550 Operators Manual For Deep Sea Controller PLC

DSE Model 550 Automatic Start Engine Management and Instrumentation System Operators Manual
TABLE OF CONTENTS
Section Page
INTRODUCTION ................................................................................................................................5
CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION........................................6
1. OPERATION................................................................................................................................7
1.1 CONTROL............................................................................................................................7
FIG 1.....................................................................................................................................7
1.2 NORMAL MANUAL OPERATION........................................................................................7
1.3 AUTOMATIC (REMOTE) OPERATION...............................................................................9
2. PROTECTIONS.........................................................................................................................12
VIEWING ALARMS................................................................................................................13
2.1 WARNINGS........................................................................................................................14
2.2 SHUTDOWNS....................................................................................................................15
2.3 ELECTRICAL TRIPS..........................................................................................................17
2.4 PRE-ALARMS AND OPTIONS ..........................................................................................17
3. DESCRIPTION OF CONTROLS...............................................................................................19
3.1 LCD DISPLAY ....................................................................................................................19
VIEWING THE INSTRUMENT AND EVENT LOG PAGES..........................................................20
SYNCHROSCOPE OPERATION (IF FITTED)..........................................................................21
OPERATOR CONFIGURATION MODE.......................................................................................22
POWER UP LCD DISPLAY ..........................................................................................................24
3.2 LED INDICATORS..................................................................................................................26
3.3 CONTROL PUSH-BUTTONS.................................................................................................27
3. INSTALLATION INSTRUCTIONS.............................................................................................28
3.1 PANEL CUT-OUT...............................................................................................................28
FIG 3...................................................................................................................................28
3.2 COOLING...........................................................................................................................28
3.3 UNIT DIMENSIONS ...........................................................................................................28
FIG 4...................................................................................................................................28
3.4 FRONT PANEL LAYOUT...................................................................................................29
FIG 5...................................................................................................................................29
3.5 REAR PANEL LAYOUT .....................................................................................................29
FIG 6...................................................................................................................................29
4. ELECTRICAL CONNECTIONS.................................................................................................30
4.1 CONNECTION DETAILS ...................................................................................................30
PLUG A 13 WAY.....................................................................................................................30
PLUG B 17 WAY.....................................................................................................................30
PLUG C 4 WAY.......................................................................................................................31
PLUG D 11 WAY (ONLY FITTED IF SYNCHRONISING OPTION IS REQUESTED) ...........31
PC CONFIGURATION INTERFACE CONNECTOR.................................................................32
EXPANSION INTERFACE CONNECTOR................................................................................32
4.2 CONNECTOR FUNCTION DETAILS.................................................................................33
PLUG A 13 WAY.....................................................................................................................33
PLUG B 17 WAY.....................................................................................................................34
PLUG C 4 WAY.......................................................................................................................34
PLUG D 11 WAY (ONLY FITTED IF SYNCHRONISING OPTION IS REQUESTED) ...........35
5. SPECIFICATION .......................................................................................................................36
6. COMMISSIONING.....................................................................................................................37
6.1 PRE-COMMISSIONING......................................................................................................37
7. FAULT FINDING........................................................................................................................38
8. TYPICAL WIRING DIAGRAMS.................................................................................................39
9 FACTORY DEFAULT CONFIGURATION.....................................................................................41
10. ICONS AND LED INDENTIFICATION...................................................................................46
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10.1 ICON DESCRIPTIONS......................................................................................................... 46
10.2 LED IDENTIFICATION DIAGRAM....................................................................................... 47
10.3 SENDER WIRING RECOMMENDATIONS.......................................................................... 47
11. NAVIGATION CHART........................................................................................................... 49
12.APPENDIX .................................................................................................................................. 50
12.1 55X IDMT TRIPPING CURVES (TYPICAL) ..................................................................... 50
12.2 55X SHORT CIRCUIT TRIPPING CURVES (TYPICAL) ............................................... 51
12.4 55X DEAD BUS OPERATION.......................................................................................... 52
12.3 USING THE 55X MODULE WITH ACBS ............................................................................ 54
12.4 OUTPUT EXPANSION......................................................................................................... 55
12.4.1 RELAY OUTPUT EXPANSION (157) ............................................................................ 55
12.4.2 LED OUTPUT EXPANSION (548)................................................................................. 55
12.5 INPUT EXPANSION............................................................................................................. 55
12. SYNCHRONISING NOTES................................................................................................... 56
13.1 CHECK SYNC VERSIONS................................................................................................... 56
13.2 AUTO SYNC VERSIONS.................................................................................................. 56
13.3 LOAD SHARE VERSIONS ............................................................................................... 56
550 OPERATING MANUAL ISSUE 6 29/07/2003 MR 4
INTRODUCTION
The DSE 550 Module, has been designed to allow the OEM to meet most of the industrys
complex specifications. It has been primarily designed to allow the user to start and stop the
generator, and if required, transfer the load to the generator either manually or automatically. The
user also has facility to view all the system operating parameters via the LCD display.
The DSE 550 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 32-Bit Micro-processor contained within the module allows for a range of complex
features to be incorporated as standard;
Full Multi-lingual LCD display (including non-western character fonts).
Up to eight different languages held on-board the module.
True RMS voltage monitoring.
Optional Power measurement facility.
Optional Communications capability (RS485 or RS232 including GSM/SMS functions)
Optional Check Sync capability
Optional Automatic Sync capability
Optional Automatic Load Share capability
Optional Multi-set communications
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 P810 For Windows software and 810 interface
Access to critical operational sequences and timers for use by qualified engineers, are barred by a
security code. Module access is barred by PIN code. Limited operator selections, such as
display language, can be changed from the module front panel.
The module is housed in a robust plastic case for the front panel mounting. Connections to the
module are via locking plug and sockets.
5
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.
Indicates facility is only available on V2.00 or later modules. If in
doubt check V number on power up display.
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.
1. OPERATION
1.1 CONTROL
Control of the DSE 550 module is via push-buttons on the front of the module with STOP/RESET,
MANUAL, START, AUTO and ALARM MUTE functions. For normal operation these are the only
controls which need to be operated. The smaller push-buttons are used to access further
information such as engine instruments. Details of their operation is detailed later in this
document.
The following descriptions detail the sequences followed by a module containing the standard
factory configuration. Always refer to your configuration source for the exact sequences and
timers observed by any particular module in the field.
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Deep Sea Electronics plc
Model 550
FIG 1
1.2 NORMAL MANUAL OPERATION
Operation Detail
To initiate a start sequence press the Manual push-
button.
The LED above the button will illuminate and the LCD
display will briefly indicate:
MANUAL MODE
7
Operation Detail
display will then indicate:
GENERATOR AT REST
Then, press and hold the START push-button, once the
module has commenced the start sequence the button
may then be released. (However, it is possible to configure
the module such the start-button must be held pressed to
maintain engine cranking until disconnect speed is reached -
Refer to your configuration Source)
display will briefly indicate:
START
If the pre-heat output option is configured, the Pre-heat
timer is then initiated, and the auxiliary output selected
is energised.
PRE-HEATING
00:09
After the pre-heat timer has expired the module will de-
energise the pre-heat output and commence engine
starting; the following sequence occurs.
PRE-HEATING
00:00
The Fuel Solenoid is energised, then after a 1 second
delay the Starter Motor is engaged
FUEL ON
The engine is cranked for the duration of the crank timer
CRANKING attempt.1
00:08
When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from
the Alternator output. Alternatively a Magnetic Pickup mounted on the flywheel housing can be
used for terminating cranking, along with options of Charge alternator voltage and oil pressure.
If a Magnetic Pick-up is utilised it is also possible to configure the module so that if the starter
motor fails to engage on the first attempt, the starter relay will be de-energised and the a second
attempt to engage will be made. For further details on this function please refer to the 810
configuration manual.
Operation Detail
Should the engine not fire on the first attempt and the
crank timer expires, the module will rest the starter for
the duration of the crank rest timer.
CRANK REST. 1
00:04
Once this has expired the module will once again
attempt to start the engine.
CRANKING attempt2
00:07
This will be repeated until either the engine fires or the pre-set number of attempts to start have
been completed
Operation Detail
In this instance the module will indicate a Fail to start
alarm.
SHUTDOWN
FAILED TO START
NOTE:- Should a Fail to start alarm occur the
module must be placed into STOP/RESET mode by
pressing the STOP/RESET PUSHBUTTON.
Determine why the engine failed to fire before
making any further attempts to start.
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If the engine start is successful, the following sequence occurs:-
Operation Detail
After the starter motor has disengaged, the Safety On
timer is activated.
WAITING FOR SAFETY
ON 00:08
This timer allows Oil Pressure, High Engine Temperature, Underspeed, Undervolts, Charge Fail
and any delayed Auxiliary fault inputs to stabilise without triggering the fault.
Operation Detail
Once the engine is running and the Safety on timer has
expired, full fault protection is made available.
GENERATOR AVAILABLE
Pressing the STOP/RESET PUSHBUTTON will de-
energise the Fuel Solenoid and bring the engine to
rest.
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While the engine runs down the module will start its
Fail to stop timer.
STOP/RESET
While the engine runs down the module will start its
Fail to stop timer.
STOPPING
00:24
If the engine is still running when the Fail to stop Timer
expires the module will alarm.
SHUTDOWN
FAIL TO STOP
Should the engine come to rest within the time allowed
by the fail to stop timer the screen will revert to
GENERATOR AT REST
NOTE:- The Load Transfer Output will not normally become active during a Manual
start. However, if the Remote Start input is activated once the engine is running then
the Load Transfer Output will be activated and remain active until the engine is stopped.
1.3 AUTOMATIC (REMOTE) OPERATION
Operation Detail
If the module is placed in AUTO mode by pressing the
AUTO PUSHBUTTON, it will monitor the auxiliary
inputs for a REMOTE START signal.
AUTO
The LCD display will briefly indicate
AUTO MODE
The LCD display will then indicate
GENERATOR AT REST
Should the REMOTE START signal be detected, the following sequence will occur
The module will start its Start Delay timer, this is used
to ensure that the start event is really required and not
just a momentary transient signal.
START DELAY
00:09
Once this timer has expired the module will continue with its normal start sequence as detailed
below. Should the remote start signal be removed during either the start delay timer or pre-heat
timer, the module will terminate its start sequence and return to its standby AUTO state until such
time as a start is signalled again.
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Operation Detail
If the pre-heat output option is configured, the pre-heat
timer is then initiated, and the auxiliary output selected
is energised.
PRE-HEATING
00:09
After the pre-heat timer has expired the module will de-
energise the pre-heat output and commence engine
starting; the following sequence occurs.
PRE-HEATING
00:00
The Fuel Solenoid is energised, then after a 1 second
delay the Starter Motor is engaged
FUEL ON
The engine is cranked for the duration of the crank timer
CRANKING attempt.1
00:06
When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from
the Alternator output. Alternatively a Magnetic Pickup mounted on the flywheel housing can be
used for terminating cranking, along with options of Charge alternator voltage and oil pressure.
If a Magnetic Pick-up is utilised it is also possible to configure the module so that if the starter
motor fails to engage on the first attempt, the starter relay will be de-energised and the a second
attempt to engage will be made. For further details on this function please refer to the 810
configuration manual.
Operation Detail
Should the engine not fire on the first attempt and the
crank timer expires, the module will rest the starter for
the duration of the crank rest timer.
CRANK REST. 1
00:04
Once this has expired the module will once again
attempt to start the engine.
CRANKING attempt2
00:07
This will be repeated until either the engine fires or the pre-set number of attempts to start have
been completed
Operation Detail
In this instance the module will indicate a Fail to start
alarm.
SHUTDOWN
FAIL TO START
NOTE:- Should a Fail to start alarm occur the
module must be placed into STOP/RESET mode by
pressing the STOP/RESET PUSHBUTTON.
Determine why the engine failed to fire before
making any further attempts to start.
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If the engine start is successful, the following sequence occurs:-
Operation Detail
After the starter motor has disengaged, the Safety On
timer is activated.
WAITING FOR SAFETY
ON 00:09
This timer allows Oil Pressure, High Engine Temperature, Underspeed, Undervolts, Charge Fail
and any delayed Auxiliary fault inputs to stabilise without triggering the fault. Once the engine is
running and the safety on timer has expired, full fault protection is made available.
Operation Detail
Once the generator is running at the correct speed and
up to voltage the Warm-up timer is then initiated
WARMING UP
00:08
Should the remote start signal be removed during either of the cranking or warm-up timers, the
module will terminate its normal auto start sequence will initialise its Cooling Timer and eventually
return to its standby AUTO state until such time as a start is signalled again.
Operation Detail
After the warm-up timer has expired the module will
energise its Load Transfer Output.
GENERATOR AVAILABLE
The generator in now up and running and is selected to supply the load.
Operation Detail
Should the remote start signal be removed the module
will first initiate a return timer to ensure that it is safe to
stop the generator.
GENERATOR AVAILABLE
00:06
Should the remote start input become active again within this time the module will continue to run
the generator on load and ignore the fluctuating remote start signal until such time as it remains
in-active for the duration of the stop delay timer. Once the return timer has expired, the module will
de-energise the Load Transfer output.
Operation Detail
The module will then commence its cooling timer, this
allows the engine to run off load to ensure that it has
adequately cooled before being brought to a standstill.
COOLING DOWN
2:34
Once the cooling timer has expired the module will de-
energise the fuel solenoid and the engine will be
brought to rest.
STOPPING
00:27
If the engine is still running when the Fail to stop Timer
expires the module will alarm.
SHUTDOWN
FAIL TO STOP
Should the engine come to rest within the time allow by
the fail to stop timer the screen will revert to
GENERATOR AT REST
Note:- It is possible that the module has been configured to perform regular
exercise runs automatically. This may be used to exercise the engine periodically in
standby applications or to assist in peak-lopping arrangements. Therefore even though
the remote start input is not active, it is possible that if the system is in the Auto mode
the engine may start unexpectedly if a scheduled run is configured to occur.
WARNING!:- Before commencing work on the generating set it is important to take
steps to ensure that a scheduled run cannot start the engine unexpectedly. The system
should, at a minimum, be taken out of the Auto mode and Stop selected. Depending on
the nature of the work to be performed - further steps to ensure safety while working may
be necessary.
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2. PROTECTIONS
The module will indicate that an alarm has occurred in several ways;
The Audible Alarm will sound. This can be silenced by
pressing the Mute button
The Common alarm LED will illuminate(Warning =
Steady, Shutdown = Flashing [steady when Muted])
The LCD display will jump from the Information page to
display the Alarm Page and the LED above the page
icon will illuminate
The LCD will the display
ALARM
Followed by the appropriate alarm text
SHUTDOWN
LOW OIL PRESSURE
If no alarms are present the LCD will display the following message and will then return to the
Information Display page;
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NO ALARM PRESENT
The LCD will display multiple alarms E.g. High Engine Temperature shutdown, Emergency Stop
and Low Coolant Warning alarms have been triggered. These will automatically scroll round in
the order that they occurred;
ALARM
SHUTDOWN
HIGH ENGINE TEMP
SHUTDOWN
EMERGENCY STOP
WARNING
LOW COOLANT LEVEL
It is also possible to manually scroll to display the different alarms;
Initial display
>>>>>>> ALARM
Pressing the DOWN button the LCD will
then show
SHUTDOWN
HIGH ENGINE TEMP
Pressing the DOWN button again the
LCD will then show
SHUTDOWN
EMERGENCY STOP
LCD will then show
WARNING
LOW COOLANT LEVEL
LCD will then show
ALARM
Pressing the UP button the LCD will
then show
etc, etc, etc.
WARNING
LOW COOLANT LEVEL
VIEWING ALARMS
If the module is operating in the normal INFORMATION PAGE display any alarm condition will
automatically be displayed.
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Jumps to >>>
If the user is viewing instrumentation, e.g.
Then the alarm page will not automatically be
displayed and must be viewed by the operator.
To view an alarm operate the page button to move to
the Alarm page.
To clear an alarm the original triggering conditions must
be removed before the alarm can be reset. Alarms are
reset by pressing the Stop/Reset pushbutton.
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2.1 WARNINGS
Warnings are non-critical alarm conditions and do not affect the operation of the generator system,
they serve to draw the operators attention to an undesirable condition.
BATTERY CHARGE FAILURE, if the module does not detect a voltage from the warning light
terminal on the auxiliary charge alternator, the module will display WARNING CHARGE ALT
FAILURE on the LCD. The COMMON ALARM LED will also illuminate.
BATTERY LOW VOLTAGE, if the module detects that the plant DC supply has fallen below the
low volts setting level , the module will display WARNING LOW BATTERY VOLTAGE on the
LCD. The COMMON ALARM LED will also illuminate.
BATTERY HIGH VOLTAGE, if the module detects that the plant DC supply has risen above the
high volts setting level , the module will display WARNING HIGH BATTERY VOLTAGE on the
LCD. The COMMON ALARM LED will also illuminate.
OIL PRESSURE SENDER/SWITCH, the module can be configured to only attempt to crank the
engine if the Oil Pressure is initially low, (engine at rest, not running). The module will display FAIL
TO STOP on the LCD. The COMMON ALARM LED will also illuminate.
LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low
oil pressure pre-alarm level after the Safety On timer has expired, a warning alarm will occur. The
LCD will indicate WARNING LOW OIL PRESSURE and the COMMON ALARM LED will
illuminate.
HIGH ENGINE TEMPERATURE, if the module detects that the engine coolant temperature has
exceeded the high engine temperature pre-alarm level after the Safety On timer has expired, a
warning alarm will occur. The LCD will indicate WARNING HI COOLANT TEMP. and the
COMMON ALARM LED will illuminate.
OVERSPEED, if the engine speed exceeds the pre-alarm level a warning is initiated. The LCD will
indicate WARNING OVERSPEED and the COMMON ALARM LED will illuminate.
UNDERSPEED, if the engine speed falls below the pre-alarm level after the Safety On timer has
expired, a warning alarm is initiated. The LCD will indicate WARNING UNDERSPEED and the
GENERATOR HIGH FREQUENCY, if the module detects a generator output frequency in excess
of the pre-alarm level a warning is initiated. The LCD will indicate WARNING GEN HIGH
FREQUENCY and the COMMON ALARM LED will illuminate.
GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the
pre-alarm level after the Safety On timer has expired, a warning is initiated. The LCD will indicate
WARNING GEN LOW FREQUENCY and the COMMON ALARM LED will illuminate.
GENERATOR HIGH VOLTAGE, if the module detects a generator output voltage in excess of the
pre-alarm level a warning is initiated. The LCD will indicate WARNING GEN HIGH VOLTAGE
WARNING and the COMMON ALARM LED will illuminate.
GENERATOR LOW VOLTAGE, if the module detects a generator output voltage below the pre-
alarm level after the Safety On timer has expired, a warning is initiated. The LCD will indicate
WARNING GEN LOW VOLTAGE WARNING and the COMMON ALARM LED will illuminate.
MAINTENANCE DUE ALARM, if the engine exceed the allowed running hours or time
between periodic maintenance a warning is initiated. The LCD will indicate MAINTENANCE NOW
DUE and the COMMON ALARM LED will illuminate. To clear the alarm a MAINTENANCE
RESET must be performed (refer to config source or P810 for Windows software manual for more
detail)
AUXILIARY INPUTS, if an auxiliary input has been configured as a warning the appropriate LCD
message will be displayed and the COMMON ALARM LED will illuminate.
2.2 SHUTDOWNS
Shutdowns are latching and stop the Generator. The alarm must be accepted and cleared, and the
fault removed to reset the module.
NOTE:- The alarm condition must be rectified before a reset will take place. If the
alarm condition remains it will not be possible to reset the unit (The exception to this is
the Low Oil Pressure alarm and the like, as the oil pressure will be low with the engine at
rest).
FAIL TO START, if the engine does not fire after the pre-set number of attempts has been made a
shutdown will be initiated. The LCD will indicate SHUTDOWN FAIL TO START and the
COMMON ALARM and LED will flash.
EMERGENCY STOP, removal of the +ve DC Supply from the Emergency Stop input initiates the
following sequence, firstly it will initiate a controlled shutdown of the Generator and prevent any
attempt to restart the Generator until the Emergency Stop push-button has been reset. Secondly it
removes the +ve DC supply from both the Fuel Solenoid and Starter Solenoid. The LCD will
indicate SHUTDOWN EMERGENCY STOP and the COMMON ALARM LED will flash.
NOTE:- The Emergency Stop +Ve signal must be present otherwise the unit will
shutdown.
LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low
oil pressure trip setting level after the Safety On timer has expired, a shutdown will occur. The
LCD will indicate SHUTDOWN LOW OIL PRESSURE and the COMMON ALARM LED will flash.
HIGH ENGINE TEMPERATURE, if the module detects that the engine coolant temperature has
exceeded the high engine temperature trip setting level after the Safety On timer has expired, a
shutdown will occur. The LCD will indicate SHUTDOWN HIGH COOLANT TEMP and the
COMMON ALARM LED will flash.
OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated. The LCD will
indicate SHUTDOWN OVERSPEED and the COMMON ALARM LED will flash. Overspeed is not
delayed, it is an immediate shutdown.
NOTE:-However during the start-up sequence the overspeed trip logic can be
configured to allow an extra trip level margin, this is used to prevent nuisance tripping on
start-up - Refer to the 8xx/810/Link500 Configuration Manual under heading Overspeed
Overshoot for details.
UNDERSPEED, if the engine speed falls below the pre-set trip after the Safety On timer has
expired, a shutdown is initiated. The LCD will indicate SHUTDOWN UNDERSPEED and the
15
GENERATOR HIGH FREQUENCY, if the module detects a generator output frequency in excess
of the pre-set trip a shutdown is initiated. The LCD will indicate SHUTDOWN GEN HIGH
FREQUENCY and the COMMON ALARM LED will flash. High frequency is not delayed, it is an
immediate shutdown.
GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the
pre-set trip after the Safety On timer has expired, a shutdown is initiated. The LCD will indicate
GEN LOW FREQUENCY and the COMMON ALARM LED will flash.
GENERATOR HIGH VOLTAGE, if the module detects a generator output voltage in excess of the
pre-set trip a shutdown is initiated. The LCD will indicate GEN HIGH VOLTAGE and the
COMMON ALARM LED will flash. High voltage is not delayed, it is an immediate shutdown.
GENERATOR LOW VOLTAGE, if the module detects a generator output voltage below the pre-
set trip after the Safety On timer has expired, a shutdown is initiated. The LCD will indicate GEN
LOW VOLTAGE and the COMMON ALARM LED will flash.
OIL PRESSURE SENDER OPEN CIRCUIT, if the module detects a loss of signal from the oil
pressure sender (open circuit) a shutdown is initiated. The LCD will indicate OIL PRESS SENDER
FAULT and the COMMON ALARM LED will flash. Sender failure is not delayed, it is an
immediate shutdown.
GENERATOR EARTH FAULT , if the module detects a generator earth fault current in excess
of the pre-set trip a shutdown is initiated. The LCD will indicate GEN EARTH FAULT and the
GENERATOR PHASE SEQUENCE WRONG , if the module detects a generator phase
rotation error a shutdown is initiated. The LCD will indicate GEN PHASE SEQ WRONG and the
AUXILIARY INPUTS, if an auxiliary input has been configured as a Shutdown the appropriate LCD
message will be displayed and the COMMON ALARM LED will flash.
= Enhanced Instrumentation Versions only
2.3 ELECTRICAL TRIPS
Electrical trips are latching and stop the Generator but in a controlled manner. On initiation of the
electrical trip condition the module will de-energise the Load Transfer Output to remove the load
from the generator. Once this has occurred the module will start the Cooling timer and allow the
engine to cool, off-load before shutting down the engine. The alarm must be accepted and cleared,
and the fault removed to reset the module.
GENERATOR REVERSE POWER , if the module detects a generator reverse power current
in excess of the pre-set trip a shutdown is initiated. The LCD will indicate GEN REVERSE
POWER and the COMMON ALARM LED will flash.
GENERATOR OVER CURRENT, if the module detects a generator output current in excess of the
pre-set trip a shutdown is initiated. The LCD will indicate GEN OVER CURRENT and the
GENERATOR SHORT CIRCUIT, if the module detects a generator fault current in excess of the
pre-set trip a shutdown is initiated. The LCD will indicate GEN SHORT CIRCUIT and the
AUXILIARY INPUTS, if an auxiliary input has been configured as an Electrical Trip the appropriate
LCD message will be displayed and the COMMON ALARM LED will illuminate.
= Enhanced Instrumentation Versions only
2.4 PRE-ALARMS AND OPTIONS
During module configuration it is possible to select pre-alarm levels for all of the above shutdowns
and electrical trips to give a warning that the trip value is being approached. This allows the
operator to take steps to prevent the shutdown from ultimately occurring by rectifying the triggering
condition.
If the module is fitted with the optional RS232 communication board, then the following alarm is
available:-
MODEM POWER FAULT, if the module detects a modem supply current in excess of 350mA
warning is initiated. The LCD will indicate MODEM POWER FAULT and the COMMON ALARM
LED will illuminate. The power supply to the modem will be removed until the alarm is reset.
If the module is fitted with the option of Check Sync , then the following alarms are available:-
FAILED TO SYNCHRONISE, if the module cannot synchronise within the timer allowed by the
Synchronising timer a warning is initiated. The LCD will indicate FAILED TO SYNC and the
BUS PHASE SEQUENCE WRONG, if the module detects a bus phase rotation error a warning is
initiated. The LCD will indicate BUS PHASE SEQ WRONG and the COMMON ALARM LED will
illuminate.
If the module is fitted with the option of Load Sharing , then the following alarms are
available:-
MSC FAILURE, if the module cannot talk to the correct number of modules on the MSC link then
the failure alarm is initiated. The LCD will indicate MSC FAILURE and the COMMON ALARM
LED will illuminate.
MSC DATA ERROR, the data being transmitted to the modules on the MSC link is being corrupted
ensure correct specification cable is used and transmission lengths are not exceeded. The LCD
will indicate MSC DATA ERROR and the COMMON ALARM LED will illuminate.
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MSC ID ERROR, each module must be configured with a unique MSC ID number. Should a
module detect another module on the MSC network with the same number it will alarm. The LCD
will indicate MSC ID ERROR and the COMMON ALARM LED will illuminate.
3. DESCRIPTION OF CONTROLS
The following section details the function and meaning of the various controls on the module.
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Up and Down
Scroll Buttons
Page Select Button Alarm Mute Button
Information Page Indicator
Alarm Page Indicator
Auto Mode Button
Engine Instruments Page Indicator
Manual Mode Button
Generator Instruments Page Indicator
Stop/Reset Button
Start Button
Event Log Page Indicator
Common Alarm Indicator
User Configurable
LED's with insert pocket
LCD Display
Operator Configuration
Mode Indicator
3.1 LCD DISPLAY
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INFORMATION PAGE
The LCD display normally indicates the status of the generator such as
GENERATOR AT REST, PRE-HEATING,GENERATOR AVAILABLE, etc.
This is the default display and is always automatically returned to after a pre-set
period of operator inactivity.
ALARM PAGE
The LCD also displays the exact nature of any alarm condition which have
occurred such as SHUTDOWN LOW OIL PRESSURE. This allows very specific
alarm conditions to be brought to the operators attention. Refer to the
Protections section of this manual for details of how to interact with the alarm
page.
ENGINE INSTRUMENTS PAGE
The LCD displays the various engine parameters such as ENGINE SPEED,
OIL PRESSURE, HOURS RUN, etc.
GENERATOR INSTRUMENT PAGE
The LCD displays the various generator output values such as GENERATOR
VOLTAGE, GENERATOR CURRENT, etc. If the enhanced instrumentation
option is fitted the LCD will also display the values of GENERATOR KW,
GENERATOR pF, GENERATOR KVAr, etc.
EVENT LOG PAGE
In the event of a shutdown alarm occurring the triggering alarm will be recorded in
the Event Log Memory. The Memory will record the last 25 such shutdowns.
Subsequent alarms will then over-write the oldest previous alarm. This feature
allows service engineers arriving on site a detailed look at the recent history of
the gen-set or plant.
19
VIEWING THE INSTRUMENT AND EVENT LOG PAGES
To view a particular instrument operate the Page
button to move to the required page. Each press of the
button will move the page indicator LED along. The
LCD will also indicate the page title.
i.e. To view the Engine Coolant temperature move to the Engine Instruments Page.
The LCD will display the page title and then
will automatically commence scrolling down
the various instrument . These will
automatically scroll round, on reaching the last
instrument the LCD display will then jump
back to the page title and resume scrolling down the page. This sequence will be repeated until
either the user moves off the page or after a period of inactivity the module will revert to the
Information Page
ENGINE
INSTRUMENTATION
ENGINE SPEED
1503 RPM
ENG OIL PRESSURE
2.5Bar 56psi
COOLANT TEMP
78deg C 105deg f
BATTERY VOLTAGE
24.5 V
CHARGE ALT VOLTAGE
27.5 V
ENGINE RUN TIME
50H 36M
NUMBER OF STARTS
65
NEXT MAINTENANCE
123 Hours
It is also possible to manually scroll to display the different instruments, once selected the
instrument will remain on the LCD display until the user selects a different instrument or page, or
after a period of inactivity the module will revert to the Information Page.
NOTE:-This description of operation is also true for the other instrument pages and
for viewing the records in the event log.
Manually Selecting an Instrument
Initial display
>>>>>>> ENGINE INSTRUMENTS
Pressing the DOWN button the LCD will
then show
ENGINE SPEED
1503 RPM
LCD will then show
ENG OIL PRESSURE
2.5Bar 56psi
LCD will then show
COOLANT TEMP
78deg C 105deg f
LCD will then show
BATTERY VOLTAGE
24.5 V
LCD will then show
CHARGE ALT VOLTAGE
27.5 V
Pressing the UP button the LCD will
then show
etc, etc, etc.
BATTERY VOLTAGE
24.5 V
If the DOWN button is pressed while the LCD display is showing NEXT MAINTENANCE DUE IN
then the display will jump round to the top of the page and display the page title; ENGINE
INSTRUMENTS. Pressing the DOWN button again will then display; ENGINE SPEED
SYNCHROSCOPE OPERATION (IF FITTED)
Display Detail
Initial stage of Synchronising display will only
show the difference between the Bus Supply and the
Generator Output.
Here the display is showing a frequency mis-match of
+2.9Hz - The gen-set frequency is too high and
should be reduced (indicated by the arrow). The
voltage is +0.2 volts high, but is within the limits set
for synchronising.
Once the difference between the Bus supply and the
Generator output has been reduced the
Synchroscope display will become active. The
moving bar will roll from left to right or right to left
depending on the mis-match between the bus supply
and the generator output. The area in the centre of
the scope indicates the set limits for synchronising to
occur.
Synchronising will only occur when both the
Frequency and the voltage differences are within
acceptable limits - Indicated by Tick marks on the
top of the display. Then the moving bar display will
show the phase difference. The engine speed should
be adjusted until the moving bar enters the centre of
the scope.
Once the bus and the generator are synchronised the
moving bar will be in the centre of the scope and the
bar will be locked into the synchronising window.
While the bar is locked the module will initiate a
breaker close to load the generator onto the bus.
Should synchronism be broken the moving bar will
pass out of the synchronising window and the locked
indication will clear.
Hz +2.9 V +0.2
Hz +0.9 V +0.2
Hz -0.2 V +0.2
Hz -0.2 V +0.2
21
OPERATOR CONFIGURATION MODE
This configuration mode allows the operator limited customising of the way the module operates.
Operation Detail
To enter the Operator configuration mode press
both the UP and DOWN scroll buttons together.
+
The module will enter Operator Configuration mode
and the Operator configuration mode indicator will
illuminate above the PAGE button.
The LCD will then display:
CONFIGURATION
To view the different configuration functions press the
PAGE button.
LANGUAGE
ENGLISH
Pressing the UP or DOWN Button will then change the
selected language.
or
The LCD will then display the new language:
LANGUAGE
French
Repeat until the required language is displayed.
LANGUAGE
GERMAN
To view the next function press the PAGE button.
CONTRAST

Pressing the UP or DOWN Button will move the sliding
bar UP (Darker) or DOWN (Lighter) - set this to the
desired position.
or
When correct, to view the next function press the PAGE
button.
AUTO SCROLL TIME
3.0 Seconds
This is the duration each instrument will be displayed for
during the automatic scrolling. Use the UP and DOWN
buttons to set this to the required value.
or
button.
Operation Detail
INDICATIONS ON LCD
YES
Digital inputs configured as indications can be viewed
on the LCD by pressing the UP or DOWN button when
the Information Page is active. To disable this
function set to NO by pressing the UP or DOWN
button.
or
button.
GEN SET RUN PRIORITY
If the set is part of a multi-set load sharing scheme this
setting will appear. Changing this setting will allow the
gen-sets duty priority to be changed to balance engine
hours for example.
or
button.
ABANDON CHANGES
AND EXIT
To exit the Operator configuration mode with-out
storing any changes made press the UP or DOWN
button.
or
If you wish to save the changes you have made to the
configuration press the PAGE button.
SAVE CHANGES AND
EXIT
To exit the Operator configuration mode and store
the changes you have made press the UP or DOWN
button.
or
The module will then return to the Information Page display and the Operator Configuration
Mode Indicator will extinguish.
23
POWER UP LCD DISPLAY
On application of the DC supply the module LCD will display information about the module.
S01 C01 V2.00
M
S C V
M550 NS 4W
Code Letter Meaning Options Detail
M Module Type 550 NS 4W Auto-start Module Variant with no Sync option, 4
wire (3ph+N) connection.
550 CS 4W Auto-start Module Variant with Check Sync
option, 4 wire (3ph+N) connection.
550 AS 4W Auto-start Module Variant with Auto Sync option,
4 wire (3ph+N) connection.
550 NS 3W Auto-start Module Variant with out Sync option, 3
wire (3ph) connection.
550 CS 3W Auto-start Module Variant with Check Sync
option, 3 wire (3ph) connection.
550 AS 3W Auto-start Module Variant with Auto Sync option,
3 wire (3ph) connection.
555 NS 4W Automatic Mains Failure Module Variant with no
Sync option, 4 wire (3ph+N) connection.
555 CS 4W Automatic Mains Failure Module Variant with
Check Sync option, 4 wire (3ph+N) connection.
555 AS 4W Automatic Mains Failure Module Variant with
check Sync option, 4 wire (3ph+N) connection.
555 NS 3W Automatic Mains Failure Module Variant with no
Sync option, 3 wire (3ph) connection.
555 CS 3W Automatic Mains Failure Module Variant with
check Sync option, 3 wire (3ph) connection.
555 AS 3W Automatic Mains Failure Module Variant with
Auto Sync option, 3 wire (3ph) connection.
S System Options 00 Basic Metering Version
01 Enhanced Metering Version
C Custom Options 00 No options fitted
01 RS232 Comms Board Fitted
02 RS485 Comms Board Fitted
09 RS232 Comms Board + Load Share (MSC-net)
Fitted
10 RS485 Comms Board + Load Share (MSC-net)
Fitted
13 RS232 Comms Board + Load Share (MSC/ CAN-
bus) Fitted
14 RS485 Comms Board + Load Share(MSC/ CAN-
bus) Fitted
Code Letter Meaning Options Detail
V Software
Version
X.XX Details internal firmware revision (FLASH
Version)
NOTE:- Some features are only
available on V2.00 or later modules.
Some feature are only available on
V3.00 or later modules.
Some feature are only available on
V4.00 or later modules.
25
3.2 LED INDICATORS
COMMON ALARM LED
This LED indicates when an alarm condition is present.
The Alarms Page on the LCD will detail the exact nature
of the alarm.
OFF - no alarm active.
FLASHING - A shutdown alarm is present, but has
not been muted.
STEADY - A warning alarm is present or a
shutdown alarm which has been muted is present.
USER CONFIGURABLE LEDs
These LED can be configured by the user to indicate
any one of 100+ different functions based around the
following:-
INDICATIONS - Monitoring of a digital input and
indicating associated functioning users equipment -
Such as Battery Charger On or Louvers 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,
Panel Locked, Generator Available, etc.
3.3 CONTROL PUSH-BUTTONS
STOP/RESET
This push-button places the module into its Stop/reset mode. This will
clear any alarm conditions for which the triggering criteria have been
removed. If the engine is running and this push-button is operated, the
module will automatically instruct the change-over device to un-load the
generator (Load transfer becomes in-active (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 the mode, a remote
start will not occur.
O
MANUAL
This push-button is used to allow manual control of the generator
functions. Entering this mode from any other mode will initially not cause
any change of operating state, but allows further push-buttons to be used
to control the generator operation. For example once in Manual mode it
is possible to manually start the engine by using the START push-
button. If the engine is running off-load in the Manual mode and a
remote start signal becomes present, the module will automatically
instruct the change-over device to place the generator on load (Load
transfer becomes active (if used)). Should the remote start signal then
be removed the generator will remain on load until either the
STOP/RESET or AUTO push-buttons are operated.
START
This push-button is used to manually start the engine. The module must
first be placed in the MANUAL mode of operation. The START button
should then be operated. The engine will then automatically attempt to
start. Should it fail on the first attempt it will re-try until either the engine
fires or the pre-set number of attempts have been made. To stop the
engine the STOP/RESET button should be operated. It is also possible
to configure the modules such that the start push-button must be held to
maintain engine cranking.
NOTE:-Different modes of operation are possible - Please refer
to your configuration source for details.
AUTO
This push-button places the module into its Automatic mode. This
mode allows the module to control the function of the generator
automatically. The module will monitor the remote start input and once
a start condition is signalled the set will be automatically started and
placed on load (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.
AUTO
ALARM MUTE
This push-button is used to silence the internal alarm sounder and also
any external sounder devices fed from the audible alarm output. Any
further alarm conditions will re-active the sounder. Once the alarm has
been muted and investigated it may then be cleared.
Refer to the Protections section of this manual for details.
When the Alarm Mute is operated a Lamp test function will also will be
implemented and all LED indicators will be illuminated.
27
3. INSTALLATION INSTRUCTIONS
The model DSE 550 Module has been designed for front panel mounting. Fixing is by 4 spring
loaded clips for easy assembly.
3.1 PANEL CUT-OUT
138.00mm
185.00mm
FIG 3
In conditions of excessive vibration the module should be mounted on suitable anti-vibration
mountings.
3.2 COOLING
The module has been designed to operate over a wide temperature range -30 to +70 C. However
allowances should be made for the temperature rise within the control panel enclosure. Care
should be taken NOT to mount possible heat sources near the module unless adequate ventilation
is provided. The relative humidity inside the control panel enclosure should not exceed 93%.
3.3 UNIT DIMENSIONS
All dimensions in mm.
144.0mm
137mm
185.0mm
110.0mm
7.5mm
Panel Cut-out:138mmx185mm
192.0mm
157
808
CE
FIG 4
3.4 FRONT PANEL LAYOUT
O
AUTO
I
i
Model 550
FIG 5
3.5 REAR PANEL LAYOUT
157
808
CE
FIG 6
29
4. ELECTRICAL CONNECTIONS
Connections to the Module are via plug and sockets.
4.1 CONNECTION DETAILS
The following describes the connections and recommended cable sizes to the plugs and sockets
on the rear of the Module. See rear panel layout FIG 5.
PLUG A 13 WAY
PIN
No
DESCRIPTION CABLE
SIZE
NOTES
1 DC Plant Supply Input
(-ve)
2.5mm
2 DC Plant Supply Input
(+ve)
2.5mm (Recommended Fuse Max. 21A)
3 Emergency Stop Input 2.5mm Plant Supply +ve. Also supplies fuel & start
outputs. (Recommended Fuse Max. 32A)
4 Fuel relay Output 2.5mm Plant Supply +ve from pin 3. 16 Amp rated.
5 Start relay Output 2.5mm Plant Supply +ve from pin 3. 16 Amp rated.
6 Auxiliary Output relay 1 1.0mm Plant Supply +ve. 5 Amp rated.
8 Charge Fail Input/ Excitation
Output
1.0mm Must NOT be connected to plant supply -ve.
9 Auxiliary Input 1 0.5mm Switch to -ve
PLUG B 17 WAY
PIN
No
DESCRIPTION CABLE
SIZE
NOTES
20 Magnetic Pickup Input (+ve) 0.5mm Connect to Magnetic Pickup device using
screened cable - See Note.
21 Magnetic Pickup Input
(-ve)
0.5mm Connect to Magnetic Pickup device using
screened cable - See Note
22 Oil Pressure Input 0.5mm Connect to Oil pressure sender
23 Coolant Temperature Input 0.5mm Connect to Coolant Temperature sender
24 Sender Common Return 0.5mm Return feed for senders**.
25 CT secondary for L1 2.5mm Connect to secondary of L1 monitoring CT
28* CT secondary common 2.5mm Connect to secondary of all monitoring CTs
29* Neutral CT secondary 2.5mm Connect to Neutral CT secondary and Earth
30 Functional Earth 2.5mm Connect to a good clean earth point
NOTE**:- If using single terminal senders refer to connection diagram. If using earth
return type senders connect return terminals to pin 24 and earth pin 24.
CAUTION!:- *Refer to Typical wiring Diagram for 3 CT and 4 CT wiring differences.
WARNING!:- Do not disconnect plug B when the gen-set is running. Disconnection
will open circuit the secondary of the CTs and dangerous voltages may then develop.
Always ensure the gen-set is at rest before making or breaking connections to the
module.
PLUG C 4 WAY
PIN
No
DESCRIPTION CABLE
SIZE
NOTES
31 Generator L1 Voltage
Monitoring Input
1.0mm Connect to generator L1 output (AC)
(Recommend 2A Fuse Max.)
Monitoring Input
Monitoring Input
34 Generator Neutral Input 1.0mm Connect to generator Neutral output (AC)
PLUG D 11 WAY (ONLY FITTED IF SYNCHRONISING OPTION IS REQUESTED)
PIN
No
DESCRIPTION CABLE
SIZE
NOTES
35 Generator Loading Relay
Contact (Aux Relay 5)
2.5mm Connect to generator contactor coil.
36 Generator Loading Relay
Contact (Aux Relay 5)
2.5mm Connect to generator contactor coil feed supply.
37 NOT USED Do not connect.
38 Auxiliary Relay 6 Normally
Closed Contact
2.5mm Voltage Free, AC Rated
39 Auxiliary Relay 6 Change-
over contact
40 Auxiliary Relay 6 Normally
Open contact
41 NOT USED Do not connect.
42 Bus L1 Voltage Monitoring
Input
1.0mm Connect to Bus L1 supply (AC) (Recommend 2A
Fuse Max.)
Input
1.0mm Connect to Bus L2 supply (AC)
Input
1.0mm Connect to Bus L3 supply (AC)
45 Bus Neutral Input 1.0mm Connect to Bus Neutral supply (AC)
NOTE:- Screened cable must be used for connecting the Magnetic Pickup, ensuring
that the screen is earthed at one end ONLY.
31
PC CONFIGURATION INTERFACE CONNECTOR
8-way connector allows connection to PC via 810 configuration interface.

Module can then be re-configured utilising the P810 for Windows software.
EXPANSION INTERFACE CONNECTOR
157
808
4-way connector allows connection to the 157 relay expansion module or the
548 LED annunciator module. A maximum of 2 relay expansion modules may
be connected in series to this port.
Auto-sync versions of the 55x can also control the P122 digital resistance module via this
port. These can be fitted in addition the any 157 relay modules required. See caution note below.
CAUTION!:- Do not connect the 808 configuration interface to this port, as it in not
possible to use the 808 software to configure the 555 module.
CAUTION!:
When used in conjunction with the P122 Digital Resistance Modules,
only P157 Relay Expansion modules with Part Number 81xxxxx MUST
be used. Please refer to the relevant 55x Manuals for details.
CAUTION!:
When used in conjunction with the P122 Digital Resistance Modules,
only P548 Relay Expansion modules with Part Number 81xxxxx MUST
be used. Please refer to the relevant 55x Manuals for details.
NOTE:-
Some versions of the module have the option of remote
communications via RS232 or RS485. The details of these
connections are covered in the Link500plus software manual
NOTE:-
Some versions of the module have the option of Load sharing. The
details of these connections are covered in the Guide to Sync and
load sharing manual.
4.2 CONNECTOR FUNCTION DETAILS
The following describes the functions of the connectors on the rear of the module. See rear panel
layout FIG 5.
PLUG A 13 WAY
PIN
No
DESCRIPTION
1 DC Supply -ve. System DC negative input. (Battery Negative).
2 DC Supply +ve. System DC positive input. (Battery Positive).
3 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. Positive Supply is also removed from Starter and Fuel therefore only
a single pole Emergency Shutdown button is required.
4 Fuel Relay output. Plant Supply +ve from pin 3. Used to control the fuel solenoid or engine
fuel control system.
5 Starter Relay output. Plant Supply +ve from pin 3. Used to control the Starter Motor.
6 Auxiliary Relay output 1. Plant Supply +ve. Configurable output, see Calibration Manual for
options available.
options available.
8 Charge Fail input / Excitation output. Supplies excitation to the Plant Battery Charging
Alternator, also an input for the Charge Fail detection circuitry.
9 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.
33
PLUG B 17 WAY
PIN
No
DESCRIPTION
options available.
options available.
20 Magnetic Input +ve. An AC signal from the magnetic pickup +ve for speed sensing.
21 Magnetic Input -ve. An AC signal from the magnetic pickup -ve for speed sensing.
22 Oil Pressure sensing input. Connect to resistive type oil pressure sender. Refer to
connection diagram for details.
23 Coolant Temperature sensing input. Connect to resistive type coolant temperature sender.
Refer to connection diagram for details.
24 Sender Common connection. Return feed from sender units - refer to connection diagram
for details.
25 Generator L1 current transformer connection.
26 Generator L2 current transformer connection. If single phase is used do not connect this
pin.
27 Generator L3 current transformer connection. If single phase is used do not connect this
pin.
28* Generator current transformer common connection.
29* Generator current transformer Neutral connection and CT earth connection.
30 Functional Earth - Ensure connection to a good clean earth point.
CAUTION!:- *Refer to Typical wiring Diagram for 3 CT and 4 CT wiring differences
WARNING!:- Do not disconnect plug B when the gen-set is running. Disconnection
will open circuit the secondary of the CTs and dangerous voltages may then develop.
Always ensure the gen-set is at rest before making or breaking connections to the
module.
PLUG C 4 WAY
PIN
No
DESCRIPTION
31 Generator L1 sensing input. Connect to alternator L1 output.
32 Generator L2 sensing input. Connect to alternator L2 output. If using single phase only do
not connect this terminal.
33 Generator L3 sensing input. Connect to alternator L3 output. If using single phase only do
not connect this terminal.
34 Generator N sensing input. Connect to alternator N output.
PLUG D 11 WAY (ONLY FITTED IF SYNCHRONISING OPTION IS REQUESTED)
PIN
No
DESCRIPTION
35 Generator Loading Relay (Aux Relay 5), Normally open, Volts free contacts to 36. Used to
connect to Generator contactor or circuit breaker.
36 Generator Loading Relay (Aux Relay 5) , Normally open, Volts free contacts to 35. Used to
connect to Generator contactor or circuit breaker.
37 DO NOT USE
38 Generator Close Request Relay (Aux Relay 6), Normally Closed Change-over, Volts free
contacts to 39
39 Generator Close Request Relay (Aux Relay 6), Change-over, Volts free contacts to 38 and 40.
40 Generator Close Request Relay (Aux Relay 6), Normally open Change-over, Volts free
contacts to 39.
41 DO NOT USE
42 Bus L1 sensing input. Connect to Bus L1 supply.
43 Bus L2 sensing input. Connect to Bus L2 supply. If using single phase only do not connect
this terminal.
44 Bus L3 sensing input. Connect to Bus L3 supply. If using single phase only do not connect
this terminal.
45 Bus N sensing input. Connect to Bus N supply.
35
5. SPECIFICATION
DC Supply 9.0 to 35 V Continuous.
Cranking Dropouts Able to survive 0 V for 50 mS, providing supply was at least
10 V before dropout and supply recovers to 5V .This is
achieved without the need for internal batteries.
Max. Operating Current 513mA at 12 V. 263 mA at 24 V.
Max. Standby Current 370 mA at 12 V. 210 mA at 24 V
Typical Standby Current 363mA at 12 V. 190 mA at 24 V.
Alternator Input Range 15V - 277 (ph-N) 3 Phase 4wire AC (+20%)
Alternator Input Frequency 50 - 60 Hz at rated engine speed (Minimum 15V AC Ph-N)
Magnetic Input Range (if fitted) +/- 0.5 V to 70 V Peak
Magnetic Input Frequency 10,000 Hz (max).
Start Relay Output 16 Amp DC at supply voltage.
Fuel Relay Output 16 Amp DC at supply voltage.
Auxiliary Relay Outputs 5 Amp DC at supply voltage.
Dimensions 192 X 144 X 138
Charge Fail / Excitation Range 0 V to 35 V
Operating Temperature Range -30 to +70C
CT Burden 2.5VA
CT Secondary 5A
CT Class Class 1 Protection Recommended (Basic Instrumentation)
Class 1 Protection Required (Enhanced Instrumentation)
Electromagnetic Compatibility BS EN 50081-2 EMC Generic Emission Standard (Industrial)
BS EN 50082-2 EMC Generic Emission Standard (Industrial)
Electrical Safety BS EN 60950
Cold Temperature BS EN 60068-2-1 to -30
o
C
Hot Temperature BS EN 60068-2-2 to +70
o
C
Humidity BS2011-2-1 to 93% RH@40
o
C for 48 Hours
Vibration 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
Shock BS EN 60068-2-27
3 Half sine shocks in each of 3 major axes
15gn amplitude, 11mS duration
Synchronising option:-
Bus Input Voltage Range 15V - 277(ph-N) 3 Phase 4wire AC (+20%)
Bus Input Frequency 50 - 60 Hz (Minimum 15V AC Ph-N)
Additional Sync Relays 8 Amp AC RMS rated
6. COMMISSIONING
6.1 PRE-COMMISSIONING
Before the system is started, it is recommended that the following checks are made:-
6.1. The unit is adequately cooled and all the wiring to the module is of a standard and rating
compatible with the system.
6.2. The unit DC supply is fused and connected to the battery and that it is of the correct polarity.
6.3. The Emergency Stop input is wired to an external normally closed switch connected to DC
positive.
NOTE:- If Emergency Stop feature is not required link this input to the DC Positive.
The module will not operate unless either the Emergency Stop is fitted correctly OR Pin 3
is connected to DC positive (+ve)
6.1. To check the start cycle operation take appropriate measures to prevent the engine from
starting (disable the operation of the fuel solenoid). After a visual inspection to ensure it is
safe to proceed, connect the battery supply. Press the MANUAL pushbutton, then press
the START pushbutton for a short time. The unit start sequence will commence.
6.2. The starter will engage and operate for the pre-set crank period. After the starter motor has
attempted to start the engine for the pre-set number of attempts the LCD will display
Shutdown Failed to start. Press the STOP/RESET pushbutton to reset the unit.
6.3. Restore the engine to operational status (reconnect the fuel solenoid), again select
MANUAL and operate the START pushbutton, this time the engine should start and the
starter motor should disengage automatically. If not then check that the engine is fully
operational (fuel available, etc.) and that the fuel solenoid is operating. The engine should
now run up to operating speed. If not, and an alarm is present, check the alarm condition for
validity, then check input wiring. The engine should continue to run for an indefinite period. It
will be possible at this time to view the engine and alternator parameters - refer to the
Description of Controls section of this manual.
6.4. Select AUTO on the front panel, the engine will run for the pre-set cooling down period,
then stop. The generator should stay in the standby mode. If not check that there is not a
signal present on the Remote Start input.
6.5. Initiate an automatic start by supplying the remote start signal. The start sequence will
commence and the engine will run up to operational speed. Once the generator is available a
load transfer will take place, the Generator will accept the load. If not, check the wiring to the
Generator Contactor Coil (if used). Check the Warming timer has timed out.
6.6. Remove the remote start signal, the return sequence will start. After the pre-set time period,
the load will be removed from the generator. The generator will then run for the pre-set
cooling down period, then shutdown into its standby mode.
6.7. If despite repeated checking of the connections between the 550 and the customers system,
satisfactory operation cannot be achieved, then the customer is requested to contact the
factory for further advice on:-
INTERNATIONAL TEL: 44 (0) 1723 890099
INTERNATIONAL FAX: 44 (0) 1723 893303
E-mail: Support@Deepseaplc.com
37
7. FAULT FINDING
SYMPTOM POSSIBLE REMEDY
Unit is inoperative Check the battery and wiring to the unit. Check the DC
supply. Check the DC fuse.
Unit shuts down Check DC supply voltage is not above 35 Volts or below 9
Volts.
Check the operating temperature is not above 70 C.
Check the DC fuse.
Unit locks out on Emergency Stop If 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.
Intermittent Magnetic Pick-up sensor
fault
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.
Low oil Pressure fault operates after
engine has fired
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 550 Module.
High engine temperature fault
operates after engine has fired.
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 550 Module.
Shutdown fault operates Check relevant switch and wiring of fault indicated on LCD
display. Check configuration of input.
Warning fault operates Check relevant switch and wiring of fault indicated on LCD
display. Check configuration of input.
Fail to Start is activated after pre-set
number of attempts to start
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 550 inputs. Refer to engine manual.
Continuous starting of generator
when in AUTO
Check that there is no signal present on the Remote
Start input. Check configured polarity is correct.
Generator fails to start on receipt of
Remote Start signal or under mains
failure conditions.
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.
Pre-heat inoperative Check wiring to engine heater plugs. Check battery supply.
Check battery supply is present on the Pre-heat output of
module. Check pre-heat has been selected in your
configuration.
Starter motor inoperative Check wiring to starter solenoid. Check battery supply.
Check battery supply is present on the Starter output of
module. Ensure that the Emergency Stop input is at +Ve.
Engine runs but generator will not
take load
Check Warm up timer has timed out. Ensure generator
load inhibit signal is not present on the module inputs.
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.
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9 FACTORY DEFAULT CONFIGURATION
P810 for Windows. Configuration for 550 module. Page 1 of 4
Configuration description
1 Default Factory Settings
2 Check Sync fitted
3 09/10/00
4 Miles Revell
Filename - 550cs.XCF
Printed on 27/11/00 16:25:56
Module settings
Base module 550 remote start module
Check sync option fitted Yes
Miscellaneous settings
Alternator fitted Yes poles : 4
Magnetic pickup fitted No
AC System 3 phase, 4 wire
Enable generator sequence alarm Yes
Enable bus sequence alarm Yes
Phase sequence L1 L2 L3
Display indications on LCD display No
Display load switching state machine No
Enable fast loading feature Yes
All warnings are latched No
Start button must be held down to crank No
Audible alarm prior to starting No
Number of start attempts 3
Input settings
Low oil pressure input type VDO 10 bar
High coolang temp input type VDO 120 degrees C
Trip Return
Low oil pressure pre-alarm 1.17 Bar 17.0 PSI 1.24 Bar 18.0 PSI
Low oil pressure shutdown 1.03 Bar 14.9 PSI
High coolant temp pre-alarm 115C 239F 110C 230F
High coolant temp shutdown 120C 248F
Digital inputs
1 Remote start Close to activate
2 Generator closed auxiliary Close to activate
3 User configured Close to activate Warning Active from safety on
Active text : Digital input 3
4 User configured Close to activate Shutdown Always active
Active text : Digital input 4
5 User configured Close to activate Shutdown Active from safety on
Active text : Auxiliary Input 5
6 User configured Close to activate Electrical trip Always active
7 User configured Close to activate Electrical trip Active from safety on
8 User configured Close to activate Indication Always active
9 Panel lock Close to activate
LED settings
1 Lit Remote start present
2 Lit Panel locked by digital input
41
3 Lit Delayed alarms armed
4 Lit Check sync
2 Check Sync fitted
3 09/10/00
4 Miles Revell
Printed on 27/11/00 16:25:57
Output settings
Module relays
1 Energise Preheat (during pre-heat timer)
2 Energise Common alarm
3 Energise Close generator
4 Energise System in auto mode
5 Energise Close generator
6 Energise Generator close request
Expansion A
1 Energise Output not used
Expansion B
Timer settings
Starting timers
Start delay 5s
Pre-heat 0s
Pre-heat bypass 0m
Sensor fail delay 2.0s
Cranking time 10s
Crank rest time 10s
Smoke limit 0s
Smoke limit off 0s
Safety on delay 10s
Overspeed overshoot 0s
Load timers
Warming up time 0s
Transfer time 0.7s
Breaker close pulse 0.0s
Breaker trip pulse 0.0s
Digital input 2 is assigned to generator auxiliary contact
Gen close timer 1.3s
Gen open timer 5s
No digital input is assigned to mains auxiliary contact
Stopping timers
Return delay 30s
Cooling time 30s
ETS solenoid hold 0s
Fail to stop delay 30s
Other timers
Battery low volts delay 1m
Battery high volts delay 1m
LCD auto scroll timer 2s
LCD page timer 5m
Reverse power alarm 0.0s
43
2 Check Sync fitted
3 09/10/00
4 Miles Revell
Printed on 27/11/00 16:25:58
Generator settings
Voltage and frequency settings Trip Return
Under volts trip 184V AC
Under volts pre-alarm 196V AC 207V AC
Over volts pre-alarm 265V AC 253V AC
Over volts trip 276V AC
Under frequency trip 40.0 Hz
Under frequency pre-alarm 42.0 Hz 45.0 Hz
Over frequency pre-alarm 55.0 Hz 52.0 Hz
Over frequency trip 57.0 Hz
Power settings
Generator CT primary 500 A
Generator full load rating 500 A
Earth fault CT primary rating 500 A
Trip Curve/Multiplier Action
Delayed overcurrent 100% ( 500 A ) 36 Electrical trip
Short circuit 300% ( 1500 A ) 6 Electrical trip
Earth fault 10% ( 50 A ) 1000 Shutdown
Reverse power 0.3 KW Electrical trip
Synchronising ( check sync ) settings
Enable synchronising Yes
Check sync phase angle 10
Check sync frequency 0.2 Hz
Check sync RMS voltage 5.0VAC
Sync advance time 0 mS
Sync hold time 100 mS
Fail to sync time 30.0s
Engine settings
Crank disconnect Trip
Crank disconnect on generator frequency 21.0 Hz
Crank disconnect on generator voltage <Disabled>
Crank disconnect on charge alternator <Disabled>
Crank disconnect on oil pressure <Disabled>
Check oil pressure prior to starting Yes
Speed settings
Overspeed overshoot 0%
Plant battery settings Trip Return
Under volts warning 8.0 V DC 9.0 V DC
Over volts warning 33.0 V DC 32.0 V DC
Charge alternator warning 8.0 V DC
Maintenance alarm settings
Enable maintenance alarm No
2 Check Sync fitted
3 09/10/00
4 Miles Revell
Printed on 27/11/00 16:25:58
Exercise scheduler settings
Enable exercise scheduler No
Language settings
Default language English (UK)
User defined language 1 Chinese (PRC)
User defined language 2 Not used
45
10. ICONS AND LED INDENTIFICATION
10.1 ICON DESCRIPTIONS
Symbol Meaning Description
Stop/Reset Stop the generator and reset any alarm conditions.
Refer to Section 1 of this Manual.
I
Start Start the generator (if in an appropriate mode).
Refer to Section 1 of this Manual.
Auto The controller will automatically start the generator
when given a remote start command.
Manual The controller will start the generator under manual
control. (Separate Start command may be
necessary)
Common Alarm An alarm condition has been detected.
(Warning = Steady, Shutdown = Flashing)
Mains Failure Simulation
(Test)
On AMF modules this is used to simulate a mains
failure event. (On load test)
Alarm Mute Silences the audible warning device.
Lamp Test Causes all indicating LEDs to illuminate to test for
correct operation
Engine Instruments Instruments page for engine details such as Oil
pressure, Engine temperature.
Generator Instruments Instruments page for generator details such as
frequency and voltage
Event Log Details recorded history of generator operation.
10.2 LED IDENTIFICATION DIAGRAM
O
AUTO
I
i
Model 550
LED1
LED2
LED3
LED4
10.3 SENDER WIRING RECOMMENDATIONS
55x / 560
module
Connection name Terminal
Oil pressure 22
Coolant temperature 23
Sender common 24
22 24 23
Using Earth return (single wire) senders
NOTE:- . It is important that terminal 24 ( 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.
47
Using insulated return (two wire) senders
55x / 560
module
22 24 23
Connection name Terminal
Oil pressure 22
Coolant temperature 23
Sender common 24
NOTE:- . It is important that terminal 24 ( sender common ) is soundly connected to
an earth point on the ENGINE BLOCK, not within the control panel .
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9
12.APPENDIX
12.1 55X IDMT TRIPPING CURVES (TYPICAL)
55x Delayed over-current protection
1
10
100
1000
10000
100000
1000000
1 2
Current as a multiple of the trip-point setting
T
r
i
p
p
i
n
g

t
i
m
e

i
n

s
e
c
o
n
d
s
3
At default setting of t = 36
12.2 55X SHORT CIRCUIT TRIPPING CURVES (TYPICAL)
Model 55x Short circuit & Earth fault curves for a 3 phase fault @ 50 Hz
100
1000
10000
100000
1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2
Current as a multiple of the trip-point setting
D
e
t
e
c
t
i
o
n

t
i
m
e

i
n

m
i
l
l
i
s
e
c
o
n
d
s
Curve 8200
Curve 6800
Curce 5600
Curve 4700
Curve 3900
Curve 3300
Curve 2700
Curve 2200
Curve 1800
Curve 1500
Curve 1200
Curve 1000
51
12.4 55X DEAD BUS OPERATION
Modules fitte
e
d with Check sync or auto sync option only
It is frequently required that two or more generators should start at the same time,
and that the first one to reach stabilised running conditions should connect to the
ad bus leaving the remainder to synchronise onto the bus, as they become available. In
this scenario, two or even more generators can reach stabilised running conditions at the same
moment in time and therefore some form of election process is required to ensure that generators
do not attempt to close onto the dead bus simultaneously. Failure to do this will almost certainly
result in out-of-phase paralleling at some time in the lifetime of the installation.
d
The problem arises from the fact that it is impossible to predict just when each of the generators
ready for load signal will occur and therefore two or more could occur at exactly the same time.
Under these circumstance, applying the ready for load signal directly to the contactor or breaker is
not satisfactory since both contactors will attempt to close together, and using N/C interlock
contacts and dead bus sensing does not resolve this problem.
There may not be a problem in the case of a two set system where both sets are always required
on the bus. In this case the bus input to the synchroniser can be derived from the generator side
of the other sets contactor, then at the point of synchronism, both contactors can be closed onto
the dead bus at the same time. However, this approach is not possible for more than two sets, and
in addition, the application may require that the first available set be connected to the bus in the
shortest possible time without waiting for the successful completion of the synchronising process.
The following figure shows one of the solutions using external electrically interlocked interposing
relays in conjunction with the 550 unit having the check synchronising option. If the close request
outputs appear simultaneously, then both interposing relays Ra/2 & Rb/2 will start to close but
because of their interlock contacts Ra2 & Rb2, one relay will become closed and the other will be
locked out. This will occur very quickly and before contacts Ra1 or Rb1 close. Thus only one of
the contacts Ra1 or Rb1 closes and only one of the contactor coils becomes energised by this
route. When one of the contactor auxiliary contacts Ma1 or Mb1 closes it will cause a closing
command to appears at terminal 36 and the close request signal at terminal 40 will disappear.
If neither the auxiliary contacts Ma1 or Mb1 close within 1.5 seconds, then this will indicate that
there is an external fault, perhaps through contact Ra1 or Rb1 or with the contactor its-self. In this
case the close request output at terminal 40 will disappear allowing another set the chance of
becoming first on the bus.
As soon as one of the generators has connected to the bus in the above manner, so others will
synchronise to the bus, and when in synchronism a closing command will appear at their
respective terminal 36. This signal will remain for as long as the generator is to remain on load.
This scheme can be extended to cover a number of parallel gen-sets.
Two generators with 550 synchronising controllers
The interposing relays Ra & Rb ensure that only one generator attempts to close onto the dead bus
Key: R = Interposing relay M = Main contactor
a = 1
st
generator b = 2
nd
generator
40
Ma2
Ra2
Rb1
Close
command
Mb
1
550 unit b
40 36
550 unit a
N
Mb2
Rb2
Ra1
Ma1
DC -ve
Close
command
Close
request
Aux IP
F
L1
35 39
Ra/2
Ma
36
N
DC -ve
Close
request
Aux IP
F
L1
35 39
Rb/2
Mb
Modules fitted with Load share option only
When using a module fitted with the load share option, then the modules must be connected
together and talking correctly on the Mutli-set Communications Link. Once the link is established
then the modules will perform the task of getting the first set on the bus themselves without the
need for the additional circuit shown above.
Simply connect the contactor or breaker to the close generator output (normally 5) and then the
modules will ensure that only one set is allowed on the dead bus.
Once the set is available it will transmit a message onto the MSC link to say that it can close onto
the dead bus, if there is no objection from the other units it will then go ahead and close. Should
another gen-set report that it is also ready to go, then the modules will vote as to who going to
actually close. Once the decision has been made to close onto the bus all other sets will be
instructed over the MSC link that the bus is live and that they must synchronise first before closing.
This system ensures that only one module can close onto the dead bus at once and the sets on
the MSC are aware of each others actions. Once the first set is on the bus, and then the others
synchronise and close, normal load sharing and sequencing will then take place, regardless of
who was first on the bus.
53
12.3 USING THE 55X MODULE WITH ACBS
The standard configuration allows the 55x module to be connected to contactors and the like.
However, it may be required to connect the to 55x module to breakers such as ACBs, etc. If so
the following connection scheme is recommended as considered a fail-safe method.
Output 3
UV Coil Supply
Internal DC Supply Internal DC Supply
DC Slave
Relay
Configure as: De-Energise - Trip Generator
Output 5
Configure as: Energise - Close Generato
*Or use DC trip Coil
55x Module
Generator
Undervolts Coil
Generator
Closing Coil
Closing Supply
35
36
18 39 40
38
19
12.4 OUTPUT EXPANSION
There are several methods of output expansion available for the 55x module:-
12.4.1 RELAY OUTPUT EXPANSION (157)
An expansion module is available, which connects to the configuration socket, and enables the 55x
to use eight additional relays on the 157 relay module, providing Volt-free contacts for customer
connection. A maximum of 2 off 157 relays modules can be connected, there are identified as A
and B and give a total of 16 extra relay outputs.
CAUTION!:- When used in conjunction with the P122 Digital Resistance Modules, only
P157 Relay Expansion modules with Part Number 81xxxxx MUST be used. The digital
resistance requires a different set of data commands to operate and the 55x module will
change the data output by the 808 port to suit the P122 when selected. The older P157
relay modules (Part No. 80xxxxx) will only function if the P122 module is not configured
for use by the 555.
Refer to technical data sheet on the 157 relay module for further details.
12.4.2 LED OUTPUT EXPANSION (548)
An expansion module is available, which connects to the configuration socket, and enables the 55x
to use eight additional LEDs on the 548 module, providing remote LEDs indication up to 50
metres away. A maximum of 2 off 548 LED modules can be connected, there are identified as A
and B and give a total of 16 extra LED outputs.
CAUTION!:- When used in conjunction with the P122 Digital Resistance Modules, only
P548 Relay Expansion modules with Part Number 81xxxxx MUST be used. The digital
resistance requires a different set of data commands to operate and the 55x module will
change the data output by the 808 port to suit the P122 when selected. The older P548
relay modules (Part No. 80xxxxx) will only function if the P122 module is not configured
for use by the 555.
Refer to technical data sheet on the 548 LED module for further details.
It is possible to use a mix of 157 and 548 modules to give both relay and LED expansion if
required (Please refer to our Technical Support department for details.).
12.5 INPUT EXPANSION
It is possible to increase the number of monitored inputs available by utilising a DSE 54x
Protection Expansion/Annunciator. Please refer to our Technical department for details.
55
o
13. SYNCHRONISING NOTES
13.1 CHECK SYNC VERSIONS
A special version of the module provides the function of Check Sync relay and
Synchroscope display. The module will control the operation of the load switching device
allow parallel operation with the mains supply only when the two supplies are in Sync.
These functions can be used to provide manual Peak lopping/ Peak shaving and short duration no-
break or bump-less transfers back to the mains supply following a mains failure.
t
13.2 AUTO SYNC VERSIONS
A special version of the module provides the function of Automatic synchronising. The
module features all the functions associated with the Check sync version and in addition
it provides control signals to the Engine Governor and the Alternator AVR to control the
speed and voltage output from the generating set.
These functions can be used to provide peak lopping/ peak shaving (without load share control)
and true no-break or bump-less transfers back to the mains supply following a mains failure.
The Auto-sync 55x module provides the ability to control the generator by adjusting the speed
(frequency) and voltage being output. Several method of providing this control are available. The
following pages give typical examples of interfacing with the engine governor and alternator AVR.
Refer to the P810 software manual an the Guide to synchronising manual for further details.
NOTE:- To verify if your particular 55x module has any of the above special features
fitted please refer to page 26 for the Power Up LCD display information.
13.3 LOAD SHARE VERSIONS
A special version of the module provides the function of Load sharing. The module
features all the functions associated with both the Check sync version and the Auto s
version and in addition it provides control signals to the Engine Governor and the
Alternator AVR to control the speed and voltage output from the generating set while
communicating with other sets it is running in parallel with
ync
These functions can be used to build a multiple parallel generating set system. Each set will share
its proportion of the load with the other sets on the bus. Additionally the sets can be configured to
start and stop as the load demand requires more or less generating power.
The load share 55x module provides the ability to control the generator by adjusting the speed
(frequency) and voltage being output, while comparing itself to the other sets on the bus.
Refer to the P810 software manual an the Guide to synchronising manual for further details.
NOTE:- To verify if your particular 55x module has any of the above special features
fitted please refer to page 26 for the Power Up LCD display information.

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8-way connector allows connection to PC via 810 configuration interface.

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