DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

Deep Sea Electronics Plc

5210 AUTOSTART MODULE OPERATING MANUAL

Author:- Anthony Manton

Deep Sea Electronics Plc Highfield House Hunmanby North Yorkshire YO14 0PH England Tel: +44 (0) 1723 890099 Fax: +44 (0) 1723 893303 email: [email protected]

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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

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TABLE OF CONTENTS Section

Page

1

INTRODUCTION .............................................................................................. 5

2

CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION. ........ 5

3

OPERATION .................................................................................................... 6 3.1 3.2

4

PROTECTIONS ................................................................................................ 9 4.1 4.2 4.3 4.4 4.5 4.6

5

AUTOMATIC MODE OF OPERATION ............................................................................... 6 MANUAL OPERATION ....................................................................................................... 8 WARNINGS ....................................................................................................................... 10 ANALOGUE PRE-ALARMS.............................................................................................. 10 HIGH CURRENT WARNING ALARM ............................................................................... 11 SHUTDOWNS.................................................................................................................... 12 HIGH CURRENT SHUTDOWN ALARM ........................................................................... 14 ELECTRICAL TRIPS......................................................................................................... 14

DESCRIPTION OF CONTROLS .................................................................... 15 5.1 TYPICAL LCD DISPLAY SCREENS ................................................................................ 16 5.2 LCD DISPLAY AREAS......................................................................................................17 5.3 VIEWING THE INSTRUMENTS ........................................................................................ 18 CANBUS MESSAGES .............................................................................................................. 19 5.4 VIEWING THE EVENT LOG.............................................................................................. 20 5.5 INDICATORS ..................................................................................................................... 20 5.6 CONTROLS ....................................................................................................................... 21

6

FRONT PANEL CONFIGURATION ............................................................... 22 6.1 ACCESSING THE FRONT PANEL CONFIGURATION EDITOR..................................... 22 6.1.1 EDITING AN ANALOGUE VALUE ............................................................................. 23 6.1.2 EDITING THE CURRENT DATE/TIME ...................................................................... 25

7

INSTALLATION INSTRUCTIONS.................................................................. 26 7.1 7.2 7.3 7.4 7.5

8

PANEL CUT-OUT..............................................................................................................26 COOLING........................................................................................................................... 26 UNIT DIMENSIONS ........................................................................................................... 26 FRONT PANEL LAYOUT.................................................................................................. 27 REAR PANEL LAYOUT .................................................................................................... 27

ELECTRICAL CONNECTIONS...................................................................... 28 8.1 CONNECTION DETAILS................................................................................................... 28 8.1.1 PLUG “A” 8 WAY ........................................................................................................ 28 8.1.2 PLUG “B” 11 WAY ...................................................................................................... 28 8.1.3 PLUG “C” 3 WAY (OPTIONAL) .................................................................................. 28 8.1.4 PLUG “D” 4 WAY (OPTIONAL) .................................................................................. 29 8.1.5 PLUG “F” 4 WAY ........................................................................................................ 29 8.1.6 PLUG “G” 5 WAY........................................................................................................ 29 8.1.7 PLUG “H” 4 WAY ........................................................................................................ 29 8.1.8 PC CONFIGURATION INTERFACE CONNECTOR .................................................. 30 8.1.9 EXPANSION OUTPUT CONNECTOR....................................................................... 30 8.2 CONNECTOR FUNCTION DETAILS................................................................................ 31 8.2.1 PLUG “A” 8 WAY ........................................................................................................ 31 8.2.2 PLUG “B” 11 WAY ...................................................................................................... 31 8.2.3 PLUG “C” 3 WAY (OPTIONAL, FITTED TO J1939 CONTROLLERS ONLY)............ 32 8.2.4 PLUG “D” 4 WAY (OPTIONAL, FITTED TO RS485 CONTROLERS ONLY) ............ 32 8.2.5 PLUG “F” 4 WAY ........................................................................................................ 32 8.2.6 PLUG “G” 5 WAY........................................................................................................ 32 8.2.7 PLUG “H” 4 WAY ........................................................................................................ 33 8.2.8 PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE............................ 33 8.3 ELECTRICAL CONNECTIONS TO J1939 ENABLED CONTROLLERS......................... 34 8.3.1 CUMMINS ISB / ISBE................................................................................................. 34 8.3.2 JOHN DEERE............................................................................................................. 35

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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

8.3.3 8.3.4 8.3.5

9

PERKINS 2800 SERIES .............................................................................................36 SCANIA S6..................................................................................................................37 VOLVO TAD12............................................................................................................38

SPECIFICATION.............................................................................................39

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COMMISSIONING .......................................................................................40 10.1.1

PRE-COMMISSIONING..............................................................................................40

11

FAULT FINDING..........................................................................................41

12

TYPICAL WIRING DIAGRAM......................................................................42

13

FACTORY DEFAULT CONFIGURATION ...................................................43

14

ICONS AND LCD IDENTIFICATION ...........................................................46

14.1 14.2 14.3

15

PUSH BUTTONS ...............................................................................................................46 STATUS / MEASUREMENT UNITS ..................................................................................46 ALARM INDICATIONS ......................................................................................................46

APPENDIX ...................................................................................................47

15.1 ALTERNATIVE WIRING TOPOLOGIES ...........................................................................47 15.1.1 3 PHASE, 3 WIRE.......................................................................................................47 15.1.2 1 PHASE, 2 WIRE.......................................................................................................47 15.1.3 2 PHASE, 3 WIRE ( 2 PHASE CENTRE TAP NEUTRAL) .........................................48 15.2 5210 IDMT TRIPPING CURVES (TYPICAL).....................................................................49 15.3 SENDER WIRING RECOMMENDATIONS .......................................................................50 15.3.1 EARTH RETURN SENDERS......................................................................................50 15.3.2 INSULATED RETURN SENDERS..............................................................................50 15.3.3 FUEL LEVEL SENDERS ............................................................................................51 15.4 J1939 CANBUS INTERFACE (OPTIONAL) .....................................................................52 15.4.1 EXAMPLE OF CONNECTING 5210 CONTROLLER TO ENGINE CANBUS. ...........52 15.5 5200 SERIES CONFIGURATION SOFTWARE AND P810 INTERFACE MODULE .......53 15.6 OUTPUT EXPANSION ......................................................................................................53 15.6.1 RELAY OUTPUT EXPANSION (157) .........................................................................53 15.6.2 LED OUTPUT EXPANSION (548) ..............................................................................53 15.7 INPUT EXPANSION...........................................................................................................54 15.8 STANDBY GENERATING SET?.......................................................................................54 15.9 FULLY INTEGRATED AUTO MAINS FAILURE...............................................................54

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1 INTRODUCTION The DSE 5210 autostart module has been designed to allow the OEM to meet most of the industry’s 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 (via external push-buttons) or automatically. The user also has facility to view all the system operating parameters via the LCD display. The DSE 5210 module monitors the engine, indicating the operational status and fault conditions; automatically shutting down the engine and giving a true first up fault condition of an engine failure by a flashing COMMON ALARM LED. Exact failure mode information is indicated by the LCD display on the front panel. The powerful Microprocessor contained within the module allows for a range of complex features to be incorporated as standard; • • • • •

Graphical Icon based LCD display (excluding the need for translations and languages). Voltage, Current and Power monitoring. Engine parameter monitoring. Fully configurable inputs for use as alarms or a range of different functions. Extensive range output functions using built in relay outputs or relay expansion available.

Selective operational sequences, timers and alarm trips can be altered by the customer via a PC using the 5200 series configuration software and P810 interface. Access to critical operational sequences and timers for use by qualified engineers, are barred by a security code. The module is housed in a robust plastic case for front panel mounting. Connections to the module are via locking plug and sockets.

2 CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION. NOTE:

Highlights an essential element of a procedure to ensure correctness.

CAUTION!

Indicates a procedure or practice which, if not strictly observed, could result in damage or destruction of equipment.

WARNING!



Indicates a procedure or practice, which could result in injury to personnel or loss of life if not followed correctly. 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. Compliant with BS EN 60950 Low Voltage Directive Compliant with BS EN 50081-2 EMC Directive Compliant with BS EN 50082-2 EMC Directive Indicates a function only applicable when the controller is configured for connection to a J1939 engine controller Year 2000 Compliant

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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

3 OPERATION The following description details 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.

FIG 1 3.1

AUTOMATIC MODE OF OPERATION NOTE:- If a digital input configured to panel lock is active, the LCD will display the

icon. When in panel lock, changing module modes will not be possible. Viewing the instruments

and event logs

is NOT affected by panel lock.

This mode is activated by pressing the action.

pushbutton. An LED indicator beside the button confirms this

When a Remote Start signal is applied to the remote start input, the following sequence is initiated:The Remote Start Active indicator illuminates (if configured). To allow for false signals the Start Delay timer is initiated. After this delay, if the pre-heat output option is selected then the pre-heat timer is initiated, and the corresponding auxiliary output (if configured) will energise.

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NOTE:- If the Remote Start signal is removed during the Start Delay timer, the unit will return to a stand-by state. After the above delays the Fuel Solenoid is energised, then one second later, the Starter Motor is engaged. The engine is cranked for a pre-set time period. If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and Fail to Start

fault will be displayed accompanied by a flashing shutdown

symbol.

When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from the Alternator output. Alternatively a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is selected by PC using the 5200 series configuration software). Rising oil pressure can also be used to disconnect the starter motor, however it cannot be used for underspeed or overspeed detection. After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault. Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to stabilise before accepting the load. If an auxiliary output has been selected to give a load transfer signal, this would then activate. NOTE:-A load transfer will not be initiated until the Oil Pressure has risen. Thus preventing excessive wear on the engine. On removal of the Remote Start signal, the Stop delay timer is initiated, once it has timed out, the load Transfer signal is de-energised, removing the load. The Cooling timer is then initiated, allowing the engine a cooling down period off load before shutting down. Once the Cooling timer expires the Fuel Solenoid is de-energised, bringing the generator to a stop. Should the Remote Start signal be re-activated during the cooling down period, the set will return on load.

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3.2

MANUAL OPERATION NOTE:- If a digital input configured to panel lock is active, the LCD will display the

icon. When in panel lock, changing module modes will not be possible. Viewing the instruments

and event logs

is NOT affected by panel lock.

To initiate a start sequence in MANUAL, press the pushbutton. When the controller is in the manual mode (indicated by an LED indicator beside the button), pressing the START (I) button will initiate the start sequence. NOTE:- There is no Start Delay in this mode of operation. If the pre-heat output option is selected this timer is then initiated, and the auxiliary output selected is energised. After the above delay the Fuel Solenoid is energised, then the Starter Motor is engaged. The engine is cranked for a pre-set time period. If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and Fail to Start

fault will be displayed accompanied by a flashing shutdown

indicator.

When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from the Alternator output. Alternatively a Magnetic Pickup mounted on the flywheel housing can be used for speed detection (This is selected by PC using the 5200 series configuration software). Rising oil pressure can also be used to disconnect the starter motor, however it cannot be used for underspeed or overspeed detection. After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault. Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to stabilise before it can be loaded. The generator will run off load, unless a Remote Start signal is applied, and if Load Transfer has been selected as a control source, the appropriate auxiliary output selected will activate. If the Remote Start signal is removed, the generator will continue to run On load until the Auto mode is selected. The Remote Stop Delay Timer will time out, the load is then disconnected. The generator will then run off load allowing the engine a cooling down period. Selecting STOP (O) de-energises the FUEL SOLENOID, bringing the generator to a stop.

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4 PROTECTIONS The module will indicate that an alarm has occurred in several ways; The LCD display will indicate a ‘common alarm’ either : (warning) or

(shutdown)

If appropriate, the LCD display or LED indicators will display the appropriate alarm icon i.e. for battery charging failure : NOTE:- Alarm icons in the LED display area are ‘hid until lit’. This means that the display area appears totally clear, and ‘free from clutter’. The advantage of this is that when an alarm does occur, the respective LED icon will illuminate on the otherwise blank fascia. This makes alarm identification much clearer.

If no alarms are present the LCD will extinguish any alarm icons.

In the event of a warning alarm the LCD will display the appropriate icon. If a shutdown then occurs the module will display the appropriate icon. The original warning alarm icon will remain displayed. Example:-

Low battery volts warning (all symbols steady)

Followed by….

Low battery volts warning indicator still present, common alarm indicator has changed to a shutdown symbol and is now flashing. Also present is the flashing underspeed LED.

Underspeed and Shutdown alarm Icons are displayed flashing. The original warning will remain displayed as long at the triggering conditions remain. Any subsequent warnings or shutdowns that occur will be displayed steady, therefore only the first-up shutdown will appear flashing.

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4.1

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. In the event of a warning alarm the LCD will display:-

BATTERY CHARGE FAILURE, if the module does not detect a voltage from the warning light terminal on the icon will illuminate. auxiliary charge alternator the BATTERY LOW VOLTAGE, if the module detects that the plant DC supply has fallen below the low volts setting level, the module will display:-

V The Battery Low Voltage alarm is delayed by the Low DC Volts Delay timer. BATTERY HIGH VOLTAGE, if the module detects that the plant DC supply has risen above the high volts setting level, the module will display:-

V FAIL TO STOP, If the module detects the engine is still running when the ‘Fail to stop timer’ expires, then the module will display:-

NOTE:- ‘Fail to Stop’ could indicate a faulty oil pressure sender - If engine is at rest check oil sender wiring and configuration. AUXILIARY INPUTS, if an auxiliary input has been configured as a warning the appropriate LCD segment will be displayed:-

! LOW FUEL LEVEL. If the fuel level detected by the fuel level sender falls below the low fuel level setting, a warning will occur. The

4.2

icon will illuminate.

ANALOGUE PRE-ALARMS

The following alarms are termed ‘pre-alarms’ as they pre warn the operator of a potentially more serious alarm condition. For instance, if the engine temperature rises past the pre alarm level, a warning condition will occur to notify the operator. If the temperature falls below the level, then the alarm ceases, and the set will continue to run as normal. However if the temperature continues to rise until the coolant temperature trip point is reached, the warning is escalated and a high coolant temperature shutdown is initiated. During a pre-alarm condition, the warning symbol icon:

is displayed on the LCD display, along with the appropriate

LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low oil pressure prealarm setting level after the Safety On timer has expired, a warning will occur. The icon will illuminate.

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HIGH ENGINE TEMPERATURE if 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, a warning will occur. icon will illuminate.

The

OVERSPEED, if the engine speed exceeds the pre-alarm trip a warning is initiated. icon will illuminate. The Overspeed is not delayed, it is an immediate warning. UNDERSPEED, if the engine speed falls below the pre-set pre-alarm after the Safety On timer has expired, a warning is initiated. icon will illuminate.

The

GENERATOR HIGH FREQUENCY if the module detects a generator output frequency in excess of the pre-set pre-alarm, a warning is initiated. The icon will illuminate. Generator High Frequency is not delayed, it is an immediate warning. GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the pre-set pre-alarm after the Safety On timer has expired, a warning is initiated. The

icon will illuminate.

GENERATOR HIGH VOLTAGE if the module detects a generator output voltage in excess of the pre-set trip a shutdown is initiated. The V icon will illuminate. High voltage is not delayed, it is an immediate shutdown. GENERATOR LOW VOLTAGE if the module detects a generator output voltage below the below the pre-set prealarm after the Safety On timer has expired, a warning is initiated. The

V

icon will illuminate.

CAN ECU ERROR If the module is configured for J1939 operation and receives an “error” message from the engine control unit, ‘Can ECU fail” is shown on the module’s display and a warning alarm is generated. Usually, an associated alarm code is also displayed, detailing the exact alarm detected. For details on these code meanings, refer to the ECU instructions provided by the engine manufacturer.

4.3

HIGH CURRENT WARNING ALARM

GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the pre-set trip a warning is initiated.

A

icon will illuminate. The If this high current condition continues for an excess period of time, then the alarm is escalated to a shutdown condition. For further details of the high current alarm, please see High Current Shutdown Alarm.

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4.4

SHUTDOWNS

Shutdowns are latching and stop the Generator. The alarm must be cleared, and the fault removed to reset the module. In the event of a shutdown alarm the LCD will display:(flashing). The appropriate icon will also be displayed flashing NOTE:- The alarm condition must be rectified before a reset will take place. If the alarm condition remains it will not be possible to reset the unit (The exception to this is the Low Oil Pressure alarm and similar ‘delayed alarms’, as the oil pressure will be low with the engine at rest). Any subsequent warnings or shutdowns that occur will be displayed steady, therefore only the first-up shutdown will appear flashing. FAIL TO START, if the engine does not fire after the pre-set number of attempts has been made a shutdown will be initiated. icon will illuminate. The 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

icon will illuminate. 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. icon will illuminate. The 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

icon will illuminate.

OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated. icon will illuminate. The Overspeed is not delayed, it is an immediate shutdown. NOTE:-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 5200 series configuration software manual under heading ‘Overspeed Overshoot’ for details. UNDERSPEED, if the engine speed falls below the pre-set trip after the Safety On timer has expired, a shutdown is initiated. The

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GENERATOR HIGH FREQUENCY if the module detects a generator output frequency in excess of the pre-set trip a shutdown is initiated. The icon will illuminate. Generator High Frequency is not delayed, it is an immediate shutdown. GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the pre-set trip after the Safety On timer has expired, a shutdown is initiated. The

icon will illuminate.

GENERATOR HIGH VOLTAGE if the module detects a generator output voltage in excess of the pre-set trip a shutdown is initiated. The V icon will illuminate. High voltage is not delayed, it is an immediate shutdown. GENERATOR LOW VOLTAGE if the module detects a generator output voltage below the below the pre-set trip after the Safety On timer has expired, a shutdown is initiated. The

V

icon will illuminate.

OIL PRESSURE SENDER OPEN CIRCUIT, if the module detects a loss of signal from the oil pressure sender (open circuit) a shutdown is initiated. The LCD will indicate:(Steady) (And ‘-----‘ on the engine oil pressure instrument). Sender failure is not delayed, it is an immediate shutdown. AUXILIARY INPUTS, if an auxiliary input has been configured as a shutdown the appropriate LCD segment will be displayed:-

! LOSS OF SPEED SIGNAL, if the speed sensing signal is lost during cranking, a shutdown is initiated. icon will illuminate. (Steady) (And ‘-----‘ on the engine RPM instrument). The NOTE:- This will only occur if the speed sensing signal is lost during cranking or during the safety on timer. If the signal is lost during normal operation the Generator will shutdown with an Under-speed alarm. CAN DATA FAIL If the module is configured for J1939 operation and does not detect data on the engine CANbus datalink, a shutdown will occur and ‘Can data fail’ is shown on the module’s display CAN ECU FAIL If the module is configured for J1939 operation and receives a “fail” message from the engine control unit, the engine is shutdown and ‘Can ECU fail” is shown on the module’s display. Usually, an associated failure code is also displayed, detailing the exact failure detected. For details on these code meanings, refer to the ECU instructions provided by the engine manufacturer.

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4.5

HIGH CURRENT SHUTDOWN ALARM

GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the pre-set trip a warning is initiated. This warning will continue for a period of time depending upon the level of overload that the generator is subjected to, and the configuration setting for Generator High Current in the 5200 series configuration software. For instance the factory default settings for Generator High Current allow for a loading of the generator to 110% for one hour. That is to say if the generator load level exceeds the trip point by 10%, a warning alarm will occur while the overload condition exists. If the load level does not drop to normal levels within one hour, the set is stopped, the 5210 module displaying either shutdown alarm or electrical trip alarm depending upon module configuration. Additionally, the

A

icon will illuminate.

NOTE:- Higher overload levels will result in a faster acting shutdown condition. For instance with the factory default configuration, an overload level twice that of the trip level ( typically 200%) will result in a Generator High Current shutdown condition after 36 seconds. For details of the relationship between the overload and the shutdown time, please see the Appendix section of this manual.

4.6

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.

In the event of an electrical trip alarm the

icon will illuminate.

Additionally, During the cooling timer the warning symbol symbol

is displayed followed by the flashing shutdown

when the cooling timer has expired.

AUXILIARY INPUTS, if an auxiliary input has been configured as an electrical trip the appropriate LCD segment will be displayed:-

! GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the pre-set trip a warning is initiated.

A

icon will illuminate. The If this high current condition continues for an excess period of time, then the alarm is escalated to either a shutdown or electrical trip condition (depending upon module configuration). For further details of the high current alarm, please see High Current Shutdown Alarm.

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5 DESCRIPTION OF CONTROLS The following section details the function and meaning of the various controls on the module.

FIG2

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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

5.1

TYPICAL LCD DISPLAY SCREENS

INSTRUMENTS The LCD displays the various engine parameters such as ‘ENGINE SPEED’, ‘OIL PRESSURE’, ‘HOURS RUN’, etc. Each instrument is displayed with the appropriate units of measure. In this example, the values being displayed are Generator phase to neutral L1-N, AC

voltages V.

STATUS ICONS The LCD also displays the status of the controller by showing (for example) an hourglass symbol when a timer is in progress or by displaying a common alarm symbol. This display is indicating that the timer is in progress and a warning alarm is present. See the ‘Protections’ section of this manual for details of the alarms. In this example the values being displayed are the three factory AC USER DEFINED INDICATIONS

currents A

The LCD displays the user-defined indications when configured and active. The icons will illuminate and point to the appropriate text insert label. These indications can be used to indicate the operation of external equipment (i.e. ‘Battery Charger On’, ‘Breaker Closed’ etc) or to indicate internal states (i.e. Engine Running, Safety On, etc).

USER DEFINED ALARMS The LCD displays the user-defined alarms when configured and active. The icons will illuminate and point to the appropriate text insert label. These alarms can be used to indicate the operation of external alarms (i.e. ‘Low Fuel Level’, ‘Low Coolant level’ etc) or to indicate internal alarms (i.e. Fail to Stop, MPU fault, etc).

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5.2

LCD DISPLAY AREAS

Instrument values

Display information & units of measure

Alarm icons

Status icons

User configurable display icons

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5.3

VIEWING THE INSTRUMENTS

It is possible to manually scroll to display the different instruments by repeatedly operating the scroll button. Once selected the instrument will remain on the LCD display until the user selects a different instrument or after a period of inactivity the module will revert to the initial display (Hz/RPM). Instrument Page Order:• Generator RPM / Frequency (Hz) • AC Voltage Line-Neutral • AC Voltage Line-Line • Oil Pressure • Coolant temperature • Fuel level (%) • Engine Hours Run • DC Battery Voltage • AC Line Current • AC Line power (kW) • AC Line power (kVA) • AC phase angle (cos ∅) • CanBus J1939 messages (optional) Manually Selecting an Instrument Initial display (Hz/RPM)

Pressing the DOWN button the LCD will then show (Generator L-N voltages)

Pressing the DOWN button the LCD will then show (Generator L-L voltages)

Pressing the button again will scroll through each individual instrument eventually returning to the original instrument displayed. NOTE:-Once selected the instrument will remain on the LCD display until the user selects a different instrument or after a period of inactivity the module will revert to the initial display.

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5.3.1

CANBUS MESSAGES

On J1939 enabled 52xx controllers connected to a CanBus ECU, alarm status messages are transmitted to the 52xx controller and displayed on the CanBus message instrumentation page. Can alarm message Suspect Parameter Number (SPN) = 102 Failure Mode Indicator (FMI) = 16

Examples of SPN / FMI numbers, taken from the Volvo Penta TAD12 manual are :

SPN 110 – Engine coolant temperature FMI 0 – Out of range FMI 3 – Above normal FMI 4 – Below normal

NOTE:- For details on these code meanings, refer to the ECU instructions provided by the engine manufacturer.

NOTE:- When using 52xx configuration and instrumentation PC software, ‘hovering’ the mouse cursor over the SPN/FMI numbers will display the J1939 messages where appropriate.

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5.4

VIEWING THE EVENT LOG

The model 5210 remote start module maintains a log of the last 15 shutdown alarms to enable the operator or engineer to view the past alarms history. Only shutdown and electrical trip alarms are logged; warning alarms are not logged. Once the log is full (15 shutdown alarms), any subsequent shutdown alarms will overwrite the oldest entry in the log. Hence the log will always contain the 15 most recent shutdown alarms. The alarm is logged, along with the date and time of the event in the format shown in this example.

To view the event log, press the log button the event log has been entered.

. The LCD display will flash the log symbol

to confirm that

In this example, the oil can symbol represents an oil pressure shutdown, backed up by the flashing shutdown symbol in the LCD display. The value displayed means that the oil pressure shutdown occurred on November 1st 2002 at 8:17.

Press down

to view the next most recent shutdown alarm : In this example, the fuel pump symbol represents a fuel level shutdown, backed up by the flashing shutdown symbol in the LCD display. The value displayed means that the oil pressure shutdown occurred on November 1st 2002 at 11:50.

will cycle through the past alarms until all 15 logged alarms have been viewed, Continuing to press down after which the most recent alarm will again be showed and the cycle will begin again. To exit the event log and return to viewing the instruments, press the log

5.5

INDICATORS

COMMON ALARM LCD indicators These indicate when an alarm condition is present. The Alarm icons or LEDs will detail the exact nature of the alarm.

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USER CONFIGURABLE LCD INDICATORS These LCD’s can be configured by the user to indicate any on of the different functions based around the following:• INDICATIONS - Monitoring of a digital input and indicating associated functioning user’s equipment - Such as Battery Charger On or Louvres Open, etc. • WARNINGS and SHUTDOWNS - Specific indication of a particular warning or shutdown condition, backed up by LCD indication (!)- Such as Low Oil Pressure Shutdown, Low Coolant level, etc. • STATUS INDICATIONS - Indication of specific functions or sequences derived from the modules operating state - Such as Safety On, Pre-heating, Generator Available, etc.

5.6

CONTROLS

STOP/RESET This button places the module into its Stop/reset mode. This will clear any alarm conditions for which the triggering criteria have been removed. If the engine is running and this position is selected, the module will automatically instruct the changeover device to un-load the generator (‘Load transfer’ becomes inactive (if used)). The fuel supply will be removed and engine will be brought to a standstill. Should a remote start signal be present while operating in this mode, a remote start will not occur. MANUAL This mode is used to allow manual control of the generator functions. Once in Manual mode the module will respond to the start (I) button and start the engine and run off load. If the engine is running off-load in the Manual mode and a remote start signal becomes present, the module will automatically instruct the changeover device to place the generator 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’ positions is selected. AUTO This button places the module into its ‘Automatic’ mode. This mode allows the module to control the function of the generator automatically. The module will monitor the remote start input and once a start condition is signalled the set will be automatically started and placed on load (‘Load transfer’ becomes active (if used)). If the starting signal is removed the module will automatically transfer the load from the generator and shut the set down observing the stop delay timer and cooling timer as necessary. The module will then await the next start event. For further details please see the more detailed description of ‘Auto Operation’ earlier in this manual. START mode. Pressing this button in manual mode This button is only active in MANUAL will start the engine and run off load. If the engine is running off-load in the Manual mode and a remote start signal becomes present, the module will automatically instruct the changeover device to place the generator 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’ positions is selected.

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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

6 FRONT PANEL CONFIGURATION Although full configuration of the module is possible using the 5200 series configuration software, selected parameters that may require adjustment in the field are able to be adjusted via the module’s fascia. NOTE:- Care should be taken to ensure that changes made via the front panel editor are carefully recorded and fed back to the generator supplier if applicable. This is to safeguard against using the 5200 series configuration software to configure the module at a later date, possibly overwriting the changes made using the front panel editor. When using the 5200 series configuration software to make configuration changes, the first operation should be to “read configuration from controller” to ensure that any changes made to the controller’s configuration by the front panel editor are ‘loaded’ into the PC before any changes are made. Full details of this procedure can be found in the 5200 series configuration software manual.

6.1

ACCESSING THE FRONT PANEL CONFIGURATION EDITOR

Press the configure/log

and Stop/Reset

buttons simultaneously. The LCD configure indicator

flash to indicate that the module is in ‘configuration mode’. Release the Stop/Reset configure/log

# will

button then release the

button.

The first configurable parameter is then displayed : The parameter being displayed in this example is the Low Oil Pressure prealarm, being indicated by the illuminated oil can. The warning symbol is indicating that it is the warning (pre-alarm) parameter that is being displayed.

NOTE:- To exit the front panel configuration editor at any time, press the Stop/Reset Ensure you have saved any changes you have made by pressing the

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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

6.1.1

EDITING AN ANALOGUE VALUE

9

Press the button to enter edit mode. This is indicated by the flashing parameter. In this example, entering edit mode will cause the 1.2 value to flash.

–

When in edit mode, pressing the + or buttons will adjust the parameter to the desired value. Press the button to ‘save’ the value. The value will stop flashing to confirm that it has been saved.

9

To select another value to edit, press the + button : The next parameter being displayed in this example is the Low Oil Pressure shutdown, being indicated by the illuminated oil can. is indicating that it is The shutdown symbol the shutdown (trip) parameter that is being displayed. Continuing to press the + or

Config’ Section

Parameter

Type

Analogue senders

Low Pressure

Pre Alarm

Low Pressure

Trip

Calendar Timers

Generator output

23

– buttons will cycle through the adjustable parameters in the following order : Icons displayed

High Temperature

Pre Alarm

High Temperature

Trip

Fuel Level

Pre Alarm

Date/time

Date/time

Start delay

Timer

2

Preheat

Timer

3

Crank attempt

Timer

4

Crank rest

Timer

5

Safety delay

Timer

6

Overspeed overshoot

Timer

7

Warming up

Timer

8

Return delay

Timer

10

Cooling run

Timer

11

E.T.S.(Energise to stop) solenoid hold

Timer

12

Generator Under Voltage L1-N

Trip

Generator Under Voltage L1-N

Pre Alarm

Generator Over Voltage

Pre Alarm

Generator Over Voltage

Trip

Generator Under Frequency

Trip

Generator Under Frequency

Pre Alarm

Generator Over Frequency

Pre Alarm

Generator Over Frequency

Trip

Delayed Overcurrent %

Trip

V V V V

)

A

DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual Front panel configurable items continued:

Config’ Section

Parameter

Type

Engine speed

Under Speed (RPM)

Trip

Under Speed (RPM)

Pre Alarm

DC Voltages

Over Speed (RPM)

Pre Alarm

Over Speed (RPM)

Trip

Icons displayed

Low DC Voltage

Warning

V

High DC Voltage

Warning

V

Charge Alternator Failure

Warning

NOTE:- The timers are numbered to enable them to be identified when in configuration mode. Some numbers are reserved so do not appear in the list. In the following example timer number 2 (‘Start delay’ from the above list) is currently set to 5.0 seconds. Ie the ‘hour glass’ indicates that it is a timer being displayed. The ‘2’ indicates that it is timer number 2 (Start delay). The current setting is 5.0 (seconds).

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6.1.2

EDITING THE CURRENT DATE/TIME

The date/time should be initially set using the 5200 series configuration software. However there may be certain circumstances where a minor change to the module’s time is required. One such instance is correction for daylight saving. NOTE:- The 5210 controller maintains the current date/time so long as it connected to a DC supply within the operating range. Disconnection of the supply will result in the date/time being frozen until the module’s power is reapplied. When this occurs, the date/time will resume operation from the time the power was disconnected. If this occurs you can use the front panel editor to correct the date/time or reset it using the 5200 series configuration software.

NOTE:- The calendar is used by the 5210’s run scheduler and the event log.

Press the configure/log

and Stop/Reset

buttons simultaneously. The LCD configure indicator

flash to indicate that the module is in ‘configuration mode’. Release the Stop/Reset configure/log

# will

button then release the

button.

Press the + button until the calendar is shown : This display is showing a time of 4:30 on 21st October 2002.

9 button. The time, 4.30 in this example, will begin flashing. Press the + or – buttons to adjust the time in one minute steps until the desired time is shown. Press the 9 button to save the change. The To edit the time, press the

time stops flashing to confirm that is has been successfully stored.

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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

7 INSTALLATION INSTRUCTIONS The model DSE 5210 Module has been designed for front panel mounting. Fixing is by 4 clips for easy assembly.

7.1

PANEL CUT-OUT

160.00mm (6.3”)

220.00mm (8.7”)

FIG 3 Maximum panel thickness – 8mm (0.3”) In conditions of excessive vibration the module should be mounted on suitable anti-vibration mountings.

7.2

COOLING

The module has been designed to operate over a wide temperature range -30 to +70º C. 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 95%.

7.3

UNIT DIMENSIONS

Panel cutout 220mm x 160mm ( 8.7” x 6.3”)

FIG 4

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7.4

FRONT PANEL LAYOUT

7.5

REAR PANEL LAYOUT

FIG 5

FIG 6

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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

8 ELECTRICAL CONNECTIONS Connections to the Module are via plug and sockets.

8.1

CONNECTION DETAILS

The following describes the connections and recommended cable sizes to the 7 plugs and sockets on the rear of the Module. See rear panel layout FIG 6.

8.1.1 PIN No 1

PLUG “A” 8 WAY DESCRIPTION

3

DC Plant Supply Input (-ve) DC Plant Supply Input (+ve) Emergency Stop Input

4 5 6 7 8

Fuel relay Output Start relay Output Auxiliary Output relay 1 Auxiliary Output relay 2 Auxiliary Output relay 3

2

8.1.2 PIN No 9 10 11 12 13 14 15 16 17 18 19

CABLE SIZE 2.5mm

NOTES

2.5mm

(Recommended Maximum Fuse 21A)

2.5mm

Plant Supply +ve. Also supplies fuel & start outputs. (Recommended Maximum Fuse 32A) Plant Supply +ve from pin 3. 16 Amp rated. Plant Supply +ve from pin 3. 16 Amp rated. Plant Supply +ve. 5 Amp rated. Plant Supply +ve. 5 Amp rated. Plant Supply +ve. 5 Amp rated.

2.5mm 2.5mm 1.0mm 1.0mm 1.0mm

PLUG “B” 11 WAY DESCRIPTION Charge fail / excite Auxiliary input 1 Auxiliary input 2 Auxiliary input 3 Auxiliary input 4 Auxiliary input 5 Auxiliary input 6 Functional Earth Magnetic pickup +ve Magnetic pickup -ve Not connected

CABLE SIZE 2.5mm 0.5mm 0.5mm 0.5mm 0.5mm 0.5mm 0.5mm 2.5mm 0.5mm 0.5mm -

NOTES Do not connect to ground (battery –ve) Switch to -ve Switch to -ve Switch to -ve Switch to -ve Switch to -ve Switch to -ve Connect to a good clean earth point Connect to Magnetic Pickup device Connect to Magnetic Pickup device

NOTE:- Ensure magnetic pickup screen is connected to ground at one end only.

NOTE:- When the module is configured for CanBus J1939 operation, terminals 17 & 18 should be left unconnected. Engine speed is transmitted to the 52xx controller on the CanBus link.

8.1.3 PIN No 20 21 22

28

PLUG “C” 3 WAY (OPTIONAL) DESCRIPTION CanBus port Common CanBus port H CanBus port L

CABLE SIZE 0.5mm 0.5mm 0.5mm

NOTES Use only 120Ω CanBus approved cable Use only 120Ω CanBus approved cable Use only 120Ω CanBus approved cable

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8.1.4 PIN No 23 24 25 26

PLUG “D” 4 WAY (OPTIONAL) DESCRIPTION RS485 port Common RS485 port B RS485 port A Not connected

CABLE SIZE 0.5mm 0.5mm 0.5mm -

NOTES Use only 120Ω RS485 approved cable Use only 120Ω RS485 approved cable Use only 120Ω RS485 approved cable

NOTE:- Connector E is not fitted to the 5210 remote start module.

8.1.5 PIN No 35 36 37 38

8.1.6 PIN No 39 40 41 42 43

8.1.7 PIN No 44 45 46 47

PLUG “F” 4 WAY DESCRIPTION Generator L1 voltage monitoring input Generator L2 voltage monitoring input Generator L3 voltage monitoring input Generator Neutral input

CABLE SIZE 1.0mm 1.0mm 1.0mm 1.0mm

NOTES Connect to generator L1 output (AC) (Recommend 2A fuse) Connect to generator L2 output (AC) (Recommend 2A fuse) Connect to generator L3 output (AC) (Recommend 2A fuse) Connect to generator Neutral terminal (AC)

PLUG “G” 5 WAY DESCRIPTION CT Secondary for L1 CT Secondary for L2 CT Secondary for L3 CT secondary common Not connected

CABLE SIZE 2.5mm 2.5mm 2.5mm 2.5mm -

NOTES Connect to secondary of L1 monitoring CT Connect to secondary of L2 monitoring CT Connect to secondary of L3 monitoring CT Connect to secondary of all monitoring CT’s

PLUG “H” 4 WAY DESCRIPTION Oil Pressure Input Coolant Temperature Input Fuel Level input Sender Common Return

CABLE SIZE 0.5mm 0.5mm

NOTES Connect to Oil pressure sender Connect to Coolant Temperature sender

0.5mm 0.5mm

Connect to Fuel Level sender Return feed for senders*.

NOTE*:- If using single terminal senders refer to connection diagram. If using earth return type senders connect return terminals to pin 47 and also connect pin 47 to earth. This is detailed in the Appendix section entitled “Sender wiring recommendations” elsewhere in this manual.

NOTE:- When the module is configured for CanBus J1939 operation, terminals 44 & 45 should be left unconnected. Engine oil pressure and coolant temperature is transmitted to the 52xx controller on the CanBus link.

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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

8.1.8

PC CONFIGURATION INTERFACE CONNECTOR 8-way connector allows connection to PC via the 810 configuration interface. Module can then be re-configured utilising the 5200 series configuration software.

8.1.9

EXPANSION OUTPUT CONNECTOR The expansion connector allows connection to the 157 relay expansion module or to the 548 LED Remote annunciator module.

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8.2

CONNECTOR FUNCTION DETAILS

The following describes the functions of the 3 connectors on the rear of the module. See rear panel layout FIG 5.

8.2.1 PIN No 1 2 3

4 5 6 7 8

8.2.2 PIN No 9 10 11 12 13 14 15 16 17 18 19

PLUG “A” 8 WAY DESCRIPTION DC Supply -ve. System DC negative input. (Battery Negative). DC Supply +ve. System DC positive input. (Battery Positive). Emergency Stop input. Internally linked to Starter and Fuel outputs. If this input is not connected to positive the module will be locked out, and if the engine is running it will shutdown immediately. The Positive Supply is also removed from Starter and Fuel outputs, therefore only a single pole Emergency Shutdown button is required. Fuel Relay output. Plant Supply +ve from pin 3. Used to control the fuel solenoid or engine fuel control system. Starter Relay output. Plant Supply +ve from pin 3. Used to control the Starter Motor. Auxiliary Relay output 1. Plant Supply +ve. Configurable output, see Calibration Manual for options available. Auxiliary Relay output 2. Plant Supply +ve. Configurable output, see Calibration Manual for options available. Auxiliary Relay output 3. Plant Supply +ve. Configurable output, see Calibration Manual for options available.

PLUG “B” 11 WAY DESCRIPTION Charge Fail input / Excitation output. Supplies excitation to the Plant Battery Charging Alternator, also an input for the Charge Fail detection circuitry. Auxiliary input 1. 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 2. 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 3. 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 4. 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 5. 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 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. Functional Earth - Ensure connection to a good clean earth point. 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. Not connected

NOTE:- Ensure magnetic pickup screen is connected to ground at one end only. NOTE:- When the module is configured for CanBus J1939 operation, terminals 17 & 18 should be left unconnected. Engine speed is transmitted to the 52xx controller on the CanBus link.

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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

8.2.3 PIN No 20 21 22

8.2.4 PIN No 23 24 25 26

PLUG “C” 3 WAY (OPTIONAL, FITTED TO J1939 CONTROLLERS ONLY) DESCRIPTION CanBus port Common. Do not connect this terminal to earth. Use only screened 120Ω cable approved specifically for use in CanBus applications. CanBus port H. Use only screened 120Ω cable approved specifically for use in CanBus applications. CanBus port L. Use only screened 120Ω cable approved specifically for use in CanBus applications.

PLUG “D” 4 WAY (OPTIONAL, FITTED TO RS485 CONTROLERS ONLY) DESCRIPTION RS485 port Common RS485 port B. Use only screened 120Ω cable approved specifically for use in RS485 applications. RS485 port A. Use only screened 120Ω cable approved specifically for use in RS485 applications. Not used. Do not connect to this terminal.

NOTE:- Connector E is not fitted to the 5210 remote start module.

8.2.5 PIN No 35 36 37 38

8.2.6 PIN No 39 40 41 42 43

32

PLUG “F” 4 WAY DESCRIPTION Generator L1 sensing input. Connect to alternator L1 output. Generator L2 sensing input. Connect to alternator L2 output. If using single phase only do not connect this terminal. Generator L3 sensing input. Connect to alternator L3 output. If using single phase only do not connect this terminal. Generator N sensing input. Connect to alternator N output.

PLUG “G” 5 WAY DESCRIPTION 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 and CT earth connection. Not used. Do not connect to this terminal.

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8.2.7 PIN No 44 45 46 47

PLUG “H” 4 WAY DESCRIPTION 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. Fuel Level sensing input. Connect to resistive type fuel level sender. Refer to connection diagram for details. Sender Common connection. Return feed from sender units - refer to connection diagram for details.

NOTE:- When the module is configured for CanBus J1939 operation, terminals 44 & 45 should be left unconnected. Engine oil pressure and coolant temperature is transmitted to the 52xx controller on the CanBus link.

8.2.8

PURCHASING ADDITIONAL CONNECTOR PLUGS FROM DSE

If you require additional plugs from DSE, please contact our Sales department using the part numbers below. 5210 Terminal 1-8 9-19 20-22 23-26 35-38 39-43 44-47

Connector A B C D F G H

Plug description BL08 8way 5.08mm spacing connector plug BL11 11way 5.08mm spacing connector plug BL03 3way 3.81mm spacing connector plug BL04 4way 3.81mm spacing connector plug BL04 4way 10.16mm spacing connector plug BL05 5way 5.08mm spacing connector plug BL04 4way 5.08mm spacing connector plug

NOTE:- Connector E is not fitted to the 5210 remote start module.

33

DSE Part number 007-125 007-135 007-409 007-408 007-003 007-329 007-100

DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

8.3

ELECTRICAL CONNECTIONS TO J1939 ENABLED CONTROLLERS

This section of the manual is intended to describe only the connections between the 52xx controller and J1939 enabled controllers. All other connection details are described in the previous sections. NOTE:- The CANbus specification, used by J1939, requires that a 120Ω terminator is fitted to each end of the communications link. This termination resistor is fitted internally into the 52xx controller so is not required externally. Ensure that the 52xx controller is the ‘last’ device on the communications link where more than one device is connected to the engine ECU’s J1939 connector.

8.3.1

CUMMINS ISB / ISBE

PLUG “A” 8 WAY 52xx 52xx PIN No DESCRIPTION 4 Fuel relay output 5 Start relay output 6

Aux output 1

PLUG “C” 3 WAY 52xx 52xx PIN No DESCRIPTION

34

Cummins ISB OEM Harness connector B 39 Use to control a 30A external slave relay to supply DC battery power to 01,07,12,13

Cummins ISB 9 pin Deutsch connector SAE J1939 shield

21

CANbus H

SAE J1939 signal

22

CANbus L

SAE J1939 return

NOTES key switch input. Connects directly to engine starter solenoid. Configure 52xx ‘aux op 1’ to be “Louvre control” and configure 52xx ‘ETS Hold Timer’ to 20 seconds. This is used to power down the engine ECU 20seconds after the set comes to rest. NOTES Screen for the J1939 cable. Connect at Cummins ECU end only. J1939 + Use only screened 120Ω impedance cable approved specifically for use in CANbus applications. J1939 - Use only screened 120Ω impedance cable approved specifically for use in CANbus applications.

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8.3.2

JOHN DEERE

PLUG “A” 8 WAY 52xx 52xx PIN No DESCRIPTION 4 Fuel relay output 5 Start relay output

John Deere 21-pin Deutsch connector G, J D

PLUG “C” 3 WAY 52xx 52xx PIN No DESCRIPTION 20 CANbus common

John Deere 21-pin Deutsch connector -

35

21

CANbus H

V

22

CANbus L

U

NOTES G = Switched ECU power, J = Ignition Start NOTES Screen for the J1939 cable. Connect at 52xx end only. J1939 + Use only screened 120Ω impedance cable approved specifically for use in CANbus applications. J1939 - Use only screened 120Ω impedance cable approved specifically for use in CANbus applications.

DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

8.3.3

PERKINS 2800 SERIES

PLUG “A” 8 WAY 52xx 52xx PIN No DESCRIPTION 4 Fuel relay output 5

Start relay output

PLUG “C” 3 WAY 52xx 52xx PIN No DESCRIPTION 20 CANbus common

Perkins Customer interface connector 1, 10, 15, 33, 34 -

Perkins Customer interface connector -

21

CANbus H

31

22

CANbus L

32

NOTES Powers up ECU and enables the injectors. Connects directly to engine starter solenoid. NOTES Screen for the J1939 cable. Connect at 52xx end only. J1939 + Use only screened 120Ω impedance cable approved specifically for use in CANbus applications. J1939 - Use only screened 120Ω impedance cable approved specifically for use in CANbus applications.

NOTE:- According to Perkins, warning lamps or equivalent must be connected to Perkins customer interface connector terminals 3, 4, 5, 8, 9, 16, 17. Failure to connect to these terminals will results in “open circuit” alarms from the ECU. Perkins have advised that a suitable equivalent for the warning lamp is a 220Ω 5W resistor. Be aware that outputs on terminals 4,5, & 16 are battery positive outputs. The outputs on terminals 3, 6, 8, 9 & 17 are battery negative outputs.

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8.3.4

SCANIA S6

PLUG “A” 8 WAY 52xx 52xx PIN No DESCRIPTION 4 Fuel relay output 5 Start relay output PLUG “C” 3 WAY 52xx 52xx PIN No DESCRIPTION 20 CANbus common

37

Scania EMS B1 connector 3 -

Scania EMS B1 connector -

21

CANbus H

9

22

CANbus L

10

NOTES Ignition U15 Connects directly to engine starter solenoid. NOTES Screen for the J1939 cable. Connect at 52xx end only. J1939 + Use only screened 120Ω impedance cable approved specifically for use in CANbus applications. J1939 - Use only screened 120Ω impedance cable approved specifically for use in CANbus applications.

DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

8.3.5

VOLVO TAD12

PLUG “A” 8 WAY 52xx 52xx PIN No DESCRIPTION 4 Fuel relay output 5 Start relay output 6 Aux output 1

Volvo TAD12 ‘Stand alone connector’ terminal H E P

PLUG “C” 3 WAY 52xx 52xx PIN No DESCRIPTION 20 CANbus common

Volvo TAD12 ‘Data bus connector’ terminal -

21

CANbus H

1 (Hi)

22

CANbus L

2 (Lo)

ADDITIONAL CONNECTIONS TO TAD12 ECU Volvo TAD12 ’Stand alone connector’ terminal R ECU Power negative supply Q ECU Power positive supply

NOTES TAD12 STOP input. TAD12 START input. Aux output 1 configured to “Louvre control”. NOTES Screen for the J1939 cable. Connect at 52xx end only. J1939 + Use only screened 120Ω impedance cable approved specifically for use in CANbus applications. J1939 - Use only screened 120Ω impedance cable approved specifically for use in CANbus applications. NOTES

NOTE:- Should the TAD12 ECU detect an engine fault not monitored by the 52xx, an ‘external reset’ must be provided to reset the ECU. Volvo specify that the reset is performed using external pushbuttons to give an input to TAD12 Standalone connector terminal J (diagnostics), P (power) and H(stop). According to Volvo, the reset sequence is : Press and hold down the diagnostic button (terminal J) and apply power to H (stop) Apply power to P (but don’t start the engine). Hold these inputs for three seconds. Release the diagnostic button (terminal J). Remove power from H (stop). Remove power from P (power).

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9 SPECIFICATION DC Supply Cranking Dropouts Typical Operating Current Max. Standby Current Alternator Input Range Single phase 2 wire system 3Phase 4Wire System 3Phase 3Wire System 2Phase 3Wire System Alternator Input Frequency Magnetic Input Range (if fitted) Magnetic Input Frequency CanBus interface type (optional) Start Relay Output Fuel Relay Output Auxiliary Relay Outputs Dimensions Panel cutout Charge Fail / Excitation Range Operating Temperature Range C.T. Burden C.T. Secondary C.T. Class Electromagnetic Compatibility Electrical Safety Cold Temperature Hot Temperature Humidity Vibration

Shock

39

8.0 to 35.0 V DC Continuous. Able to survive 0 V for 50mS, providing supply was at least 10 V before dropout and supply recovers to 5V. This is achieved without the need for internal batteries. 250mA at 12 V. 125mA at 24 V. 425mA at 12 V. 215mA at 24 V. 15V AC - 277 V AC (ph-N) (+20%) 15V AC - 277 V AC (ph-N) 3 Phase 4wire (+20%) 30V AC - 480 V AC (ph-ph) 3 Phase 3wire (+20%) 30V AC - 480 V AC (ph-ph) / 15V AC - 277V AC (ph-N) (+20%) 50Hz - 60 Hz at rated engine speed +/- 0.5 V to 70 V Peak 10,000 Hz (max) at rated engine speed. J1939 16 Amp DC at supply voltage. 16 Amp DC at supply voltage. 5 Amp DC at supply voltage. 240mm x 172mm x 57mm (9.45” x 6.77” x 2¼”) 220mm x 160mm ( 8.7” x 6.3”) Maximum panel thickness 8mm (0.3”) 0 V to 35 V -30 to +70°C 2.5VA 5A Protection Class Recommended BS EN 50081-2 EMC Generic Emission Standard (Industrial) BS EN 50082-2 EMC Generic Immunity Standard (Industrial) BS EN 60950 Safety of I.T. equipment, including electrical business equipment. BS EN 60068-2-1 to -30 oC BS EN 60068-2-2 to +70oC BS2011-2-1 to 93% RH @ 40°C 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

DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

10 COMMISSIONING 10.1.1 PRE-COMMISSIONING Before the system is started, it is recommended that the following checks are made:7.1. The unit is adequately cooled and all the wiring to the module is of a standard and rating compatible with the system. 7.2. The unit DC supply is fused and connected to the battery and that it is of the correct polarity. 7.3. The Emergency Stop input is wired to an external normally closed switch connected to DC positive. NOTE:- If Emergency Stop feature is not required link this input to the DC Positive. The module will not operate unless either the Emergency Stop is fitted correctly OR Pin 3 is connected to DC positive (+ve) 7.4. To check the start cycle operation take appropriate measures to prevent the engine from starting (disable the operation of the fuel solenoid). After a visual inspection to ensure it is safe to proceed, connect the battery supply. Select “MANUAL”, the unit start sequence will commence. 7.5. The starter will engage and operate for the pre-set crank period. After the starter motor has attempted to start the engine for the pre-set number of attempts the LCD will display its icon indicating; ‘Failed to start’ Select the STOP/RESET position to reset the unit.

.

7.6. Restore the engine to operational status (reconnect the fuel solenoid), again select “MANUAL”, this time the engine should start and the starter motor should disengage automatically. If not then check that the engine is fully operational (fuel available, etc.) and that the fuel solenoid is operating. The engine should now run up to operating speed. If not, and an alarm is present, check the alarm condition for validity, then check input wiring. The engine should continue to run for an indefinite period. It will be possible at this time to view the engine and alternator parameters - refer to the ‘Description of Controls’ section of this manual. 7.7. Select “AUTO” on the front panel, the engine will run for the pre-set cooling down period, then stop. The generator should stay in the standby mode. If not check that there is not a signal present on the Remote start input. 7.8. 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. 7.9. 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 it’s standby mode. 7.10. Set the modules internal clock/calendar to ensure correct operation of the scheduler and event logging functions. For details of this procedure see section entitled Front Panel Configuration – Editing the date/time. 7.11. If despite repeated checking of the connections between the 5210 and the customer’s system, satisfactory operation cannot be achieved, then the customer is requested to contact the factory for further advice on:INTERNATIONAL TEL: +44 (0) 1723 890099 INTERNATIONAL FAX: +44 (0) 1723 893303 E-mail: [email protected] Website : www.deepseaplc.com

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11 FAULT FINDING SYMPTOM Unit is inoperative Unit shuts down Unit locks out on Emergency Stop Intermittent Magnetic Pickup sensor fault Low oil Pressure fault operates after engine has fired High engine temperature fault operates after engine has fired. Shutdown fault operates Warning fault operates Fail to Start is activated after pre-set number of attempts to start Continuous starting of generator when in AUTO Generator fails to start on receipt of Remote Start signal. Pre-heat inoperative Starter motor inoperative Engine runs but generator will not take load Incorrect reading on Engine gauges

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 70 °C. Check the DC fuse. If an Emergency Stop Switch is not fitted, ensure that a positive is connected to the Emergency Stop input. Check emergency stop switch is functioning correctly. Check Wiring is not open circuit. Ensure that Magnetic pick-up screen is only connected at one end, if connected at both ends, this enables the screen to act as an aerial and will pick up random voltages. Check engine oil pressure. Check oil pressure switch/sender and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sender is compatible with the 5210 Module and is correctly configured. Check engine temperature. Check switch/sender and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sender is compatible with the 5210 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 5210 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. Check engine is operating correctly. Check sender and wiring paying particular attention to the wiring to terminal 47 (refer to appendix). Check that sender is compatible with the 5210 Module and is correctly configured.

NOTE:- The above fault finding is provided as a guide check-list only. As it is possible for the module to be configured to provide a wide range of different features always refer to the source of your module configuration if in doubt.

41

N

1

5210 OPERATING MANUAL ISSUE 2

F

Starter motor

2

Supply for controller

39

3

41

F

Battery

Crank

5

internal emergency stop

40

+

Fuel

4

43

9

Oil pressure sender Charge WL alt.

42

37

38

45

46

47

These ground connections must be on the engine block and must be a sound electrical connection to the sender bodies. The wire to terminal 47 must not be used to provide a ground connection to any other device.

44

36

F2A

H

21

20

10

L

11

22

Optional CanBus

COM

5210 controller

35

Coolant temp. sender

CT common

Not connected

F2A

Fuel level sender

F2A

Configurable auxiliary input 1

L3

Emergency stop

CT Earth

12

13

9 way D

Optional RS232 25

26

14

15

To plant supply +ve

A

24

23

B

810 interface

Optional RS485 SCR

Configurable auxiliary input 5

L2

Configurable auxiliary input 2

5200 series configuration software

Configurable auxiliary input 6

L1

Configurable auxiliary input 4

Not connected

N

8

7

16

17 18

157/548

6

19 810

Output expansion 157 relay board or 548 annunciator

Configurable auxiliary output 1

LOAD L2 L3

Not connected

Configurable auxiliary output 2

42 Configurable auxiliary output 3

L1

Functional Earth

Ground screen at one end only

MPU

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12 TYPICAL WIRING DIAGRAM

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Configurable auxiliary input 3

DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

13 FACTORY DEFAULT CONFIGURATION In the tables below, the icon # indicates an item that can be adjusted from the module’s front panel editor. Absence of the # icon beside an item means that adjustment of this parameter is only possible using the 5200 series configuration software in conjunction with the P810 interface. For further details on adjustment from the front panel editor, see the section entitled “Front panel configuration” elsewhere within this manual. 5200 series configuration software. Configuration for 5210 module. Filename – 5210a.XCF Printed on 14/04/03 12:25:18 Module settings Base module

Value 5210 remote start module

Miscellaneous settings Alternator fitted Poles Magnetic pickup fitted J1939 enabled AC System Enable fast loading feature Number of start attempts

Value Yes 4 No No 3 phase, 4 wire No 3

Input settings - Analogue Low oil pressure input type High coolant temp input type

Value VDO 10 bar VDO 120 degrees C

# # # #

Trip 1.17 Bar 17.0 PSI 1.03 Bar 14.9 PSI 115°C 239°F 120°C 248°F

Fuel level input type Fuel pump control Low fuel level

#

VDO Ohm Range No 10%

Input settings - Digital 1 Remote start 2 User configured 3 User configured 4 User configured 5 User configured 6 User configured

Value Close to activate Close to activate, Indication Always active Close to activate, Warning Active from safety on Close to activate, Shutdown Always active Close to activate, Shutdown Active from safety on Close to activate, Electrical trip Always active

Low oil pressure pre-alarm Low oil pressure shutdown High coolant temp pre-alarm High coolant temp shutdown

LCD indicator settings 1 Lit 2 Lit 3 Lit 4 Lit Output settings – Relay 1 Energise 2 Energise 3 Energise

43

Value Remote start present Digital input 2 active System in auto mode Common alarm Value Preheat (during pre-heat timer) Common alarm Close generator

Return 1.24 Bar 18.0 PSI N/A 110°C 230°F N/A

DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

Output settings – Expansion A 1 Energise 2 Energise 3 Energise 4 Energise 5 Energise 6 Energise 7 Energise 8 Energise

Value Output not used Output not used Output not used Output not used Output not used Output not used Output not used Output not used

Timer settings Start delay Pre-heat Sensor fail delay Cranking time Crank rest time Smoke limit Smoke limit off Safety on delay Overspeed overshoot Warming up time Transfer time Breaker close pulse Breaker trip pulse Return delay Cooling time ETS solenoid hold Fail to stop delay Generator transient delay Battery low volts delay Battery high volts delay LCD page timer

Value 5s 0s 2.0s 10s 10s 0s 0s 10s 0s 0s 0.7s 0.0s 0.0s 30s 30s 0s 30s 1s

# # # # # # #

# # #

1m 1m 5m

Generator settings – Voltage/frequency Under volts trip Under volts pre-alarm Over volts pre-alarm Over volts trip Under frequency trip Under frequency pre-alarm Over frequency pre-alarm Over frequency trip Generator settings – Current/power Generator CT primary Generator full load rating Delayed overcurrent Trip Curve

44

# # # # # # # #

#

Trip 184V AC 196V AC 265V AC 276V AC 40.0 Hz 42.0 Hz 55.0 Hz 57.0 Hz

Return N/A 207V AC 253V AC N/A N/A 45.0 Hz 52.0 Hz N/A

Value 500 A 500 A 100% ( 500 A ) 36

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Engine settings – Crank disconnect Crank disconnect on generator frequency Crank disconnect oil pressure Check oil pressure prior to starting Engine settings – speed Underspeed trip Underspeed prealarm Overspeed prealarm Overspeed trip Overspeed overshoot Plant battery settings Under volts warning Over volts warning Charge alternator warning Exercise scheduler settings Enable exercise scheduler

45

Value 21.0 Hz Yes

Value 1250 RPM 1350 RPM 1650 RPM 1750 RPM 0%

# # # #

# # #

Trip 8.0 V DC 33.0 V DC 8.0 V DC

Value No

Return 9.0 V DC 32.0 V DC N/A

DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

14 ICONS AND LCD IDENTIFICATION 14.1 PUSH BUTTONS Display

Description

Display

Description

Stop/Reset

I

Configure / log

Display

Description

Auto mode

Manual mode

Start (when in manual mode)

Scroll

14.2 STATUS / MEASUREMENT UNITS Display

L1 L1-

Description

Display

L2

Phase

N

Phase - Neutral

L2-

L1- L2

Phase - Phase

L2- L3

BAR

Pressure

V

Voltage

A

Amperes

kW

KiloWatts

¤ #

Description Phase

N

Display

L3

Description Phase

Phase - Neutral

L3-

Phase - Phase

L3- L1

Phase - Phase

KPa Oil Pressure Units

PSI

Pressure

o

F

Temperature

Hz

Frequency

o

C

Temperature

RPM

Speed

kVA

Apparent power

KW divided by kVA

Hours Run

AC

Generator

Timer in progress

DC

KPa

Configuration mode active Panel locked by configurable input

N

)

Phase -Neutral

Factory (load)

Fuel level

Event log

Canbus J1939 messages

14.3 ALARM INDICATIONS Display

Description

Display

Warning Alarm

Shutdown Alarm

Fuel

Low Oil Pressure

High Coolant Temperature Fail to start (Overcrank)

Charge Fail

Emergency Stop

46

Description

V

Over Voltage (DC)

V

Under Voltage (DC) Auxiliary Indication

!

Display

Description Electrical Trip

A

High Current Warning

V

Over Voltage (AC)

V

Under Voltage (AC)

Over-speed

Over frequency

Under-speed

Under frequency

Auxiliary Alarm (Warning or Shutdown)

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15 APPENDIX 15.1 ALTERNATIVE WIRING TOPOLOGIES The 5200 series controllers can support many different wiring topologies (AC systems) to suit the many systems in use world-wide. The ‘Typical connection diagram’ details how to connect the module when used in a 3 phase, 4 wire system (3 phase star connected alternators). Changes to this typical wiring diagram for other AC systems are detailed below. NOTE:- The factory default configuration for the 5210 module is for use with the 3 phase, 4 wire AC system. If another system is to be used, the controller must be reconfigured using the 5200 series configuration software.

15.1.1 3 PHASE, 3 WIRE The alternator is 3 phase delta connected. Phases are separated by 120°

15.1.2 1 PHASE, 2 WIRE Single phase alternator with neutral conductor.

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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

15.1.3 2 PHASE, 3 WIRE ( 2 PHASE CENTRE TAP NEUTRAL) The alternator is 2 phase star connected. The live phases are separated by 180°

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15.2 5210 IDMT TRIPPING CURVES (TYPICAL) 5210 Delayed over-current protection

1000000

100000

Tripping time in seconds

10000

1000

100

10

1 1

2 Current as a multiple of the trip-point setting (tripping curve = 36)

49

3

DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

15.3 SENDER WIRING RECOMMENDATIONS 15.3.1 EARTH RETURN SENDERS Connection Name

Terminal Number

Oil pressure Sender

44

Coolant temperature sender

45

Fuel level sender

46

Sender common

47

NOTE:- . It is important that terminal 47 ( sender common ) is soundly connected to an earth point on the ENGINE BLOCK, not within the control panel, and must be a sound electrical connection to the sender bodies.

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.

15.3.2 INSULATED RETURN SENDERS Connection Name

Terminal Number

Oil pressure Sender

44

Coolant temperature sender

45

Fuel level sender

46

Sender common

47

NOTE:- . It is important that terminal 47 ( sender common ) is soundly connected to an earth point on the ENGINE BLOCK, not within the control panel .

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15.3.3 FUEL LEVEL SENDERS The resistive fuel level senders supported by the 5200 series controllers are devices that translate fuel level into resistance. A change in fuel level translates directly to a change in the resistance of the sender. In the case of a parallel sided fuel tank, an accurate measure of the fuel level can easily be made, however as shown in the example below, this is not the case with non-parallel sided fuel tanks. Therefore it is recommended that only parallel sided fuel tanks are used to ensure correct fuel level detection. The fuel sender measures the distance between the top of the tank and the fuel level. Typically, they use a ball float. In this example, the distance between the top of the tank and the level of the fuel is 50% of the height of the tank. The fuel level sender will report the tank correctly as being 50% full. For a parallel-sided tank like this one, 50% distance between the top of the tank and the level of the fuel will occur when the tank is 50% full of fuel. In this example, the distance between the top of the tank and the level of the fuel is again 50% of the height of the tank, the fuel level sender will report the tank as being 50% full. However, as the bottom of the tank is curved, the actual amount of fuel in the tank is only about 40%. The fuel sender is incorrectly reporting the amount of remaining fuel.

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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

15.4 J1939 CANBUS INTERFACE (OPTIONAL) Modules fitted with the J1939 CANbus interface (specify on ordering) are capable of receiving engine data from engine CANbus controllers compliant with the J1939 standard. Canbus enabled engine controllers monitor the engines operating parameters such as engine speed, oil pressure, engine temperature (among others) in order to closely monitor and control the engine. The data that is gathered by the engine controller is transmitted on an industry standard communications interface (Canbus J1939). This allows generator controllers such as the DSE 52xx range to access these engine parameters with no physical connection to the sensor device.

15.4.1 EXAMPLE OF CONNECTING 5210 CONTROLLER TO ENGINE CANBUS. LOAD L2 L3

L1

N

COM

L

H

5200 series configuration software

L1 CT Earth

Output expansion 157 relay board or 548 annunciator

L2

F2A

9

Starter motor

45

F

Fuel

Crank + Battery

Charge WL alt.

25

5210 controller 46

47

10

Fuel level sender

F

44

B

24

These ground connections must be on the engine block and must be a sound electrical connection to the sender bodies. The ground connection to terminal 47 must not be used to provide a ground connection to any other device.

COM

11

L

H

20

26 19

21

22

810

CanBus

157/548

Not connected 17 Not connected 18

To plant supply +ve

12

13

14

15

6

7

8

16

Configurable auxiliary output 3

4

5

A

23

Configurable auxiliary output 2

3

9 way D

Configurable auxiliary output 1

2

Emergency stop

1

38

Configurable auxiliary input 6

Supply for controller

37

Configurable auxiliary input 5

internal emergency stop

36

Not connected

35

43

Configurable auxiliary input 1

42

Not connected

41

Not connected

40

Not connected

39

Optional RS485 SCR

Configurable auxiliary input 4

Optional RS232

CT common

Not connected

F2A

Configurable auxiliary input 3

F2A

Configurable auxiliary input 2

N

810 interface

L3

Functional Earth

NOTE:- Many CanBus ECU modules require a reset signal to clear any present alarms before the engine can be restarted. A signal for this can be generated by configuring one of the 52xx modules auxiliary outputs to “System in Stop Mode”. Depending upon the ECUs input requirements, an interposing relay may be required ie 52xx output (system in stop mode)

CanBus ECU RESET input

Automotive or plug-in relay

Battery negative

For details on the requirements of your engine ECU with regards to ‘Reset’ , you are referred to the manufacturer of your engine ECU.

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15.5 5200 SERIES CONFIGURATION SOFTWARE AND P810 INTERFACE MODULE The 5210 module can be configured using PC with Interface Module 810 and 52xx series PC configuration software. The 5200 series configuration software kit comprises the following:• • • •

810 Interface Module 25 to 9 way adapter RJ45 (8 Pin) Connecting Lead DSE SoftwareCD with configuration software

15.6 OUTPUT EXPANSION There are several methods of output expansion available for the 5210 module:-

15.6.1 RELAY OUTPUT EXPANSION (157) An expansion module is available, which connects to the configuration socket, and enables the 5210 to use eight additional relays, providing Volt-free contacts for customer connection.

POWER ON LED RELAY ACTIVE LED'S

LINK LOST LED FUNCTION SELECTOR

Refer to technical data sheet on the 157 relay module for further details.

15.6.2 LED OUTPUT EXPANSION (548) An expansion module is available, which connects to the configuration socket, and enables the 5210 to use eight additional LED’s, providing remote LED indication up to 50 metres away.

Refer to technical data sheet on the 548 LED module for further details. It is possible to use a mix of 157 and 548 modules to give both relay and LED expansion of the same 8 items if required (Please refer to our Technical Support department for details.).

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DSE Model 5210 Automatic Start Engine Management and Instrumentation System Operators Manual

15.7 INPUT EXPANSION It is possible to increase the number of monitored inputs available by utilising a DSE 540/541 Protection Expansion/Annunciator. Please refer to our Technical department for details.

15.8 STANDBY GENERATING SET? The 5210 needs to be given a remote start signal to initiate an engine start. This can be supplied by a Mains/Utility monitoring module to make the generating set start up automatically should the mains/utility supply fail. The 5210 module may be used in conjunction with DSE Automatic transfer switch controllers such as the model 500 (pictured below), 705 or 530. These not only monitor the mains and issue a start command to the 5210, they also provide control of the contactors or other changeover devices. Please refer to our Technical Support department for details.

Deep Sea Electronics plc

Model 500

15.9 FULLY INTEGRATED AUTO MAINS FAILURE The 5210 module can easily be upgraded with a 5220 controller. It has exactly the same mounting details and uses exactly the same rear connectors. Upgrading takes seconds and instantly provides integral mains (utility) monitoring and changeover functions in the same controller. Please refer to our website for details (http://www.deepseaplc.com)

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