Deep Sea Electronics Plc 5520 Operator's Manual
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Deep Sea Electronics Plc 5520 Operator's Manual

Automatic mains failure control and instrumentation system
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DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual
Deep Sea Electronics Plc
5520 Operators Manual
A u t h o r – T o n y Ma n t o n
Deep Sea Electronics Plc
Highfield House
Hunmanby Industrial Estate
North Yorkshire
YO14 0PH
ENGLAND
Tel +44 (0) 1723 890099
Fax +44 (0) 1723 893303
Email : sales@deepseaplc.com
5520 OPERATING MANUAL ISSUE 1 04/02/05 AM
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  • Page 1 DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual Deep Sea Electronics Plc 5520 Operators Manual A u t h o r – T o n y Ma n t o n Deep Sea Electronics Plc Highfield House...
  • Page 2 DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual <<< THIS PAGE INTENTIONALLY BLANK >>> 5520 OPERATING MANUAL ISSUE 1 04/02/05 AM...

  • Page 3: Table Of Contents

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual TABLE OF CONTENTS Section Page INTRODUCTION ....................5 CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION......6 OPERATION.....................7 CONTROL ........................7 AUTOMATIC MODE OF OPERATION................8 MANUAL OPERATION ....................10 TEST OPERATION.......................12 PROTECTIONS ....................14 WARNINGS........................15...
  • Page 4 DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 5.3.4 P L U G “ D ” 3 WA Y....................43 5.3.5 P L U G “ E ” 5 WA Y....................44 5.3.6 P L U G “ F ” 8 WA Y....................44 5.3.7...

  • Page 5: Introduction

    The DSE 5520 module monitors the incoming AC mains supply for under or over voltage / under or over frequency and instructs the generating set to start and to supply the load.

  • Page 6: Clarification Of Notation Used Within This Publication

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 1.1 CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION. Highlights an essential element of a procedure to ensure NOTE: correctness. Indicates a procedure or practice which, if not strictly observed, CAUTION!: could result in damage or destruction of equipment.

  • Page 7: Operation

    2 OPERATION 2.1 CONTROL Control of the DSE 5520 module is via push buttons mounted on the front of the module with STOP/RESET, MANUAL, TEST, AUTO, LAMP TEST and ALARM MUTE and START 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 and load switching operations.

  • Page 8: Automatic Mode Of Operation

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 2.2 AUTOMATIC MODE OF OPERATION NOTE:- If a digital input configured to panel lock is active, changing module modes will not be possible. Viewing the instruments is NOT affected by panel lock.
  • Page 9 DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise without triggering the fault.

  • Page 10: Manual Operation

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 2.3 MANUAL OPERATION NOTE:- If a digital input configured to panel lock is active, changing module modes will not be possible. Viewing the instruments and event logs is NOT affected by panel lock.
  • Page 11 DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual The generator will run off load unless: 1. The mains supply fails, 2. A Remote Start on load signal is applied, 3. The Close Generator button is pressed.

  • Page 12: Test Operation

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 2.4 TEST OPERATION NOTE:- If a digital input configured to panel lock is active, changing module modes will not be possible. Viewing the instruments and event logs is NOT affected by panel lock.
  • Page 13 DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual Once the engine is running, the Warm Up timer (if selected) is initiated, allowing the engine to stabilise before it can be loaded. The set is then synchronised and paralleled with the mains supply, before the mains load switching device is opened.

  • Page 14: Protections

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 3 PROTECTIONS When an alarm is present the Audible Alarm will sound and the Common alarm LED (if configured) will illuminate. T h e a u d i b l e a l a r m c a n b e s i l e n c e d b y p r e s s i n g t h e ‘ Mute’ b u t t o n T h e L C D d i s p l a y w i l l j u mp f r o m t h e ‘...

  • Page 15: Warnings

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 3.1 WARNINGS Warnings are non-critical alarm conditions and do not affect the operation of the generator system. They draw the operators attention to an undesirable condition. In the event of an alarm the LCD will jump to the alarms page and scroll through all active warnings and shutdowns.
  • Page 16 DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual AUXILIARY INPUTS, auxiliary inputs can be user configured and will display the message as written by the user. Example Alarm Warning Bearing temp high LOW FUEL LEVEL, will be displayed if the fuel level detected by the fuel level sender falls below the low fuel level setting.

  • Page 17: Analogue Pre-Alarms

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 3.2 ANALOGUE PRE-ALARMS T h e f o l l o w i n g a l a r ms a r e t e r me d ‘ p r e - a l a r ms ’ a s t h e y p r e w a r n t h e o p e r a t o r o f a p o t e n t i a l l y mo r e serious alarm condition.
  • Page 18 DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual GENERATOR HIGH FREQUENCY, if the module detects a generator output frequency in excess of the pre-set pre-alarm, a warning is initiated. Alarm Warning High frequency will be displayed, it is an immediate warning.

  • Page 19: Shutdowns

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 3.3 SHUTDOWNS Shutdowns are latching and stop the Generator. The alarm must be 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 i s t h e L o w Oi l P r e s s u r e a l a r m a n d s i mi l a r ‘...
  • Page 20 DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated. Alarm Shutdown Overspeed will be displayed. Overspeed is not delayed, it is an immediate shutdown.
  • Page 21 DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual OIL PRESSURE SENDER OPEN CIRCUIT, if the module detects a loss of signal from the oil pressure sender (open circuit) a shutdown is initiated. Alarm Shutdown Sender Fault will be displayed.
  • Page 22 10%, a warning alarm will occur while the overload condition exists. If the load level does not drop to normal levels within one hour, the set is stopped, the 5520 module displaying either shutdown alarm or electrical trip alarm depending upon module configuration.

  • Page 23: Electrical Trips

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 3.4 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 ‘ C l o s e G e n e r a t o r ’ Output to remove the load from the generator.

  • Page 24: Description Of Controls

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual DESCRIPTION OF CONTROLS The following section details the function and meaning of the various controls on the module. 3.5 TYPICAL LCD DISPLAY SCREENS 3.5.1 TYPICAL STATUS DISPLAY Indicates that the module is in Automatic and that the mains is on Status load (closed).

  • Page 25: Typical Instrument Display

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 3.5.2 TYPICAL INSTRUMENT DISPLAY Engine oil pressure 0 PSI The display of the engine oil pressure 0.0 bar 0 kPa Coolant temerature 74  C The display of the engine coolant temperature 165 ...

  • Page 26: Viewing The Instrument And Event Log

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 3.6 VIEWING THE INSTRUMENT AND EVENT LOG PAGES T o v i e w a p a r t i c u l a r i n s t r u me n t o p e r a t e t h e “ Page” b u t t o n t o mo v e t o t h e r e q u i r e d page.

  • Page 27: Synchroscope Operation

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 3.6.1 SYNCHROSCOPE OPERATION (When enabled) Display Detail Initial stage of Synchronising display will only show the difference between the Mains Supply and the V +0.2 Hz +2.9 Generator Output. Here the display is showing a frequency mismatch of +2.9Hz - The genset...

  • Page 28: Complete Instrumentation List

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 3.7 COMPLETE INSTRUMENTATION LIST 3.7.1 BASIC INSTRUMENTATION Engine Speed Engine Oil pressure Coolant temperature Battery voltage Charge alt volts Engine run time Number of starts Next maintenance (if enabled)

  • Page 29: Operator Configuration Mode

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 3.8 OPERATOR CONFIGURATION MODE This configuration mode allows the operator limited customising of the way the module operates. 3.9 ACCESSING THE FRONT PANEL CONFIGURATION EDITOR Operation Detail To enter the ‘ O p e r a t o r c o n f i g u r a t i o n mo d e ’ press both the INFO and STOP buttons together.

  • Page 30: Editing Values

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 3.9.2 EDITING VALUES If the PIN number has not been set, or has been correctly entered : Operation Detail The LCD will then display: CONFIGURATION To view the different configuration functions press the + or - buttons.

  • Page 31: List Of Adjustable Parameters

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 3.9.3 LIST OF ADJUSTABLE PARAMETERS (Factory default settings are shown in bold italicised text) Section Parameter as shown on display Values Input settings Oil Pressure Pre Alarm 0 bar -4bar (1.17bar) Oil Pressure Shutdown 0 bar -4bar (1.03bar)

  • Page 32: Led Indicators

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 3.10 LED INDICATORS U S E R C O N F I G U R A B L E L E D ’ s These LEDs can be configured by the user to indicate...

  • Page 33: Control Push-Buttons

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 3.11 CONTROL PUSH-BUTTONS STOP/RESET T h i s p u s h - b u t t o n p l a c e s t h e mo d u l e i n t o i t ’ s Stop/reset mode. This will clear any alarm conditions for which the triggering criteria have been removed.
  • Page 34 DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual TEST T h i s p u s h - b u t t o n p l a c e s t h e mo d u l e i n t o i t ’ s ‘ T e s t ’ mode. This mode is used to test the function and timing of the generator start and load sequence.
  • Page 35 DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual TRANSFER TO MAINS This push button is used to control the closure of the mains load switching device and has three modes of operation : 1. Synchronising is NOT enabled. Pressing this button when the generator is running on load and in MANUAL mode, the generator load switch is opened.

  • Page 36: Installation Instructions

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 4 INSTALLATION INSTRUCTIONS The model DSE 5520 Module has been designed for front panel mounting. Fixing is by 4 clips for easy assembly. 4.1 PANEL CUT-OUT 160.00mm ( 6 . 3 ” ) 220.00mm...

  • Page 37: Front Panel Layout

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 4.4 FRONT PANEL LAYOUT 5520 OPERATING MANUAL ISSUE 1 04/02/05 AM...

  • Page 38: Electrical Connections

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 5 ELECTRICAL CONNECTIONS Connections to the Module are via plug and sockets. 5.1 CONNECTION DETAILS The following describes the connections and recommended cable sizes to the 8 plugs and sockets on the rear of the Module.

  • Page 39: P L U G " C " 9 Wa Y

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 5.1.3 P L U G “ C ” 9 WA Y DESCRIPTION CABLE NOTES SIZE Magnetic pickup screen 0.5mm Connect at module end only! Magnetic pickup 0.5mm Connect to magnetic pickup device Magnetic pickup 0.5mm...

  • Page 40: P L U G " F " 8 Wa Y

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 5.1.6 P L U G “ F ” 8 WA Y DESCRIPTION CABLE NOTES SIZE Mains Loading Relay 2.5mm Connect to mains contactor coil feed supply. Normally Closed Contact Mains Loading Relay 2.5mm...

  • Page 41: Pc Configuration Interface Connector

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 5.1.9 PC CONFIGURATION INTERFACE CONNECTOR 8-way connector allows connection to PC via 810 configuration interface. Module can then be re-configured u t i l i s i n g t h e 5 x x x f o r Wi n d o w s ™ s o f t w a r e .

  • Page 42: Connector Function Details

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 5.2 CONNECTOR FUNCTION DETAILS The following describes the functions of the 4 connectors on the rear of the module. See rear panel layout. 5.3 CONNECTION DETAILS The following describes the connections and recommended cable sizes to the 8 plugs and sockets on the rear of the Module.

  • Page 43: P L U G " C " 9 Wa Y

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual CAUTION!:- Refer to Typical wiring Diagram for different wiring topologies. WA R N I N G! : - D o n o t d i s c o n n e c t p l u g ‘ B ’ wh e n t h e g e n s e t i s r u n n i n g .

  • Page 44: P L U G " E " 5 Wa Y

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 5.3.5 P L U G “ E ” 5 WA Y DESCRIPTION Governor output B. For connection to electronic speed governors for synchronising / load sharing. Governor output A. For connection to electronic speed governors for synchronising / load sharing.

  • Page 45: P L U G " H " 1 2 Wa Y

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 5.3.8 P L U G “ H ” 1 2 WA Y DESCRIPTION CT Secondary for generator I1 CT Secondary for generator I2 CT Secondary for generator I3...

  • Page 46: Electrical Connections To J1939 Enabled Controllers

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 5.4 ELECTRICAL CONNECTIONS TO J1939 ENABLED CONTROLLERS This section of the manual is intended to describe only the connections between the 55xx controller and J1939 enabled controllers. All other connection details are described in the previous sections.

  • Page 47: Deutz Emr2

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 5.4.2 DEUTZ EMR2 P L U G “ A ” 8 WA Y 55xx 55xx Deutz Vehicle side (F) NOTES DESCRIPTION connector Crank output Connects directly to engine starter solenoid.

  • Page 48: John Deere

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 5.4.3 JOHN DEERE P L U G “ A ” 8 WA Y 55xx 55xx John Deere 21-pin Deutsch NOTES DESCRIPTION connector Fuel relay G, J G = Switched ECU power, J =...

  • Page 49: Perkins 2800 Series

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 5.4.4 PERKINS 2800 SERIES P L U G “ A ” 8 WA Y 55xx 55xx Perkins Customer interface NOTES DESCRIPTION connector Fuel relay 1, 10, 15, 33, 34...

  • Page 50: Scania S6

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 5.4.5 SCANIA S6 DSE 55xx controller has support for the Scania Keyword 2000 protocol. This is used to read d i a g n o s t i c ‘ t r o u b l e c o d e s ’ f r o m t h e e n g i n e E C U , r e mo v i n g t h e n e e d t o u s e S c a n i a d i a g n o s t i c t o o l s .

  • Page 51: Volvo Tad9 / Tad16

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 5.4.6 VOLVO TAD9 / TAD16 P L U G “ A ” 8 WA Y 55xx PIN No 55xx DESCRIPTION Volvo TAD9/16 NOTES EDC III connector Aux output 1 TAD9/16 STOP input.

  • Page 52: Volvo Tad12

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 5.4.7 VOLVO TAD12 P L U G “ A ” 8 WA Y 55xx 55xx V o l v o T A D 1 2 ‘ S t a n d a l o n e...

  • Page 53: Specification

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 6 SPECIFICATION DC Supply 8.0 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.

  • Page 54: Commissioning

    Part1 and Part2. 6.8. If despite repeated checking of the connections between the 5520 a n d t h e c u s t o me r ’ s system, satisfactory operation cannot be achieved, then the customer is requested to contact...

  • Page 55: Fault Finding

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 8 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...

  • Page 56: Typical Wiring Diagram

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 9 TYPICAL WIRING DIAGRAM 5520 OPERATING MANUAL ISSUE 1 04/02/05 AM...

  • Page 57: Factory Default Configuration

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 10 FACTORY DEFAULT CONFIGURATION 5520 OPERATING MANUAL ISSUE 1 04/02/05 AM...
  • Page 58 DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 1.0s 1.0s 1.0s 1.0s 5520 OPERATING MANUAL ISSUE 1 04/02/05 AM...
  • Page 59 DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 5520 OPERATING MANUAL ISSUE 1 04/02/05 AM...
  • Page 60 DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual Simplified Chinese 5520 OPERATING MANUAL ISSUE 1 04/02/05 AM...

  • Page 61: Icons And Led Identification

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 10. ICONS AND LED IDENTIFICATION 10.1 ICON DESCRIPTIONS Symbol Meaning Description Stop the generator and reset any alarm conditions. Stop/Reset Refer to Section 1 of this Manual. Start Start the generator (if in an appropriate mode).

  • Page 62: Configurable Led Identification Diagram

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 10.2 CONFIGURABLE LED IDENTIFICATION DIAGRAM LED 1 LED 2 LED 3 LED 4 10.3 SENDER WIRING RECOMMENDATIONS 10.3.1 USING EARTH RETURN (SINGLE WIRE) SENDERS. Coolant Fuel level EARTH...

  • Page 63: Using Insulated Return (Two Wire) Senders

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 10.3.2 USING INSULATED RETURN (TWO WIRE) SENDERS. Fuel Coolant EARTH level Pressure temperature NOTE:- . It is important that terminal 60 ( sender common ) is soundly connected to an earth point on the ENGINE BLOCK, not within the control panel.

  • Page 64: Appendix

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 12. APPENDIX 10.3.3 5520 IDMT TRIPPING CURVES (TYPICAL) 5520 Delayed over-current protection 1000000 100000 10000 1000 Current as a multiple of the trip-point setting At default setting of t = 36...

  • Page 65: 5520 Short Circuit Tripping Curves (Typical)

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 12.2 5520 SHORT CIRCUIT TRIPPING CURVES (TYPICAL) Model 5520 Short circuit & Earth fault curves for a 3 phase fault @ 50 Hz 100000 Curve 8200 10000 Curve 6800...

  • Page 66: Output Expansion

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 10.4 OUTPUT EXPANSION There are several methods of output expansion available for the 5xxx module:- 10.4.1 RELAY OUTPUT EXPANSION (157) An expansion module is available, which connects to the configuration socket and enables the 5xxx to use eight additional relays on the 157 relay module, providing Volt-free contacts for customer connection.

  • Page 67: Synchronising Notes

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 13. SYNCHRONISING NOTES Optionally, the 5520 controller can be configured to synchronise, volts match and parallel with the mains supply. This facility can be used to supply a fixed amount of power to the load and/or mains supply or provide no-break (closed transition) transfers to and from the generator supply.

  • Page 68: Typical Peak Lopping System

    DSE Model 5520 Automatic Mains Failure Control and Instrumentation System Operators Manual 10.5.4 13.3 TYPICAL PEAK LOPPING SYSTEM For further details on this subject you are referred to the Deep Sea Electronics Guide to Synchronising and Load Sharing. This document includes diagrams to show connections to many of the most common electronic governors and interfaces.

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