Deif GPU 300 Installation Instructions Manual
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Deif GPU 300 Installation Instructions Manual

Deif GPU 300 Installation Instructions Manual

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INSTALLATION INSTRUCTIONS
Generator Protection Unit
GPU 300
DEIF A/S · Frisenborgvej 33 · DK-7800 Skive
Tel.: +45 9614 9614 · Fax: +45 9614 9615
Info@deif.com · www.deif.com
Document no.: 4189341031A

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  • Page 1 INSTALLATION INSTRUCTIONS Generator Protection Unit GPU 300 DEIF A/S · Frisenborgvej 33 · DK-7800 Skive Tel.: +45 9614 9614 · Fax: +45 9614 9615 Info@deif.com · www.deif.com Document no.: 4189341031A...

  • Page 2: Table Of Contents

    1.1.1 General purpose ............................................. 1.1.2 Intended users of the Installation instructions ................................1.1.3 Technical support ............................................1.1.4 List of technical documentation for GPU 300 ................................1.2 Warnings and safety ..............................................1.2.1 Safety during installation and operation ..................................1.2.2 Metal fragments and other objects ....................................
  • Page 3 GPU 300 Installation instructions 4189341031 UK 4.2 Hardware configurations ..........................................4.2.1 Hardware configuration .......................................... 4.3 PSM3.1 terminal connections and default wiring ............................... 4.3.1 PSM3.1 terminal connections ......................................4.3.2 Default wiring for controller PSM3.1 ..................................... 4.4 ACM3.1 terminal connections and default wiring ...............................
  • Page 4 GPU 300 Installation instructions 4189341031 UK 7. Wiring the communication 7.1 DEIF Ethernet network communícation ....................................7.1.1 Communication ............................................7.1.2 Connecting the communication ......................................8. Wiring the display unit 8.1 Display unit overview and wiring ......................................8.1.1 Display unit terminal overview ......................................

  • Page 5: Introduction

    1.1.1 General purpose These are the installation instructions for DEIF’s Generator Protection Unit, GPU 300. The installation instruction provide information for the correct installation of GPU 300. The primary focus of these instructions is the physical installation of the equipment.

  • Page 6: List Of Technical Documentation For Gpu 300

    GPU 300 Installation instructions 4189341031 UK 1.1.4 List of technical documentation for GPU 300 Document Contents • Controller application, functions, hardware and protections • Technical specifications Data sheet • Hardware modules, display unit, and accessories • Ordering information • Mounting •...

  • Page 7: Warnings And Safety

    GPU 300 Installation instructions 4189341031 UK 1.2 Warnings and safety 1.2.1 Safety during installation and operation Installing and operating the equipment may require work with dangerous currents and voltages. The installation must only be carried out by authorised personnel who understand the risks involved in working with electrical equipment.

  • Page 8: Legal Information

    1.3 Legal information 1.3.1 Third party equipment DEIF takes no responsibility for the installation or operation of any third party equipment, including the genset. Contact the genset company if you have any doubt about how to install or operate the genset.

  • Page 9: Preparing For The Installation

    Trim cable ties *Note: The size of the torque wrench attachment depends on the nut and bolt size of the mounting bolts. These parts are not supplied by DEIF and the sizes mentioned are only a recommendation. CAUTION Do not use power tools during the installation. Too much torque will damage the equipment.

  • Page 10: Materials

    GPU 300 Installation instructions 4189341031 UK Figure 2.1 Tools required to install a controller rack PSM3.1 ACM3.1 IOM3.1 PCM3.1 CAN-A CAN-B CAN-A CAN-B 2.2 Materials 2.2.1 Materials required The following materials are required to install the controllers and display units.

  • Page 11: Site

    GPU 300 Installation instructions 4189341031 UK Installation Materials Purpose More information step Wire the measurement points, See the Data sheet for the wiring switchboard and/or third party Wires specifications for each terminal equipment to the controller/display unit See the drawings from the system designer...

  • Page 12: Mounting The Equipment

    You can mount the hardware modules in a different order from that recommended in these instructions. If you choose to do this, DEIF recommends that you document where you have chosen to deviate from the default configuration and ensure that this information is included in the system documentation.

  • Page 13: Mounting Hardware Modules In The Rack

    The manufacturer's warranty will not apply if the rack has been opened by unauthorised persons. However, you are allowed to replace or add hardware modules (dedicated printed circuit boards) supplied by DEIF. To retain the warranty, each hardware module must be mounted by a qualified person, in accordance with these written instructions.
  • Page 14 GPU 300 Installation instructions 4189341031 UK Safety: Hazardous live currents and voltages DANGER! Hazardous live currents and voltages may be present in a rack that is already installed. Contact with these could kill you. Only authorised personnel, who understand the precautions needed and the risks involved in working with live electrical equipment, may do this work.

  • Page 15: Mounting The Controller Rack

    GPU 300 Installation instructions 4189341031 UK c. Tighten the screws on the hardware module faceplate using a screwdriver with a TX20 bit, and 0.5 N·m (4.4 lb-in) of torque. d. Replace all the terminal blocks, including any Ethernet cables to the module.

  • Page 16: Rack Drilling Drawing

    GPU 300 Installation instructions 4189341031 UK 3.3.2 Rack drilling drawing The diagram below can be used to make a drilling template for the four bolt holes required to mount the rack. Dimensions are in mm (followed by approximate dimensions in inches).
  • Page 17 GPU 300 Installation instructions 4189341031 UK CAUTION Dust accumulation may damage the controller or cause overheating. DEIF recommends mounting the rack in a cabinet with a filter on the air supply. CAUTION Protect the controller terminals from static discharge during installation, especially while the frame ground is not connected.
  • Page 18 GPU 300 Installation instructions 4189341031 UK Figure 3.1 Example of the minimum space above and below the rack for an Ethernet cable (plug = 40 mm, plus cable bend radius = 40 mm) Free space 80.0 (3.16) This side up ACM3.1...
  • Page 19 GPU 300 Installation instructions 4189341031 UK Calculating minimum bolt length example For bolts, the minimum length is 12 mm (0.47 in) for the rack mounting loop. Length is also needed for the washer thickness (typically 1.5 mm), the nut (typically 4 mm) and the cabinet back plate thickness.

  • Page 20: Rack Cable Strain Relief

    GPU 300 Installation instructions 4189341031 UK 3.3.4 Rack cable strain relief Use the cable strain relief plates or the cable tie slots to secure cables and wiring. Cable strain relief You can use the cable strain relief plates mounted at the top and bottom of the front of the rack to hold cables in place.
  • Page 21 GPU 300 Installation instructions 4189341031 UK Figure 3.2 Cable tie slot positions shown on the top of the rack by red cable ties (Slot detail shown in A) PCM3.1 PSM3.1 Figure 3.3 Cable tie slot positions shown on the bottom of the rack by red cable ties (Slot detail shown in A) PSM3.1...

  • Page 22: Mounting The Display Unit

    GPU 300 Installation instructions 4189341031 UK 3.4 Mounting the display unit 3.4.1 Display unit dimensions The diagram below shows a first-angle projection of the display unit, with dimensions. Dimensions are in mm (followed by approximate dimensions in inches). 238.0 (9.4) 52.4 (2.1)

  • Page 23: Mounting The Display Unit

    The back of the display unit is not protected against dust. Dust accumulation may damage the display unit or lead to overheating. DEIF recommends mounting the display unit so that its back is in a cabinet with a filter on the air supply.
  • Page 24 GPU 300 Installation instructions 4189341031 UK CAUTION Protect the display unit terminals from static discharge during installation. Protecting the terminals is very important while the frame ground is not connected. Ventilation requirements and spacing For proper ventilation, the display unit must be mounted with its back vertical, and its long axis horizontal. The writing on the front of the display unit must be horizontal.

  • Page 25: Display Unit Cable Strain Relief

    GPU 300 Installation instructions 4189341031 UK INFO DEIF recommends that you always follow the cable manufacturer's bend radius requirements. As a guideline, Ethernet cables may require a minimum bend radius of around 40 mm (1.6 in). Cable strain relief You can use the two "+" shaped slots on the back of the display units for cable strain relief and hold cables in place. Thread a cable tie (maximum 4 mm (0.15 in) wide) through the horizontal or vertical slot.
  • Page 26 GPU 300 Installation instructions 4189341031 UK www.deif.com Page 26 of 76...

  • Page 27: Default Wiring For The Controller

    Drawings are not given for the hardware modules with no default wiring. Custom configurations You can connect the inputs and outputs to terminals other than the terminals specified in the default configuration. DEIF recommends that you keep a record of where the wiring deviates from the default configuration.

  • Page 28: Hardware Configurations

    GPU 300 Installation instructions 4189341031 UK 4.2 Hardware configurations 4.2.1 Hardware configuration The controller minimum hardware is described below. Up to three additional IOM3.1 hardware modules can be ordered, and installed in the empty slots. Spare hardware modules may also be ordered for installation in the field.

  • Page 29: Psm3.1 Terminal Connections And Default Wiring

    GPU 300 Installation instructions 4189341031 UK 4.3 PSM3.1 terminal connections and default wiring 4.3.1 PSM3.1 terminal connections Terminal Name Type Function Ground Frame ground* 12 or 24 V DC PSM3.1 (nominal) Power supply* 0 V DC Normally open Alarm > Status OK*...

  • Page 30: Default Wiring For Controller Psm3.1

    GPU 300 Installation instructions 4189341031 UK 4.3.2 Default wiring for controller PSM3.1 Supply Frame ground PSM3.1 Alarm > Status OK Alarm > Horn 1 Alarm > Any alarm Common www.deif.com Page 30 of 76...

  • Page 31: Acm3.1 Terminal Connections And Default Wiring

    GPU 300 Installation instructions 4189341031 UK 4.4 ACM3.1 terminal connections and default wiring 4.4.1 ACM3.1 terminal connections Terminal Name Type Function L1 voltage Busbar L1* Voltage** L2 voltage Busbar L2* ACM3.1 100 to 690 V AC phase-to- L3 voltage Busbar L3*...

  • Page 32: Mounting Voltage Encoding Pins

    CAUTION To prevent the voltage measurements from being swapped around, DEIF recommends that the voltage measurement terminals are fitted with voltage encoding pins. Check that the wiring to the terminals has not been swapped around during installation if voltage encoding pins are used.
  • Page 33 GPU 300 Installation instructions 4189341031 UK Figure 4.1 Where and how to fit voltage encoding pins, shown in red, on the voltage measurement terminals ACM3.1 *Click* www.deif.com Page 33 of 76...

  • Page 34: Default Wiring For Controller Acm3.1

    GPU 300 Installation instructions 4189341031 UK 4.4.3 Default wiring for controller ACM3.1 ACM3.1 BB-L1 BB-L2 BB-L3 GEN-L1 GEN-L2 GEN-L3 GEN-L1 GEN-L2 GEN-L3 INFO Alternatively, you can ground the S1 side of the current transformers, instead of S2 as shown. www.deif.com...

  • Page 35: Iom3.1 Terminal Connections And Default Wiring

    GPU 300 Installation instructions 4189341031 UK 4.5 IOM3.1 terminal connections and default wiring 4.5.1 IOM3.1 slot 3 terminal connections Terminal Name Type Function Normally open Synchronisation check > Sync. OK* Common or configurable Normally IOM3.1 closed Normally open Generator breaker > Control >...

  • Page 36: Default Wiring For Controller Iom3.1

    GPU 300 Installation instructions 4189341031 UK 4.5.2 Default wiring for controller IOM3.1 Supply IOM3.1 Synchronisation check > Sync. OK Generator breaker > Control > Open Generator breaker > Feedback > Open (12/24 V DC) Generator breaker > Feedback > Closed (12/24 V DC) Common www.deif.com...

  • Page 37: Pcm3.1 Terminal Connections And Default Wiring

    GPU 300 Installation instructions 4189341031 UK 4.6 PCM3.1 terminal connections and default wiring 4.6.1 PCM3.1 terminal connections Terminal Name Function CAN high CAN bus A (for future use) CAN cable shield PCM3.1 CAN low CAN high CAN cable shield CAN bus B (for future use)
  • Page 38 Display unit* Bottom of rack, back port DEIF network / SCADA / AMS / Modbus TCP/IP *Note: The default Ethernet connections. The Ethernet ports on the controllers are not assigned to a particular service. The controllers detect the equipment connected to the port.

  • Page 39: Wiring For The Hardware Modules

    GPU 300 Installation instructions 4189341031 UK 5. Wiring for the hardware modules 5.1 Introduction 5.1.1 Introduction This chapter describes the wiring for each of the controller hardware modules in detail. Each terminal's wiring is described, with examples. However, wiring the system communication (including the connection to the display unit) is described in another chapter.

  • Page 40: Frame Ground Wiring

    Supply 1 12/24 V DC 0 V DC 0 V DC INFO DEIF recommends that a 2A slow blow fuse is used for F1 and F2, and that the diodes are rated 50V or higher. www.deif.com Page 40 of 76...

  • Page 41: Relay Output Wiring

    GPU 300 Installation instructions 4189341031 UK 5.2.4 Relay output wiring The following diagram shows the connection of the relay output to an external relay. For the wiring shown, there is no voltage on the external relay when the controller relay is open.

  • Page 42: Internal Communication Connections

    For future use. INFO Do not try to use these connections for Ethernet communication (for example, over the DEIF network to other controllers, or to a service PC). There will be no communication, since these connections are dedicated to DEIF internal communication.

  • Page 43: Voltage Measurements Wiring

    See Default wiring for unit, ACM3.1 terminal connections and default wiring for more information about the default wiring for voltage measurements. DANGER! DEIF recommends that you install fuses (2 A rating) on the voltage measurement lines, as close to the busbar as possible. These fuses protect the voltage measurement lines. 5.3.3 Current measurements wiring See Default wiring for unit, ACM3.1 teminal connections and default wiring for more information about the...

  • Page 44: Relay Output Wiring

    GPU 300 Installation instructions 4189341031 UK Terminal Symbol Name Type Normally open Common Normally closed Relay output (250 V AC or 30 V DC, and 6 A) Normally open Common Normally closed Bi-directional input Bi-directional input Bi-directional input Bi-directional input Bi-directional input Digital input (OFF: 0 to 2 V DC, ON: 8 to 36 V DC, Impedance: 4.7 kΩ)
  • Page 45 The current will flow through the equipment connected to the normally open terminal when the relay is energised. 230 V AC Contactor Contactor 0 V AC INFO For 230 V AC contactors, DEIF strongly recommends that you use an RC snubber for noise suppression across the contactor. www.deif.com Page 45 of 76...

  • Page 46: Digital Inputs Wiring

    GPU 300 Installation instructions 4189341031 UK 5.4.3 Digital inputs wiring The digital inputs are bi-directional inputs. This means that wiring to the input and common terminals may be swapped around without affecting their operation. However, all the digital inputs on a module share a common terminal. The digital input common for a module may be either low (connected to 0 V), or high (connected to 12 or 24 V).
  • Page 47 GPU 300 Installation instructions 4189341031 UK Figure 5.3 Example of digital input wiring (common = 12 or 24 V) 12/24 V DC Digital signal 0 V DC Safety function wiring The controller function Emergency stop is safety function that requires a normally closed digital signal to be wired to the controller.

  • Page 48: Processor And Communication Module Pcm3.1

    RJ45 Service PC RJ45 Display unit RJ45 DEIF network / SCADA / AMS / Modbus TCP/IP RJ45 The Ethernet connections listed above are the recommended defaults, to help troubleshooting. The Ethernet ports are in fact fully interchangeable. www.deif.com Page 48 of 76...

  • Page 49: Can Bus Communication Wiring

    GPU 300 Installation instructions 4189341031 UK INFO Only one display unit may be connected to each controller rack. DEIF recommends mounting the display unit close to the controller rack. 5.5.2 CAN bus communication wiring The CAN bus terminals on the PCM3.1 module are reserved for future use for communication with a Engine Control Unit (ECU) or a digital Automatic Voltage Regulator (AVR).

  • Page 50: Wiring Examples For Functions

    GPU 300 Installation instructions 4189341031 UK 6. Wiring examples for functions 6.1 Introduction This chapter includes wiring diagrams for a variety of controller functions. See the Designer's handbook for more information about each controller function. 6.2 AC measurement wiring 6.2.1 System AC configuration See AC configuration and nominal settings, AC configuration, System in the Designer's handbook for information about setting the parameters for these configurations.
  • Page 51 GPU 300 Installation instructions 4189341031 UK Single-phase wiring Figure 6.1 Example of single-phase L1 AC wiring ACM3.1 BB-L1 BB-N GEN-L1 GEN-N GEN-L1 GEN-N www.deif.com Page 51 of 76...
  • Page 52 GPU 300 Installation instructions 4189341031 UK INFO Single-phase does NOT mean split-phase (where the waveforms are offset by a half-cycle (180 degrees) from the neutral wire). INFO Alternatively, you can ground the S1 side of the current transformers, instead of S2 as shown.
  • Page 53 GPU 300 Installation instructions 4189341031 UK Split-phase wiring Figure 6.2 Example of split-phase L1-N-L2 wiring ACM3.1 BB-L1 BB-L2 GEN-L1 GEN-L2 BB-N GEN-N GEN-L1 GEN-L2 GEN-N www.deif.com Page 53 of 76...
  • Page 54 GPU 300 Installation instructions 4189341031 UK INFO For split-phase, the waveforms are offset by a half-cycle (180 degrees) from the neutral wire. Split-phase is sometimes called L1-N-L2, or single-phase in the USA. INFO Alternatively, you can ground the S1 side of the current transformers, instead of S2 as shown.
  • Page 55 GPU 300 Installation instructions 4189341031 UK Wiring phase-to-neutral voltage measurements Figure 6.3 Example of wiring required for the phase-to-neutral voltage measurements ACM3.1 BB-L1 BB-L2 GEN-L1 BB-L3 GEN-L2 BB-N GEN-L3 GEN-N GEN-L1 GEN-L2 GEN-L3 GEN-N www.deif.com Page 55 of 76...

  • Page 56: Controlled Equipment] Ac Configuration

    GPU 300 Installation instructions 4189341031 UK INFO Alternatively, you can ground the S1 side of the current transformers, instead of S2 as shown. 6.2.2 [Controlled equipment] AC configuration See AC configuration and nominal settings, AC configuration, [Controlled equipment] in the Designer's handbook for information about setting the parameters for this configuration.
  • Page 57 GPU 300 Installation instructions 4189341031 UK Figure 6.4 Example of generator voltage transformer wiring Primary Voltage transformer (Busbar) Secondary ACM3.1 Step-up transformer Voltage transformer (Generator) GEN-L1 GEN-L2 GEN-L3 Secondary Primary GEN-L1 GEN-L2 GEN-L3 INFO Alternatively, you can ground the S1 side of the current transformers, instead of S2 as shown.

  • Page 58: Busbar] Ac Configuration

    GPU 300 Installation instructions 4189341031 UK 6.2.3 [Busbar] AC configuration See AC configuration and nominal settings, AC configuration, [Busbar] in the Designer's handbook for information about setting the parameters for this configuration. www.deif.com Page 58 of 76...
  • Page 59 GPU 300 Installation instructions 4189341031 UK Figure 6.5 Example of busbar voltage transformer wiring Primary Voltage transformer (Busbar) Secondary ACM3.1 Step-up transformer Voltage transformer (Generator) GEN-L1 GEN-L2 GEN-L3 Secondary Primary GEN-L1 GEN-L2 GEN-L3 INFO Alternatively, you can ground the S1 side of the current transformers, instead of S2 as shown.

  • Page 60: Breaker Wiring

    GPU 300 Installation instructions 4189341031 UK 6.3 Breaker wiring 6.3.1 Breaker An example of the wiring for the Activate breaker close function is shown below. See Breaker in the Designer's handbook for information about configuring the inputs, outputs and parameters.

  • Page 61: Wiring The Communication

    • The Ethernet lines must meet or exceed the SF/UTP CAT5e specification. CAUTION The internal communication ports on the PSM must not to be used for the DEIF Ethernet network communication. They are for future use for connecting extension racks together. Do not use either of the internal communication ports in your communication setup.
  • Page 62 INFO DEIF recommends that the Ethernet port protectors remain installed in the top Ethernet ports (connection 1 and 2) when these are not in use. The Ethernet port protectors protects the ports from dust and foreign objects. www.deif.com...
  • Page 63 Bends in the Ethernet cables must not be tighter than the minimum bend radius specified by the cable manufacturers. INFO DEIF recommends that you always follow the cable manufacturer's bend radius requirements. As a guideline, Ethernet cables may require a minimum bend radius of 40 mm (1.6 in).
  • Page 64 GPU 300 Installation instructions 4189341031 UK Figure 7.1 T-568A "Straight-through" Ethernet cable wiring Shield Pin 1 T-568A T-568A Figure 7.2 T-568B "Straight-through" Ethernet cable wiring Shield Pin 1 T-568B T-568B www.deif.com Page 64 of 76...
  • Page 65 GPU 300 Installation instructions 4189341031 UK Figure 7.3 RJ-45 "Crossover" Ethernet cable wiring Shield Pin 1 T-568A T-568A T-568B www.deif.com Page 65 of 76...

  • Page 66: Wiring The Display Unit

    GPU 300 Installation instructions 4189341031 UK 8. Wiring the display unit 8.1 Display unit overview and wiring 8.1.1 Display unit terminal overview Figure 8.1 Back of display unit DU 300, with the terminal positions Table 8.1 Display unit electrical terminals...

  • Page 67: Frame Ground Wiring

    Connect the power supply (+) to the 12 or 24 V DC power supply. Connect the power supply (-) to the 0 V DC power supply. Backup power supply The DEIF equipment does not contain a backup power supply. The power supply source must therefore include the power backup needed. www.deif.com...

  • Page 68: Relay Output Wiring

    0 V DC INFO DEIF recommends that a 2A slow blow fuse is used for F1 and F2, and that the diodes are rated 50V or higher. 8.1.4 Relay output wiring The following diagram shows how the display unit status OK relay can be connected to a third party device ("1"). This could be an alarm monitoring system (AMS), a horn or a light.

  • Page 69: Ethernet Connections

    Recommended default connection Right side, top port Controller Right side, bottom port Additional display unit (optional) Figure 8.3 The recommended connection of the DEIF display unit and optional additional display unit to the controller. Display Controller Display www.deif.com Page 69 of 76...

  • Page 70: Glossary

    NOT recommended. Changing hardware modules while the equipment is Hot swapping powered, which may damage the equipment. Input output module A replaceable PCB, with four relay outputs, and 10 digital inputs. Used in the DEIF IOM3.1 controller. Internet Protocol A protocol for communication across networks. IPv4 currently routes the most...
  • Page 71 Multi-line 300 ML 300 A DEIF product platform. GPU 300 is part of ML 300. Neutral The neutral line in a three-phase electrical system. An Ethernet connection topology where the controllers are connected in a line, and Network ring the last controller is connected back to the first.

  • Page 72: Units

    GPU 300 Installation instructions 4189341031 UK Term Abbreviation Explanation Equipment other than the DEIF controller. For example: The genset, the genset Third-party equipment engine control system, the wiring, the busbars, and the switchboard. Time Transmission control The Internet protocol suite. It provides end-to-end connectivity by specifying data...

  • Page 73: Symbols

    GPU 300 Installation instructions 4189341031 UK Unit Name Measures US unit US name Conversion Alternative units millisecond Time N·m newton metre Torque lb-in pound-force inch 1 N·m = 8.85 lb-in Frequency of revolutions per rotation (rotational minute speed) second Time...
  • Page 74 GPU 300 Installation instructions 4189341031 UK Table 9.2 Electrical symbols Symbol Symbol name 3-phase breaker Capacitor Contactor with RC snubber Contactor Connector dot Current transformer (S1 and · show "current in"; S2 shows "current out") Diode Fuse Ω Ohmmeter Relay with freewheeling diode...

  • Page 75: Module Faceplate Symbols

    GPU 300 Installation instructions 4189341031 UK Symbol Symbol name Laptop Non-essential load Part of a module faceplate, to show examples of terminal wiring Rack R7 Server or desktop PC 9.3.3 Module faceplate symbols Table 9.4 Terminals Symbol Symbol name Frame ground...
  • Page 76 GPU 300 Installation instructions 4189341031 UK Symbol Symbol name Digital input Relay output (normally open) Relay with wire break detection (normally open) Relay output (changeover relay, with normally open and normally closed terminals) H, CAN-#, L CAN bus connection Table 9.5...

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