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DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
TABLE OF CONTENTS
Section
Page
INTRODUCTION................................................................................................................................ 5
CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION. ...................................... 6
1.
OPERATION ............................................................................................................................... 7
1.1
CONTROL ........................................................................................................................... 7
FIG 1 .................................................................................................................................... 7
1.2
NORMAL MANUAL OPERATION ....................................................................................... 7
1.3
AUTOMATIC (MAINS FAILURE/REMOTE) OPERATION .................................................. 9
1.4
TEST (SIMULATE MAINS FAILURE) OPERATION.......................................................... 12
2.
PROTECTIONS ........................................................................................................................ 15
VIEWING ALARMS ............................................................................................................... 16
2.1
WARNINGS ....................................................................................................................... 17
2.2
SHUTDOWNS ................................................................................................................... 18
2.3
ELECTRICAL TRIPS ......................................................................................................... 20
2.4
PRE-ALARMS AND OPTIONS .......................................................................................... 20
3.
DESCRIPTION OF CONTROLS............................................................................................... 21
3.1
LCD DISPLAY.................................................................................................................... 21
VIEWING THE INSTRUMENT AND EVENT LOG PAGES.......................................................... 22
SYNCHROSCOPE OPERATION (IF FITTED) ......................................................................... 23
OPERATOR CONFIGURATION MODE....................................................................................... 24
POWER UP LCD DISPLAY.......................................................................................................... 26
3.2 LED INDICATORS.................................................................................................................. 28
3.3 CONTROL PUSH-BUTTONS................................................................................................. 29
3.
INSTALLATION INSTRUCTIONS............................................................................................. 31
3.1
PANEL CUT-OUT .............................................................................................................. 31
FIG 3 .................................................................................................................................. 31
3.2
COOLING........................................................................................................................... 31
3.3
UNIT DIMENSIONS ........................................................................................................... 31
FIG 4 .................................................................................................................................. 31
3.4
FRONT PANEL LAYOUT .................................................................................................. 32
FIG 5 .................................................................................................................................. 32
3.5
REAR PANEL LAYOUT ..................................................................................................... 32
FIG 6 .................................................................................................................................. 32
4.
5.
SPECIFICATION....................................................................................................................... 39
6.
COMMISSIONING .................................................................................................................... 40
6.1 PRE-COMMISSIONING...................................................................................................... 40
7.
8.
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
10.
ICONS AND LED IDENTIFICATION .....................................................................................46
10.1 ICON DESCRIPTIONS .........................................................................................................46
10.2 LED IDENTIFICATION DIAGRAM ........................................................................................47
10.3 SENDER WIRING RECOMMENDATIONS ..........................................................................47
11.
NAVIGATION CHART............................................................................................................49
12.
APPENDIX .............................................................................................................................50
12.1 55X IDMT TRIPPING CURVES (TYPICAL) ......................................................................50
12.2 55X SHORT CIRCUIT TRIPPING CURVES (TYPICAL)................................................51
12.3 USING THE 55X MODULE WITH ACBS .............................................................................52
12.4 OUTPUT EXPANSION..........................................................................................................53
12.4.1 RELAY OUTPUT EXPANSION (157).............................................................................53
12.4.2 LED OUTPUT EXPANSION (548) .................................................................................53
12.5 INPUT EXPANSION..............................................................................................................53
13.
........................................................................................54
......................................................................................54
13.2 AUTO SYNC VERSIONS
13.2.1 GOVERNOR AND AVR CONTROL USING INTERNAL RELAYS DIRECTLY..............55
TYPICAL CONNECTIONS.....................................................................................................55
MODULE CONFIGURATION SETTING FOR 555 AUXILIARY RELAYS .............................55
13.2.2 GOVERNOR AND AVR CONTROL USING INTERNAL RELAYS TO DRIVE
MOTORISED/ELECTRONIC POTENTIOMETER. ...................................................................56
TYPICAL CONNECTIONS.....................................................................................................56
MODULE CONFIGURATION SETTING FOR 555 AUXILIARY RELAYS .............................56
13.2.3 GOVERNOR AND AVR CONTROL USING P122 DIGITAL RESISTANCE MODULES57
TYPICAL CONNECTIONS.....................................................................................................57
13.2.4 DIRECT GOVERNOR CONTROL AND AVR CONTROL USING P122 DIGITAL
RESISTANCE MODULES .........................................................................................................58
TYPICAL CONNECTIONS.....................................................................................................58
MODULE CONFIGURATION SETTING FOR 555 AUXILIARY RELAYS .............................58
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
INTRODUCTION
The DSE 555 Module, has been designed to allow the OEM to meet most of the industrys complex
specifications. It has been primarily designed to allow the user to start and stop the generator, and
if required, transfer the load to the generator either manually or automatically, or in the event of the
module detecting a mains failure. The user also has facility to view all the system operating
parameters via the LCD display.
The DSE 555 module monitors the incoming AC mains supply for under or over voltage/ under or
over frequency and instructs the generating set to start and to supply the load.
The DSE 555 module also monitors the engine, indicating the operational status and fault
conditions; automatically shutting down the engine and giving a true first up fault condition of an
engine failure by a flashing COMMON ALARM LED. Exact failure mode information is indicated by
the LCD display on the front panel.
The powerful 32-Bit Micro-processor contained within the module allows for a range of complex
features to be incorporated as standard;
Selective operational sequences, timers and alarm trips can be altered by the customer via a PC
using the P810 For Windows software and 810 interface
Access to critical operational sequences and timers for use by qualified engineers, are barred by a
security code. Module access is barred by PIN code.
Limited operator selections, such as
display language, can be changed from the module front panel.
The module is housed in a robust plastic case suitable for panel mounting. Connections to the
module are via locking plug and sockets.
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
NOTE:
CAUTION!:
WARNING!:
Deep Sea Electronics Plc owns the copyright to this manual, which
cannot be copied, reproduced or disclosed to a third party without
prior written permission.
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
1.
OPERATION
1.1
CONTROL
Control of the DSE 555 module is via push-buttons mounted on the front of the module with
STOP/RESET, MANUAL, START, AUTO, TEST and ALARM MUTE 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 engine instruments. Details of their operation is detailed
later in this document.
The following descriptions detail the sequences followed by a module containing the standard
factory configuration. Always refer to your configuration source for the exact sequences and
timers observed by any particular module in the field.
i
O
AUTO
FIG 1
1.2
Operation
To initiate a start sequence, press the Manual pushbutton.
The LED above the button will illuminate and the LCD
display will briefly indicate:
Detail
MANUAL MODE
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Operation
The LED above the button will illuminate and the LCD
display will then indicate:
Detail
GENERATOR AT REST
The LED above the button will illuminate and the LCD
display will briefly indicate:
START
PRE-HEATING
CRANKING ATTEMPT.1
00:08
00:09
PRE-HEATING
00:00
FUEL ON
When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from
the Alternator output. Alternatively a Magnetic Pickup mounted on the flywheel housing can be used
for terminating cranking, along with options of Charge alternator voltage and oil pressure.
If a Magnetic Pick-up is utilised it is also possible to configure the module so that if the starter motor
fails to engage on the first attempt, the starter relay will be de-energised and the a second attempt
to engage will be made. For further details on this function please refer to the P810 for Windows
configuration manual.
Operation
Should the engine not fire on the first attempt and the
crank timer expires, the module will rest the starter for
the duration of the crank rest timer.
Once this has expired the module will once again
attempt to start the engine.
Detail
CRANK REST.
00:04
CRANKING ATTEMPT 2
00:07
This will be repeated until either the engine fires or the pre-set number of attempts to start have
been completed
Operation
In this instance the module will indicate a Fail to start
alarm.
Detail
SHUTDOWN
FAILED TO START
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Detail
This timer allows Oil Pressure, High Engine Temperature, Underspeed, Undervolts, Charge Fail
and any delayed Auxiliary fault inputs to stabilise without triggering the fault.
Operation
Once the engine is running and the Safety on timer has
expired, full fault protection is made available.
Detail
GENERATOR AVAILABLE IN
MANUAL
Pressing the STOP/RESET PUSHBUTTON will deenergise the Fuel Solenoid and bring the engine to rest.
O
The LCD screen will acknowledge the button press
STOP/RESET
While the engine runs down the module will start its Fail
to stop timer.
STOPPING
SHUTDOWN
FAIL TO STOP
GENERATOR AT REST
00:24
NOTE:- The Load Transfer Output will not normally become active during a Manual
start. However, if the Remote Start input is activated once the engine is running then the
Load Transfer Output will be activated and remain active until the engine is stopped.
1.3
Operation
If the module is placed in AUTO mode by pressing the
AUTO PUSHBUTTON, it will monitor the auxiliary
inputs for a REMOTE START signal. In addition the
module will monitor the incoming AC mains supply.
Detail
AUTO
AUTO MODE
GENERATOR AT REST
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Should the REMOTE START signal be detected, or the Mains supply become outside of
acceptable limits, the following sequence will occur
The module will start its Start Delay timer, this is used
START DELAY
to ensure that the start event is really required and not
00:09
just a momentary transient signal.
Once this timer has expired the module will continue with its normal start sequence as detailed
below. Should the remote start signal be removed or the mains return to within limits during either
the start delay timer or pre-heat timer, the module will terminate its start sequence and return to its
standby AUTO state until such time as a start is signalled again.
Operation
If the pre-heat output option is configured, then the preheat timer is then initiated, and the auxiliary output
selected is energised.
After the pre-heat timer has expired the module will deenergise the pre-heat output and commence engine
starting; the following sequence occurs.
The Fuel Solenoid is energised, then after a 1 second
delay the Starter Motor is engaged
The engine is cranked for the duration of the crank timer
Detail
PRE-HEATING
00:09
PRE-HEATING
00:00
FUEL ON
CRANKING ATTEMPT.1
00:06
When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from
the Alternator output. Alternatively a Magnetic Pickup mounted on the flywheel housing can be used
for terminating cranking, along with options of Charge alternator voltage and oil pressure.
If a Magnetic Pick-up is utilised it is also possible to configure the module so that if the starter motor
fails to engage on the first attempt, the starter relay will be de-energised and the a second attempt
to engage will be made. For further details on this function please refer to the P810 For Windows
configuration manual.
Operation
Should the engine not fire on the first attempt and the
crank timer expires, the module will rest the starter for
the duration of the crank rest timer.
Once this has expired the module will once again
attempt to start the engine.
Detail
CRANK REST.
00:04
CRANKING ATTEMPT 2
00:07
This will be repeated until either the engine fires or the pre-set number of attempts to start have
been completed
Operation
In this instance the module will indicate a Fail to start
alarm.
10
Detail
SHUTDOWN
FAIL TO START
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Detail
This timer allows Oil Pressure, High Engine Temperature, Underspeed, Undervolts, Charge Fail
and any delayed Auxiliary fault inputs to stabilise without triggering the fault. Once the engine is
running and the safety on timer has expired, full fault protection is made available.
Operation
Once the generator is running at the correct speed and
up to voltage the Warm-up timer is then initiated
Detail
WARMING UP
00:08
Should the remote start signal be removed or the mains return to within limits during either of the
cranking or warm-up timers, the module will terminate its normal auto start sequence will initialise
its Cooling Timer and eventually return to its standby AUTO state until such time as a start is
signalled again.
Operation
After the warm-up timer has expired the module will
open the mains contactor relay.
After a short transfer delay to allow the mains contactor
to open the generator contactor will close.
Detail
GENERATOR AVAILABLE
IN AUTO
GENERATOR AVAILABLE
The generator in now up and running and is selected to supply the load.
Operation
Should the remote start signal be removed, or the mains
return the module will first initiate a return timer to
ensure that it is safe to stop the generator.
Detail
GENERATOR AVAILABLE
00:06
Should the remote start input become active again or the mains fall outside of acceptable limits
again within this time the module will continue to run the generator on load and ignore the
fluctuating remote start signal or mains supply until such time as it remains in-active for the duration
of the stop delay timer.
Once the return timer has expired, the module will de-energise the Load Transfer output.
Operation
The module will then commence its cooling timer, this
allows the engine to run off load to ensure that it has
adequately cooled before being brought to a standstill.
Once the cooling timer has expired the module will deenergise the fuel solenoid and the engine will be
brought to rest.
If the engine is still running when the Fail to stop Timer
expires the module will alarm.
Should the engine come to rest within the time allow by
the fail to stop timer the screen will revert to
Detail
COOLING DOWN
2:34
STOPPING
00:27
SHUTDOWN
FAIL TO STOP
GENERATOR AT REST
11
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Note:It is possible that the module has been configured to perform regular
exercise runs automatically. This may be used to exercise the engine periodically in
standby applications or to assist in peak-lopping arrangements. Therefore even though
the remote start input is not active and the mains supply is healthy, it is possible that if the
system is in the Auto mode the engine may start unexpectedly if a scheduled run is
configured to occur.
WARNING!:- Before commencing work on the generating set it is important to take
steps to ensure that a scheduled run cannot start the engine unexpected. The system
should at a minimum be taken out of the Auto mode and Stop selected. Depending on
the nature of the work to be performed - further steps to ensure safety while working may
be necessary.
1.4
Operation
To place the module into TEST mode press TEST
PUSHBUTTON. This mode is used to simulate an
automatic start and will start the generator and transfer
the load.
Detail
TEST MODE
GENERATOR AT REST
The LED above the button will illuminate and the LCD
display will briefly indicate:
START
PRE-HEATING
CRANKING ATTEMPT.1
00:08
00:09
PRE-HEATING
00:00
FUEL ON
When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from
the Alternator output. Alternatively a Magnetic Pickup mounted on the flywheel housing can be used
for terminating cranking, along with options of Charge alternator voltage and oil pressure.
If a Magnetic Pick-up is utilised it is also possible to configure the module so that if the starter motor
fails to engage on the first attempt, the starter relay will be de-energised and the a second attempt
to engage will be made. For further details on this function please refer to the 810 configuration
manual.
12
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Operation
Should the engine not fire on the first attempt and the
crank timer expires, the module will rest the starter for
the duration of the crank rest timer.
Once this has expired the module will once again
attempt to start the engine.
Detail
CRANK REST.
00:04
CRANKING ATTEMPT 2
00:07
This will be repeated until either the engine fires or the pre-set number of attempts to start have
been completed
Operation
In this instance the module will indicate a Fail to start
alarm.
Detail
SHUTDOWN
FAIL TO START
Detail
This timer allows Oil Pressure, High Engine Temperature, Underspeed, Undervolts, Charge Fail
and any delayed Auxiliary fault inputs to stabilise without triggering the fault. Once the engine is
running and the safety on timer has expired, full fault protection is made available.
Operation
Once the generator is running at the correct speed and
up to voltage the Warm-up timer is then initiated
Detail
WARMING UP
GENERATOR AVAILABLE IN
MANUAL
00:08
The generator in now up and running and is selected to supply the load. To test the generator
stopping sequence press the Auto pushbutton.
Operation
If the module is placed in AUTO mode by pressing the
AUTO PUSHBUTTON, it will monitor the auxiliary
inputs for a REMOTE START signal. In addition the
module will monitor the incoming AC mains supply.
Detail
AUTO
AUTO MODE
GENERATOR AVAILABLE
00:06
13
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Should the remote start input become active again within this time the module will continue to run
the generator on load and ignore the fluctuating remote start signal until such time as it remains inactive for the duration of the stop delay timer.
Once the return timer has expired, the module will de-energise the Load Transfer output.
Operation
The module will then commence its cooling timer, this
allows the engine to run off load to ensure that it has
adequately cooled before being brought to a standstill.
Once the cooling timer has expired the module will deenergise the fuel solenoid and the engine will be
brought to rest.
If the engine is still running when the Fail to stop Timer
expires the module will alarm.
Should the engine come to rest within the time allow by
the fail to stop timer the screen will revert to
14
Detail
COOLING DOWN
2:34
STOPPING
00:27
SHUTDOWN
FAIL TO STOP
GENERATOR AT REST
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
2.
PROTECTIONS
The module will indicate that an alarm has occurred in several ways;
The Audible Alarm will sound. This can be silenced by
pressing the Mute button
ALARM
SHUTDOWN
LOW OIL PRESSURE
If no alarms are present the LCD will display the following message and will then return to the
Information Display page;
NO ALARM PRESENT
i
The LCD will display multiple alarms E.g. High Engine Temperature shutdown, Emergency Stop
and Low Coolant Warning alarms have been triggered. These will automatically scroll round in
the order that they occurred;
ALARM
SHUTDOWN
HIGH ENGINE TEMP
SHUTDOWN
EMERGENCY STOP
WARNING
LOW COOLANT LEVEL
15
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
>>>>>>> ALARM
Initial display
SHUTDOWN
HIGH ENGINE TEMP
SHUTDOWN
EMERGENCY STOP
WARNING
LOW COOLANT LEVEL
ALARM
WARNING
LOW COOLANT LEVEL
If the module is operating in the normal INFORMATION PAGE display any alarm condition will
automatically be displayed.
Jumps to >>>
i
If the user is viewing instrumentation, e.g.
Then the alarm page will not automatically be
displayed and must be viewed by the operator.
To view an alarm operate the page button to move to
the Alarm page.
16
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
2.1
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.
BATTERY CHARGE FAILURE, if the module does not detect a voltage from the warning light
terminal on the auxiliary charge alternator, the module will display WARNING CHARGE ALT
FAILURE on the LCD. The COMMON ALARM LED will also illuminate.
BATTERY LOW VOLTAGE, if the module detects that the plant DC supply has fallen below the low
volts setting level , the module will display WARNING LOW BATTERY VOLTAGE on the LCD.
The COMMON ALARM LED will also illuminate.
BATTERY HIGH VOLTAGE, if the module detects that the plant DC supply has risen above the
high volts setting level , the module will display WARNING HIGH BATTERY VOLTAGE on the
LCD. The COMMON ALARM LED will also illuminate.
OIL PRESSURE SENDER/SWITCH, the module can be configured to only attempt to crank the
engine if the Oil Pressure is initially low, (engine at rest, not running). The module will display FAIL
TO STOP on the LCD. The COMMON ALARM LED will also illuminate.
LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low
oil pressure pre-alarm level after the Safety On timer has expired, a warning alarm will occur. The
LCD will indicate WARNING LOW OIL PRESSURE and the COMMON ALARM LED will
illuminate.
HIGH ENGINE TEMPERATURE, if the module detects that the engine coolant temperature has
exceeded the high engine temperature pre-alarm level after the Safety On timer has expired, a
warning alarm will occur. The LCD will indicate WARNING HI COOLANT TEMP. and the
COMMON ALARM LED will illuminate.
OVERSPEED, if the engine speed exceeds the pre-alarm level a warning is initiated. The LCD will
indicate WARNING OVERSPEED and the COMMON ALARM LED will illuminate.
UNDERSPEED, if the engine speed falls below the pre-alarm level after the Safety On timer has
expired, a warning alarm is initiated. The LCD will indicate WARNING UNDERSPEED and the
COMMON ALARM LED will illuminate.
GENERATOR HIGH FREQUENCY, if the module detects a generator output frequency in excess
of the pre-alarm level a warning is initiated. The LCD will indicate WARNING GEN HIGH
FREQUENCY and the COMMON ALARM LED will illuminate.
GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the
pre-alarm level after the Safety On timer has expired, a warning is initiated. The LCD will indicate
WARNING GEN LOW FREQUENCY and the COMMON ALARM LED will illuminate.
GENERATOR HIGH VOLTAGE, if the module detects a generator output voltage in excess of the
pre-alarm level a warning is initiated. The LCD will indicate WARNING GEN HIGH VOLTAGE
WARNING and the COMMON ALARM LED will illuminate.
GENERATOR LOW VOLTAGE, if the module detects a generator output voltage below the prealarm level after the Safety On timer has expired, a warning is initiated. The LCD will indicate
WARNING GEN LOW VOLTAGE WARNING and the COMMON ALARM LED will illuminate.
, if the module detects a generator phase rotation error
MAINS PHASE SEQUENCE WRONG
a warning is initiated. The LCD will indicate MAINS PHASE SEQ WRONG and the COMMON
ALARM LED will illuminate.
17
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
2.2
SHUTDOWNS
Shutdowns are latching and stop the Generator. The alarm must be accepted and cleared, and the
fault removed 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 the like, as the oil pressure will be low with the engine at rest).
FAIL TO START, if the engine does not fire after the pre-set number of attempts has been made a
shutdown will be initiated. The LCD will indicate SHUTDOWN FAIL TO START and the COMMON
ALARM and LED will flash.
EMERGENCY STOP, removal of the +ve DC Supply from the Emergency Stop input initiates the
following sequence, firstly it will initiate a controlled shutdown of the Generator and prevent any
attempt to restart the Generator until the Emergency Stop push-button has been reset. Secondly it
removes the +ve DC supply from both the Fuel Solenoid and Starter Solenoid. The LCD will
indicate SHUTDOWN EMERGENCY STOP and the COMMON ALARM LED will flash.
NOTE:- The Emergency Stop +Ve signal must be present otherwise the unit will
shutdown.
LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low
oil pressure trip setting level after the Safety On timer has expired, a shutdown will occur. The
LCD will indicate SHUTDOWN LOW OIL PRESSURE and the COMMON ALARM LED will flash.
HIGH ENGINE TEMPERATURE, if the module detects that the engine coolant temperature has
exceeded the high engine temperature trip setting level after the Safety On timer has expired, a
shutdown will occur. The LCD will indicate SHUTDOWN HIGH COOLANT TEMP and the
COMMON ALARM LED will flash.
OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated. The LCD will
indicate SHUTDOWN OVERSPEED and the COMMON ALARM LED will flash. Overspeed is not
delayed, it is an immediate shutdown.
NOTE:-However 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 P810 for Window Configuration Manual under heading Overspeed
Overshoot for details.
UNDERSPEED, if the engine speed falls below the pre-set trip after the Safety On timer has
expired, a shutdown is initiated. The LCD will indicate SHUTDOWN UNDERSPEED and the
COMMON ALARM LED will flash.
18
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
GENERATOR HIGH FREQUENCY, if the module detects a generator output frequency in excess
of the pre-set trip a shutdown is initiated. The LCD will indicate SHUTDOWN GEN HIGH
FREQUENCY and the COMMON ALARM LED will flash. High frequency is not delayed, it is an
immediate shutdown.
GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the
pre-set trip after the Safety On timer has expired, a shutdown is initiated. The LCD will indicate
GEN LOW FREQUENCY and the COMMON ALARM LED will flash.
GENERATOR HIGH VOLTAGE, if the module detects a generator output voltage in excess of the
pre-set trip a shutdown is initiated. The LCD will indicate GEN HIGH VOLTAGE and the
COMMON ALARM LED will flash. High voltage is not delayed, it is an immediate shutdown.
GENERATOR LOW VOLTAGE, if the module detects a generator output voltage below the pre-set
trip after the Safety On timer has expired, a shutdown is initiated. The LCD will indicate GEN LOW
VOLTAGE and the COMMON ALARM LED will flash.
OIL PRESSURE SENDER OPEN CIRCUIT, if the module detects a loss of signal from the oil
pressure sender (open circuit) a shutdown is initiated. The LCD will indicate OIL PRESS SENDER
FAULT and the COMMON ALARM LED will flash. Sender failure is not delayed, it is an
immediate shutdown.
, if the module detects a generator earth fault current in excess
GENERATOR EARTH FAULT
of the pre-set trip a shutdown is initiated. The LCD will indicate GEN EARTH FAULT and the
COMMON ALARM LED will flash.
, if the module detects a generator phase
GENERATOR PHASE SEQUENCE WRONG
rotation error a shutdown is initiated. The LCD will indicate GEN PHASE SEQ WRONG and the
COMMON ALARM LED will flash.
AUXILIARY INPUTS, if an auxiliary input has been configured as a Shutdown the appropriate LCD
message will be displayed and the COMMON ALARM LED will flash.
19
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
2.3
ELECTRICAL TRIPS
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 Load Transfer 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.
, if the module detects a generator reverse power current in
GENERATOR REVERSE POWER
excess of the pre-set trip a shutdown is initiated. The LCD will indicate GEN REVERSE POWER
and the COMMON ALARM LED will flash.
GENERATOR OVER CURRENT, if the module detects a generator output current in excess of the
pre-set trip a shutdown is initiated. The LCD will indicate GEN OVER CURRENT and the
COMMON ALARM LED will flash.
GENERATOR SHORT CIRCUIT, if the module detects a generator fault current in excess of the
pre-set trip a shutdown is initiated. The LCD will indicate GEN SHORT CIRCUIT and the
COMMON ALARM LED will flash.
AUXILIARY INPUTS, if an auxiliary input has been configured as an Electrical Trip the appropriate
LCD message will be displayed and the COMMON ALARM LED will illuminate.
= Enhanced Instrumentation Versions only
2.4
During module configuration it is possible to select pre-alarm levels for all of the above shutdowns
and electrical trips to give a warning that the trip value is being approached. This allows the
operator to take steps to prevent the shutdown from ultimately occurring by rectifying the triggering
condition.
If the module is fitted with the optional RS232 communication board, then the following alarm is
available:MODEM POWER FAULT, if the module detects a modem supply current in excess of 350mA
warning is initiated. The LCD will indicate MODEM POWER FAULT and the COMMON ALARM
LED will illuminate. The power supply to the modem will be removed until the alarm is reset.
If the module is fitted with the option of Check Sync
following alarm is available:-
or Auto Sync
, then the
FAILED TO SYNCHRONISE, if the module cannot synchronise within the timer allowed by the
Synchronising timer a warning is initiated. The LCD will indicate FAILED TO SYNC and the
COMMON ALARM LED will illuminate.
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DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
3.
DESCRIPTION OF CONTROLS
The following section details the function and meaning of the various controls on the module.
LCD Display
User Configurable
LED's with insert pocket
Up and Down
Scroll Buttons
Operator Configuration
Mode Indicator
Page Select Button
AUTO
Stop/Reset Button
Mains Instruments Page Indicator
Test Mode Button
Generator Instruments Page Indicator
Start Button
INFORMATION PAGE
The LCD display normally indicates the status of the generator such as
GENERATOR AT REST, PRE-HEATING, GENERATOR AVAILABLE, etc.
This is the default display and is always automatically returned to after a pre-set
period of operator inactivity.
ALARM PAGE
The LCD also displays the exact nature of any alarm condition which have
occurred such as SHUTDOWN LOW OIL PRESSURE. This allows very specific
alarm conditions to be brought to the operators attention. Refer to the
Protections section of this manual for details of how to interact with the alarm
page.
ENGINE INSTRUMENTS PAGE
The LCD displays the various engine parameters such as ENGINE SPEED, OIL
PRESSURE, HOURS RUN, etc.
21
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
ENGINE
INSTRUMENTATION
ENGINE SPEED
1503 RPM
ENG OIL PRESSURE
2.5Bar
56psi
COOLANT TEMP
78deg C
105deg f
BATTERY VOLTAGE
24.5 V
CHARGE ALT VOLTAGE
27.5 V
ENGINE RUN TIME
50H 36M
NUMBER OF STARTS
67
NEXT MAINTENANCE
123 HOURS
It is also possible to manually scroll to display the different instruments, once selected the
instrument will remain on the LCD display until the user selects a different instrument or page, or
after a period of inactivity the module will revert to the Information Page.
NOTE:-This description of operation is also true for the other instrument pages and for
viewing the records in the event log.
22
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
If the DOWN button is pressed while the LCD display is showing ENGINE RUN TIME then the
display will jump round to the top of the page and display the page title; ENGINE INSTRUMENTS.
Pressing the DOWN button again will then display; ENGINE SPEED
Hz +2.9
V +0.2
Hz +0.9
V +0.2
Hz -0.2
V +0.2
Hz -0.2
V +0.2
Detail
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 mis-match of +2.9Hz - The gen-set
frequency is too high and should be reduced
(indicated by the arrow). The voltage is +0.2 volts
high, but is within the limits set for synchronising.
Once the difference between the Mains supply and
the Generator output has been reduced the
Synchroscope display will become active. The
moving bar will roll from left to right or right to left
depending on the mis-match between the Mains
supply and the generator output. 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
should be adjusted until the moving bar enters the
centre of the scope.
Once the Mains and the generator are synchronised
the moving bar will be in the centre of the scope and
the bar will be locked into the synchronising window.
While the bar is locked the module will initiate a
breaker close to load the generator onto the Mains.
Should synchronism be broken the moving bar will
pass out of the synchronising window and the
locked indication will clear.
23
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Detail
CONFIGURATION
LANGUAGE
ENGLISH
or
LANGUAGE
FRENCH
LANGUAGE
GERMAN
CONTRAST
o
24
or
or
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Operation
The LCD will then display:
Digital inputs configured as indications can be viewed on
the LCD by pressing the UP or DOWN button when the
Information Page is active. To disable this function
set to NO by pressing the UP or DOWN button.
When correct, to view the next function press the PAGE
button.
Detail
INDICATIONS ON LCD
YES
or
ABANDON CHANGES
AND EXIT
or
The module will then return to the Information Page display and the Operator Configuration
Mode Indicator will extinguish.
25
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
M550 NS 4W
S01 C01 V2.00
S
Code Letter
M
Meaning
Module Type
Options
550 NS 4W
550 CS 4W
550 AS 4W
550 NS 3W
550 CS 3W
550 AS 3W
555 NS 4W
555 CS 4W
555 AS 4W
555 NS 3W
555 CS 3W
555 AS 3W
System Options
Custom Options
00
01
00
01
02
09
10
13
14
26
Detail
Auto-start Module Variant with no Sync option, 4
wire (3ph+N) connection.
Auto-start Module Variant with Check Sync
option, 4 wire (3ph+N) connection.
Auto-start Module Variant with Auto Sync option,
4 wire (3ph+N) connection.
Auto-start Module Variant with out Sync option, 3
wire (3ph) connection.
Auto-start Module Variant with Check Sync
option, 3 wire (3ph) connection.
Auto-start Module Variant with Auto Sync option,
3 wire (3ph) connection.
Automatic Mains Failure Module Variant with no
Sync option, 4 wire (3ph+N) connection.
Automatic Mains Failure Module Variant with
Check Sync option, 4 wire (3ph+N) connection.
Automatic Mains Failure Module Variant with
check Sync option, 4 wire (3ph+N) connection.
Automatic Mains Failure Module Variant with no
Sync option, 3 wire (3ph) connection.
Automatic Mains Failure Module Variant with
check Sync option, 3 wire (3ph) connection.
Automatic Mains Failure Module Variant with Auto
Sync option, 3 wire (3ph) connection.
Basic Metering Version
Enhanced Metering Version
No options fitted
RS232 Comms Board Fitted
RS485 Comms Board Fitted
RS232 Comms Board + Load Share (CAN-bus)
Fitted
RS485 Comms Board + Load Share (CAN-bus)
Fitted
RS232 Comms Board + Load Share (2x CANbus) Fitted
RS485 Comms Board + Load Share(2x CAN-bus)
Fitted
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Code Letter
V
Meaning
Software
Version
Options
X.XX
Detail
Details internal firmware revision (FLASH
Version)
NOTE:Some features are only
available on V2.00 or later modules.
Some feature are only available on
V3.00 or later modules.
27
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
28
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
MANUAL
This push-button is used to allow manual control of the generator
functions. Entering this mode from any other 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 manually 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
change-over device to place the generator on load (Load transfer
becomes active (if used)). 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 manually 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 modules such that the start push-button must be held to
maintain engine cranking.
AUTO
29
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
TEST
This push-button places the module into its Test mode. This mode is
used to test the function and timing of the generator start and load
sequence. The mode is initiated by pressing the Start Button and the
set will be automatically started and placed on load. The set will run on
load continuously. To test the off-loading and stopping sequence return
the set to the Auto mode, 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
Test Operation earlier in this manual.
ALARM MUTE
This push-button is used to silence the internal alarm sounder and also
any external sounder devices fed from the audible alarm output. Any
further alarm conditions will re-active the sounder. Once the alarm has
been muted and investigated it may then be cleared.
Refer to the Protections section of this manual for details.
When the Alarm Mute is operated a Lamp test function will also be
implemented and all LED indicators will be illuminated.
30
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
3.
INSTALLATION INSTRUCTIONS
The model DSE 555 Module has been designed for front panel mounting. Fixing is by 4 spring
loaded clips for easy assembly.
3.1
PANEL CUT-OUT
138.00mm
185.00mm
FIG 3
In conditions of excessive vibration the module should be mounted on suitable anti-vibration
mountings.
3.2
COOLING
The module has been designed to operate over a wide temperature range -30 to +70 C. However
allowances should be made for the temperature rise within the control panel enclosure. Care
should be taken NOT to mount possible heat sources near the module unless adequate ventilation
is provided. The relative humidity inside the control panel enclosure should not exceed 93%.
3.3
UNIT DIMENSIONS
144.0mm
137mm
157
808
CE
185.0mm
110.0mm
192.0mm
Panel Cut-out:138mmx185mm
7.5mm
FIG 4
31
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
3.4
i
O
AUTO
FIG 5
3.5
:
157/548
808
CE
FIG 6
32
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
4.
ELECTRICAL CONNECTIONS
4.1
CONNECTION DETAILS
The following describes the connections and recommended cable sizes to the 3 plugs and sockets
on the rear of the Module. See rear panel layout FIG 5.
PLUG A 13 WAY
PIN
No
1
2
3
4
5
6
7
8
9
10
11
12
13
DESCRIPTION
CABLE
SIZE
2.5mm
NOTES
2.5mm
2.5mm
2.5mm
2.5mm
1.0mm
1.0mm
1.0mm
0.5mm
0.5mm
0.5mm
0.5mm
0.5mm
Switch to -ve
Switch to -ve
Switch to -ve
Switch to -ve
Switch to -ve
PLUG B 17 WAY
PIN
No
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28*
29*
30
DESCRIPTION
Auxiliary Input 6
Auxiliary Input 7
Auxiliary Input 8
Auxiliary Input 9
Auxiliary Output relay 3
Auxiliary Output relay 4
Magnetic Pickup Input (+ve)
Magnetic Pickup Input
(-ve)
Oil Pressure Input
Coolant Temperature Input
Sender Common Return
CT secondary for L1
CT secondary for L2
CT secondary for L3
CT secondary common
Neutral CT secondary
Functional Earth
CABLE
SIZE
NOTES
0.5mm
0.5mm
0.5mm
0.5mm
1.0mm
1.0mm
0.5mm
0.5mm
Switch to -ve
Switch to -ve
Switch to -ve
Switch to -ve
Plant Supply +ve. 5 Amp rated.
Plant Supply +ve. 5 Amp rated.
Connect to Magnetic Pickup device
Connect to Magnetic Pickup device
0.5mm
0.5mm
0.5mm
2.5mm
2.5mm
2.5mm
2.5mm
2.5mm
2.5mm
NOTE**:- If using single terminal sender refer to connection diagram. If using earth
return type senders connect return terminals to pin 24 and earth pin 24.
33
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
PLUG C 4 WAY
PIN
No
31
32
33
34
DESCRIPTION
Generator L1 Voltage
Monitoring Input
Generator L2 Voltage
Monitoring Input
Generator L3 Voltage
Monitoring Input
Generator Neutral Input
CABLE
SIZE
1.0mm
1.0mm
1.0mm
1.0mm
NOTES
Connect to generator L1 output (AC)
(Recommend 2A Fuse Max.)
Connect to generator L2 output (AC)
(Recommend 2A Fuse Max.)
Connect to generator L3 output (AC)
(Recommend 2A Fuse Max.)
Connect to generator Neutral output (AC)
PLUG D 11 WAY
PIN
No
DESCRIPTION
CABLE
SIZE
35
2.5mm
2.5mm
2.5mm
Do not connect.
Connect to mains contactor coil feed supply.
2.5mm
2.5mm
36
37
38
39
40
41
42
43
44
45
1.0mm
1.0mm
1.0mm
1.0mm
NOTES
NOTE:- Screened cable must be used for connecting the Magnetic Pickup, ensuring
that the screen is earthed at one end ONLY.
34
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
4-way connector allows connection to the 157 relay expansion module or 548
LED expansion modules. A maximum of 2 relay or LED expansion modules
may be connected in series to this port.
Auto-sync versions of the 55x can also control the P122 digital
resistance module via this port. These can be fitted in addition the any 157 relay modules required.
See caution note below.
CAUTION!:- Do not connect the 808 configuration interface to this port, as it in not
possible to use the 808 software to configure the 555 module.
CAUTION!:
35
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
4.2
The following describes the functions of the 4 connectors on the rear of the module. See rear panel
layout FIG 5.
PLUG A 13 WAY
PIN
No
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
36
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
PLUG B 17 WAY
PIN
No
DESCRIPTION
14
Auxiliary input 6. This is a negative switched configurable input, see Calibration Manual for
options available. It is possible to configure the input to be a normally closed signal or a
normally open signal.
Auxiliary input 7. This is a negative switched configurable input, see Calibration Manual for
options available. It is possible to configure the input to be a normally closed signal or a
normally open signal.
Auxiliary input 8. This is a negative switched configurable input, see Calibration Manual for
options available. It is possible to configure the input to be a normally closed signal or a
normally open signal.
Auxiliary input 9. This is a negative switched configurable input, see Calibration Manual for
options available. It is possible to configure the input to be a normally closed signal or a
normally open signal.
Auxiliary Relay output 3. Plant Supply +ve. Configurable output, see Calibration Manual for
options available.
Auxiliary Relay output 4. Plant Supply +ve. Configurable output, see Calibration Manual for
options available.
Magnetic Input +ve. An AC signal from the magnetic pickup +ve for speed sensing.
Magnetic Input -ve. An AC signal from the magnetic pickup -ve for speed sensing.
Oil Pressure sensing input. Connect to resistive type oil pressure sender. Refer to
connection diagram for details.
Coolant Temperature sensing input. Connect to resistive type coolant temperature sender.
Refer to connection diagram for details.
Sender Common connection. Return feed from sender units - refer to connection diagram
for details.
Generator L1 current transformer connection.
Generator L2 current transformer connection. If single phase is used do not connect this
pin.
Generator L3 current transformer connection. If single phase is used do not connect this
pin.
Generator current transformer common connection.
Generator current transformer Neutral connection and CT earth connection.
Functional Earth - Ensure connection to a good clean earth point.
15
16
17
18
19
20
21
22
23
24
25
26
27
28*
29*
30
37
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
PLUG C 4 WAY
PIN
No
DESCRIPTION
31
32
33
34
PLUG D 11 WAY
PIN
No
DESCRIPTION
35
Generator Loading Relay, Normally open, Volts free contacts to 36. Used to connect to
Generator contactor or circuit breaker.
Generator Loading Relay , Normally open, Volts free contacts to 35. Used to connect to
Generator contactor or circuit breaker.
DO NOT USE
Mains Loading Relay, Normally Closed Change-over, Volts free contacts to 39 Used to
connect to Mains contactor or circuit breaker.
Mains Loading Relay, Change-over, Volts free contacts to 38 and 40. Used to connect to
Mains contactor or circuit breaker.
Mains Loading Relay, Normally open Change-over, Volts free contacts to 39. Used to
connect to Mains contactor or circuit breaker.
DO NOT USE
Mains L1 sensing input. Connect to Mains L1 supply.
Mains L2 sensing input. Connect to Mains L2 supply. If using single phase only do not
connect this terminal.
Mains L3 sensing input. Connect to Mains L3 supply. If using single phase only do not
connect this terminal.
Mains N sensing input. Connect to Mains N supply.
36
37
38
39
40
41
42
43
44
45
38
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
5.
SPECIFICATION
DC Supply
Cranking Dropouts
Shock
9.0 to 35 V Continuous.
Able to survive 0 V for 50 mS, providing supply was at least
10 V before dropout and supply recovers to 5V .This is
achieved without the need for internal batteries.
513mA at 12 V. 263 mA at 24 V.
370 mA at 12 V. 210 mA at 24 V
363mA at 12 V. 190 mA at 24 V.
15V - 277(ph-N) 3 Phase 4wire AC (+20%)
50 - 60 Hz at rated engine speed (Minimum 15V AC Ph-N)
+/- 0.5 V to 70 V Peak
10,000 Hz (max) at rated engine speed.
16 Amp DC at supply voltage.
16 Amp DC at supply voltage.
5 Amp DC at supply voltage.
192 X 144 X 138
0 V to 35 V
-30 to +70C
2.5VA
5A
Class 1 Recommended (Basic Instrumentation)
Class 1 Required (Enhanced Instrumentation)
15V - 277(ph-N) 3 Phase 4wire AC (+20%)
50 - 60 Hz (Minimum 15V AC Ph-N)
8 Amp AC RMS rated
BS EN 50081-2 EMC Generic Emission Standard (Industrial)
BS EN 50082-2 EMC Generic Emission Standard (Industrial)
BS EN 60950
BS EN 60068-2-1 to -30 oC
BS EN 60068-2-2 to +70oC
BS2011-2-1 to 93% RH@40oC for 48 Hours
BS EN60068-2-6
10 sweeps at 1 octave/minute in each of 3 major axes.
5Hz to 8Hz @ +/-7.5mm constant displacement
8Hz to 500Hz @ 2gn constant acceleration
BS EN 60068-2-27
3 Half sine shocks in each of 3 major axes
15gn amplitude, 11mS duration
39
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
6.
COMMISSIONING
6.1 PRE-COMMISSIONING
Before the system is started, it is recommended that the following checks are made:6.1. The unit is adequately cooled and all the wiring to the module is of a standard and rating
compatible with the system.
6.2. The unit DC supply is fused and connected to the battery and that it is of the correct polarity.
6.3. The Emergency Stop input is wired to an external normally closed switch connected to DC
positive.
NOTE:- If Emergency Stop feature is not required link this input to the DC Positive. The
module will not operate unless either the Emergency Stop is fitted correctly OR Pin 3 is
connected to DC positive (+ve)
6.1. To check the start cycle operation take appropriate measures to prevent the engine from
starting (disable the operation of the fuel solenoid). After a visual inspection to ensure it is
safe to proceed, connect the battery supply. Press the MANUAL pushbutton, then press
the START pushbutton for a short time. The unit start sequence will commence.
6.2. The starter will engage and operate for the pre-set crank period. After the starter motor has
attempted to start the engine for the pre-set number of attempts the LCD will display
Shutdown Failed to start. Press the STOP/RESET pushbutton to reset the unit.
6.3. Restore the engine to operational status (reconnect the fuel solenoid), again select
MANUAL and operate the START pushbutton, this time the engine should start and the
starter motor should disengage automatically. If not then check that the engine is fully
operational (fuel available, etc.) and that the fuel solenoid is operating. The engine should
now run up to operating speed. If not, and an alarm is present, check the alarm condition for
validity, then check input wiring. The engine should continue to run for an indefinite period. It
will be possible at this time to view the engine and alternator parameters - refer to the
Description of Controls section of this manual.
6.4. Select AUTO on the front panel, the engine will run for the pre-set cooling down period,
then stop. The generator should stay in the standby mode. If not check that there is not a
signal present on the Remote Start input.
6.5. Initiate an automatic start by supplying the remote start signal. The start sequence will
commence and the engine will run up to operational speed. Once the generator is available a
load transfer will take place, the Generator will accept the load. If not, check the wiring to the
Generator Contactor Coil (if used). Check the Warming timer has timed out.
6.6. Remove the remote start signal, the return sequence will start. After the pre-set time period,
the load will be removed from the generator. The generator will then run for the pre-set
cooling down period, then shutdown into its standby mode.
6.7. If despite repeated checking of the connections between the 555 and the customers system,
satisfactory operation cannot be achieved, then the customer is requested to contact the
factory for further advice on:-
40
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
7.
FAULT FINDING
SYMPTOM
Unit is inoperative
Unit shuts down
POSSIBLE REMEDY
Check the battery and wiring to the unit. Check the DC
supply. Check the DC fuse.
Check DC supply voltage is not above 35 Volts or below 9
Volts
Check the operating temperature is not above 55 C.
Check the DC fuse.
If an Emergency Stop Switch is not fitted, ensure that a
positive is connected to the Emergency Stop input. Check
emergency stop switch is functioning correctly. Check
Wiring is not open circuit.
Ensure that Magnetic pick-up screen is only connected at
one end, if connected at both ends this enables the screen
to act as an aerial and will pick up random voltages.
Check engine oil pressure. Check oil pressure
switch/sender and wiring. Check configured polarity (if
applicable) is correct (i.e. Normally Open or Normally
Closed) or that sender is compatible with the 555 Module.
Check engine temperature. Check switch/sender and
wiring. Check configured polarity (if applicable) is correct
(i.e. Normally Open or Normally Closed) or that sender is
compatible with the 555 Module.
Check relevant switch and wiring of fault indicated on LCD
display. Check configuration of input.
Check relevant switch and wiring of fault indicated on LCD
display. Check configuration of input.
Check wiring of fuel solenoid. Check fuel. Check battery
supply. Check battery supply is present on the Fuel output
of the module. Check the speed sensing signal is present
on the 555 inputs. Refer to engine manual.
Check that there is no signal present on the Remote Start
input. Check configured polarity is correct.
Check Start Delay timer has timed out. If remote start fault,
check signal is on Remote Start input. Confirm input is
configured to be used as Remote Start.
Check wiring to engine heater plugs. Check battery supply.
Check battery supply is present on the Pre-heat output of
module. Check pre-heat has been selected in your
configuration.
Check wiring to starter solenoid. Check battery supply.
Check battery supply is present on the Starter output of
module. Ensure that the Emergency Stop input is at +Ve.
Check Warm up timer has timed out. Ensure generator
load inhibit signal is not present on the module inputs.
NOTE:- The above fault finding is provided as a guide check-list only. As it is possible
for the module to be configured to provide a wide range of different features always refer
to the source of your module configuration if in doubt.
41
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
8.
L2
L3
Current
Transformers
ALTERNATOR
MAINS
Generator
Contactor
Mains
Contactor
Electrical Interlock
29 34 33
25 26 27
32
31
36
35
Generator Loading
Relay
38
40 39
Mains Loading
Relay
42
43
44 45
FCC68 - 8 Way
1
22
20 21
24
9 10 11 12 13 14 15 16 17
23
18
19
30
4
Oil
Sender
NOTE:When connected to a
completed Panel / Gen-set
Real-time diagnostic display
is available
5
This Ground connection must be
on the engine block and must
be a sound electrical connection
to the sender bodies.
The wire to Terminal 24 must not
be used to provide a ground
connection to any other device
6
7
8
9
Configurable inputs
42
Temp
Sender
MPU
810
Configuration
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
L2
L3
Current
Transformers
ALTERNATOR
MAINS
Generator
Contactor
Mains
Contactor
Electrical Interlock
28 34 33
25 26 27 29
32
31
36
35
Generator Loading
Relay
38
40 39
Mains Loading
Relay
42
43
44 45
18
19
FCC68 - 8 Way
1
22
20 21
24
9 10 11 12 13 14 15 16 17
23
30
4
Oil
Sender
810
Configuration
Temp
Sender
MPU
NOTE:When connected to a
completed Panel / Gen-set
Real-time diagnostic display
is available
5
This Ground connection must be
on the engine block and must
be a sound electrical connection
to the sender bodies.
The wire to Terminal 24 must not
be used to provide a ground
connection to any other device
6
7
8
9
Configurable inputs
43
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
44
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Mains Settings
Under volts trip
Over volts trip
Under frequency trip
Over frequency trip
Trip Restore
184 V 207 V
276 V 253 V
450 V 480 V
550 V 520 V
45
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Meaning
Stop/Reset
Description
Stop the generator and reset any alarm conditions.
Refer to Section 1 of this Manual.
Start the generator (if in an appropriate mode).
Start
Auto
Alarm Mute
Lamp Test
Manual
Common Alarm
Engine Instruments
46
Generator Instruments
Mains Instruments
Event Log
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
LED2
LED3
LED4
i
O
AUTO
Connection name
Oil pressure
Coolant temperature
Sender common
Terminal
22
23
24
22
24
55x / 560
module
23
NOTE:- . If you use PTFE insulating tape on the sender thread when using earth return
senders, ensure you do not insulate the entire thread as this will prevent the sender body
from being earthed via the engine block.
47
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Connection name
Oil pressure
Coolant temperature
Sender common
Terminal
22
23
24
22
24
55x / 560
module
23
48
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Information Page
Alarm Page
With no Alarm
Engine Speed
1500 RPM
Logged EVENT 1
Alarm Text 1
Oil Pressure
2.5 Bar 56PSI
LOGGED EVENT 2
etc
ALarm Text 2
Etc ....
Coolant Temp
78 Deg C 105 Deg F
Gen L1 L2 L3
A
45 48 43
MAINS
Hz
51.2
Battery Voltage
24.5V
LCD Indication 1
Alarm
LCD Indication 2
LCD Indication 3
No Alarm Present
LCD Indication 4
ETC....
Gen
Hz
51.2
Number of Starts
24
CONFIGURATION Page
LANGUAGE
ENGLISH UK
CONTRAST
instrumentation only
Gen L1 L2 L3
Kw 45 48 43
Gen
KWh 56
Gen Total
KW
47
Gen
KVAH 43
Gen L1 L2 L3
KVA 34 37 33
Gen
KVARH 47
Gen Total
KVA
42
INDICATIONS ON LCD
YES
ABANDON CHANGES
AND EXIT
SAVE CHANGES
AND EXIT
Gen L1 L2 L3
Pf 0.82 0.78 0.84
Hz -0.2
V +0.2
Gen Average
pf 0.82
Gen L1 L2 L3
KVAR 34 37 33
Gen Total
KVAr
37
49
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
12. APPENDIX
12.1 55X IDMT TRIPPING CURVES (TYPICAL)
55x Delayed over-current protection
1000000
100000
10000
1000
100
10
1
1
2
Current as a multiple of the trip-point setting
At default setting of t = 36
50
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
100000
Curve 8200
10000
Detection time in milliseconds
Curve 6800
Curce 5600
Curve 4700
Curve 3900
Curve 3300
Curve 2700
Curve 2200
Curve 1800
Curve 1500
Curve 1200
1000
Curve 1000
100
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
51
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Output 6
Output 5
Closing Supply
Output 3
Output 4
Configure as: Energise - Trip Mains
38
Internal DC Supply
19
Closing Supply
39
55x Module
18
40
DC Slave
Relay
Mains Shunt
Trip Coil
52
Mains Closing
Coil
35
Interlock
Electrical
Tripping Supply
36
Internal DC Supply
UV Coil Supply
DC Slave
Relay
Generator
Closing Coil
Generator
Undervolts Coil
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Refer to technical data sheet on the 157 relay module for further details.
Refer to technical data sheet on the 548 LED module for further details.
It is possible to use a mix of 157 and 548 modules to give both relay and LED expansion if required
(Please refer to our Technical Support department for details.).
53
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
54
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
TYPICAL CONNECTIONS
(See Note 1)
Interposing
Relay
555 Module
Governor
Aux 1
Speed Up
+Ve
Aux 2
(See Note 1)
Interposing
Relay
Speed Down
Aux 3
Aux 4
Actuator
(See Note 1)
Interposing
Relay
AVR
Volts Up
(See Note 1)
Interposing
Relay
Volts Down
To Alternator
Note 1:- Interposing relay should connect to recommended polarity and voltage for
Governor/AVR input. Refer to Governor or AVR manufacturer for details.
55
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
TYPICAL CONNECTIONS
(See Note 1)
Interposing
Relay
555 Module
Potentiometer
Governor
(See Note 2)
Aux 1
Resistance Up
+Ve
Aux 2
(See Note 1)
Interposing
Relay
Resistance Down
Speed Trim
Aux 3
Aux 4
Actuator
(See Note 1)
Interposing
Relay
Potentiometer
(See Note 2)
AVR
Resistance Up
(See Note 1)
Interposing
Relay
Resistance Down
Volts Trim
To Alternator
Note 1:- Interposing relay should connect to recommended polarity and voltage for
potentiometer input. Refer to potentiometer manufacturer for details.
Note 2:- The Potentiometer output should be a suitable resistance as recommended by
the Governor/AVR manufacturer.
56
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
TYPICAL CONNECTIONS
555 Module
Aux 1
+Ve
P122 Digital
Resistance
Governor
AVR
Governor
Speed Trim
Aux 2
To Interface/Exp.
Aux 3
To Controller
Aux 4
Actuator
P122 Digital
Resistance
AVR
AVR
Governor
Volts Trim
To Interface/Exp.
P808 Port on 555
To Controller
To Alternator
57
DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
13.2.4 DIRECT GOVERNOR CONTROL AND AVR CONTROL USING P122 DIGITAL
RESISTANCE MODULES
This scheme uses a mixture of the possible control options from the 55x modules to control the
speed and voltage output via the P122 (Governor and AVR) digital resistance boxes. This method
gives a cost effective solution to interfacing to the Governor and AVR. It is only possible to use this
system of control if the Governor supports speed up/down inputs and the AVR in question supports
voltage control via an external potentiometer.
CAUTION!:- When used in conjunction with the P122 Digital Resistance Modules, only
P157 Relay Expansion modules with Part Number 81xxxxx MUST be used. The digital
resistance requires a different set of data commands to operate and the 55x module will
change the data output by the 808 port to suit the P122 when selected. The older P157
relay modules (Part No. 80xxxxx) will only function if the P122 module is not configured for
use by the 555.
When used in conjunction with the P122 Digital Resistance Modules, only P548 Relay
Expansion modules with Part Number 81xxxxx MUST be used. The digital resistance
requires a different set of data commands to operate and the 55x module will change the
data output by the 808 port to suit the P122 when selected. The older P548 relay modules
(Part No. 80xxxxx) will only function if the P122 module is not configured for use by the 555.
TYPICAL CONNECTIONS
(See Note 1)
Interposing
Relay
555 Module
Governor
Aux 1
Speed Up
+Ve
Aux 2
(See Note 1)
Interposing
Relay
Speed Down
Aux 3
Aux 4
Actuator
P122 Digital
Resistance
AVR
AVR
Governor
Volts Trim
To Interface/Exp.
P808 Port on 555
To Controller
To Alternator
58