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

057-011 5210 OPERATING MANUAL ISSUE 5.1 18/06/2007 AM

COMPLEX SOLUTIONS
MADE SIMPLE.

DEEP SEA ELECTRONICS PLC

DSE5210

AUTOSTART CONTROL MODULE

OPERATING MANUAL

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1-888-POWER-58

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Summary of Contents for 5210

Page 1: ... Operators Manual 057 011 5210 OPERATING MANUAL ISSUE 5 1 18 06 2007 AM 1 COMPLEX SOLUTIONS MADE SIMPLE DEEP SEA ELECTRONICS PLC DSE5210 AUTOSTART CONTROL MODULE OPERATING MANUAL CALL US TODAY 1 888 POWER 58 REQUEST A QUOTE parts genpowerusa com SHOP ONLINE www genpowerusa com ...

Page 2: ...ial form including photocopying or storing in any medium by electronic means or other without the written permission of the copyright holder except in accordance with the provisions of the Copyright Designs and Patents Act 1988 Applications for the copyright holder s written permission to reproduce any part of this publication should be addressed to Deep Sea Electronics Plc at the address above An...

Page 3: ...EL CONFIGURATION EDITOR 22 7 1 1 ENTERING THE CONFIGURATION EDITOR PIN NUMBER 22 7 2 EDITING AN ANALOGUE VALUE 23 7 2 1 EDITING THE CURRENT DATE TIME 25 8 INSTALLATION INSTRUCTIONS 26 8 1 PANEL CUT OUT 26 8 2 COOLING 26 8 3 UNIT DIMENSIONS 26 8 4 FRONT PANEL LAYOUT 27 8 5 REAR PANEL LAYOUT 27 9 ELECTRICAL CONNECTIONS 28 9 1 CONNECTION DETAILS 28 9 1 1 PLUG A 8 WAY 28 9 1 2 PLUG B 11 WAY 28 9 1 3 P...

Page 4: ... 41 16 1 2 1 PHASE 2 WIRE 41 16 1 3 2 PHASE 3 WIRE 2 PHASE CENTRE TAP NEUTRAL 42 16 2 5210 IDMT TRIPPING CURVES TYPICAL 43 16 3 SENDER WIRING RECOMMENDATIONS 44 16 3 1 EARTH RETURN SENDERS 44 16 3 2 INSULATED RETURN SENDERS 44 16 3 3 FUEL LEVEL SENDERS 45 16 4 5200 SERIES CONFIGURATION SOFTWARE AND P810 INTERFACE MODULE 46 16 5 OUTPUT EXPANSION 46 16 5 1 RELAY OUTPUT EXPANSION 157 46 16 5 2 LED OU...

Page 5: ... configurable inputs for use as alarms or a range of different functions Extensive range output functions using built in relay outputs or relay expansion available Selective operational sequences timers and alarm trips can be altered by the customer via a PC using the 5200 series configuration software and P810 interface Access to critical operational sequences and timers for use by qualified engi...

Page 6: ... start input the following sequence is initiated The Remote Start Active indicator illuminates if configured To allow for false signals the Start Delay timer is initiated After this delay if the pre heat output option is selected then the pre heat timer is initiated and the corresponding auxiliary output if configured will energise NOTE If the Remote Start signal is removed during the Start Delay ...

Page 7: ...hout triggering the fault Once the engine is running the Warm Up timer if selected is initiated allowing the engine to stabilise before accepting the load If an auxiliary output has been selected to give a load transfer signal this would then activate NOTE A load transfer will not be initiated until the Oil Pressure has risen Thus preventing excessive wear on the engine On removal of the Remote St...

Page 8: ...tor When the engine fires the starter motor is disengaged and locked out at a pre set frequency from the Alternator output Alternatively a Magnetic Pickup mounted on the flywheel housing can be used for speed detection This is selected by PC using the 5200 series configuration software Rising oil pressure can also be used to disconnect the starter motor however it cannot be used for underspeed or ...

Page 9: ... identification much clearer If no alarms are present the LCD will extinguish any alarm icons In the event of a warning alarm the LCD will display the appropriate icon If a shutdown then occurs the module will display the appropriate icon The original warning alarm icon will remain displayed Example Low battery volts warning all symbols steady Followed by Low battery volts warning indicator still ...

Page 10: ...s at rest check oil sender wiring and configuration AUXILIARY INPUTS if an auxiliary input has been configured as a warning the appropriate LCD segment will be displayed LOW FUEL LEVEL If the fuel level detected by the fuel level sender falls below the low fuel level setting a warning will occur The icon will illuminate 4 2 ANALOGUE PRE ALARMS The following alarms are termed pre alarms as they pre...

Page 11: ...mmediate warning GENERATOR LOW FREQUENCY if the module detects a generator output frequency below the pre set pre alarm after the Safety On timer has expired a warning is initiated The icon will illuminate GENERATOR HIGH VOLTAGE if the module detects a generator output voltage in excess of the pre set trip a shutdown is initiated The V icon will illuminate High voltage is not delayed it is an imme...

Page 12: ...tor until the Emergency Stop push button has been reset Secondly it removes the positive DC supply from both the Fuel Solenoid and Starter Solenoid The icon will illuminate NOTE The Emergency Stop positive 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 Saf...

Page 13: ...enerator output voltage below the below the pre set trip after the Safety On timer has expired a shutdown is initiated The V icon will illuminate OIL PRESSURE SENDER OPEN CIRCUIT if the module detects a loss of signal from the oil pressure sender open circuit a shutdown is initiated The LCD will indicate Steady In addition on the engine oil pressure instrument Sender failure is not delayed it is a...

Page 14: ... condition after 36 seconds For details of the relationship between the overload and the shutdown time please see the Appendix section of this manual 4 6 ELECTRICAL TRIPS Electrical trips are latching and stop the Generator but in a controlled manner On initiation of the electrical trip condition the module will de energise the Load Transfer Output to remove the load from the generator Once this h...

Page 15: ...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 These indicators are annunciated using a removable insert card Additionally the module s logo can be changed to suit generator manufacturer s requirements This can be used for instance to give cus...

Page 16: ...rs Manual 16 057 011 5210 OPERATING MANUAL ISSUE 5 1 18 06 2007 AM 6 DESCRIPTION OF CONTROLS The following section details the function and meaning of the various controls on the module CALL US TODAY 1 888 POWER 58 REQUEST A QUOTE parts genpowerusa com SHOP ONLINE www genpowerusa com ...

Page 17: ...ipment i e Battery Charger On Breaker Closed etc or to indicate internal states i e Engine Running Safety On etc USER DEFINED ALARMS The LCD displays the user defined alarms when configured and active The icons will illuminate and point to the appropriate text insert label These alarms can be used to indicate the operation of external alarms i e Low Fuel Level Low Coolant level etc or to indicate ...

Page 18: ...al 18 057 011 5210 OPERATING MANUAL ISSUE 5 1 18 06 2007 AM 6 2 LCD DISPLAY AREAS Instrument values Display information units of measure Alarm icons Status icons User configurable display icons CALL US TODAY 1 888 POWER 58 REQUEST A QUOTE parts genpowerusa com SHOP ONLINE www genpowerusa com ...

Page 19: ... Oil Pressure Coolant temperature Fuel level Engine Hours Run DC Battery Voltage AC Line Current AC Line power kW AC Line power kVA AC phase angle cos Manually Selecting an Instrument Initial display Hz RPM Pressing the DOWN button the LCD will then show Generator L N voltages Pressing the DOWN button the LCD will then show Generator L L voltages Pressing the button again will scroll through each ...

Page 20: ...ill flash the log symbol to confirm that the event log has been entered In this example the oil can symbol represents an oil pressure shutdown backed up by the flashing shutdown symbol in the LCD display The value displayed means that the oil pressure shutdown occurred on November 1st 2002 at 8 17 Press down to view the next most recent shutdown alarm In this example the fuel pump symbol represent...

Page 21: ... generator functions Once in Manual mode the module will respond to the start I button and start the engine and run off load If the engine is running off load in the Manual mode and a remote start signal becomes present the module will automatically instruct the changeover device to place the generator on load Load transfer becomes active if used Should the remote start signal then be removed the ...

Page 22: ...o maintain security 1 Pin The second is now flashing Press or buttons to adjust it to the correct value for the second digit of the PIN number Press 9 when the second digit is correctly entered Pin The third is now flashing Press or buttons to adjust it to the correct value for the third digit of the PIN number Press 9 when the third digit is correctly entered Pin The fourth is now flashing Press ...

Page 23: ... following order Config Section Parameter Type Icons displayed Analogue senders Low Pressure Pre Alarm Low Pressure Trip High Temperature Pre Alarm High Temperature Trip Fuel Level Pre Alarm Calendar Date time Date time Timers Start delay Timer 2 Preheat Timer 3 Crank attempt Timer 4 Crank rest Timer 5 Safety delay Timer 6 Overspeed overshoot Timer 7 Warming up Timer 8 Return delay Timer 10 Coolin...

Page 24: ...iguration mode Some numbers are reserved so do not appear in the list In the following example timer number 2 Start delay from the above list is currently set to 5 0 seconds Ie the hour glass indicates that it is a timer being displayed The 2 indicates that it is timer number 2 Start delay The current setting is 5 0 seconds CALL US TODAY 1 888 POWER 58 REQUEST A QUOTE parts genpowerusa com SHOP ON...

Page 25: ... disconnected If this occurs you can use the front panel editor to correct the date time or reset it using the 5200 series configuration software NOTE The calendar is used by the 5210 s run scheduler and the event log Press the configure log and Stop Reset buttons simultaneously The LCD configure indicator will flash to indicate that the module is in configuration mode Release the Stop Reset butto...

Page 26: ...e should be mounted on suitable anti vibration mountings 8 2 COOLING The module has been designed to operate over a wide temperature range 30 to 70º C Allowances should be made for the temperature rise within the control panel enclosure Care should be taken NOT to mount possible heat sources near the module unless adequate ventilation is provided The relative humidity inside the control panel encl...

Page 27: ...nt and Instrumentation System Operators Manual 057 011 5210 OPERATING MANUAL ISSUE 5 1 18 06 2007 AM 27 8 4 FRONT PANEL LAYOUT 8 5 REAR PANEL LAYOUT CALL US TODAY 1 888 POWER 58 REQUEST A QUOTE parts genpowerusa com SHOP ONLINE www genpowerusa com ...

Page 28: ...y Output relay 1 1 0mm Plant Supply positive 5 Amp rated 7 Auxiliary Output relay 2 1 0mm Plant Supply positive 5 Amp rated 8 Auxiliary Output relay 3 1 0mm Plant Supply positive 5 Amp rated 9 1 2 PLUG B 11 WAY PIN No DESCRIPTION CABLE SIZE NOTES 9 Charge fail excite 2 5mm Do not connect to ground battery ve 10 Auxiliary input 1 0 5mm Switch to negative 11 Auxiliary input 2 0 5mm Switch to negativ...

Page 29: ... for L2 2 5mm Connect to secondary of L2 monitoring CT 41 CT Secondary for L3 2 5mm Connect to secondary of L3 monitoring CT 42 CT secondary common 2 5mm Connect to secondary of all monitoring CT s 43 Not connected 9 1 6 PLUG H 4 WAY PIN No DESCRIPTION CABLE SIZE NOTES 44 Oil Pressure Input 0 5mm Connect to Oil pressure sender 45 Coolant Temperature Input 0 5mm Connect to Coolant Temperature sende...

Page 30: ...ary 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 11 Auxiliary input 2 This is a negative switched configurable input see Calibration Manual for options available It is possible to configure the input to be a normally closed signal or a normally open ...

Page 31: ...single phase is used do not connect this pin 42 Generator current transformer common connection and CT earth connection 43 Not used Do not connect to this terminal 9 2 6 PLUG H 4 WAY PIN No DESCRIPTION 44 Oil Pressure sensing input Connect to resistive type oil pressure sender Refer to connection diagram for details 45 Coolant Temperature sensing input Connect to resistive type coolant temperature...

Page 32: ...pologies 3 Phase 4wire Single phase 2 wire 3 phase 3 wire 2 Phase 3 wire L1 L2 2 Phase 3 wire L1 L3 CT s Burden 0 5VA Primary rating 1A 6000A user selectable Secondary rating 5A secondary Accuracy of measurement 1 of full load rating when using 0 5 or better CTs Lower class CTs will reduce the overall accuracy of the reading Recommendations Class 1 required for instrumentation Protection class req...

Page 33: ...losures IP55 Front of module when module is installed into the control panel with the optional sealing gasket IP42 front of module when module is installed into the control panel WITHOUT being sealed to the panel NEMA Rating Approximate 12 Front of module when module is installed into the control panel with the optional sealing gasket 2 front of module when module is installed into the control pan...

Page 34: ...enoid is operating The engine should now run up to operating speed If not and an alarm is present check the alarm condition for validity then check input wiring The engine should continue to run for an indefinite period It will be possible at this time to view the engine and alternator parameters refer to the Description of Controls section of this manual 7 7 Select AUTO on the front panel the eng...

Page 35: ...ed 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 5210 inputs Refer to engine manual Continuous starting of generator when in AUTO Check that there is no sign...

Page 36: ...e Management and Instrumentation System Operators Manual 36 057 011 5210 OPERATING MANUAL ISSUE 5 1 18 06 2007 AM 13 TYPICAL WIRING DIAGRAM CALL US TODAY 1 888 POWER 58 REQUEST A QUOTE parts genpowerusa com SHOP ONLINE www genpowerusa com ...

Page 37: ... type VDO 10 bar High coolant 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 N A High coolant temp pre alarm 115 C 239 F 110 C 230 F High coolant temp shutdown 120 C 248 F N A Fuel level input type VDO Ohm Range Fuel pump control No Low fuel level 10 Input settings Digital Value 1 Remote start...

Page 38: ...er time 0 7s Breaker close pulse 0 0s Breaker trip pulse 0 0s Return delay 30s Cooling time 30s ETS solenoid hold 0s Fail to stop delay 30s Generator transient delay 1s Battery low volts delay 1m Battery high volts delay 1m LCD page timer 5m Generator settings Voltage frequency Trip Return Under volts trip 184V AC N A Under volts pre alarm 196V AC 207V AC Over volts pre alarm 265V AC 253V AC Over ...

Page 39: ...re prior to starting Yes Engine settings speed Value Underspeed trip 1250 RPM Underspeed prealarm 1350 RPM Overspeed prealarm 1650 RPM Overspeed trip 1750 RPM 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 N A Exercise scheduler settings Value Enable exercise scheduler No CALL ...

Page 40: ... PSI Pressure V Voltage o F Temperature Hz Frequency A Amperes o C Temperature RPM Speed kW KiloWatts kVA Apparent power KW divided by kVA Hours Run AC Generator Timer in progress DC Factory load Configuration mode active Fuel level Event log Panel locked by configurable input 15 3 ALARM INDICATIONS Display Description Display Description Display Description Warning Alarm Shutdown Alarm Electrical...

Page 41: ...hase 4 wire system 3 phase star connected alternators Changes to this typical wiring diagram for other AC systems are detailed below NOTE The factory default configuration for the 5210 module is for use with the 3 phase 4 wire AC system If another system is to be used the controller must be reconfigured using the 5200 series configuration software 16 1 1 3 PHASE 3 WIRE The alternator is 3 phase de...

Page 42: ...anual 42 057 011 5210 OPERATING MANUAL ISSUE 5 1 18 06 2007 AM 16 1 3 2 PHASE 3 WIRE 2 PHASE CENTRE TAP NEUTRAL The alternator is 2 phase star connected The live phases are separated by 180 CALL US TODAY 1 888 POWER 58 REQUEST A QUOTE parts genpowerusa com SHOP ONLINE www genpowerusa com ...

Page 43: ...E 5 1 18 06 2007 AM 43 16 2 5210 IDMT TRIPPING CURVES TYPICAL 5210 Delayed over current protection 1 10 100 1000 10000 100000 1000000 1 2 3 Current as a multiple of the trip point setting tripping curve 36 Tripping time in seconds CALL US TODAY 1 888 POWER 58 REQUEST A QUOTE parts genpowerusa com SHOP ONLINE www genpowerusa com ...

Page 44: ...anel 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 16 3 2 INSULATED RETURN SENDERS Connection Name Terminal Number Oil pressure Sender 44 Coolant temperature sender 45 Fue...

Page 45: ...he fuel sender measures the distance between the top of the tank and the fuel level Typically they use a ball float In this example the distance between the top of the tank and the level of the fuel is 50 of the height of the tank The fuel level sender will report the tank correctly as being 50 full For a parallel sided tank like this one 50 distance between the top of the tank and the level of th...

Page 46: ... and 548 modules to give both relay and LED expansion of the same 8 items if required Please refer to our Technical Support department for details 16 6 INPUT EXPANSION It is possible to increase the number of monitored inputs available by utilising a DSE 540 541 Protection Expansion Annunciator Please refer to our Technical department for details 16 7 STANDBY GENERATING SET The 5210 needs to be gi...

Page 47: ...ed against ingress of solid objects with a diameter of more than 2 5 mm Tools wires etc with a thickness of more than 2 5 mm are prevented from approach 3 Protection against water falling at any angle up to 60 from the vertical There must be no harmful effect spray water 4 Protected against ingress of solid objects with a diameter of more than 1 mm Tools wires etc with a thickness of more than 1 m...

Page 48: ...gree of protection against windblown dust rain and sleet undamaged by the formation of ice on the enclosure 3R IP32 Provides a degree of protection against rain and sleet undamaged by the formation of ice on the enclosure 4 X IP66 Provides a degree of protection against splashing water windblown dust and rain hose directed water undamaged by the formation of ice on the enclosure Resist corrosion 1...

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