor is displayed:

Ensure the engine is at rest and the module is in STOP mode by pressing the Stop/Reset button. Press the Stop/Reset and Info buttons simultaneously. If a module security PIN has been set, the PIN number request is then shown: Press, the first ‘#’ changes to ‘0’. Press (up or down) to adjust it to the correct value.

Note: The PIN number is not set by DSE when the module leaves the factory. If the module has a PIN code set, this has been affected by your generator supplier who should be contacted if you require the code. If the code has been 'lost' or 'forgotten', the module must be returned to the DSE factory to have the module's code removed. A charge will be made for this procedure. NB - This procedure cannot be performed away from the DSE factory.

Press (right) when the first digit is correctly entered. The digit you have just entered will now show ‘#’ for security.

Editing A Parameter Description

Icon

Press the (left) or (right) buttons to cycle to the section you wish to view/ change

Press the (up or down) buttons to select the parameter you wish to view/ change within the currently selected section.

207

9813/2550-1

207

DSE Model 8660 ATS and Mains Controller Protections To edit the parameter, press to enter edit mode. The parameter begins to flash to indicate that you are editing the value.

Press the (up or down) buttons to change the parameter to the required value.

Press to save the value. The parameter ceases flashing to indicate that it has been saved.

To exit the editor at any time, press and hold the button.

208

9813/2550-1

208

DSE Model 8660 ATS and Mains Controller Protections Adjustable Parameters Front Panel Configuration Editor Section

Parameter as shown on display

Factory Settings

Display

Contrast

53%

Language

English, others.

Current Date and Time

hh:mm

LCD Page Timer

Timers

Mains

Bus

209

Scroll Delay

Battery Under Voltage Warning Delay

Battery Over Voltage Warning Delay

Start Delay off Load

Start Delay on Load

Start Delay Telemetry

Start Delay Mains Fail

Mains Transient Delay

Return Delay

30s

Mains Transient Time

0.7s

Under Voltage Trip

184v

Over Voltage Trip

276v

Under Frequency Trip

45Hz

Over Frequency Trip

55Hz

CT Primary

600A

CT Secondary

Mains KW Rating

345kw

Mains KVar Rating

258kw

AC system

3 phase 4 wire

Start Delay On Load

Insufficient capacity Delay

Battery Under Volts Warning

Active

Battery Under Volts Warning Delay

Battery Under Volts Warning

10v

Battery Over Volts Warning

Active

Battery Over Volts Warning Del ay

Battery Over Volts warning

30v

Load Level For More Sets

80%

Load Level For Less Sets

70%

Load Ramp Rate

3%/s

9813/2550-1

209

DSE Model 8660 ATS and Mains Controller Protections Section

Parameter as shown on display

Factory Settings

Schedule

Scheduler

Inactive

Schedule Loading On Load

Inactive (Only Available when Scheduler Is Active)

Schedule period

Weekly (Only Available when Scheduler Is Active)

Schedule Time and Date selection (1-16)

Press to begin editing then or when selecting the different parameters in the Scheduler.

210

9813/2550-1

210

DSE Model 8660 ATS and Mains Controller Protections

Accessing the â&#x20AC;&#x2DC;Runningâ&#x20AC;&#x2122; Configuration Editor

Press and hold the 0 button to enter the running editor.

The 'running' editor can be entered while the engine is running. All protections remain active if the engine is running while the running editor is entered.

Editing A Parameter

Description

Icon

Press the (left) or (right) buttons to cycle to the section you wish to view/ change

Press the (up or down) buttons to select the parameter you wish to view/ change within the currently selected section.

To edit the parameter, press to enter edit mode. The parameter begins to flash to indicate that you are editing the value.

Press the (up or down) buttons to change the parameter to the required value.

211

9813/2550-1

211

DSE Model 8660 ATS and Mains Controller Protections Press to save the value. The parameter ceases flashing to indicate that it has been saved.

To exit the editor at any time, press and hold the button.

Adjustable Parameters (Running Editor) Running Editor (Factory default settings are shown in bold italicised text) Section

Parameter as shown on display

Factory Settings

Display

Contrast

53%

212

Language

English

Load parallel power

30%

Load power factor

63%

Commissioning screens

Inactive

Mains decoupling test mode (Stop mode only)

Inactive

Voltage adjust (manual mode only engine running breaker open)

0V L-N

Frequency adjust (manual mode only engine running breaker open)

0Hz

9813/2550-1

212

DSE Model 8660 ATS and Mains Controller Commissioning

Commissioning Pre-Commissioning Before the system is started, it is recommended that the following checks are made:1

The unit is adequately cooled and all the wiring to the module is of a standard and rating compatible with the system.

Check all mechanical parts are installed correctly and that all electrical connections (including earths) are sound. The unit DC supply is fused and connected to the battery and that it is of the correct polarity.

Check the operation of the MSC datalink. Use the DSE Config Suite to check this on the SCADA I BUS I MSC LINK page. Verify the number of sets on the bus.

Ensure all 8610 controllers in the system have been fully commissioned using the DSE "Four Steps to Successful Synchronising".

Place the 8660 module into STOP mode. Place the 8610(s) into AUTO mode. Initiate a start by pressing the START button of the 8660. All 8610's start upon receipt of the MSC start command.

The bus will remain off load so long as the mains supply is healthy and on load.

Press the 8610 STOP button to remove the start request and stop the set(s).

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 and time.

If, despite repeated checking of the connections between the 8600 series controller and the customer's system, satisfactory operation cannot be achieved, then the customer is requested to contact the factory for further advice on:-

213

9813/2550-1

213

DSE Model 8660 ATS and Mains Controller Fault Finding

Fault Finding Symptom

Possible Remedy

Unit is inoperative

Check the battery and wiring to the unit. Check the DC supply. Check the DC fuse.

Read/Write configuration does not operate Unit Shuts down

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.

Continuous starting of generator when in AUTO

Check that there is no signal present on the "Remote Start" input. Check configured polarity is correct. Check the mains supply is available and within configured limits.

Generators fail to start on receipt of Remote Start signal.

Check Start Delay timer has timed out. Check signal is on "Remote Start" input. Confirm correct configuration of input is configured to be used as "Remote Start". Check MSC link operation Check 8660 ATS and 8610 engine controllers are in AUTO mode.

Module appears to 'revert' to an earlier configuration

When editing a configuration using the PC software it is vital that the configuration is first 'read' from the controller before editing it. This edited configuration must then be "written" back to the controller for the changes to take effect. When editing a configuration using the fascia editor, be sure to press the Accept. button to save the change before moving to another item or exiting the fascia editor

Bus will not take load

Ensure the generator available LED is lit Check that the output configuration is correct to drive the load switch device and that all connections are correct. Remember that the set will not take load in manual mode unless the mains supply fails, a remote start on load input is present or the close generator button is pressed.

214

9813/2550-1

214

DSE Model 8660 ATS and Mains Controller Fault Finding Symptom

Possible Remedy

Inaccurate measurements on controller display

Check that the CT primary, CT secondary and VT ratio settings are correct for the application. Check that the CTs are wired correctly with regards to the direction of current flow (p1, p2 and s1, s2) and additionally ensure that CTs are connected to the correct phase (errors will occur if CT1 is connected to phase 2). Remember to consider the power factor. i.e. (kW = kVA x powerfactor) The 8600 series controller is true RMS measuring so gives more accurate display when compared with an 'averaging' meter such as an analogue panel meter or some lower specified digital multimeters. Accuracy of the controller is better than 1% of full scale. I.e. Gen volts full scale is 333V ph-n so accuracy is Âą3.33V (1% of 333V).

Note: The above fault finding is provided as a guide check-list only. As the module can be configured to provide a wide range of different features, always refer to the source of your module configuration if in doubt.

215

9813/2550-1

215