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DSE Model 7560 ATS and Mains Controller Operators Manual 

2      057-017    7560 OPERATING MANUAL ISSUE 10.2 10/02/09  AM  

 

 

Deep Sea Electronics Plc 
Highfield House 
Hunmanby 
North Yorkshire 
YO14 0PH 
ENGLAND 
 
Sales Tel:  +44 (0) 1723 890099 
Sales Fax: +44 (0) 1723 893303 
 
E-mail: 

[email protected]

 

Website: 

www.deepseaplc.com

 

 
DSE Model 7560MK1 Main Control and ATS Operators

 Manual

 

 

© Deep Sea Electronics Plc 
All rights reserved. No part of this publication may be reproduced in any material 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. 
 
The DSE logo and the names DSEUltra, DSEControl, DSEPower, DSEExtra, DSEMarine and DSENet are UK 
registered trademarks of Deep Sea Electronics PLC. 
 
Any reference to trademarked product names used within this publication is owned by their respective 
companies. 
 
Deep Sea Electronics Plc reserves the right to change the contents of this document without prior notice.  
 
 
Amendments since last publication 
 
Amd. No. 

Comments 

1 

Converted 7560 V8 manual to 7560 V10 

2 

Update to wiring diagrams (issue10.1) 

3 

Update to typical wiring diagram (issue10.2) 

 
 
 
 
 

Clarification of notation used within this publication. 

 

NOTE: 

 
Highlights an essential element of a procedure to ensure correctness. 

 

CAUTION! 

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

 

WARNING!  

 
Indicates a procedure or practice, which could result in injury to personnel or 
loss of life if not followed correctly. 

 

Summary of Contents for DSE7560

Page 1: ...DSEPOWER DSE7560 MK1 Mains Control Module Document Number 057 089 Author Anthony Manton ...

Page 2: ...ication should be addressed to Deep Sea Electronics Plc at the address above The DSE logo and the names DSEUltra DSEControl DSEPower DSEExtra DSEMarine and DSENet are UK registered trademarks of Deep Sea Electronics PLC Any reference to trademarked product names used within this publication is owned by their respective companies Deep Sea Electronics Plc reserves the right to change the contents of...

Page 3: ...NTING 11 3 10 1 FIXING CLIPS 12 3 10 2 CABLE TIE FIXING POINTS 13 3 10 3 SILICON SEALING GASKET 13 3 11 APPLICABLE STANDARDS 14 4 INSTALLATION 15 4 1 USER CONNECTIONS 15 4 2 TERMINAL DESCRIPTION 16 4 2 1 DC SUPPLY FUEL AND START OUTPUTS OUTPUTS E F G 16 4 2 2 MSCMAGNETIC PICKUP CAN AND EXPANSION 16 4 2 3 LOAD SWITCHING AND MAINS VOLTAGE SENSING 17 4 2 4 BUS VOLTAGE SENSING 17 4 2 5 MAINS AND BUS C...

Page 4: ...1 ACCESSING THE FRONT PANEL CONFIGURATION EDITOR 47 7 5 2 LIST OF ADJUSTABLE PARAMETERS IN MAIN CONFIGURATION EDITOR 48 7 6 RUNNING EDITOR 49 7 6 1 ACCESSING THE RUNNING CONFIGURATION EDITOR 49 8 COMMISSIONING 50 8 1 1 PRE COMMISSIONING 50 8 2 COMMISSIONING SCREENS 51 8 2 1 SCREEN 1 51 8 2 2 SCREEN 2 51 8 2 3 SCREEN 3 51 9 FAULT FINDING 52 9 1 ACCESSORIES 53 9 1 1 OUTPUT EXPANSION 53 RELAY OUTPUT ...

Page 5: ... instructions 053 054 DSE7560 installation instructions 053 055 DSE850 installation instructions 053 062 DSE860 DSE865 installation instructions 1 2 TRAINING GUIDES Training Guides are produced to give handout sheets on specific areas of the module operation DSE PART DESCRIPTION 056 001 Four Steps to Synchronising and Load Sharing 056 005 Using CTs with DSE products 056 006 Introduction to Comms 0...

Page 6: ... to the following third party publications REFERENCE DESCRIPTION ISBN 1 55937 879 4 IEEE Std C37 2 1996 IEEE Standard Electrical Power System Device Function Numbers and Contact Designations Institute of Electrical and Electronics Engineers Inc ISBN 0 7506 1147 2 Diesel generator handbook L L J Mahon ISBN 0 9625949 3 8 On Site Power Generation EGSA Education Committee ...

Page 7: ... peak lopping fixed generator output Alternatively the 7560MK1 can be used to parallel with other DSE 7560MK1 load sharing controllers Up to 16 sets can be connected in paralleling and load share as a standalone prime power system Additionally they can parallel with the mains supply when used in conjunction with DSE 7560MK1 The DSE 7560MK1 module also monitors the engine indicating the operational...

Page 8: ... time of this document production there have been no revisions to the module hardware 3 1 1 SHORT NAMES Short name Description DSE7000 All modules in the DSE7000 Series DSE7500 All modules in the DSE7500 sync load share range DSE7560 DSE7560 module Product type DSE 7560 Mains controller and ATS Module 7560 Variant Standard version 00 Hardware revision Revision 1 000 ...

Page 9: ...in cable size 0 5mm AWG 24 Max cable size 2 5mm AWG 10 3 4 GENERATOR VOLTAGE FREQUENCY SENSING Measurement type True RMS conversion Sample Rate 5KHz or better Harmonics Up to 10 th or better Input Impedance 300K Ω ph N Phase to Neutral 15V to 333V AC max Phase to Phase 25V to 576V AC max Common mode offset from Earth 100V AC max Resolution 1V AC phase to neutral 2V AC phase to phase Accuracy 1 of ...

Page 10: ...ature Built in load dump feature 3 7 COMMUNICATION PORTS 810 port For connection to the DSE810 interface only Expansion port For connection to DSE130 DSE157 DSE545 DSE548 expansion modules only DSENet DSE7510 Mk1 controller does not have DSENet expansion capability CAN Port Engine CAN Port Standard implementation of Slow mode up to 250K bits s Non Isolated Internal Termination provided 120Ω RS485 ...

Page 11: ...2 10 02 09 AM 11 3 9 SOUNDER DSE7000 Series features an internal sounder to draw attention to warning shutdown and electrical trip alarms Sounder level 84db 1m 3 10 DIMENSIONS AND MOUNTING DIMENSIONS 240 0mm x 181 1mm x 41 7mm 9 4 x 7 1 x 1 6 PANEL CUTOUT 220mm x 160mm 8 7 x 6 3 WEIGHT 0 7kg 1 4lb ...

Page 12: ...lip into the slots in the side of the 7000 series module case Pull the fixing clip backwards towards the back of the module ensuring all three prongs of the clip are inside their allotted slots Turn the fixing clip screws clockwise until they make contact with the panel fascia Turn the screws a little more to secure the module into the panel fascia Care should be taken not to over tighten the fixi...

Page 13: ...ance of future connection failures Care should be taken not to over tighten the cable tie for instance with cable tie tools to prevent the risk of damage to the module case Cable tie fixing point With cable and tie in place 3 10 3 SILICON SEALING GASKET The supplied silicon gasket provides improved sealing between the 7000 series module and the panel fascia The gasket is fitted to the module befor...

Page 14: ...nstalled into the control panel with the supplied sealing gasket 2 Front of module when installed into the control panel WITHOUT being sealed to the panel IEEE C37 2 Standard Electrical Power System Device Function Numbers and Contact Designations Under the scope of IEEE 37 2 function numbers can also be used to represent functions in microprocessor devices and software programs The 7000 series co...

Page 15: ... CONNECTIONS To aid user connection icons are used on the rear of the module to help identify terminal functions An example of this is shown below NOTE Availability of some terminals depends upon module version Full details are given in the section entitled Terminal Description elsewhere in this manual Terminals 1 13 Terminals 15 18 Terminals 22 36 Terminals 39 46 Terminals 47 50 Terminals 51 57 T...

Page 16: ...tive from terminal 2 3 Amp rated 10 Output relay G 1 0mm AWG 18 Plant Supply Positive from terminal 2 3 Amp rated NOTE Terminals 3 to 6 and 11 to 14 are not fitted to the DSE7560 MK1 controller NOTE Terminals 11 to 30 are not fitted to the DSE7560 MK1 controller 4 2 2 MSC MAGNETIC PICKUP CAN AND EXPANSION PIN No DESCRIPTION CABLE SIZE NOTES MSC 31 MSC H 0 5mm AWG 20 Use only 120Ω CAN approved cabl...

Page 17: ... Mains L2 S voltage monitoring 1 0mm AWG 18 Connect to Mains L1 S incoming supply AC Recommend 2A fuse 45 Mains L3 T voltage monitoring 1 0mm AWG 18 Connect to Mains L1 T incoming supply AC Recommend 2A fuse 46 Mains Neutral N input 1 0mm AWG 18 Connect to Mains N incoming supply AC NOTE The above table describes connections to a three phase four wire alternator For alternative wiring topologies p...

Page 18: ...nnect to s1 secondary of L1 monitoring CT 52 CT Secondary for Mains L2 2 5mm AWG 13 Connect to s1 secondary of L2 monitoring CT 53 CT Secondary for Mains L3 2 5mm AWG 13 Connect to s1 secondary of L3 monitoring CT Connection to terminals 54 55 The function of terminals 54 and 55 change position depending upon wiring topology as follows Type Topology Pin No Description CABLE SIZE 7300 series No ear...

Page 19: ...SIZE NOTES 60 Configurable digital input A 0 5mm AWG 20 Switch to negative 61 Configurable digital input B 0 5mm AWG 20 Switch to negative 62 Configurable digital input C 0 5mm AWG 20 Switch to negative 63 Configurable digital input D 0 5mm AWG 20 Switch to negative 64 Configurable digital input E 0 5mm AWG 20 Switch to negative 65 Configurable digital input F 0 5mm AWG 20 Switch to negative 66 Co...

Page 20: ...TION This socket must not be used for any other purpose 4 2 8 EXPANSION INTERFACE CONNECTOR 4 way connector allows connection to the P130 input expansion P157 relay expansion module or 545 548 LED expansion modules A maximum of 2 relay or LED expansion modules may be connected in series to this port CAUTION Do not connect the 808 configuration interface to this port as it is not possible to use th...

Page 21: ...10 2 10 02 09 AM 21 4 2 9 RS485 CONNECTOR PIN No NOTES A Two core screened twisted pair cable 120Ω impedance suitable for RS485 use Recommended cable type Belden 9841 Max distance 1000m 1km when using Belden 9841 or direct equivalent B SCR Location of RS485 connector Location of RS485 connector ...

Page 22: ...n 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 These LEDs 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...

Page 23: ...and Mains Controller Operators Manual 057 017 7560 OPERATING MANUAL ISSUE 10 2 10 02 09 AM 23 4 3 TYPICAL WIRING DIAGRAMS NOTE The LOAD CT is only required on multiple mains systems multiple 7560s installed in the system ...

Page 24: ...DSE Model 7560 ATS and Mains Controller Operators Manual 24 057 017 7560 OPERATING MANUAL ISSUE 10 2 10 02 09 AM 4 3 1 SINGLE MAINS MULTIPLE GENERATORS ...

Page 25: ...DSE Model 7560 ATS and Mains Controller Operators Manual 057 017 7560 OPERATING MANUAL ISSUE 10 2 10 02 09 AM 25 4 3 2 DUAL MAINS MULTIPLE GENERATORS ...

Page 26: ...DSE Model 7560 ATS and Mains Controller Operators Manual 26 057 017 7560 OPERATING MANUAL ISSUE 10 2 10 02 09 AM 4 3 3 MULTIPLE MAINS MULTIPLE GENERATORS ...

Page 27: ...change the state of the load switching devices when in manual mode Details of their operation are provided 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 CAUTION The module may instruct...

Page 28: ... of the various controls on the module Menu navigation buttons Four configurable LEDs Select Stop mode Select Manual mode Select Auto mode Mute alarm Lamp test Start engine s when in manual or Testmode Transfer to Bus manual mode only Transfer to mains manual mode only Main status and instrumentation display Bus available LED Mains on load LED Select Test mode Bus on load LED Mains available LED ...

Page 29: ...he 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 module such that the start push button must be held ...

Page 30: ...his button is only active in MANUAL mode NOTE If the bus is live when the manual button is pressed synchronising will take place before the load switch is closed mode CLOSE GENERATOR This push button is used to control the closure of the generator load switching device and has two modes of operation 3 Synchronising is NOT enabled Pressing this button when the generator is running off load and in M...

Page 31: ...ence Status Start request Manual mode Once the Minimum number of sets set using 75xx software have synchronised onto the bus the 7560 will display Status Mains on load Manual mode Pressing the transfer to bus open mains button will synchronise the bus to the mains The 7560 will display Status Synchronise bus Manual mode Once the bus has synchronised to the mains the bus will close and power will b...

Page 32: ...lleling Manual Mode The system will remain in this mode until further action is taken Operation Detail Pressing the transfer to mains open bus button again will transfer the remaining load onto the mains The 7560 will display Status Ramp off bus 10 kW 12 kVAr Manual mode Once the bus loading has reached 0kW the bus will open and the 7560 will display Status Mains on load Manual mode Pressing the r...

Page 33: ...if configured Mains supply failure Remote start input either on load on load demand or in island mode Once a call to start is received the module will initiate its Start Delay timer This is used to ensure that the start event is required and not just a momentary condition The 7560 will display Status Start delay 00 05 Auto mode Once this timer has expired any available 7510 in auto mode will be is...

Page 34: ...e to run the generators on load and ignore the fluctuating call to stop until such a time as it remains inactive for the duration of the stop delay timer MAINS AVAILABLE If the mains supply is available when the sets are called to take load the generator bus must first be synchronised with the mains supply This will occur if The sets are started by remote start if configured The sets are started d...

Page 35: ... mode the load is then ramped fully onto the generators The 7560 will display Status Ramp onto bus 76 kW 80 kVAr Auto mode Once the mains loading has reached 0kW the bus load switch will be opened and the 7560 will display Status Bus on load Auto mode Should the remote start signal be deactivated the module will first initiate a return timer to ensure that it is not a transient condition The 7560 ...

Page 36: ...to Mains Auto mode The load is then ramped back onto the mains The 7560 will display Status Ramp off bus 10 kW 12 kVAr Auto mode Once the bus loading has reached 0kW the bus load switch will be opened and the 7560 will display Status Mains on load Auto mode Any 7510 running in Auto mode will be issued a stop command and will display Please refer to the 7510 operator manual for details on the stopp...

Page 37: ...perating manual for further details of the 7510 start sequence START DELAY 00 05 The 7560 will display Status Start request Test mode Once the Minimum number of sets set using 75xx software have synchronised onto the bus the 7560 will display Status Synchronise to bus Test mode Once the bus has synchronised to the mains the bus will close and power will be ramped onto the bus generators The 7560 w...

Page 38: ...before The load with the mains supply that has failed will remain without power Cease peak lopping and backup the failed mains supply NOTE At no time are the generators paralleled with more than one mains supply at a time Paralleling with mains supplies is always taken in turn 6 4 1 7560 PRIORITY Where more than one 7560 controller is present they must determine which one is to take control over t...

Page 39: ...extra CT measuring the size of the load Used in conjunction with the CTs measuring the amount of load on the mains supply this CT allows the 7560 to determine what portion of the load is being supplied by the generators This allows the 7560 to remove the sets from this load when there is little or no current passing through the bus breaker For example When the generators are ramping off load ...

Page 40: ...isplay the Alarm The LCD will then display Followed by the appropriate alarm text ALARM Bus failed to open If no alarms are present the LCD will display the following message and will then return to the Status Display page No alarm present The LCD will display multiple alarms E g Bus fail to open Fail to synchronise and Mains fail to close alarms have been triggered These will automatically scroll...

Page 41: ...ted The LCD will indicate MAINS FAILED TO OPEN and the COMMON ALARM LED will illuminate INSUFFICIENT CAPACITY if the generators reach full load when they are in parallel with the mains utility The LCD will indicate INSUFFICIENT CAPACITY and the COMMON ALARM LED will illuminate MINIMUM SETS NOT REACHED if the minimum number of sets on the bus has not been reached prior to closing the generator bus ...

Page 42: ...perators Manual 42 057 017 7560 OPERATING MANUAL ISSUE 10 2 10 02 09 AM MSC ALARMS INHIBITED if an input has been configured as MSC ALARMS INHIBIT and is active the LCD will indicate MSC ALARMS INHIBIT and the COMMON ALARM LED will illuminate ...

Page 43: ... will provide 100 of its capacity and the loading on the mains will increase MAINS REVERSE POWER if the module is configured for Mains CT and the amount of power being exported to the mains supply is above the setting for the export power level alarm then mains reverse power is displayed and the COMMON ALARM LED will flash OLD UNITS ON BUS if the module detects that there is one or more 7560 contr...

Page 44: ... to Clear ROCOF Vector shift if this has been provided 3 Press and button together and hold for 5 seconds The ROCOF Vector shift instrument is displayed and all peak hold values are reset clearing the ROCOF Vector shift alarm For details on activating and configuring the ROCOF Vector shift protection you are referred to the 75xx for Windows configuration software manual 7 3 1 MAINS DECOUPLING TEST...

Page 45: ...he area in the centre of the scope indicates the set limits for synchronising to occur Hz 0 2 V 0 2 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 will be automatically adjusted altering the phase until the mov...

Page 46: ...lts L1 L2 L2 L3 L3 L1 Bus Hz These values are calculated by reading the information from the modules via the MultiSet Communications MSC link Bus kW Bus kVAr Bus phase sequence Load Amps pf Load kW kVA kVAr Mains Volts L1 N L2 N L3 N Mains Volts L1 L2 L2 L3 L3 L1 Mains Hz Mains Amps Mains kW Mains kVA Mains pf Mains kVAr Mains kWh Mains kVAh Mains kVArh Mains phase sequence ROCOF Vector shift Sync...

Page 47: ...st re enter the PIN If the PIN has been successfully entered or the module PIN has not been enabled the editor is displayed EDITING A PARAMETER Enter the editor as described above Press the left or right buttons to cycle to the section you wish to view change To edit the parameter press to enter edit mode The parameter begins to flash to indicate that you are editing the value Press the up or down...

Page 48: ... Volt Alarm 0 40V 10V 10V 10V 10V Plant Battery Over Alarm 0 40V 30V 30V 30V 30V Misc Language English Other Alternative Frequency Enable Disable Disable Disable Disable Alternative Voltage Enable Disable Disable Disable Disable AC System 3 phase 4 wire 3 phase 4 wire 3 phase 4 wire 3 phase 4 wire Single phase 2 Wire 3 phase 3 wire 2 phase 3 wire L1 L2 3 phase 4 wire ED 2 phase 3 wire L1 L3 Contra...

Page 49: ...sh to view change Press the up or down buttons to change the parameter to the required value To save paremeters scroll to save changes and exit followed by the down buttton To cancel changes scroll to Abandon changes and exit followed by the down button ADJUSTABLE PARAMETERS Running editor Running Editor Section Parameter as shown on display Factory Settings DISPLAY Contrast l Language English Loa...

Page 50: ...ble parameters 6 4 Initiate an automatic start by supplying the remote start signal The start sequence will commence and once the pre set number of generators is running in parallel the 7560 will synchronise the bus to the mains and the Bus breaker will be closed The load will be ramped on to the Bus until the pre set KW and KVAr levels have been reached 6 5 Remove the remote start signal the retu...

Page 51: ...oltage and total kW Load on the set s and total kVAr Ramp level and of full load kW of full load kVAr 8 2 2 SCREEN 2 B kW B Tgt B Tgt Sets load 0 0 0 0 0 0 0 kVAr kW kVAr 0 0 0 0 5 0 Bus load levels kW kVAr Target and actual of full load buskW Target and actual of full load bus kVAr Load on the set s 8 2 3 SCREEN 3 M Tgt M Tgt Pf L N 0 0 0 00 0V kW kVAr Sets load Amps 0 0 0 0A Target and actual of...

Page 52: ...ng temperature is not above 70 C Check the DC fuse Warning fault operates Check relevant switch and wiring of fault indicated on LCD display Check configuration of input Continuous starting of generators when in AUTO Check that there is no signal present on the Remote Start input Check configured polarity is correct Check that the mains supply is within limits and load level on the mains is not ab...

Page 53: ...XPANSION 548 An expansion module is available which connects to the configuration socket and enables the 75xxMK1 to use the eight additional LED s on the 548 module providing remote LED s indication A maximum of two of these units can be used give 16 independent remote LED s The 548 s need to be identified as module A and module B Refer to technical data sheet on the 548 LED modules for further de...

Page 54: ...g operating modes etc The various operating parameters such as output volts oil pressure etc on the remote generator can also be viewed The information contained in this manual should be read in conjunction with the appropriate module documentation This manual only details the operation of the communications software and how it should be used The operation of the module is detailed in its own rele...

Page 55: ... TO ETHERNET CONNECTION To connect a 7560MK1 to the Ethernet the following items are required 7510MK1 Module 1 to 6 DSE7510 controllers are supported and up to 2 DSE7560 controllers 75xx series configuration software DSE850 multiset Ethernet module Sample screenshot of 4 x DSE7510 and 1 x DSE7560 controllers RS485 Cable Ethernet ...

Page 56: ...nditioning fire alarm system etc NOTE The RS485 system will comprise of one MODBUS master typically a PC and up to 31 MODBUS slaves The 7560MK1 modules are always MODBUS slave devices To ensure correct operation a suitable 120Ω Ω Ω Ω terminal resistor must be fitted to each end of the RS485 connection bus Caution The A and B lines of the RS485 network should be terminated at each end with a 120Ω Ω...

Page 57: ...e to monitor and control the 7560MK1 module via this protocol Please refer to Deep Sea Electronics Plc for details 9 2 5 MODBUS The RS485 output uses Modbus communications protocol This uses a master slave technique to communicate Only the Master can initiate a packet transaction called a query When appropriate the slave 7560MK1 Module responds to the query and provides the information requested b...

Page 58: ...s falling at an angle 3 Protected 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 wi...

Page 59: ...r and dirt 3 IP64 Provides a degree 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 t...

Page 60: ...pproximately equal to that of another machine source or system 18 accelerating or decelerating device A device that is used to close or cause the closing of circuits that are used to increase or decrease the speed of a machine 25 synchronizing or synchronism check relay A synchronizing device produces an output that causes closure at zero phase angle difference between two circuits It may or may n...

Page 61: ...PERATING MANUAL ISSUE 10 10 02 09 AM 61 51 ac time overcurrent relay A device that functions when the ac input current exceeds a predetermined value and in which the input current and operating time are inversely related through a substantial portion of the performance range ...

Page 62: ...ng of a piece of equipment into operation and in the other position prevents the circuit breaker or the equipment from being operated 71 level switch A device that operates at a given level value or on a given rate of change of level 74 alarm relay A device other than an annunciator as covered under device function 30 that is used to operate or that operates in connection with a visual or audible ...

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