DSE4610 DSE4620 Operators Manual
DSE4610 DSE4620 Operators Manual
DSE4610 DSE4620 Operators Manual
Issue
Comments
Initial release
Minimum
Module version
required
Minimum
Configuration
Suite Version
required
V1.0.0
Release 2013.64
Version 1.121.19
Typeface: The typeface used in this document is Arial. Care should be taken not to mistake the upper case letter I with the numeral 1. The
numeral 1 has a top serif to avoid this confusion.
CAUTION!
WARNING!
TABLE OF CONTENTS
Section
1
BIBLIOGRAPHY .............................................................................................. 6
1.1
1.2
1.3
1.4
2
3
Page
INTRODUCTION .............................................................................................. 7
SPECIFICATIONS............................................................................................ 8
3.1
SHORT NAMES.............................................................................................................. 8
3.2
OPERATING TEMPERATURE ....................................................................................... 8
3.3
REQUIREMENTS FOR UL CERTIFICATION ................................................................. 8
3.4
TERMINAL SPECIFICATION ......................................................................................... 9
3.5
POWER SUPPLY REQUIREMENTS .............................................................................. 9
3.5.1
MODULE SUPPLY INSTRUMENTATION DISPLAY ................................................ 9
3.6
VOLTAGE & FREQUENCY SENSING ......................................................................... 10
3.7
CURRENT SENSING .................................................................................................... 10
3.7.1
VA RATING OF THE CTS ...................................................................................... 11
3.7.2
CT POLARITY........................................................................................................ 12
3.7.3
CT PHASING ......................................................................................................... 12
3.7.4
CT CLASS ............................................................................................................. 12
3.8
INPUTS......................................................................................................................... 13
3.8.1
DIGITAL INPUTS ................................................................................................... 13
3.8.2
ANALOGUE INPUTS ............................................................................................. 13
3.8.2.1
OIL PRESSURE .............................................................................................. 13
3.8.2.2
COOLANT TEMPERATURE ........................................................................... 13
3.8.2.3
FUEL LEVEL SENSOR ................................................................................... 14
3.8.2.4
FLEXIBLE SENSOR (WHEN CONFIGURED) ................................................. 14
3.8.3
CHARGE FAIL INPUT ............................................................................................ 14
3.8.4
MAGNETIC PICKUP .............................................................................................. 15
3.9
OUTPUTS..................................................................................................................... 15
3.9.1
DC OUTPUTS A & B (FUEL & START) .................................................................. 15
3.9.2
CONFIGURABLE DC OUTPUTS C & D ................................................................. 15
3.9.3
CONFIGURABLE DC OUTPUTS E & F (DSE4620 ONLY) ..................................... 15
3.10
USB PORT ................................................................................................................ 16
3.10.1 USB PORT USAGE .............................................................................................. 16
3.11
ADDING AN EXTERNAL SOUNDER ........................................................................ 17
3.12
ACCUMULATED INSTRUMENTATION .................................................................... 17
3.13
DIMENSIONS AND MOUNTING ............................................................................... 18
3.13.1 DIMENSIONS ........................................................................................................ 18
3.13.2 PANEL CUTOUT.................................................................................................... 18
3.13.3 WEIGHT ................................................................................................................ 18
3.13.4 FIXING CLIPS ........................................................................................................ 19
3.13.5 SILICON SEALING GASKET ................................................................................. 20
3.13.6 APPLICABLE STANDARDS ................................................................................... 21
3.13.7 ENCLOSURE CLASSIFICATIONS ......................................................................... 23
3.13.7.1 IP CLASSIFICATIONS .................................................................................... 23
3.13.7.2 NEMA CLASSIFICATIONS ............................................................................. 24
INSTALLATION ............................................................................................. 25
4.1
TERMINAL DESCRIPTION .......................................................................................... 25
4.1.1
DC SUPPLY, FUEL AND START OUTPUTS, OUTPUTS C, D, E & F .................... 26
4.1.2
ANALOGUE SENSOR ........................................................................................... 26
4.1.3
CONFIGURABLE DIGITAL INPUTS & MAGNETIC PICKUP.................................. 27
4.1.4
GENERATOR / MAINS VOLTAGE & FREQUENCY SENSING .............................. 27
4.1.5
GENEATOR CURRENT TRANSFORMERS........................................................... 28
4.1.5.1
CT CONNECTIONS ........................................................................................ 28
4.1.6
PC CONFIGURATION INTERFACE CONNECTOR ............................................... 29
4.2
TYPICAL WIRING DIAGRAM ....................................................................................... 30
4.2.1
DSE4610 TYPICAL WIRING DIAGRAM (3 PHASE 4 WIRE) ................................. 31
4.2.2
DSE4620 TYPICAL WIRING DIAGRAM (3 PHASE 4 WIRE) ................................. 32
4.3
ALTERNATE TOPOLOGY WIRING DIAGRAMS ......................................................... 33
4.3.1
GENERATOR ........................................................................................................ 33
4.3.2
MAINS (4620 ONLY) .............................................................................................. 34
4.4
EARTH SYSTEMS........................................................................................................ 35
4.4.1
NEGATIVE EARTH ................................................................................................ 35
4.4.2
POSITIVE EARTH ................................................................................................. 35
4.4.3
FLOATING EARTH ................................................................................................ 35
OPERATION .................................................................................................. 53
6.1
QUICKSTART GUIDE .................................................................................................. 53
6.1.1
STARTING THE ENGINE ...................................................................................... 53
6.1.2
STOPPING THE ENGINE ...................................................................................... 54
6.2
STOP/RESET MODE.................................................................................................... 55
6.3
AUTOMATIC MODE .................................................................................................... 56
6.3.1
WAITING IN AUTO MODE..................................................................................... 56
6.3.2
STARTING SEQUENCE ........................................................................................ 56
6.3.3
ENGINE RUNNING ................................................................................................ 56
6.3.4
STOPPING SEQUENCE ........................................................................................ 57
6.4
MANUAL/START MODE .............................................................................................. 58
6.4.1
WAITING IN MANUAL MODE ................................................................................ 58
6.4.2
STARTING SEQUENCE ........................................................................................ 58
6.4.3
ENGINE RUNNING ................................................................................................ 59
6.4.4
STOPPING SEQUENCE ........................................................................................ 59
6.5
MAINTENANCE ALARM .............................................................................................. 60
6.6
SCHEDULER ................................................................................................................ 61
6.6.1
STOP MODE ......................................................................................................... 61
6.6.2
MANUAL/START MODE ........................................................................................ 61
6.6.3
AUTO MODE ......................................................................................................... 61
COMMISSIONING .......................................................................................... 80
10
STARTING ................................................................................................................... 81
LOADING ..................................................................................................................... 81
ALARMS ....................................................................................................................... 82
INSTRUMENTS ............................................................................................................ 82
MISCELLANEOUS ....................................................................................................... 83
10.1
PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE ............................ 84
10.1.1 PACK OF PLUGS .................................................................................................. 84
10.1.2 INDIVIDUAL PLUGS .............................................................................................. 84
10.2
PURCHASING ADDITIONAL FIXING CLIPS FROM DSE......................................... 84
10.3
PURCHASING ADDITIONAL SEALING GASKET FROM DSE................................. 84
11
WARRANTY................................................................................................ 85
12
DISPOSAL .................................................................................................. 85
12.1
12.2
Bibliography
1 BIBLIOGRAPHY
This document refers to and is referred to by the following DSE publications which can be obtained
from the DSE website: www.deepseaplc.com
1.3 MANUALS
Product manuals are can be downloaded from the DSE website: www.deepseaplc.com
DSE Part
Description
057-201
DSE46xx Configuration Suite PC Software Manual
IEEE Std C37.2-1996 IEEE Standard Electrical Power System Device Function
Numbers and Contact Designations. Institute of Electrical and Electronics Engineers Inc
Diesel generator handbook. L.L.J. Mahon
On-Site Power Generation. EGSA Education Committee.
Introduction
2 INTRODUCTION
This document details the installation and operation requirements of the DSE4610 & DSE4620
modules, part of the DSEGenset range of products.
The manual forms part of the product and should be kept for the entire life of the product. If the
product is passed or supplied to another party, ensure that this document is passed to them for
reference purposes.
This is not a controlled document. You will not be automatically informed of updates. Any future
updates of this document will be included on the DSE website at www.deepseaplc.com
The DSE4xxx 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 DSE46xx series module has been designed to allow the operator to start and stop the generator,
and if required, transfer the load to the generator either manually or automatically. Additionally, the
DSE4620 automatically starts and stops the generator set depending upon the status of the mains
(utility) supply.
The user also has the facility to view the system operating parameters via the LCD display.
The DSE46xx module monitors the engine, indicating the operational status and fault conditions,
automatically shutting down the engine and giving a true first up fault condition of an engine failure
by the LCD display.
The powerful ARM microprocessor contained within the module allows for incorporation of a range of
complex features:
Using a PC and the DSE Configuration Suite software allows alteration of selected operational
sequences, timers, alarms and operational sequences. Additionally, the modules integral front panel
configuration editor allows adjustment of this information.
A robust plastic case designed for front panel mounting houses the module. Connections are via
locking plug and sockets.
Access to critical operational sequences and timers for use by qualified engineers, can be protected
by a security code. Module access can also be protected by PIN code. Selected parameters can be
changed from the modules 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.
Specification
3 SPECIFICATIONS
3.1 SHORT NAMES
Short Name
DSE4000,DSE4xxx
DSE4600,DSE46xx
DSE4610
DSE4620
Description
All modules in the DSE4000 range.
All modules in the DSE4600 range.
DSE4610 module/controller
DSE4620 module/controller
Description
-30C to +70C (-40C to +70C for variants fitted with display heaters)
Conductors
Current Inputs
Communication
Circuits
Output Pilot Duty
Mounting
Operating
Temperature
Storage
Temperature
Specification
Connection Type
3.5.1
8V continuous
Able to survive 0V for 100ms providing the supply was at least
10V before the dropout and recovers to 5V afterwards.
35V continuous (60V protection)
-35V continuous
96mA at12V
85mA at 24V
51mA at 12V
47mA at 24V
35mA at 12V
32mA at 24V
Less than 10A at 12V
Less than 10A at 24V
Range
Resolution
Accuracy
Specification
Phase To Phase
100V AC (max)
1V AC phase to neutral
2V AC phase to phase
1% of full scale phase to neutral
2% of full scale phase to phase
3.5 Hz
75.0 Hz
0.1 Hz
0.2 Hz
10
Specification
3.7.1
The VA burden of the module on the CTs is 0.5VA. However depending upon the type and length of
cabling between the CTs and the module, CTs with a greater VA rating than the module are required.
The distance between the CTs and the
measuring module should be
estimated and cross-referenced
against the chart opposite to find the
VA burden of the cable itself.
If the CTs are fitted within the
alternator top box, the star point
(common) of the CTs should be
connected to system ground (earth) as
close as possible to the CTs. This
minimises the length of cable used to
connect the CTs to the DSE module.
Example.
If 1.5mm cable is used and the
distance from the CT to the measuring
module is 20m, then the burden of the
cable alone is approximately 15VA. As
the burden of the DSE controller is
0.5VA, then a CT with a rating of at
least 15+0.5V = 15.5VA must be used.
If 2.5mm cables are used over the
same distance of 20m, then the
burden of the cable on the CT is
approximately 7VA. CTs required in
this instance is at least 7.5VA (7+0.5).
NOTE: Details for 4mm cables are shown for reference only. The connectors on the DSE
modules are only suitable for cables up to 2.5mm.
11
Specification
3.7.2
CT POLARITY
NOTE: Take care to ensure correct polarity of the CT primary as shown above. If in doubt,
check with the CT supplier.
Take care to ensure the correct polarity of the CTs. Incorrect CT orientation will lead to negative kW
readings when the set is supplying power. Take note that paper stick-on labels on CTs that show the
orientation are often incorrectly placed on the CT (!). It is more reliable to use the labelling in the
case moulding as an indicator to orientation (if available).
To test orientation, run the generator in island mode (not in parallel with any other supply) and load
the generator to around 10% of the set rating. Ensure the DSE module shows positive kW for all
three individual phase readings.
labelled as p2,
l or L
labelled as p1,
k or K
TO GENERATOR
TO LOAD
POLARITY OF CT PRIMARY
3.7.3
CT PHASING
Take particular care that the CTs are connected to the correct phases. For instance, ensure that the
CT on phase 1 is connected to the terminal on the DSE module intended for connection to the CT for
phase 1.
Additionally ensure that the voltage sensing for phase 1 is actually connected to generator phase 1.
Incorrect connection of the phases as described above will result in incorrect power factor (pf)
measurements, which in turn results in incorrect kW measurements.
One way to check for this is to make use of a single-phase load. Place the load on each phase in
turn, run the generator and ensure the kW value appears in the correct phase. For instance if the
load is connected to phase 3, ensure the kW figure appears in phase 3 display and not in the display
for phase 1 or 2.
3.7.4
CT CLASS
Ensure the correct CT type is chosen. For instance if the DSE module is providing overcurrent
protection, ensure the CT is capable of measuring the overload level you wish to protect against, and
at the accuracy level you require.
For instance, this may mean fitting a protection class CT (P10 type) to maintain high accuracy while
the CT is measuring overload currents.
Conversely, if the DSE module is using the CT for instrumentation only (current protection is disabled
or not fitted to the controller), then measurement class CTs can be used. Again, bear in mind the
accuracy you require. The DSE module is accurate to better than 1% of the full-scale current reading.
To maintain this accuracy you should fit Class 0.5 or Class 1 CTs.
You should check with your CT manufacturer for further advice on selecting your CTs
12
Specification
3.8 INPUTS
3.8.1
DIGITAL INPUTS
Number
Arrangement
Low Level Threshold
High Level Threshold
Maximum Input Voltage
Minimum Input Voltage
Contact Wetting Current
Open Circuit Voltage
3.8.2
ANALOGUE INPUTS
13
Specification
3.8.3
Minimum Voltage
Maximum Voltage
Resolution
Accuracy
Excitation
Output Power
Current At 12V
Current At 24V
0V
35V (plant supply)
0.2V
1% of max measured voltage
Active circuit constant power output
2.5W nominal at 12V and 24V
210mA
105mA
The charge fail input is actually a combined input and output. Whenever the generator is required to
run, the terminal provides excitation current to the charge alternator field winding.
When the charge alternator is correctly charging the battery, the voltage of the terminal is close to
the plant battery supply voltage. In a failed charge situation, the voltage of this terminal is pulled
down to a low voltage. It is this drop in voltage that triggers the charge failure alarm. The level at
which this operates and whether this triggers a warning or shutdown alarm is configurable using the
DSE Configuration Suite Software.
14
Specification
3.8.4
MAGNETIC PICKUP
Type
Minimum Voltage
Max Common Mode Voltage
Maximum Voltage
Maximum Frequency
Resolution
Accuracy
Flywheel Teeth
3.9 OUTPUTS
3.9.1
Type
Rating
3.9.2
Type
Rating
3.9.3
Type
Rating
15
Specification
3.10
USB PORT
USB Port
USB 2.0 Device for connection to PC running DSE configuration suite only.
Max distance 6m (18 yards)
DSE46xx Controller
NOTE: The DC supply must be connected to the module for configuration by PC.
NOTE: For further details of module configuration, refer to DSE Publication: 057-201
DSE46xx Configuration Software Manual.
16
Specification
3.11
Should an external alarm or indicator be required, this can be achieved by using the DSE
Configuration Suite PC software to configure an auxiliary output for Audible Alarm, and by
configuring an auxiliary input for Alarm Mute (if required).
The audible alarm output activates and de-activates at the same time as the modules internal
sounder. The Alarm mute input and internal alarm mute button activate in parallel with each other.
Either signal will mute both the internal sounder and audible alarm output.
Example of configuration to achieve external sounder with external alarm mute button:
3.12
ACCUMULATED INSTRUMENTATION
Accumulated Power
(Not available on the DSE46xx-01
variant)
The number of logged Engine Hours and Number of Starts can be set/reset using the DSE
Configuration Suite PC software. Depending upon module configuration, this may have been PIN
number locked by your generator supplier
17
Specification
3.13
3.13.1 DIMENSIONS
140.0mm x 113mm x 43mm
(5.5 x 4.4 x 1.7)
3.13.3 WEIGHT
0.16kg
(0.35lb)
18
Specification
Fixing clip
Fixing clip
fitted to module
19
Specification
Sealing gasket
Gasket fitted
to module
20
Specification
Continued overleaf...
21
Specification
IEEE C37.2
(Standard Electrical
Power System Device
Function Numbers and
Contact Designations)
ContinuedY
50 Instantaneous Overcurrent Relay
52 AC Circuit Breaker
53 Exciter Or DC Generator Relay
54 Turning Gear Engaging Device
59AC AC Overvoltage Relay
59DC DC Overvoltage Relay
62 Time Delay Stopping Or Opening Relay
63 Pressure Switch
71 Level Switch
74 Alarm Relay
81 Frequency Relay
83 Automatic Selective Control Or Transfer Relay
86 Lockout Relay
In line with our policy of continual development, Deep Sea Electronics, reserve the right to change specification without notice.
22
Specification
IP CLASSIFICATIONS
First Digit
Second Digit
No protection
No protection
23
Specification
3.13.7.2
NEMA CLASSIFICATIONS
NOTE: There is no direct equivalence between IP / NEMA ratings. IP figures shown are
approximate only.
1
Provides a degree of protection against contact with the enclosure equipment and against a limited amount of falling dirt.
IP30
2
Provides a degree of protection against limited amounts of falling water and dirt.
IP31
3
Provides a degree of protection against windblown dust, rain and sleet; undamaged by the formation of ice on the
enclosure.
IP64
3R
Provides a degree of protection against rain and sleet:; undamaged by the formation of ice on the enclosure.
IP32
4 (X)
Provides a degree of protection against splashing water, windblown dust and rain, hose directed water; undamaged by the
formation of ice on the enclosure. (Resist corrosion).
IP66
12/12K
Provides a degree of protection against dust, falling dirt and dripping non corrosive liquids.
IP65
13
Provides a degree of protection against dust and spraying of water, oil and non corrosive coolants.
IP65
24
4 INSTALLATION
The 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.
UL Ratings
Terminals 21-24
Terminals 1-9
Terminals 25-28
Terminals 10-20
25
Terminals 29-32
USB
PC Configuration
4.1.1
Pin
No
Cable Size
2.5mm
AWG 13
2.5 mm
AWG 13
2.5mm
AWG 13
2.5mm
AWG 13
DC Output A (FUEL)
DC Output B (START)
DC Output C
DC Output D
DC Output E
DC Output F
Notes
2.5mm
AWG 13
1.0mm
AWG 18
1.0mm
AWG 18
1.0mm
AWG 18
1.0mm
AWG 18
4.1.2
Pin
No
ANALOGUE SENSOR
Description
Cable
Size
Notes
10
0.5mm
AWG 20
11
12
13
0.5mm
AWG 20
0.5mm
AWG 20
0.5mm
AWG 20
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.
NOTE: For further details of module configuration, refer to DSE Publication: 057-201
DSE46xx Configuration Software Manual.
26
4.1.3
Pin
No
14
15
16
17
18
19
20
Cable
Size
0.5mm
AWG 20
0.5mm
AWG 20
0.5mm
AWG 20
0.5mm
AWG 20
0.5mm
AWG 20
0.5mm
AWG 20
N/A
Notes
Switch to negative
Switch to negative
Switch to negative
Switch to negative
Connect to Magnetic Pickup device
Connect to Magnetic Pickup device
Do not connect the other end to earth!
NOTE: For further details of module configuration, refer to DSE Publication: 057-201
DSE46xx Configuration Software Manual.
4.1.4
Pin
No
21
22
23
24
25
26
27
28
Cable
Size
1.0mm
AWG 18
1.0mm
AWG 18
1.0mm
AWG 18
1.0mm
AWG 18
1.0mm
AWG 18
1.0mm
AWG 18
1.0mm
AWG 18
1.0mm
AWG 18
Notes
Connect to generator L1 (U) output (AC)
(Recommend 2A fuse)
Connect to generator L2 (V) output (AC)
(Recommend 2A fuse)
Connect to generator L3 (W) output (AC)
(Recommend 2A fuse)
Connect to generator Neutral terminal (AC)
Connect to Mains L1 (R) output (AC)
(Recommend 2A fuse)
Connect to Mains L2 (S) output (AC)
(Recommend 2A fuse)
Connect to Mains L3 (T) output (AC)
(Recommend 2A fuse)
Connect to Mains Neutral terminal (AC)
NOTE: The above table describes connections to a three phase, four wire alternator. For
alternative wiring topologies, please see the Alternate Topology Wiring Diagrams section of
this manual.
27
4.1.5
NOTE: Current Sensing (terminals 29 to 32) is not fitted to the DSE46xx-01 variant.
WARNING!: Do not disconnect this plug when the CTs are carrying current.
Disconnection will open circuit the secondary of the C.T.s and dangerous voltages may then
develop. Always ensure the CTs are not carrying current and the CTs are short circuit
connected before making or breaking connections to the module.
NOTE: The module has a burden of 0.5VA on the CT. Ensure the CT is rated for the
burden of the controller, the cable length being used and any other equipment sharing the
CT. If in doubt, consult your CT supplier.
Pin
No
Description
29
CT Secondary for L1
30
CT Secondary for L2
31
CT Secondary for L3
32
CT Common
Cable
Size
2.5mm
AWG 13
2.5mm
AWG 13
2.5mm
AWG 13
2.5mm
AWG 13
Notes
Connect to s1 secondary of L1 monitoring CT
Connect to s1 secondary of L2 monitoring CT
Connect to s1 secondary of L3 monitoring CT
4.1.5.1 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 Modules input for the CT measuring
s2 is the secondary of the CT that should be commoned with the s2 connections of all the other CTs
and connected to the CT common terminal of the module.
labelled as p2,
l or L
labelled as p1,
k or K
TO LOAD
TO GENERATOR
POLARITY OF CT PRIMARY
28
4.1.6
Cable
Size
0.5mm
AWG 20
Notes
This is a standard
USB type A to type B
connector.
NOTE: The USB connection cable between the PC and the 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.
CAUTION!: Care must be taken not to overload the PCs USB system by connecting more
than the recommended number of USB devices to the PC. For further information, consult
your PC supplier.
NOTE: For further details of module configuration, refer to DSE Publication: 057-201
DSE46xx Configuration Software Manual.
29
Description
Breaker Control (Training guide)
30
4.2.1
31
4.2.2
32
GENERATOR
33
4.3.2
34
NEGATIVE EARTH
The typical wiring diagrams located within this document show connections for a negative earth
system (the battery negative connects to Earth)
4.4.2
POSITIVE EARTH
When using a DSE module with a Positive Earth System (the battery positive connects to Earth), the
following points must be followed:
4.4.3
Follow the typical wiring diagram as normal for all sections EXCEPT the earth points
All points shown as Earth on the typical wiring diagram should connect to BATTERY
NEGATIVE (not earth).
FLOATING EARTH
Where neither the battery positive nor battery negative terminals are connected to earth the following
points must to be followed
Follow the typical wiring diagram as normal for all sections EXCEPT the earth points
All points shown as Earth on the typical wiring diagram should connect to BATTERY
NEGATIVE (not earth).
35
Description Of Controls
5 DESCRIPTION OF CONTROLS
NOTE: 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.
Control of the module is via push buttons mounted on the front of the module with
, Auto Mode
and Manual/Start Mode
functions. For normal operation,
Stop/Reset Mode
these are the only controls which need to be operated. Details of their operation are provided later in
this document.
Menu
Navigation
Module
Display
Manual / Start
Mode LED.
Will flash
upon Waiting
in Manual
Mode
Stop / Reset
Mode LED.
Will flash
upon
Electrical Trip
and Shutdown
Fault
Stop / Reset
Mode
Auto Mode
Manual / Start
Mode
CAUTION: The module may instruct an engine start event due to external influences.
Therefore, it is possible for the engine to start at any time without warning. Prior to
performing any maintenance on the system, it is recommended that steps are taken to remove
the battery and isolate supplies.
36
Description Of Controls
Description
Stop / Reset Mode
. This will clear any
This button places the module into its Stop/Reset Mode
alarm conditions for which the triggering criteria have been removed. If the engine
is running and the module is put into Stop mode, the module will automatically
instruct the generator to unload (Close Generator and Delayed Load Output 1,
2, 3 & 4 become inactive (if used)). The fuel supply de-energises and the engine
comes to a standstill. Should any form of remote start signal be present while
operating in this mode, a start will not occur.
Auto Mode
This button places the module into its Auto Mode
. This mode allows the
module to control the function of the generator automatically. The module will
monitor the remote start input and battery charge status and once a start request is
made, the set will be automatically started and placed on load (Close Generator
and Delayed Load Output 1, 2, 3 & 4 become active in order from lowest to
highest (if used)).
Upon removal of the starting signal, the module will remove the load from the
generator and shut the set down observing the stop delay timer and cooling timer
as necessary (Close Generator and Delayed Load Output 1, 2, 3 & 4 become
inactive at once (if used)). 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.
Manual / Start Mode
This button will start the engine and run off load. To place the generator on load,
digital inputs are required to be assigned to perform this function.
If the engine is running off-load in Manual/Start Mode
button and a remote
start signal becomes present, the module will automatically instruct the
changeover device to place the generator on load (Close Generator and
Delayed Load Output 1, 2, 3 & 4 becomes active (if used)). Upon removal of the
Remote Start Signal, the generator remains on load until either selection of the
Stop/Reset Mode
or Auto Mode
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.
37
Instrumentation
Unit
Active
Config
Instrumentation
Unit
FPE /
Auto
Run
Instrumentation
Unit
L2N
230
230
L3N
230
L1N
230 V
230 V
L1N
L2N
230 V
230 V
230 V
L3N
230 V
38
Alarm
Icon
Mode
Icon
5.2.1
INSTRUMENTATION ICONS
When viewing instrumentation pages, an icon is displayed in the Inst. Icon section to indicate what
section is currently being displayed.
Icon
Details
The default home page which displays generator voltage and
mains voltage (DSE4620 only)
Generator voltage and frequency instrumentation screen
Mains voltage and frequency instrumentation screen (DSE4620 only)
Generator current instrumentation screen
Mains current instrumentation screen (DSE4620 only when CT in load location)
Load power instrumentation screen
Engine speed instrumentation screen
Hours run instrumentation screen
Battery voltage instrumentation screen
Oil pressure instrumentation screen
Coolant temperature instrumentation screen
Flexible sender instrumentation screen
Appears when the event log is being displayed
Current time held in the unit
The current value of the scheduler run time and duration
Oil Filter maintenance timers
Air Filter maintenance timers
Fuel Filter maintenance timers
39
5.2.2
ACTIVE CONFIGURATION
An icon is displayed in the Active Config section to indicate the active configuration within the
currently selected within the controller.
Icon
Details
Appears when the main configuration is selected.
Appears when the alternative configuration is selected.
5.2.3
NOTE: For further details about the Front Panel Editor, see the section entitled Front
Panel Editor elsewhere in this manual.
Mains failure
Appears when a scheduled run is active
5.2.4
MODE ICON
An icon is displayed in the Mode Icon section to indicate the mode the controller is currently in.
Icon
Details
Appears when the engine is at rest and the unit is in stop mode.
Appears when the engine is at rest and the unit is in auto mode.
Appears when the engine is at rest and the unit is waiting for a manual start.
Appears when a timer is active, for example cranking time, crank rest etc.
Appears when the engine is running, and all timers have expired, either on or off load.
The animation speed is reduced when running in idle mode.
Appears when the unit is in the front panel editor.
Appears when a USB connection is made to the controller.
Appears if either the configuration file or engine file becomes corrupted.
40
5.2.5
An icon is displayed in the Load Switching Icon section to indicate the current operation status of
the controller.
Icon
Details
Appears when the generator is at rest or not available and when the
generator breaker is open.
Appears when the generator is at rest or not available and the generator
breaker has failed to open.
Appears when the generator is available and the generator breaker is open.
Appears when the generator is available and the generator breaker is
closed.
Appears when the mains supply is not available and the mains breaker is
open. (DSE4620 Only)
Appears when the mains supply is not available and the mains breaker is
closed. (DSE4620 Only)
Appears when the mains supply is available and the mains breaker is open.
(DSE4620 Only)
Appears when the mains supply is available and the mains breaker is
closed. (DSE4620 Only)
5.2.6
BACKLIGHT
The LCD backlight is on if the unit has sufficient voltage while the unit is turned on, unless the unit is
cranking for which the backlight is turned off.
41
5.2.7
An icon is displayed in the Alarm Icon section to indicate the alarm that is current active on the
controller.
In the event of a warning alarm, the LCD only displays the Alarm Icon. In the event of an electrical
trip or shutdown alarm, the module displays the Alarm Icon and the Stop/Reset Mode
LED begins to flash.
button
If multiple alarms are active at the same time, the Alarm Icon automatically cycles through all the
appropriate icons to indicate each alarm which is active.
Example:
If the DSE controller was sensing a charge alternator failure alarm, delay over current alarm and a
AC under voltage alarm at the same time, it would cycle through all of the icons to show this.
Icon cycle
procedure
42
Fault
Auxiliary Inputs
Analogue Input
Configured As Digital
Fail To Stop
Charge Failure
Low Fuel Level
High Fuel Level
Description
The module detects that an auxiliary input which has been user
configured to create a fault condition has become active.
The analogue inputs can be configured to digital inputs.
The module detects that an input configured to create a fault
condition has become active.
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. If engine is at rest check oil sensor wiring and
configuration.
The auxiliary charge alternator voltage is low as measured from the
W/L terminal.
The level detected by the fuel level sensor is below the low fuel
level pre-set pre-alarm setting.
The level detected by the fuel level sensor is above the high fuel
level pre-set pre-alarm setting.
Battery Under
Voltage
The DC supply has fallen below or risen above the low volts pre-set
pre-alarm setting.
The DC supply has risen above the high volts 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.
Generator Over
Voltage
The generator output voltage has risen above the pre-set pre-alarm
setting.
Generator Under
Frequency
The generator output frequency has fallen below the pre-set prealarm setting after the Safety On timer has expired.
Generator Over
Frequency
The generator output frequency has risen above the pre-set prealarm setting.
Immediate Over
Current
The measured current has risen above the configured trip level.
The measured current has risen above the configured trip level for
a configured duration.
43
Icon
Fault
Description
Oil Filter
Maintenance Alarm
Air Filter
Maintenance Alarm
Fuel Filter
Maintenance Alarm
Magnetic Pickup
Open Circuit
Loss Of Mag. Pickup
Signal
button on
NOTE: The alarm condition must be rectified before a reset will take place. If the alarm
condition remains, it is not 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 is low with the
engine at rest).
Icon
Fault
Auxiliary Inputs
Analogue Input
Configured As Digital
Low Fuel Level
High Fuel Level
Delayed Over Current
kW Overload
Description
The module detects that an auxiliary input which has been user
configured to create a fault condition has become active.
The analogue inputs can be configured to digital inputs.
The module detects that an input configured to create a fault
condition has become active.
The level detected by the fuel level sensor is below the low fuel
level pre-set alarm setting.
The level detected by the fuel level sensor is above the high fuel
level pre-set alarm setting.
The measured current has risen above the configured trip level for
a configured duration.
The measured kW has risen above the configured trip level for a
configured duration.
44
button on the
NOTE: The alarm condition must be rectified before a reset will take place. If the alarm
condition remains, it is 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 is low with the
engine at rest).
Icon
Fault
Auxiliary Inputs
Analogue Input
Configured As Digital
Fail To Start
Low Oil Pressure
Engine High
Temperature
Under Speed
Over Speed
Charge Failure
Low Fuel Level
High Fuel Level
Description
The module detects that an auxiliary input which has been user
configured to create a fault condition has become active.
The analogue inputs can be configured to digital inputs.
The module detects that an input configured to create a fault
condition has become active.
The engine has failed to start after the configured number of start
attempts
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.
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.
The engine speed has fallen below the under speed pre alarm
setting
The engine speed has risen above the over speed pre alarm setting
The auxiliary charge alternator voltage is low as measured from the
W/L terminal.
The level detected by the fuel level sensor is below the low fuel
level pre-set alarm setting.
The level detected by the fuel level sensor is above the high fuel
level pre-set alarm setting.
Generator Under
Voltage
The generator output voltage has fallen below the pre-set alarm
setting. after the Safety On timer has expired.
Generator Over
Voltage
The generator output voltage has risen above the pre-set alarm
setting.
45
Icon
Fault
Description
Generator Under
Frequency
The generator output frequency has fallen below the pre-set alarm
setting after the Safety On timer has expired.
Generator Over
Frequency
The generator output frequency has risen above the pre-set alarm
setting.
The measured current has risen above the configured trip level for
a configured duration.
The measured kW has risen above the configured trip level for a
configured duration.
The emergency stop button has been depressed. This failsafe
(normally closed to emergency stop) input and immediately stops
the set should the signal be removed.
The oil pressure sensor has been detected as being open circuit.
Coolant Temperature
Sender Open Circuit
Oil Filter
Maintenance Alarm
Air Filter
Maintenance Alarm
Fuel Filter
Maintenance Alarm
Magnetic Pickup
Open Circuit
Loss Of Mag. Pickup
Signal
46
NAVIGATION MENU
(up) and
Once the desired icon is at the top, press the Auto Mode
section.
If the Auto Mode
(
() button is not pressed, the display automatically returns to the Home
Description
Generator and mains voltage instrumentation (DSE4620 only)
Generator instrumentation
Mains instrumentation (DSE4620 only)
Current and load instrumentation
(Not available in on the DSE46xx-01 variant)
Engine instrumentation
Module information
Event Log
47
5.3.2
GENERAL NAVIGATION
It is possible to scroll through the display to view different pages of information by repeatedly
operating the
(up) or
Example:
And so on until the last page is reached.
Home
Press
Generator
Press
Mains
(down)
Once selected, the page will remain on the LCD display until the user selects a different page or,
after an extended period of inactivity (Page Delay Timer), the module reverts back to the Home
(
) page.
The Page Delay Timer is configurable using the DSE Configuration Suite Software or by using the
Front Panel Editor.
NOTE: For further details of module configuration, refer to DSE Publication: 057-201
DSE46xx Configuration Software Manual.
48
5.3.3
HOME
This is the page that is displayed when no other page has been selected and is automatically
displayed after a period of inactivity (Page Delay Timer) of the module facia buttons. It also contains
the voltage reading of the generator and mains that is measured from the modules voltage inputs.
Mains
Voltage
5.3.4
Generator
Voltage
230 V
230 V
L1N
L2N
230 V
230 V
230 V
L3N
230 V
GENERATOR
These pages contain electrical values of the generator, measured or derived from the modules
voltage inputs.
V
L2N
230
230
L3N
230
L1N
49
5.3.5
These pages contain electrical values of the mains, measured or derived from the modules voltage
inputs.
V
L2N
230
230
L3N
230
L1N
5.3.6
LOAD
These pages contain electrical values of the load, measured or derived from the modules voltage
and current inputs. The power values displayed depend on which supply is on load.
kW
L2
20
20
L3
20
kW
L1
50
kW
5.3.7
ENGINE
These pages contain instrumentation gathered about the engine measured or derived from the
modules inputs.
1500
5.3.8
RPM
Engine Speed
Engine Run Time
Engine Battery Volts
Engine Coolant Temperature
Engine Oil Pressure
Engine Fuel Level / Flexible Sensor
Engine Maintenance Due Oil
Engine Maintenance Due Air
Engine Maintenance Due Fuel
INFO
Start time of
scheduled run
13:30:00
M T W T F S S 3 Wk
2:45:00
Duration of
scheduled run
51
5.3.9
EVENT LOG
This modules event log contains a list of the last 15 record electrical trip or shutdown events and the
engine hours at which they occurred.
Once the log is full, any subsequent electrical trip or shutdown alarms overwrites the oldest entry in
the log. Hence, the log always contains the most recent shutdown alarms. The module logs the
alarm, along with the engine running hours.
(up) and
(up) or
(up) or
(down) buttons will cycle through the past alarms after
Continuing to press down the
which the display shows the most recent alarm and the cycle begins again.
(up) and
(down) buttons simultaneously to enter the
To exit the event log, press the
navigation menu. Once entered, cycle to the desired intrunmentation section.
23 h
11
50
56 m
52
Icon to indicate
the electrical trip
or shutdown
alarm that has
been recorded
Current operating
state of the module
Operation
6 OPERATION
NOTE: 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.
6.1.1
NOTE: For further details, see the section entitled OPERATION elsewhere in this
manual.
53
Operation
6.1.2
Select Stop/Reset
mode. The generator
is stopped.
NOTE: For further details, see the section entitled OPERATION elsewhere in this
manual.
54
Operation
button.
, the module removes the generator from load (if necessary) before stopping
In Stop/Reset Mode
the engine if it is already running.
If the engine does not stop when requested, the FAIL TO STOP alarm is activated (subject to the
setting of the Fail to Stop timer). To detect the engine at rest the following must occur :
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 are reset when Stop/Reset Mode
The engine is not started when in Stop/Reset Mode
ignored until Auto Mode
is entered.
is entered.
NOTE: For further details of module configuration, refer to DSE Publication: 057-201
DSE46xx Configuration Software Manual.
55
Operation
button.
Auto mode allows the generator to operate fully automatically, starting and stopping as required with
no user intervention.
6.3.1
6.3.2
STARTING SEQUENCE
To allow for false start requests, the start delay timer begins.
Should all start requests be removed during the start delay timer, the unit returns to a stand-by state.
If a start request is still present at the end of the start delay timer, the fuel relay is energised and the
engine is cranked.
If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the
crank rest duration after which the next start attempt is made. Should this sequence continue beyond
the set number of attempts, the start sequence is terminated and the display shows
6.3.3
Fail to Start.
ENGINE RUNNING
Once the engine is running and all starting timers have expired, the animated Engine
Running
icon is displayed.
56
Operation
6.3.4
STOPPING SEQUENCE
The return delay timer operates to ensure that the starting request has been permanently removed
and isnt just a short term removal. Should another start request be made during the cooling down
period, the set returns on load.
If there are no starting requests at the end of the return delay timer, the load is removed from the
generator to the mains supply and the cooling timer is initiated.
The cooling timer allows the set to run off load and cool sufficiently before being stopped. This is
particularly important where turbo chargers are fitted to the engine.
After the cooling timer has expired, the set is stopped.
57
Operation
6.4.1
NOTE: For further details of module configuration, refer to DSE Publication: 057-201
DSE46xx Configuration Software Manual.
6.4.2
STARTING SEQUENCE
58
Operation
6.4.3
ENGINE RUNNING
Once the engine is running and all starting timers have expired, the animated Engine
Running
icon is displayed.
In manual mode, the load is not transferred to the generator unless a loading request is made.
A loading request can come from a number of sources.
Activation of an auxiliary input that has been configured to Remote Start On Load or Auxiliary
Mains Fail.
Activation of the inbuilt exercise scheduler if configured for on load runs.
NOTE: The load transfer signal remains inactive until the Oil Pressure has risen. This
prevents excessive wear on the engine.
Once the generator has been placed on load, it is not automatically removed. To manually remove
the load either:
button to return to automatic mode. The set observes all auto mode
Press the Auto Mode
start requests and stopping timers before beginning the Auto Mode Stopping Sequence.
6.4.4
STOPPING SEQUENCE
button is pressed. The set observes all auto mode start requests and
The Auto Mode
stopping timers before beginning the Auto Mode Stopping Sequence.
59
Example 3
Screen capture from DSE Configuration Suite
Software showing the Maintenance Alarm
Reset button in the DSE Configuration Suite
SCADA | MAINTENANCE section.
60
Operation - Scheduler
6.6 SCHEDULER
The controller contains an inbuilt exercise run scheduler, capable of automatically starting and
stopping the set. Up to 8 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
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.
6.6.1
6.6.2
STOP MODE
Scheduled runs do not occur when the module is in Stop/Reset Mode
MANUAL/START MODE
waiting for a
Scheduled runs do not occur when the module is in Manual/Start Mode
manual start.
Activation of a Scheduled Run On Load when the module is operating OFF LOAD in
Manual/Start Mode
6.6.3
AUTO MODE
or Manual/Start Mode
with no Shutdown or
when a scheduled run
begins, the engine is not 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.
and a scheduled run configured to On
If the engine is running OFF LOAD in Auto Mode
Load begins, the set is placed ON LOAD for the duration of the Schedule.
61
Next Section
(101201301)
Previous Section
(301201101)
Previous Parameter
(103102101)
Edit or Save
Parameter
62
Next Parameter
(101102103)
Press the
Press the or navigation buttons to cycle through the front panel editor to select the required
page in the configuration tables.
Press the
(+) or
Press the
() button the save the current value, the value ceases flashing.
Press and hold the () button to save and exit the editor, the configuration icon
removed from the display.
(-) and
mode.
is
NOTE: The editor automatically exits after 5 minutes of inactivity to ensure security.
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 modules code removed. A charge will be made for
this procedure.
NB - This procedure cannot be performed away from the DSE factory.
NOTE: The PIN number is automatically reset when the editor is exited (manually or
automatically) to ensure security.
63
MODULE SETTINGS
Functionality in all DSE4610 & DSE4620 variants
Functionality in all DSE4620 variants
Functionality in DSE4610 & DSE4620 current sensing variants only
Functionality in DSE4610 & DSE4620 RT & RTH variants only
0 (%)
On (1), Off (0)
On (1), Off (0)
On (1), Off (0)
On (1), Off (0)
On (1), Off (0)
On (1), Off (0)
On (1), Off (0)
0 (Power Up Mode)
64
7.2.2
INPUT SETTINGS
65
0 (Input Source)
0 (Polarity)
0 (Action)
0 (Arming)
0s
0 (Input Source)
0 (Polarity)
0 (Action)
0 (Arming)
0s
0 (Input Source)
0 (Polarity)
0 (Action)
0 (Arming)
0s
0 (Input Source)
0 (Polarity)
0 (Action)
0 (Arming)
0s
0 (Input Source)
0 (Polarity)
0 (Action)
0 (Arming)
0s
0 (Input Source)
0 (Polarity)
0 (Action)
0 (Arming)
0s
0 (Input Source)
0 (Polarity)
0 (Action)
0 (Arming)
0s
7.2.3
x
x
x
x
OUTPUT SETTINGS
Functionality in all DSE4610 & DSE4620 variants
Functionality in all DSE4620 variants
Functionality in DSE4610 & DSE4620 current sensing variants only
Functionality in DSE4610 & DSE4620 RT & RTH variants only
7.2.4
0 (Output Source)
0 (Output Polarity)
0 (Output Source)
0 (Output Polarity)
0 (Output Source)
0 (Output Polarity)
0 (Output Source)
0 (Output Polarity)
0 (Output Source)
0 (Output Polarity)
0 (Output Source)
0 (Output Polarity)
TIMER SETTINGS
66
7.2.5
x
x
x
x
GENERATOR SETTINGS
Functionality in all DSE4610 & DSE4620 variants
Functionality in all DSE4620 variants
Functionality in DSE4610 & DSE4620 current sensing variants only
Functionality in DSE4610 & DSE4620 RT & RTH variants only
67
7.2.6
x
x
x
x
MAINS SETTINGS
Functionality in all DSE4610 & DSE4620 variants
Functionality in all DSE4620 variants
Functionality in DSE4610 & DSE4620 current sensing variants only
Functionality in DSE4610 & DSE4620 RT & RTH variants only
0 (AC System)
On (1), Off (0)
On (1), Off (0)
On (1), Off (0)
0V
0V
On (1), Off (0)
0V
0V
On (1), Off (0)
0.0 Hz
0.0 Hz
On (1), Off (0)
0 Hz
0.0 Hz
68
7.2.7
ENGINE SETTINGS
69
0
0%
0s
0s
0s
0s
On (1), Off
On (1), Off
0.00 Bar
0.0 Hz
0 RPM
On (1), Off
0 RPM
0 RPM
On (1), Off
0.0 V
0.0 V
0:00:00
On (1), Off
0.0 V
0.0 V
0s
On (1), Off
0.0 V
0s
On (1), Off
0.0 V
0s
On (1), Off
0.0 V
0s
0s
On (1), Off
0
(0)
(0)
(0)
(0)
(0)
(0)
(0)
(0)
(0)
7.2.8
70
7.2.9
x
x
x
x
SCHEDULER SETTINGS
Functionality in all DSE4610 & DSE4620 variants
Functionality in all DSE4620 variants
Functionality in DSE4610 & DSE4620 current sensing variants only
Functionality in DSE4610 & DSE4620 RT & RTH variants only
0:00:00
0 (1=Monday)
1-52
1-31
1-12
0-99
71
72
(0)
(0)
(0)
(0)
(0)
(0)
(0)
x
x
x
x
73
0A
0A
On (1), Off (0)
On (1), Off (0)
0 (Action)
00:00:00
0%
0 kW
On (1), Off (0)
0 (Action)
0%
0s
0 (AC system)
On (1), Off (0)
On (1), Off (0)
On (1), Off (0)
0V
0V
On (1), Off (0)
0V
0V
On (1), Off (0)
0.0 Hz
0.0 Hz
On (1), Off (0)
0.0 Hz
0.0 Hz
On (1), Off (0)
0 RPM
0 RPM
INPUT SOURCES
Functionality in all DSE4610 & DSE4620 variants
Functionality in all DSE4620 variants
Functionality in DSE4610 & DSE4620 current sensing variants only
Functionality in DSE4610 & DSE4620 RT & RTH variants only
INPUT SOURCES
0
User Configured
1
Alarm Mute
2
Alarm Reset
3
Alternative Configuration
4
Auto Restore Inhibit
5
Auto Start Inhibit
6
Auxiliary Mains Fail
7
Coolant Temperature Switch
8
Emergency Stop
9
External Panel Lock
10
Generator Load Inhibit
11
Lamp Test
12
Low Fuel Level Switch
13
Mains Load Inhibit
14
Oil Pressure Switch
15
Remote Start Off Load
16
Remote Start On Load
17
Simulate Mains Available
18
Simulate Stop Button
19
Simulate Auto Button
20
Simulate Start Button
21
Smoke Limiting
22
Close Generator
23
Close Mains
24
Maintenance Reset Oil
25
Maintenance Reset Air
26
Maintenance Reset Fuel
Open Mains
Open Generator
74
7.3.2
x
x
x
x
OUTPUT SOURCES
Functionality in all DSE4610 & DSE4620 variants
Functionality in all DSE4620 variants
Functionality in DSE4610 & DSE4620 current sensing variants only
Functionality in DSE4610 & DSE4620 RT & RTH variants only
OUTPUT SOURCES
0
Not Used
1
Air Flap Relay
2
Audible Alarm
3
Battery Over Volts Warning
4
Battery Under Volts Warning
5
RESERVED
6
RESERVED
7
RESERVED
8
RESERVED
9
RESERVED
10
Charge Alternator Shutdown
11
Charge Alternator Warning
12
Close Gen Output
13
Close Gen Output Pulse
14
Close Mains Output
15
Close Mains Output Pulse
16
Combined Mains Failure
17
Common Alarm
18
Common Electrical Trip
19
Common Shutdown
20
Common Warning
21
Cooling Down
22
Digital Input A
23
Digital Input B
24
Digital Input C
25
Digital Input D
26
RESERVED
27
RESERVED
28
RESERVED
29
Emergency Stop
30
Energise To Stop
31
Fail To Start
32
Fail To Stop
33
Fuel Relay
34
Gas Choke On
35
Gas Ignition
36
Generator Available
37
Generator Over Voltage Shutdown
38
Generator Under Voltage Shutdown
39
kW Overload Alarm
40
Over Current Immediate Warning
41
Delayed Over Current Trip Alarm
42
High Coolant Temperature Shutdown
43
Low Oil Pressure Shutdown
44
Mains High Frequency
45
Mains High Voltage
46
Mains Low Frequency
47
Mains Low Voltage
More output sources overleaf...
75
x
x
x
x
OUTPUT SOURCES
48
Oil Pressure Sender Open Circuit
49
Open Gen Output
50
Open Gen Output Pulse
51
Open Mains Output
52
Open Mains Output Pulse
53
Over Frequency Shutdown
54
Over Speed Shutdown
55
Preheat During Preheat Timer
56
Preheat Until End Of Crank
57
Preheat Until End Of Safety Timer
58
Preheat Until End Of Warming
59
Smoke Limiting
60
Start Relay
61
Temperature Sender Open Circuit
62
Under Frequency Shutdown
63
Under Speed Shutdown
64
Waiting For Manual Restore
65
Flexible Sender C High Alarm
66
Flexible Sender C High Alarm
67
Flexible Sender C Low Pre-Alarm
68
Flexible Sender C Low Alarm
69
RESERVED
70
RESERVED
71
RESERVED
72
RESERVED
73
Fuel Sender High Alarm
74
Fuel Sender High Alarm
75
Fuel Sender Low Pre-Alarm
76
Fuel Sender Low Alarm
77
Delayed Load Output 1
78
Delayed Load Output 2
79
Delayed Load Output 3
80
Delayed Load Output 4
81
Air Filter Maintenance Output
82
Oil Filter Maintenance Output
83
Fuel Filter Maintenance Output
84
System In Stop Mode
85
System In Auto Mode
86
System In Manual Mode
87
RESERVED
88
Analogue Input A (Digital)
89
Analogue Input B (Digital)
90
Analogue Input C (Digital)
91
RESERVED
92
RESERVED
93
Loss of MPU Signal
94
MPU Open Circuit
95
Over Speed Overshoot
96
Over Frequency Overshoot
97
Display Heater Fitted and Active
76
7.3.3
ALARM ACTION
ALARM ACTION
Index
0
1
2
7.3.4
Action
Electrical Trip
Shutdown
Warning
7.3.5
POWER UP MODE
POWER UP MODE
Index
0
1
2
7.3.6
SENSOR TYPE
SENSOR TYPE
Index
0
1
2
3
4
7.3.7
Mode
Stop
Manual
Auto
Type
None
Digital Input
Percentage Sensor
Pressure Sensor
Temperature Sensor
AC SYSTEM
AC SYSTEM
Index
0
1
2
3
4
5
Type
2 Phase 3 Wire (L1-L2)
2 Phase 3 Wire (L1-L3)
3 Phase 3 Wire
3 Phase 4 Wire
3 Phase 4 Wire (Delta)
Single Phase 2 Wire
77
7.3.8
7.3.9
Units
Litres
Imperial Gallons
US Gallons
78
79
Commissioning
8 COMMISSIONING
Before the system is started, it is recommended that the following checks are made:
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 fitted 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.
The Emergency Stop input is wired to an external normally closed switch connected to DC
negative.
NOTE: If Emergency Stop feature is not required, link the input to the DC Negative or
disable the input. For further details of module configuration, refer to DSE Publication: 057201 DSE46xx Configuration Software Manual.
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/Start Mode
sequence will commence.
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 Failed to
start. Press the Stop/Reset Mode
Restore the engine to operational status (reconnect the fuel solenoid). Press the Manual/Start
Mode
button. 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.
Initiate an automatic start by supplying the remote start signal (if configured). The start sequence
will commence and the engine will run up to operational speed. Once the generator is available
the delayed load outputs will activate, the Generator will accept the load. If not, check the wiring
to the delayed load output contactors. Check the Warming timer has timed out.
Remove the remote start signal. The return sequence will begin. After the pre-set time, the
generator is unloaded. The generator will then run for the pre-set cooling down period, then
shutdown into its standby mode.
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
If, despite repeated checking of the connections between the controller and the customers
system, satisfactory operation cannot be achieved, then the customer is requested to the DSE
Technical Support Department
80
9 FAULT FINDING
9.1 STARTING
Symptom
Unit is inoperative
Read/Write configuration
does not operate
Unit shuts down
Pre-heat inoperative
Possible Remedy
Check the battery and wiring to the unit. Check the DC supply.
Check the DC fuse.
9.2 LOADING
Symptom
Engine runs but generator will
not take load
Possible Remedy
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 load signal.
Check engine is operating correctly.
Check that sensor is compatible with the module and that the
module configuration is suited to the sensor.
81
9.3 ALARMS
Symptom
Low oil Pressure fault
operates after engine has
fired
Possible Remedy
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 module and is correctly configured.
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 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 relevant switch and wiring of fault indicated on LCD display.
Check configuration of input.
Check engine is operating correctly. Check sensor and wiring paying
particular attention to the wiring to terminal 10 (refer to appendix).
Check that sensor is compatible with the module and that the
module configuration is suited to the sensor.
9.4 INSTRUMENTS
Symptom
Inaccurate generator
measurements on controller
display
Possible Remedy
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 (kW = kVA x powerfactor).
The 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. Generator
voltage full scale is 415V ph-N, accuracy is 4.15V (1% of 415V).
82
9.5 MISCELLANEOUS
Symptom
Module appears to revert to
an earlier configuration
Possible Remedy
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
() button to save the change before moving
the the Auto Mode
to another item or exiting the fascia editor
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.
83
10
The controller is Fit and Forget. As such, there are no user serviceable parts within the controller.
In the case of malfunction, you should contact your original equipment manufacturer (OEM).
10.1
If you require additional plugs from DSE, please contact our Sales department using the part
numbers below.
10.2
Part No.
007-166
007-155
007-451
007-003
007-003
007-282
016-125
10.3
Plug Description
9 way 5.08mm
7 way 5.08mm
11 way 5.08mm
4 way 10.16mm
4 way 10.16mm
4 way 5.08mm
PC Configuration interface lead
(USB type A USB type B)
Description
Part No.
020-406
Description
Part No.
020-282
84
Warranty
11 WARRANTY
DSE provides limited warranty to the equipment purchaser at the point of sale. For full details of any
applicable warranty, you are referred to your original equipment supplier (OEM).
12
DISPOSAL
12.1
Directive 2002/96/EC
If you use electrical and electronic equipment you must store, collect, treat, recycle and
dispose of WEEE separately from your other waste.
12.2
85
86