DST4600A Operating Manual DOCUMENT N° EAAM0020I rev. 10 FILE: Date: Issued by: Checked by:
EAAM002010I.doc 24/10/03 Andrea Rizzon Walter Caielli
This document document is owned by SICES s.r.l.. All rights reserved.SICES s.r.l. reserves the right to modify this document without prior notice. The disclosure by any means of this document to third parties is not allowed.
EAAM002010I.doc
Revision Revision
Date
Pages
Notes
00
18/04/01
49
01
15/06/01
58
02
13/07/01
57
First English version
03
10/09/01
66
Modified par. 1.2, 1.3, 2.1.8, 2.2, 2.2.1.2, 2.2.2, 5.1, 5.1.x, 5.5, 6.4.1, 6.4.3, 6.4.7, 6.4.10, 6.4.11, 7.1.1, 7.1.2, 7.3.1, 7.3.2, 7.4.2, 7.4.5, 7.4.7, 8.5, 9.2.x,
04
14/02/02
76
1.2, 1.3, 1.4, 2.1.1, 2.1.4, 2.2.1.1, 2.2.1.2, 2.2.3, 5, 5.1, 5.1.3, 5.1.4, 5.1.9, 5.1.11, 5.1.15, 5.1.18, 6.4.7, 6.4.10.1, 7.1.1, 7.2, 7.3.2, 7.3.3, 7.4.2, 7.4.9, 8.5, 9.1.1, 9.1.3, 9.1.4, 10.4, 10.6, 10.7, 10.8, 11, 12, 13 A.1
05
30/04/02
82
2.2, 2.2.1.2, 5.1, 5.1.15, 5.1.19, 5.1.20, 5.1.21, 5.2, 5.5, 6.1, 6.2.7, 6.2.8, 6.4.2, 6.4.11.1, 7.1.3.1, 7.1.3.2, 10.1, 10.2, 10.7, 10.7.1, 10.7.2, 10.7.3, 10.7.4, 10.7.4.1, 10.7.4.2, 10.7.5, 11, 11.2, 11.3, 11.4, 11.5, 11.6, A6, A.6.1, A.6.2, A7
07
07/01/03
78
2.1.7 - 2.1.8 - 2.2.1.1 - 2.2.1.2 - 2.2.2 - 3 - 5.1 -5.1.1 - 5.1.2 5.1.6 - 5.1.7 - 5.1.10 - 5.1.11 - 5.1.15 - 5.1.19 - 5.1.20 - 5.1.22 - 5.1.23 - 5.5 - 6.1 - 6.4.11.2 - 6.4.12 - 7.1.3.2 - 10.1 - 10.5, 10.5, 10.6 - 10.7.1 - 10.8.4 - 10.9 - 11.4
08
04/02/03
80
2.2.1.2, 2.2.2, 4.2.1, 5.1, 5.1.14, 5.1.15, 5.1.23, 5.5, 6.1, 6.2.9, 6.4.1.12, 10.5, 10.6, 10.6.1, 10.6.2, 10.8.4, A5
09
18/03/03
81
2.2.1.2, 2.2.2, 5.1, 5.1.6, 5.1.7, 5.1.24, 6.2.7, 6.4.11.1, 6.4.11.2, 6.4.12, 10.1
10
24/10/03
85
1.1, 2.1.5, 2.2.2, 5.1, 5.1.6, 5.1.24, 6.1, 6.2.1.1, 6.2.1.2, 6.2.7, 6.3.1, 6.3.2, 6.4.4.1, 6.4.4.2, 6.4.7, 6.4.8, 6.4.9, 6.4.10.2, 6.4.14, 6.4.16, 6.4.17, 6.4.20, 7.3.1, 7.3.2, 7.4, 7.4.1, 7.4.2, 7.4.6, 7.4.9, 7.5, 10.8.4, 10.9, 10.11
DST4600A Operating Manual - 24/10/03 – page
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EAAM002010I.doc
CONTENTS FILE: EAAM002010I.DOC ................................................................................................................................I EVISION ...............................................................................................................................................................II II R EVISION 1.
GENERAL GENERAL INFORMA INFORMATION TION......................................................................................................................... ......................................................................................................................... 1
1.1 1.2 1.3 2.
DEFINITIONS .................................................................................................................................................1 SYMBOLS ......................................................................................................................................................1 DOCUMENT VALIDITY ....................................................................................................................................1
DESCRIPT DESCRIPTION ION OF THE BOARD BOARD DST4600 DST4600A.............................................................................................. A.............................................................................................. 2
2.1 BACK PANEL .................................................................................................................................................2 2.1.1 Opto-insulated Opto-insulated Digital Inputs.............................................................................................................. 2 2.1.2 Relay Digital Outputs (generator set controls) ............ ...... ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ........ 3 2.1.3 Remote signals d igital outputs outpu ts ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ........ 3 2.1.4 Various Outputs..................................................................................................................................4 2.1.5 Analog Inputs ... ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ........... ..... 4 2.1.6 Board Power Supply ......... ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ........ 4 2.1.7 Current Inputs and Measurements Measurements ...................................................................................................... 5 2.1.8 Contactors Outputs.............................................................................................................................5 2.1.9 Generator’s Generator’s Voltages Inputs................................................................................................................ 6 2.1.10 Mains Voltages Inputs ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ......... ... 6 2.2 FRONT PANEL ...............................................................................................................................................7 2.2.1 Operating Operating and Functions Functions Controls Area.............................................................................................. 8 2.2.1.1 2.2.1.2
2.2.2 2.2.3
Operating Operating area.................................. ............................... ............................... ................................ .......... 8 Functions Functions Area.. ............................... ............................... ............................... ................................ .........10
Operating Operating Conditions and Measurements Measurements Area Area ................................................................................. 12 Faults Area ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ...... ............ ...... ............ ............ ............ ............ ............ ......... ... 14
3.
START START INITIALI INITIALIZATI ZATION.......................................................................................................................... ON.......................................................................................................................... 16
4.
CALIBRA CALIBRATION TION PROCEDUR PROCEDURE E .................................................................................................................. 17
4.1 E NTERING THE CALIBRATION PROCEDURE . ............................................................................................. 17 4.2 QUITTING THE CALIBRATION PROCEDURE. .............................................................................................. 17 4.2.1 Calibration Calibration of the Fuel Level Sensor................................................................................................. 17 5.
PROGRA PROGRAMMI MMING NG PROCEDU PROCEDURE............................................................................................................... RE............................................................................................................... 19
5.1 TABLE OF DESCRIPTION OF THE DST4600A PARAMETERS . ........................................................................... 19 5.1.1 Parameter P16.... ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ........ 24 5.1.2 Parameter P17.... ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ........ 24 5.1.3 Parameter P37.... ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ........ 25 5.1.4 Parameter P39.... ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ........ 25 5.1.5 Parameter P45.... ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ........ 25 5.1.6 Parameter P46.... ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ........ 25 5.1.7 Parameter P47.... ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ........ 26 5.1.8 Parameter P48.... ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ........ 26 5.1.9 Parameter P49.... ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ........ 26 5.1.10 Parameter P50 ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ...... 27 5.1.11 Parameter P51 ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ...... 27 5.1.12 Parameter P52 and P53. ........ ............ ...... ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ........ 27 5.1.13 Parameter P55 ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ...... 28 5.1.14 Parameters P56-P60 ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ......... ... 28 5.1.15 Parameter P61 ............ ...... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ...... 28
DST4600A Operating Manual - 24/10/03 – page iii
EAAM002010I.doc 5.1.16 Parameter P62 ............................................................................................................................. 29 5.1.17 Parameter P63 ............................................................................................................................. 29 5.1.18 Parameter P64 ............................................................................................................................. 29 5.1.19 Parameters P68 and P69 .............................................................................................................. 29 5.1.20 Parameters P70, P71 and P73. ..................................................................................................... 30 5.1.21 Parameters P72 and P74 .............................................................................................................. 30 5.1.22 Parameter P76 ............................................................................................................................. 30 5.1.23 Parameter P77 ............................................................................................................................. 31 5.1.24 Parameter P79 ............................................................................................................................. 31 5.2 ACTIVATION OF THE PROGRAMMING PROCEDURE ...................................................................................32 5.3 QUITTING THE PROGRAMMING PROCEDURE ............................................................................................32 5.4 SELECTING A PARAMETER ...........................................................................................................................32 5.5 SETTING A PARAMETER ...............................................................................................................................32 5.6 LOADING THE DEFAULT VALUES ..................................................................................................................33 5.7 WORK SEQUENCE DURING THE PROGRAMMING . ............................................................................................ 33 5.8 LAMP TEST DURING THE PROGRAMMING PROCEDURE . .................................................................................. 33 6.
FAULTS........................................................................................................................................................ 35
6.1 LIST OF FXX CODES .....................................................................................................................................36 6.2 ALARMS .....................................................................................................................................................36 6.2.1 Low oil pressure........ ........................................................................................................................ 36 6.2.1.1 6.2.1.2
6.2.2
High Cooling Water Temperature ..................................................................................................... 37
6.2.2.1 6.2.2.2
6.2.3 6.2.4
From Digital Input...................................................................................................................................37 From Analogue Input........ ............................... ................................ ............................... .........................37
Starting Battery Fault ....................................................................................................................... 37 Minimum Fuel Level in the Tank....................................................................................................... 37
6.2.4.1 6.2.4.2
6.2.5
From digital input....................................................................................................................................36 From Analogue Input........ ............................... ................................ ............................... .........................36
From Digital Input...................................................................................................................................37 From Analogue Input........ ............................... ................................ ............................... .........................37
Maximum Fuel Level in the Tank ...................................................................................................... 37
6.2.5.1 6.2.5.2
From Digital Input...................................................................................................................................37 From Analogue Input........ ............................... ................................ ............................... .........................38
6.2.6 Auxiliary Alarm ................................................................................................................................ 38 6.2.7 KR close failure ................................................................................................................................ 38 6.2.8 KG close failure ................................................................................................................................ 38 6.2.9 Max power........................................................................................................................................ 38 6.3 DEACTIVATIONS..........................................................................................................................................38 6.3.1 Generator’s Voltage Under Minimum Threshold (“UNDERVOLTAGE”).......................................... 38 6.3.2 Generator’s Frequency Under the Minimum Threshold (“UNDERFREQUENCY”) .......................... 39 6.4 BLOCKS ......................................................................................................................................................39 6.4.1 Emergency STOP.............................................................................................................................. 39 6.4.2 Manual Stop in AUTO ...................................................................................................................... 39 6.4.3 Fuel END ......................................................................................................................................... 39 6.4.3.1 6.4.3.2
6.4.4
Low Oil Pressure .............................................................................................................................. 40
6.4.4.1 6.4.4.2
6.4.5
Digital input............................................................................................................................................39 From Analogue Input........ ............................... ................................ ............................... .........................39 From Digital Input...................................................................................................................................40 From Analogue Input........ ............................... ................................ ............................... .........................40
High Cooling Water Temperature ..................................................................................................... 40
6.4.5.1 6.4.5.2
From Digital Input...................................................................................................................................40 From Analogue Input........ ............................... ................................ ............................... .........................40
6.4.6 Non-masked Auxiliary Block ............................................................................................................. 40 6.4.7 Masked Auxiliary Block .................................................................................................................... 40 6.4.8 Generator’s Voltage Over the Maximum Threshold (“OVERVOLTAGE”)......................................... 41 6.4.9 Generator’s Frequency Over the Maximum Threshold (“OVERFREQUENCY”)............................... 41 6.4.10 Engine Over speed ....................................................................................................................... 41
DST4600A Operating Manual - 24/10/03 – page iv
EAAM002010I.doc 6.4.10.1 6.4.10.2
6.4.11 6.4.11.1 6.4.11.2
6.4.12 6.4.13 6.4.14 6.4.15 6.4.16 6.4.17 6.4.18 6.4.19 6.4.20 7.
From Digital Input...................................................................................................................................41 From Frequency ............................... ............................... ............................... ................................ .........41
Overload ...................................................................................................................................... 41 From Digital Input (“OVERLOAD”) ............................... ............................... ................................ .........41 From Current (“OVERCURRENT”)................................ ............................... ................................ .........42
Short circuit ................................................................................................................................. 42 Belt Break .................................................................................................................................... 42 Operating Speed not reached ....................................................................................................... 42 “OVERCRANK” .......................................................................................................................... 42 Hardware fault ............................................................................................................................. 43 Shutdown Failure ......................................................................................................................... 43 Energy Inversion .......................................................................................................................... 43 Inhibition of the generator set Use ... ............................................................................................ 43 Engine not in thresholds when KG closed ..................................................................................... 43
OPERATING SEQUENCE.......................................................................................................................... 44
7.1 DEFINITIONS ...............................................................................................................................................44 7.1.1 Mains Voltages Status ....................................................................................................................... 44 7.1.2 Generator’s Voltages Status.............................................................................................................. 45 7.1.3 Engine Status .................................................................................................................................... 46 7.1.3.1 7.1.3.2 7.1.3.3 7.1.3.4
Definition of Engine Running...... ............................... ............................... ................................ ..............46 Definition of Dead Engine........... ............................... ............................... ................................ ..............46 Starting Request......................................................................................................................................47 Stop Requests..........................................................................................................................................47
7.2 SHUTDOWN SYSTEM....................................................................................................................................47 7.3 SEQUENCE IN “MAN” MODE ........................................................................................................................48 7.3.1 Entering the MANUAL mode .... ........................................................................................................ 48 7.3.2 Engine Starting.................................................................................... ............................................. 48 7.3.3 Engine Shutdown ........ ...................................................................................................................... 48 7.3.4 Power Change-over .......................................................................................................................... 49 7.4 SEQUENCE IN “AUTO” MODE ......................................................................................................................49 7.4.1 Start Requests Wait...........................................................................................................................49 7.4.2 Engine Starting Attempts. ................................................................................................................. 49 7.4.3 Generator Waiting............................................................................... ............................................. 50 7.4.4 Delay before supply the power .......................................................................................................... 50 7.4.5 Switching users on the Generator...................................................................................................... 50 7.4.6 No start requests wait ..... .................................................................................................................. 51 7.4.7 Switching users to Mains................................................................................................................... 51 7.4.8 Engine Cooling Cycle ....................................................................................................................... 51 7.4.9 Engine Shutdown Cycle .................................................................................................................... 51 7.5 SEQUENCE IN “TEST” MODE .......................................................................................................................51 8.
POWER MEASUREMENT......................................................................................................................... 53
8.1 8.2 8.3 8.4 8.5 8.6 9.
POWER FACTOR ..........................................................................................................................................53 ACTIVE POWER ...........................................................................................................................................53 R EACTIVE POWER .......................................................................................................................................54 APPARENT POWER .......................................................................................................................................54 E NERGY METER ..........................................................................................................................................54 CONNECTION CAUTION ................................................................................................................................54
SERIAL COMMUNICATION..................................................................................................................... 56
9.1 HARDWARE CONNECTIONS ..........................................................................................................................56 9.1.1 Direct Connection to a PC ................................................................................................................ 56 9.1.2 Connection to an analogue modem ................................................................................................... 56 9.1.3 Connection to a GSM modem............................................................................................................ 56 9.1.4 Connection to a RS-485 network ....................................................................................................... 57 9.2 SOFTWARE PROTOCOLS ...............................................................................................................................57
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EAAM002010I.doc 9.2.1 9.2.2 9.2.3 10.
DST4600 Protocol ........ .................................................................................................................... 57 MODBUS – RTU Protocol ................................................................................................................ 57 SMS Protocol....................................................................................................................................57
AUXILIARY FUNCTIONS........................................................................ ............................................. 58
10.1 AUTOMATIC RECOVERY FROM KR CLOSE FAILURE....................................................................................58 10.2 AUTOMATIC PERIODICAL TEST ................................................................................................................59 10.3 FUEL PUMP.............................................................................................................................................59 10.4 R EMOTE TEST ........................................................................................................................................59 10.5 R EMOTE SIGNALS ...................................................................................................................................59 10.6 LOW POWER OR MAX POWER SIGNALING .........................................................................................60 10.6.1 Low load status signal. ................................................................................................................. 61 10.6.2 Maximum power........................................................................................................................... 61 10.7 R EAL TIME CLOCK OPTION ......................................................................................................................63 10.7.1 How to display Time and Date of RTC.......................................................................................... 63 10.7.2 Setting time and date....................................................................................................................63 10.7.3 Storing time/date into Data Record databases.............................................................................. 64 10.7.4 Automatic Periodical Test ............................................................................................................ 64 10.7.4.1 10.7.4.2
RTC based periodical test........................................................................................................................64 Standard mode periodical test................................ ............................... ............................... ....................64
10.7.5 Generator set Time Lock function................................................................................................. 64 10.8 DATA RECORD ........................................................................................................................................66 10.8.1 Databases .................................................................................................................................... 66 10.8.2 Memory device ............................................................................................................................. 66 10.8.3 Time and date...............................................................................................................................67 10.8.4 Event database ............................................................................................................................. 67 10.8.5 Analogue data database .................................................................. ............................................. 71 10.8.6 Databases lock ............................................................................................................................. 72 10.9 DATA CALL AND SMS FUNCTIONS...........................................................................................................73 10.9.1 Setup............................................................................................................................................73 10.9.2 Data Call Function Enable........................................................................................................... 73 10.9.3 Description .................................................................................................................................. 73 10.9.4 PC SW procedure ......................................................................................................................... 74 10.10 DIFFERENCES BETWEEN DST4600A AND DST4600A/P...........................................................................75 10.10.1 ALARM2 input for PARALLEL FAULT ........... ............................................................................. 75 10.10.2 KR management .............................................................................. ............................................. 75 10.10.3 KG management in test operation ................................................................................................ 75 10.10.4 “MAINS SIMULATION” delay time............................................................................................. 75 10.11 DIFFERENCES WITH DST4600A/P FOR ASYNCHRONOUS ENGINES ..............................................................75 10.11.1 Generator frequency and voltages................................................................................................ 75 10.11.2 Terminal 8 function......................................................................................................................75 10.11.3 Terminal 10 function .................................................................................................................... 75 10.11.4 “Engine not in threshold with KG closed” alarm ......................................................................... 76 11.
11.1 11.2 11.3 11.4 12.
REFERENCES......................................................................................................................................... 77
SMS PROTOCOL FOR BOARDS DST4600A AND REMOTE SIGNALS......... ............................................. 77 DTS4600-PC COMMUNICATION PROTOCOL ............................................................................................77 MODBUS PROTOCOL IMPLEMENTATION FOR SICES EQUIPMENT ................................................................77 R EMOTE SIGNAL OPERATING MANUAL ......................................................................................................77 ANNEXES ................................................................................................................................................ 78
A NNEX A: SELFTEST PROCEDURE ......................................................................................................................78 A1 Activating the SELFTEST procedu re ..................................................................................................... 78 A2 Quitting the SELFTEST procedure. ....................................................................................................... 78 A3 Main functions of the SELFTEST procedure .......................................................................................... 78 A4 SELFTEST with selector on “OFF/RESET” .......................................................................................... 79
DST4600A Operating Manual - 24/10/03 – page vi
EAAM002010I.doc A5 A6 A7 A8
SELFTEST with selector on “PROG.”................................................................................................... 80 SELFTEST with selector on “MAN”...................................................................................................... 82 SELFTEST with selector in “AUTO”..................................................................................................... 82 SELFTEST with selector on “TEST” ..................................................................................................... 83
DST4600A Operating Manual - 24/10/03 – page vii
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1. General Information The board DST4600A, included into a special electric switchboard, is able to control the automatic intervention of a generator set, to monitor it during the operation and to keep it in the best possible conditions while inactive, in order to assure a quick and safe intervention in the event of power failure. It works with both three- and s ingle-phase systems.
1.1
Definitions Throughout this document the word “BLOCK” is used to indicate an alarm that makes generation function impossible and causes the automatic generator shutdown with the emergency procedure (without cooling cycle). The word “DEACTIVATION” is used to indicate an alarm that makes generation function impossible and causes the automatic generator shutdown with the normal procedure (with cooling cycle). The word “ALARM” is used to indicate a warning that requires an operator action but doesn’t require the automatic generator shutdown. Throughout this document the words “SOFTWARE” and “FIRMWARE are used as synonymous if they are referred to the board firmware. Software code is reported in short format on the board back panel. It is in the form xx.yy.uu, where xx is the firmware short identified code, yy is the major version number and uu is the minor version number. The complete SW identification number for the standard DST4600A is EB0220008yyuu reported in back panel as (for example) 8.00.22. The complete SW identification number for the DST4600A/P is EB0220012yyuu reported in back panel as (for example) 12.05.22. The complete SW identification number for the DST4600A for asynchronous engines is EB0220029yyuu reported in back panel as (for example) 29.07.39. The minor version is consistent between the two types of software (uu field is kept aligned). The major version for the DST4600A/P is increased by 5 respect the standard version. The major version for the DST4600A for asynchronous engines is increased by 7 respect the standard version. Thus the SWs 08.00.39, 12.05.39 and 29.07.39 share the same main features and functions.
1.2
Symbols In this document a vertical bar on the right margin or a gray background indicates that the chapter or the paragraph has been amended with respect to the last document’s version.
1.3
Document validity This manual is valid starting from SW 00.38 release; for previous SW release, please check manual version 09 or previous. Otherwise use this version very carefully checking document version notes on page ii. If the SW version number is greater than this, this manual maybe nevertheless consistent; please in case check for new document release.
DST4600A Operating Manual - 24/10/03 - page
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2. Description of the board DST4600A 2.1
Back Panel
The back panel includes all the terminal strips to connect the board DST4600A to the electric switchboard. There are nine terminal strips (called JA...JL) and the serial connector. Here follows a short description.
2.1.1 Opto-insulated Digital Inputs To activate these inputs connect the corresponding terminal to the negative pole of the battery. This is valid for all the digital inputs, but the “EMERGENCY STOP” input (terminal 03) is managed in the opposite way by the software (i.e., the block is activated if the “EMERGENCY STOP” input is not active). This is to connect directly to the terminal 03 the contact of the emergency pushbutton that is normally closed and which opens when the pushbutton is pressed. Name
Conn.
Term. Description
ALARM 1
JA
01
Non-masked auxiliary block
ALARM 2
JA
02
Masked auxiliary block for SW type 08 Parallel fault for SW type 12
EMERGENCY STOP
JA
03
Emergency stop input
HIGH LEVEL FUEL
JA
04
High fuel level alarm
LOW LEVEL FUEL
JA
05
Low fuel level alarm
FUEL END
JA
06
Fuel end block
OIL P. ALARM
JA
07
Low oil pressure block
OIL WARNING
JA
08
Low oil pressure alarm
WATER ALARM
JA
09
High water temperature block
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EAAM002010I.doc Name
Conn.
Term. Description
WATER WARNING
JA
10
High water temperature alarm
OVERLOAD
JA
11
Overload block
INPUT ‘C’ (OVERSPEED)
JA
12
Normally act as external engine over speed block. P61 may configure the input for KR status monitoring.
INPUT ‘B’
JB
13
Auxiliary alarm (generates “F10”)
INPUT ‘A’
JB
14
KG status monitoring if enabled by P61
MAINS SIMULATION
JC
24
Simulates mains presence (external mains sensor or generator set intervention inhibition)
REMOTE TEST
JE
46
It commands a start for an engine test (only in AUTOMATIC)
2.1.2 Relay Digital Outputs (generator set controls) When these digital outputs are activated, the corresponding terminal supplies the external voltage supplied on the terminal 21 (“COMMON PLUS”). Characteristics of the relays: 24V DC, 4 A max Name
Conn.
Term. Description
AUX OUTPUT 1 (PREHEAT OUTPUT)
JB
15
Diesel engines preheating control
ALARM OUTPUT
JB
16
Audible alarm control
AUX OUTPUT 2 (FUEL PUMP)
JC
17
Fuel pump control (For tank filling)
STOP SOLENOID
JC
18
Stop control for excitation shutdown
START
JC
20
Starter control
FUEL SOLENOID
JC
22
Fuel control electro valve (for drop-out shutdown)
2.1.3 Remote signals digital outputs When these outputs are activated, the corresponding terminal is connected to the negative pole of the battery, otherwise it remains floating. The load must be connected between the terminal 34 (“COMMON PLUS”) and the terminal associated to the outputs. It is possible to drawn a maximum of 150 mA from the terminal “COMMON PLUS”; if it is required a greater amount of current, loads must be connected to battery voltage providing an adequate protection to the board (alternatively consider to use our relays board E61020151xxxx). Name
Conn.
Term. Description
ENGINE RUNNING
JD
25
Engine running
GENERAL ALARM
JD
26
At least one alarm present
TRIP ALARM
JD
27
At least one block or deactivation present
FUEL ALARM
JD
28
At least one fault relating to fuel present
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EAAM002010I.doc Name
Conn.
Term. Description
ENGINE ALARM
JD
29
At least one fault in the engine present
SPEED ALARM
JD
30
At least one fault relating to the generator frequency present
GENERATOR ALARM
JD
31
At least one fault in the generator present
OFF-PROG-MAN
JD
32
Key selector in AUTO or TEST (not activated with the selector in OFF/RESET, PROG or MAN).
OFF SELECTION
JD
33
Key selector in MAN, AUTO or TEST (not activated with the selector in OFF/RESET or PROG).
Name
Conn.
Term. Description
EXC. D+ 12V
JE
35
12V alternator excitation. On this terminal there are 12 V when the output FUEL SOLENOID is activated (terminal 22)
EXC. D+ 24V
JE
38
24V alternator excitation. On this terminal there are 24 V when the output FUEL SOLENOID is activated (terminal 22) (if the board is powered at 24 V)
OUTPUT 1
JE
37
Transistor output (max 300 mA). It is used to report the LOW LOAD STATUS.
OUTPUT 2
JE
36
Transistor output (max 300 mA). It is used as switch to turn on/off the GSM modem connected to the board.
Name
Conn.
Term. Description
D+WL
JE
39/40
Engine running from D+ input
NEGATIVE REF
JE
41
Common terminal for engine analogue measurements (pressure, temperature and level).
OIL PRESSURE
JE
42
Oil pressure sensor input for analogue measurement (the sensor must be connected between the terminal 42 and the terminal 41)
TEMPERATURE
JE
43
Water temperature sensor input for analogue measurement (the sensor must be connected between the terminal 43 and the terminal 41)
ANALOG REF
JE
44
Not used
FUEL LEVEL
JE
45
Fuel level sensor input for analogue measurement (the terminal must be connected between the terminal 45 and the terminal 41)
2.1.4 Various Outputs
2.1.5 Analog Inputs
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EAAM002010I.doc Name
Conn.
Term. Description
+24
JF
47
24V Battery positive pole
-V Batt. (Ground)
JF
48
Battery negative pole
+12
JF
49
12 V Battery positive pole
2.1.7 Current Inputs and Measurements The TA of the generator’s phases have to be connected to these terminals. The maximum measurement current allowed in these terminals is 5 Ampere. The board is also able to support and to measure currents up to 20-30 Ampere for a few time (with a lower precision). This feature makes it possible to integrate the short circuit protection into the board, with no need for external devices. The negative pole of all the TA (terminals 50,52 and 54) must be connected to the battery negative in order to have a reliable measurement. Name
Conn.
Term. Description
C.T. 1
JH
50/51
TA phase L1
C.T. 2
JH
52/53
TA phase L2
C.T. 3
JH
54/55
TA phase L3
WARNING: if the board has the POWER MEASUREMENT OPTION, be sure that all the TA share the same phase connected to ground and check for the correct phase connection. Otherwise the board will issue a reverse power alarm or a wrong power measurement (see par. 8.6).
2.1.8 Contactors Outputs The contactors are controlled through two relays of which the changeover contacts are supplied. Characteristics of the relays: 250V DC, 2 A max Name
Conn.
Term. Description
N.O. GEN
JI
57
Normally opening of the relay controlling the generator set contactor
C. GEN
JI
58
Common of the relay generator set contactor
N.C. GEN
JI
59
Normally closing of the relay controlling the generator set contactor
Name
Conn.
Term. Description
N.O. MAINS
JI
60
Normally opening of the relay controlling the mains contactor
C. MAINS
JI
61
Common of the relay controlling the mains contactor
N.C. MAINS
JI
62
Normally closing of the relay controlling the mains contactor
controlling
the
The command for the closing of the mains contactor must be taken from terminals 61 / 62 (normally closed) while the command for the closing of the generator set contactor must be taken from the terminals 57 / 58 (normally open). This is to assure the mains power the users when the DST4600A is not powered (both contactors commands open). For SW type
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EAAM002010I.doc 12, the mains contactor is not used for this function: it is used as a remote signal of the mains presence status (if the mains is connected to the board).
2.1.9 Generator’s Voltages Inputs Name
Conn.
Term. Description
L1
JL
63
Phase L1 of the generator
L2
JL
65
Phase L2 of the generator
L3
JL
67
Phase L3 of the generator
Name
Conn.
Term. Description
R
JL
70
Phase R of the mains
S
JL
72
Phase S of the mains
T
JL
74
Phase T of the mains
2.1.10 Mains Voltages Inputs
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2.2
Front Panel
DST4600A and DST4600A/P front panels.
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EAAM002010I.doc The front part of the board is made by a polycarbonate panel, oil- and solvent-resistant with the identifying symbols and inscriptions. There are two slightly different front panels. The DST4600A front panel is the standard one. The DST4600A/P front panel is used mainly for switchboard for parallel application; the boards with the DST4600A/P panel have different part number. “/P” version assigns a special meaning to the followings signals: •
“ALARM 1” signal means “EXTERNAL SHUTDOWN”
•
“ALARM 2” signal means “AUX ALARM”
•
“MAINS VOLTAGE” signal means “MAINS VOLT./SIM. STATUS »
Substantially, the panel is divided into the three operational areas as described below.
2.2.1 Operating and Functions Controls Area This area can be functionally further divided in two different areas.
2.2.1.1
Oper atin g area It corresponds to the right bottom part of the front panel. It groups all the available control units. It includes: •
A button (“START”) for the manual starting of the generator set engine. The manual start can be executed only with the key selector on MAN. This button, alone or combined with the others, can also take other meanings during some particular procedures not directly related with the management of the generator set (programming, calibration, etc.).
•
A button (“STOP”) for the manual shutdown of the generator set engine. The manual shutdown can be executed only with the key selector on MAN. By pressing this button with the key selector in other working positions (AUTO or TEST) the engine shutdown will be executed through the emergency procedure (see the faults management). This button, alone or combined with the others, can also take other meanings during some particular procedures not directly related with the management of the generator set (programming, calibration, etc.).
•
A button (bearing the symbol of a siren, from now on called “MODE / ACK”) for the faults’ acknowledgement and the consequent muting of the audible alarm and to reset the alarms, too. This button, alone or combined with other buttons, can also have other meanings.
•
Two buttons (bearing the symbols of two arrows, from now on called “F1” and “F2”) used to select what to show on the display “MULTIFUNCTION” (see par.2.2.1.2). These buttons, alone or combined with other buttons, can also have other meanings.
•
A key selector allowing to select the board’s controlling mode of the generator set’s operation: OFF/RESET - PROGRAMMING - MANUAL - AUTOMATIC – TEST. The key can be extracted only in the positions OFF/RESET and AUTOMATIC. Here follows a short description of the operating modes: a) OFF/RESET: in this mode the board is on, but all the functions for the control and the running of the generator set are disabled. It is used in all the cases in which the intervention of the generator set is not required (i.e. in order to prevent unnecessary automatic interventions during the closing periods of a factory etc.) and above all as a safety position during the maintenance. Actually, when the selector is on OFF/RESET, the control device is completely disabled and therefore the generator set cannot intervene in the event of mains voltage
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EAAM002010I.doc failure. The mains contactor is forced at work therefore the users are powered by the mains (if it’s present). The monitoring of the mains status, of t he engine and of the generator are anyway enabled and the indicators belonging to the “functional status and measurements” area mirror such conditions. By switching the selector to “OFF/RESET” the following operations are executed: 1) Activation of the engine shutdown sequence 2) Forced control of mains power supply 3) Reset of any stored fault causing the generator set shutdown When the board is in the “OFF/RESET” mode the direct current consumption is reduced to a minimum si nce the displays show only a central dash, while all the signals are off except the indicator “KR” (turned on, only for SW type 08) as well as the indicators “ENGINE RUNNING”, “GENERATOR LIVE” and “MAINS LIVE” showing respectively the engine, the generator and the mains status (normally only the indicator “MAINS LIVE” is turned on). b) PROG. (PROGRAMMING): in this mode the board behaves exactly as in the “OFF/RESET” mode but with the opportunity to view and/or change the value of the parameters configuring the operating sequences of the generator set (see par.5 for the programming procedure and par. 7 for the operating sequence). c)
MAN. (MANUAL): in this mode the board is set to manage the manual running of the generator set. In short: 1) The procedures for the manual starting and shutdown of the engine are enabled, while those for the automatic starting and shutdown of the engine are disabled (therefore the board will never automatically start the engine). 2) It is possible to manual operate the power changeover on the generator set through an explicit command of the operator (if the generator is ready to supply, of course). In MAN, the board will never execute such switching automatically. When the selector is switched on “MAN”, the engine keeps its status (running/dead).
d) AUTO (AUTOMATIC): this is the normal operating mode of the board. In this mode the engine is automatically started/stopped in case of mains failure or at regular intervals to keep it efficient. In the same way, the power changeover is automatically switched on mains or on the generator according to their status. Warning: when the selector is on this mode any maintenance of the generator set and/or on the electric switchboard is forbidden. e) TEST: this mode allows starting the generator set keeping all the functions for the management of the changeover as in the AUTOMATIC mode. By switching the selector on TEST, a series of starting attempts will be executed (automatically, the operator will not have to press “START”), independently from the mains status. In the same way, by quitting the TEST mode (for the AUTOMATIC mode), if the mains is present the engine will stop (with the usual cooling cycle). Normally, in the TEST mode the users are switched on the mains. They can be switched on the generator set (if it is ready to supply) only in the following two cases:
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EAAM002010I.doc 1) Mains failure 2) Explicit command of the operator (in order to test the entire system, not only the generator set). For the SW version 12 (/P boards), KG is activated in the TEST mode if the generator is ready to supply power. It can be deactivated by manual command.
2.2.1.2
Func tion s Ar ea In this area is located a digital display (called display “MULTIFUNCTION”) showing the measurements of various quantities that can be selected through the buttons “F1” and “F2” and indicated to the operator through the corresponding indicators. The available quantities are: •
“DATA – HOURS COUNT / START COUNTER”: by selecting this function the display “MULTIFUNCTION” normally shows the number of operating hours of the generator set engine. The hours count doesn’t consider if the users are connected to the generator but the condition of engine running only. By keeping pressed the button “MODE / ACK”, you can view the number of starts of the engine (the number refers to the performed starts, not to the start attempts). As soon as “MODE / ACK” is released the engine’s operating hours can be viewed again. The corresponding indicator is turned on when the display shows the engine’s operating hours, while it flashes when the number of starting attempts is viewed. If the number of starts of the operating hours exceeds 999, the number is divided by 10 and displayed with a decimal point on the right digit. It is possible to program (through the parameter P50) a number of operating hours for the engine after which maintenance has to be carried out. When the hour-counter reaches or exceeds such parameter (NB: it is set by tens of hours) in order to signal the maintenance request the number of operating hours will flash alternatively to the message “SER” (with the selector on MAN, AUTO and TEST the function to view the operating hours is automatically selected after 60 seconds without pressing any button). This condition stays until the hour-counter is reset or until the value of the Parameter P50 is changed (by increasing it or by forcing it to 0). Both t he counters are reset with a common operation (they cannot be reset separately): Ø
By pressing the “F1” and “F2” select the “DATA – HOURS COUNT / START COUNTER” function
Ø
Switch the key selector to OFF_RESET.
Ø
Press at the same time “MODE / ACK” and “STOP” for 5 seconds. After 5 seconds the counters will be reset. The display does not indicate the reset in any way; therefore the operator has to count the 5 seconds.
There is another hour counter. It cannot be cleared in any way. Its value is not shown on the DST4600A front panel, but can be read by the serial port. •
“GEN-SET FREQUENCY”: when this function is selected, the display “MULTIFUNCTION” shows the frequency measured on the phase L1 (terminal 63) of the generator (in Hz with a decimal).
•
“MAINS VOLTAGE (Vac) / (MAINS VOLT./SIM STATUS) / REACTIVE POWER (kvar)”: when this function is selected, the display “MULTIFUNCTION” shows one of the phase-to-phase voltages measured by the board, according with the status of the indicators “L1/L2”, “L2/L3” and “L3/L1” located between the displays “A” and “V”: - Indicator “L1/L2” turned on: phase R-S - Indicator “L2/L3” turned on: phase S-T - Indicator “L3/L1” turned on: phase T-R If the board is programmed not to use the internal mains sensor, display shows “---“. If the board is programmed to use the internal mains sensor and the input “MAINS
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EAAM002010I.doc SIMULATION” (terminal 24) is enabled, the indicator “MAINS VOLTAGE (Vac) / REACTIVE POWER (kvar)” flashes. If the board is supplied with the power measurement option and if the displays “V” and “A” are showing the active power and the power factor (POWER DISPLAY FUNCTION), the display “MULTIFUNCTION” shows the reactive power (in this case, the measure could blink if at least one of the current measure circuits of the board is saturated, that means that the current is higher than the TA nominal value). •
“BATTERY VOLTAGE (V) / APPARENT POWER (kVA)”: when this function is selected, the display “MULTIFUNCTION” indicates the voltage measured on the battery (terminals 47-48 or 49-48) (in Volts with a decimal). If POWER DISPLAY FUNCTION is active, the display indicates the apparent power (in this case, the measure could blink if at least one of the current measure circuits of the board is saturated, that means that the current is higher than the TA nominal value).
•
“OIL PRESSURE (bar)”: when this function is selected, the display “MULTIFUNCTION” shows the engine’s oil pressure measured on the analogue sensor (terminal 42) (in Bars with a decimal). If the sensor isn’t configured (P47=0), the display will show three dashes (“---“).
•
“TEMPERATURE (°C)”: when this function is selected, the display “MULTIFUNCTION” shows the cooling water temperature measured on the analogue sensor (terminal 43) (in °C). If the sensor isn’t configured (P46=0), the display shows three dashes (“---“).
•
“FUEL LEVEL (%)”: when this function is selected, the display “MULTIFUNCTION” shows the fuel level in the tank measured on the analogue sensor (terminal 45) (percentage). If the sensor isn’t configured (P48=0), the display will show three dashes (“---“).
Under particular conditions, during the operation the display “MULTIFUNCTION” can show messages having no relation with the selected function. In this situation, all indicators related to display “MULTIFUNCTION” are turned off. In detail, the messages are the following: •
“STA” during a starting attempt, that is when the output “START” (terminal 20) is activated.
•
“PRE” during the preheating phase preceding the starting attempt in diesel engines, that is when the “PREHEAT OUTPUT” (“AUX OUTPUT 1”, terminal 15) is activated.
•
“SER” signals that the generator set requires field service maintenance.
•
“F01” in presence of the deactivation for generator’s voltage under the minimum threshold (“UNDERVOLTAGE”).
•
“F02” in presence of the block for generator’s voltage over the maximum threshold (“OVERVOLTAGE”).
•
“F03” in presence of the deactivation for generator’s frequency under the minimum threshold (“UNDERFREQUENCY”).
•
“F04” in presence of the block for generator’s frequency over the maximum threshold (“OVERFREQUENCY”).
•
“F05” in presence of block for belt break (“BELT BREAK”).
•
“F06” in presence of block for maximum current supplied by the generator (“OVERCURRENT”).
•
“F07” in presence of block for “STOP” pressed in the AUTOMATIC or in the TEST mode.
•
“F08” in presence of block for operating condition not reached.
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“F09” in presence of alarm for data error in the non-volatile memory
•
“ F10” in presence of alarm from “IN PUT ‘B’” (terminal 13)
•
“F11” in presence of block for “ENERGY INVERSION”
•
“F12” in presence of block for “INHIBITION OF THE GENERATOR SET USE”
•
“F13” in presence of alarm “KR CLOSE FAILURE”
•
“F14” in presence of alarm “KG CLOSE FAILURE”
•
“F16” in presence of alarm “SHORT CIRCUIT”
•
“F21” in presence of block for “SHUTDOWN FAILURE”
•
“F40” if the “engine in threshold” signal is missing while KR is closed (for asynchronous engine version only)
•
“F49” in presence of alarm for “MAX POWER”
•
“F50” in presence of block for “BOARD FAULT”
During the shutdown cycle the display “MULTIFUNCTION” alternates, every two seconds, the message “STO” with the message it would display if the shutdown cycle was not in progress.
2.2.2 Operating Conditions and Measurements Area In this area (right top of the front panel) is displayed the status of the generator set and of the mains. The following signals are provided: •
Indicators “KG” and “KR” (green): indicate the status of the contactors managing the power changeover. The indicator “KR” is not present for SW type 12 (/P boards). If the green indicator is turned on the corresponding external connected contactor is closed. The external connected contactors can never be both closed, while they can be both open during the switching. The default configuration shows the KG and KR command status, not the actual status. However it is possible to configure the board to use two inputs to monitor the status: •
“INPUT A” (terminal 14) for KG status
•
“INPUT C” (EXTERNAL OVERSPEED default configuration) (terminal 12) for KR status
Connect the proper terminal to ground when KG or KR is activated. When this function is enabled the indicators “KG” and “KR” work in a different way:
•
•
OFF: the contactor is open
•
ON: the contactor is closed
•
Flashing at 50% duty cycle: the contactor is open but the command is on
•
Flashing at 90% ON: the contactor is closed but the command is off
Indicator “ENGINE RUNNING” (green): it indicates the status of the engine of the generator set. It takes the following meanings: Ø
Turned off: engine shut down
Ø
Flashing: engine cooling (this condition occurs only in the AUTOMATIC mode).
Ø
Turned on: engine running
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•
Indicator “GENERATOR LIVE” (green): it indicates the status of the generator set. It takes the following meanings: Ø
Turned off: the generator doesn’t produce any voltage.
Ø
Flashing: The generator is living but some of the parameters (voltages on one or more phases or frequency) are not within the programmed tolerance limits, therefore the users cannot be switched on it.
Ø
Turned on: The generator is living and all its parameters are within the programmed tolerance limits, therefore it is possible to switch the users on it.
“MAINS LIVE” indicator (green): It indicates the mains status. It takes the following meanings: Ø
Turned of: mains failure.
Ø
Flashing: the mains is present but the voltage on one or more phases is not within the limits of the programmed tolerance thresholds, therefore if the users are currently switched on the generator, they will have to stay on it.
Ø
Turned on: the mains is present and within the programmed tolerance limits, therefore the users can be switched on it.
NB: the board has an input (“MAINS SIMULATION”, terminal 24) that can be used to inhibit the automatic operation of the genset. If this digital input is activated, independently from what has been acquired with the mains sensor, the engine is not automatically started.
Furthermore, there are two digital displays (each of them having 3 digits) to show the electric quantities measured on the generator. The left display (called display “V”) shows the generator’s voltages (phase-to-phase for three-phase systems, phase-to-neutral for single-phase systems) Volts. The right one (called display “A”) shows the phase currents in Amperes. The view format changes according to the set TA ratio (P17): §
P17 < 10: the currents are displayed with two decimals
§
P17 >=10 and <100: the currents are displayed with one decimal
§
P17 >=100: the currents are displayed without any decimal. If the current measurement exceeds 999 Ampere, it is displayed divided by 10 and the indicator “X10” (yellow), located over the display “A” turns on.
If the current measured (in the board side of TA) is higher then 5 Amperes, the display “A” blinks to indicate lower measure precision. If the board is supplied with the power measurement option it is possible to view the power factor (indicated by “POWER FACTOR (cos φ)”) on the display “V” and the active power (indicated by “ACTIVE POWER (kW)”) on the display “A” (POWER DISPLAY FUNCTION). Furthermore, it is possible to view the energy meter (kWh on the display “A” and MWh on the display “V”). All these measures will blink if at least one of the current measurement circuits of the board is saturated (see description at the previous paragraph).
Three yellow indicators (called “L1/L2”, “L2/L3” and “L3/L1”) located between the two displays are also present. They indicate to which phase the measurements displayed in any moment refer. On single-phase systems the voltage and the current of the only present phase are always displayed, therefore the indicator “L1/L2” is always turned on, while the “L2/L3” and “L3/L1” are always off. On three-phase systems, the three phases are periodically alternated every 4 seconds on the displays and the indicators “ L1/L2”, “L2/L3” and “L3/L1” show the current phase. However, it is possible to force the display of one
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EAAM002010I.doc phase only even on three-phase systems by pressing at the same time the buttons “F1” and “F2” when the displays show the quantities relating to the phase one intends to force: the phases scanning will be interrupted and will start again when the two buttons “F1” and “F2” will be pressed at the same time again.
2.2.3 Faults Area This area (top left of the front panel) contains all the indicators for the generator set’s common faults Here follows a short description of the indicators, for a more detailed description of all the faults, see paragraph 6. At the fault acquisition, the corresponding indicator flashes, by pressing the “MODE / ACK“ button it stops flashing to indicate that the operator acknowledge it. •
Indicator “TEMPERATURE” (red): it indicates the alarm or block status due to the high cooling water temperature. The indicator flashes at a different speed to indicate an alarm (more quickly) or a block (more slowly, as for all other blocks). It can be acquired from: Ø
Digital input “WATER WARNING” (terminal 10)
Ø
Digital input “WATER. ALARM” (terminal 09)
Ø
•
Indicator “LOW OIL PRESSURE” (red): it indicates the alarm or block status due to the low oil pressure of the engine. The indicator flashes at a different speed to indicate an alarm (more quickly) or a block (more slowly, as for all other blocks). It can be acquired from: Ø
Digital input “OIL WARNING” (terminal 08)
Ø
Digital input “OIL P. ALARM” (terminal 07)
Ø
•
Analogue input “OIL PRESSURE” (terminal 42)
Indicator “MAX LEVEL” (yellow): It indicates the alarm status due to the maximum fuel level in the tank. It can be acquired from: Ø Ø
•
Analogue input “TEMPERATURE” (terminal 43)
Digital input “HIGH LEVEL FUEL” (terminal 04) Analogue input “FUEL LEVEL” (terminal 45)
Indicator “ALARM1” (“EXTERNAL SHUTDOWN”) (red): it indicates the non-masked general block status. It can be acquired from: Ø
Digital input “ALARM 1” (terminal 01)
•
Indicator “OVERCRANK” (red): It indicates the block status due to a failure in the automatic start of the engine. It is produced by the operating sequence in the AUTOMATIC mode.
•
Indicator “DISCHARGED” (yellow) it indicates the alarm status due to the charge level of the starting battery of the generator set. Such battery also powers the board DST4600A. The alarm is produced if the battery voltage exceeds the tolerance limits:
•
Ø
11.8 … 15 V (for nominal voltage of 12 V battery)
Ø
23.2 … 30 V (for nominal voltage of 24 V battery)
Indicator “MIN LEVEL” (yellow): it indicates the alarm status due to the minimum fuel level in the tank. It can be acquired from: Ø Ø
Digital input “LOW LEVEL FUEL” (terminal 05) Analogue input “FUEL LEVEL” (terminal 45)
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Indicator “ALARM2” (“AUX. ALARM”) (red): it indicates the masked generic block status. It can be acquired from: Ø
•
•
Indicator “OVERSPEED” (red): it indicates that the engine is running too fast and it could damage the alternator or the engine itself. It can be acquired from: Ø
Digital input “OVERSPEED” (“INPUT C” terminal 12)
Ø
Generator’s frequency exceeding the set threshold (parameter P21)
Indicator “OVERLOAD” (red): it indicates a system overload. It can only be acquired from: Ø
•
Digital input “OVERLOAD” (terminal 11)
Indicator “NO FUEL” (red): it indicates the block due to the end of the fuel in the tank. It can be acquired from: Ø Ø
•
Digital input “ALARM 2” (terminal 02)
Digital input “FUEL END” (terminal 06) Analogue input “FUEL LEVEL” (terminal 45)
Indicator “EMERGENCY STOP” (red): it indicates the block that follows the pressing of the emergency button. It can be acquired from: Ø
Digital input “EMERGENCY STOP” (terminal 03). NB: the block is enabled when the digital input is not activated.
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3. Start Initialization As soon as the board is powered it executes the following operations: •
Lamp Test: during this phase it turns on all the indicators in the front panel and it shows 888 (with the decimal points turned on) on the three displays. This operation lasts two seconds and allows the identification of any failure in the front panel that could involve visual signaling of a fault.
•
It checks if it has to execute the CALIBRATION procedure. To request the execution of such procedure press “MODE / ACK” while turning the board on (see par.4). In this phase all the indicators on the front panel are turned off as well as the displays “V” and “A”, while the display “MULTIFUNCTION” shows three question marks (this procedure can be made only by trained operator using proper measurement systems).
•
Display the software level. The display “MULTIFUNCTION” shows the message “REL” (release). The display “V” shows the main version; the display “A” shows the secondary version. For instance, for a software level 1.23 the display “V” will indicate “1” and the display “A” will indicate “23”. In this phase all the indicators on the front panel are turned off. This phase lasts one second.
In the event of data errors in the non-volatile memory, the display “MULTIFUNCTION” shows, in place of “REL” the message: •
“INI” if the non-volatile memory doesn’t contain any data
•
“F09” if the non-volatile memory contains mis taken data
After the execution of the above-mentioned operations, the board starts executing the work sequences, according to the position of the key selector.
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4. Calibration Procedure The calibration procedure is carried out by the producer and not by the user. Such procedure requires particular instruments and working conditions. The only function requiring a user’s calibration is that of the level sensor. The user will strictly follow the instructions given in this paragraph; otherwise, he could alter the calibration factors and would have to return the DST4600A board to SICES S.R.L. for a new calibration.
4.1
Entering the CALIBRATION Procedure. To activate the CALIBRATION procedure turn on the board by pressing “MODE / ACK” until the display “MULTIFUNCTION” shows the message “CAL”. It takes about 4 seconds to get the message “CAL”: 2 seconds for the board initialization (LAMP TEST phase) and 2 seconds for the confirmation of the CALIBRATION activation (“???” on the display “MULTIFUNCTION”). After you’ve entered the CALIBRATION the message “CAL” is shown for one more second.
4.2
Quitting the CALIBRATION Procedure. To quit the CALIBRATION procedure, turn off the board. Turning it on again without pressing “MODE / ACK” the board will execute the normal operating procedure using the calibration settings you’ve just entered.
4.2.1 Calibration of the Fuel Level Sensor. The calibration procedure of the level sensor is to adapt the measuring range to the sensor used. Actually, it may occur that, due to the tank shape, the float cannot move on the whole range. Without this procedure we would have a view ranging from 10% to 80% for example, with a real level variation from 0% to 100%. First of all set the key selector in any position except TEST. In these conditions the indicator “L1/L2” is turned on, “L2/L3” is turned off and the display “MULTIFUNCTION” shows a message identifying an analogue input. Do not set the selector in the TEST position. To calibrate the level sensor then place the display “MULTIFUNCTION” on the above mentioned input by using “F1” and “F2”. By pressing them it changes the selected analogue input and, consequently, the corresponding message. Go on until the display “MULTIFUNCTION” shows the message “S L” (level sensor). The management of these buttons supports the “AUTOREPEAT” function, that is by pressing and soon releasing “F1” or “F2” you move of one analogue input each time, while by keeping it pressed you move of one analogue input as soon as you press the button and after one second you move of one position every 0.1 seconds. The scanning of the inputs is cyclic, that is by pressing “F2” you move from the last to the first and vice versa. To abort the calibration of the level sensor simply turn off the board in any moment. When the display “MULTIFUNCTION” shows “S L”, to proceed with the calibration press “MODE / ACK”. Do not press such button if the display “MULTIFUNCTION” shows any other message except “S L”. Then the procedure evolves through the following s tages: 1.
The indicator “L1/L2” turns off and “L2/L3” flashes. The display “V” shows a 0 value while the display “A” shows the level value calculated according to the actual parameters.
DST4600A Operating Manual - 24/10/03 - page 17
EAAM002010I.doc 2.
Place the level sensor at the minimum level it can reach within the tank. Then wait until the value on the display “A” gets stable (it can take a lot of seconds). Then you can change the value showed on the display “V” to associate any percentage to the current physical level in the tank. Normally with the sensor at the minimum level the system should indicate 0% but there may be situations in which you need it indicates 10%, for instance. To change the percentage use the buttons “F1” and “F2”, for which the “AUTOREPEAT” function is enabled.
3.
When the display “V” shows the percentage you want to associate to the minimum level and the valued indicated by the display “A” is stable, by pressing “MODE / ACK” you will pass to the next stage
4.
The indicator “L1/L2” stays off and “L2/L3” keeps flashing. The display “V” shows a 100 value while the display “A” shows the level value calculated according the actual parameters.
5.
Place the sensor at the maximum level it can reach within the tank. Then wait until the value showed on the display “A” gets stable. Now you can change the value showed on the display “V” to associate any percentage to the current physical level in the tank. Normally with the sensor at the maximum level t he system should indicate 100% but there may be situations in which you need it indicates 90% or 110%, for instance. To change the percentage use the buttons “F1” and “F2”, for which the “AUTOREPEAT” function is enabled.
6.
When the display “V” shows the percentage you want to associate to the maximum level and the valued indicated by the display “A” is stable, by pressing the “MODE / ACK” button you will pass to the next stage
7.
Then the system calculates the parameters it has to use to obtain the level, it turns the indicator “L2/L3” off and “L1/L2” on and shows the level calculated according to the new parameters The new parameters are immediately stored in the non-volatile memory.
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5. Programming Procedure With this procedure it is possible to configure all the parameters controlling the board’s operation. Those parameters can be thresholds or times, but also operating options or hardware configuration. The parameters are stored in the non-volatile memory. When the board is turned off a consistency test is carried out on such parameters and in the event of an error the alarm F09 is produced and the default values are loaded. Some parameters are bit-managed. Each 1 bit enables a function and each 0 bit disables a function. Each bit corresponds to a value. The parameter must be set with the result obtained by summing the values associated to the bits you wish to put at 1. 8 bits are available. A table like the following one explains the bit-managed parameters:
5.1
Bit Value
Description
0
1
Enable function 1
1
2
Enable function 2
2
4
Enable function 3
3
8
Enable function 4
4
16
Enable function 5
5
32
Enable function 6
6
64
Enable function 7
7
128
Enable function 8
•
If it’s required to disable all functions set the value 0 for the parameter.
•
If it’s required to enable all functions, set 255 (1+2+4+8+16+32+64+128) for the parameter.
•
If it’s required to enable only selected functions, values of the selected are to be summed (for example, to enable only the functions 3, 4, 6 and 8, the value 4+8+32+128 = 172 is to be set for the parameter).
Table of Description of the DST4600A Parameters. Cod e
Description
From Level
Min Value
Max Value
Default Value
Unit of measure
Disable Value
P01
Intervention threshold for minimum mains voltage
0.00
0
999
320
V
-
P02
Hysteresis for mains and generator voltage
0.00
3
20
10
%
-
P03
Generator’s voltage presence recognition threshold
0.00
0
999
80
V
-
P04
Generator set intervention delay for mains voltage failures
0.00
0
999
2
s
-
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Description
From Level
Min Value
Max Value
Default Value
Unit of measure
Disable Value
P05
Mains contactor closing delay from mains restoration
0.00
0
999
30
s
-
P06
Generator set contactor closing delay from generator at operating speed
0.00
0
999
5
s
-
P07
Engine’s cooling cycle duration
0.00
0
999
45
s
-
P08
Starter impulse duration
0.00
1
20
5
s
-
P09
Impulse duration for excitation shutdown
0.00
0
300
20
s
-
P10
Number of starting attempts of the generator set
0.00
1
15
3
-
-
P11
Protection threshold for generator’s minimum frequency
0.00
10
60
45
Hz
Min
P12
Protection threshold for generator’s maximum frequency
0.00
52
99
55
Hz
Max
P13
Protection threshold for generator’s minimum voltage
0.00
10
999
300
V
Min
P14
Protection threshold for generator’s maximum voltage
0.00
100
999
450
V
Max
P15
Intervention threshold for maximum mains voltage
0.00
100
999
440
V
-
P16
Protection threshold from overload current
0.00
0
100
0
%
Min
P17
TA Ratio
0.00
0
6000
5
/5A
-
P18
Interval for generator set test
0.00
0
999
0
Ore
Min
P19
Operating duration for generator set test
0.00
0
60
0
Min.
Min
P20
Duration of preheat cycle
0.00
0
99
0
S
Min
P21
Protection threshold for frequency over speed
0.00
55
99
60
Hz
Max
P22
Dead time between contactors changeover
0.00
1
30
2
s
-
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Description
From Level
Min Value
Max Value
Default Value
Unit of measure
Disable Value
P23
Delay time of generator’s minimum and maximum frequency protections
0.00
1
20
5
s
-
P24
Delay time of generator’s minimum and maximum voltage protections
0.00
1
20
3
s
-
P25
Low oil pressure alarm threshold
0.00
0.0
9.9
0.0
Bar
Min
P26
High water temperature alarm threshold
0.00
0
199
199
°C
Max
P27
Maximum fuel level alarm threshold
0.00
0
100
100
%
Max
P28
Fuel end block threshold
0.00
0
100
0
%
Max
P29
Fuel pump starting threshold
0.00
0
100
0
%
Max
P30
Fuel pump stopping threshold
0.00
0
100
0
%
Max
P31
Disable time from starting for oil block/alarm and for auxiliary block 2
0.03
5
120
15
S
-
P32
Maximum time from engine running for generator’s voltage and frequency in operating window
0.03
5
999
30
S
-
P33
Minimum fuel level alarm threshold
0.03
0
100
0
%
Min
P34
Low oil pressure block threshold
0.03
0
9.9
0.0
Bar
Min
P35
High water temperature block threshold
0.03
0
199
0
°C
Min
P37
Board’s address for serial communication
0.03
0
247
1
-
-
P38
Waiting time between two starting attempts
0.03
2
99
5
s
-
P39
Enable mask 1
0.03
0
255
127
-
-
P40
External faults filter time
0.03
0.5
10.0
0.5
s
-
P41
Minimum holding time for contactors’ controls
0.03
0
15
6
s
-
P42
Engine running recognition frequency
0.03
5
20
10
Hz
-
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Description
From Level
Min Value
Max Value
Default Value
Unit of measure
Disable Value
P43
Dead engine recognition frequency
0.03
2
10
5
Hz
-
P45
Type of mains sensor
0.03
0
3
2
-
-
P46
Type of temperature sensor
0.03
0
11
1
-
0
P47
Type of pressure sensor
0.03
0
11
1
-
0
P48
Type of level sensor
0.03
0
1
1
-
0
P49
Enable mask 2
0.03
0
255
191
-
-
P50
Next maintenance occurrence
0.03
0
999
0
Tenths of Hours
0
P51
Type of serial communication
0.03
0
11
1
-
-
P52
Energy inversion block threshold (only for version with power measurement)
0.05
0
999
0
kW
Min
P53
Energy inversion block filter time (only for version with power measurement)
0.05
0
999
5
s
-
P54
Horn activation duration
0.05
0
999
60
s
Max= always 0=never
P55
Engine heating end temperature threshold
0.05
0
199
0
°C
Min
P56
Active Power threshold for LOW POWER or MAX POWER signal activation
0.12
0
9999
0
kW
Min
Delay time for P56 threshold
0.12
0
999
3
s
-
Active Power threshold for LOW POWER or MAX POWER signal deactivation
0.12
0
9999
0
kW
Min
Delay time for P58 threshold
0.12
0
999
3
s
-
P60
LOW POWER signal deactivation duration time from KG closed
0.12
0
999
5
s
-
P61
Enable mask 3
0.12
0
255
128
-
-
P62
Serial port baud rate configuration
0.12
3
192
96
Bps/100
-
P57
P58
P59
0.37
0.37
0.37
0.37
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Description
From Level
Min Value
Max Value
Default Value
Unit of measure
Disable Value
P63
Serial port parity and stop bits configuration
0.12
0
5
0
-
-
P64
Analogue data collection time rate
0.18
1
3600
60
s
-
P65
ALARM2 (terminal 02) filter time
0.22
0
999
1-STD 180-/P
s
-
P66
Generator set intervention delay from MAINS SIMULATION (terminal 24) de-activation
0.22
0
999
2-STD 0- /P
s
-
P67
Generator set shutdown delay from MAINS SIMULATION (terminal 24) activation
0.22
0
999
3
s
-
P68
Generator Secondary winding – Primary winding turns ratio
0.23
1
1000
1000
Thousandth
-
P69
MAINS Secondary winding – Primary winding turns ratio
0.23
1
1000
1000
Thousandth
-
P70
AUTO mode enable day time (generator set Time Lock function)
0.24
00.00
23.59
00.00
Hour.Min
-
P71
AUTO mode disable day time (generator set Time Lock function)
0.24
00.00
23.59
00.00
Hour.Min
-
P72
AUTO mode function week mask (generator set Time Lock function)
0.24
0
127
127
-
0
P73
Generator set test day time
0.24
00.00
23.59
00.00
Hour.Min
-
P74
Generator set test week mask
0.24
0
127
127
-
0
P75
KR and KG close fault delay time
0.24
0
60
5
s
Min
P76
Nominal trip time for timedependent over-current protection
0.33
0
999
0
s
0
P77
Short circuit threshold
0.33
100
999
500
%
P76=0
P78
Delay for protection
0.37
0.0
3.0
0.1
s
-
P79
Enable mask 4
0.38
0
255
16STD 20- /P
-
-
short
circuit
DST4600A Operating Manual - 24/10/03 - page 23
EAAM002010I.doc Parameters P52, P53, P56, P57, P58, P59 and P60 are displayed only if the board is equipped by power measurement option. Parameters P70, P71, P72, P73 and P74 are displayed only if the board is equipped by Real Time Clock option. Default values are referred to 400V-50Hz generator set system. The following table outline the main parameters change depending on generator set configuration. Code
Description
230 V
400 V
440 V
50 Hz
60 Hz
P01
Intervention threshold for minimum mains frequency
150
320
360
P03
Generator’s voltage presence recognition threshold
80
80
80
P11
Protection threshold for generator’s minimum frequency
45
55
P12
Protection threshold for generator’s maximum frequency
55
65
P13
Protection threshold for generator’s minimum voltage
130
300
330
P14
Protection threshold for generator’s maximum voltage
280
450
490
P15
Intervention threshold for maximum mains voltage
270
440
480
P21
Protection threshold for frequency over speed
60
70
5.1.1 Parameter P16 The current protection threshold is expressed in percentage with respect to the maximum measurable current, set through the parameter P17 (TA ratio). If, f or instance, you set P17 = 5000/5 (5000 Ampere full-scale in the current measurement) and P16 = 70, the over-current threshold will be 3500 Ampere (3.5 Ampere in the board side of TA). The F06 block will be immediately (with a delay of about 4 seconds) produced if the current exceeds this threshold (or, starting from SW 08.00.33, after a time related to the amount of the over-current if P76 is greater than 0). Caution: If you use time dependent over-current protection and short circuit protection, be sure that your system will be able to measure the maximum threshold current. Especially, if the maximum threshold current is greater than the nominal TA (Current Transformer) value, be sure that: a) Power rating of TA is adequate (at least 9 VA, but to be checked) b) The whole protection system is working (test it) c) Maximum continuous (or long term current) current will be less than 1.6 times TA value (2 times TA value for less than 20 seconds)
5.1.2 Parameter P17 For this parameter, since there are a few available values but they ranges from 0 to 6000 the whole table of the available values has been stored and through the buttons “F1” and “F2” you move only in the table values.
DST4600A Operating Manual - 24/10/03 - page 24
EAAM002010I.doc Available values: 0
1
5
10
15
20
25
30
35
40
50
60
70
75
80
100
120
125
150
200
250
300
400
500
600
700
750
800
1000
1200
1250
1500
1600
2000
2500
3000
4000
5000
6000
5.1.3 Parameter P37 This parameter assigns the board a numeric address used to distinguish more boards communicating over a serial bus. Both implemented protocols can operate over RS-485 physical link. The standard DST4600 protocol requires address from 0 to 9, while MODBUS can use address from 1 to 247. If this parameter has a value greater than 9 while operating with DST4600 protocol (P51=0), only the unit value of the parameter is taken in account for address setting. Until SW version 08.00.17, if the parameter was set to a value of 0, it was assumed that the used physical link was RS232 with or without connected modem. If the value was greater than 0 it was assumed that the link was RS485. Starting from SW version 08.00.18 the selection of the physical layer is made by means P.51.
5.1.4 Parameter P39 This parameter is a bit-managed one. Each 1 bit enables a function and each 0 bit disables a function. Each bit corresponds to a value. The parameter must be set with the result obtained by summing the values associated to the bits you wish to put at 1. 8 bits are available: Bit Value
Description
0
1
Enable water temperature contact alarm (terminal 10)
1
2
Enable water temperature contact block (terminal 09)
2
4
Enable oil pressure contact alarm (terminal 08)
3
8
Enable oil pressure contact block (terminal 07)
4
16
Enable engine running from D+ (terminals 39 and 40)
5
32
Enable fuel level contact block (terminal 06)
6
64
Enable fuel level contact alarms (terminals 05 and 04)
7
128
Enable belt break block (terminals 39 and 40)
5.1.5 Parameter P45 This parameter configures the type of mains sensor (and also the number of phases of the generator): 0: external three-phase sensor (connected to the input “MAINS_SIMULATION”, terminal 24) 1: external single-phase sensor (connected to the input “MAINS_SIMULATION”, terminal 24) 2: internal three-phase sensor 3: internal single-phase sensor NB: The selection of the single-phase sensor, will force the view of the R-S and L1-L2 phase-to-phase voltages and of the L1 current only.
5.1.6 Parameter P46 DST4600A Operating Manual - 24/10/03 - page 25
EAAM002010I.doc This parameter allows the configuration of the temperature sensor. The available values are: Value
Trademark
Scale
Characteristics
0
No
-
-
1
VDO
40..150 °C
288..10 Ohm
2
BORLETTI
40..150 °C
1185..39 Ohm
10
MTU
0..120 °C
0..10 V
11
SCANIA
40..120 °C
10 V PWM
5.1.7 Parameter P47 This parameter allows the configuration of the pressure sensor. The available values are: Value
Trademark
Scale
Characteristics
0
No
-
-
1
VDO
0..10 Bar 10..180 Ohm
2
BORLETTI
0..8 Bar
300.20 Ohm
3
VDO
0..5 Bar
10..180 Ohm
10
MTU
0..10 Bar 0..10 V
11
SCANIA
0..7 Bar
10 V PWM
5.1.8 Parameter P48 This parameter allows the configuration of the level sensor. The available values are: Value
Trademark
Scale
Characteristics
0
No
-
-
1
VDO
0..100 %
180..10 Ohm
5.1.9 Parameter P49 This parameter is a bit-managed one. Each 1 bit enables a function and each 0 bit disables a function. Each bit corresponds to a value. The parameter must be set with the result obtained by summing the values associated to the bits you wish to put at 1. 8 bits are available: Bit Value
Description
0
1
Enable block for “ALARM 1” (terminal 1)
1
2
Enable block for “ALARM 2” (terminal 2)
2
4
Enable overload contact block (terminal 11)
3
8
Enable over-speed contact block (terminal 12)
4
16
Enable F10 contact alarm (terminal 13)
5
32
Disable of generator’s voltage measure averaging
6
64
Enable dead/running engine frequency detection
DST4600A Operating Manual - 24/10/03 - page 26
EAAM002010I.doc Bit Value
Description
7
Enable discharged battery alarm
128
5.1.10 Parameter P50 This parameter allows the setting of a number of hours after which is required the maintenance of the generator set. Here you have to enter the “absolute value” of hourcounter at which the next service shall be required. If, for instance, the hour-counter indicates 12 (120 hours) and you wish the new maintenance to be carried out after 500 hours, you’ll have to enter 62 (620 hours expressed in tens of hours). Next time, if you want again 500 hours period, you‘ll have to enter 112 (1120 hours expressed in tens of hours). Entering 0 disables the function. When the hour-counter exceeds the P50 value, it will flash the message “SER” alternating it with its display and the display function of the hour-counter is automatically selected after 60 seconds each time no button is pressed. The maximum hour-counter value is 9999 as well as for the parameter P50. If, for instance, the hourcounter indicates 9500 and you want to carry out maintenance after 1000 hours you should enter 9500+1000, which is 10500 that exceeds the maximum limit. In this case the only possibility is to reset the hour-counter before setting the parameter P50 (see par 2.2.1.2.).
5.1.11 Parameter P51 This parameter allows the configuration of the protocol types the board has to adopt for the serial communication. Until SW version 08.00.17 the following values were allowed: 0: DST4600 protocol 1: MODBUS RTU protocol Starting from SW version 08-00-18, valid values become: 0: DST4600 protocol (RS-232 or modem) 1: MODBUS RTU protocol (RS-232 or modem) 10: DST4600 protocol (RS-232 or RS-485) 11: MODBUS RTU protocol (RS-232 or RS-485) Other values are invalid. The board must be informed if the physical layer is RS-485. In such case it never must begin a data transaction but can only answers to command or request (it acts as slave). If the physical layer is not RS-485, then it can manage to recognize if a modem is connected. To do that it has to send AT command over the line: this operation can’t be done over RS-485 line by a slave device. Until SW version 08.00.17 the value of parameter P37 was used to set the full slave mode required by a RS-485 line. If it was 0, it was assumed that there was not RS-485 connection; for different values the RS485 connection was assumed. The old solution yield in some problems (for example in using a ModBus connection with a modem). In the programming procedure, if the parameter P51 is viewed and a GSM modem is connected to the serial connector, 4 indicators are used for the signal level of the GSM (see paragraph 9). If you select the ModBus protocol (entering 1 or 11) you have also to set parameter P37 to any value except 0.
5.1.12 Parameter P52 and P53. These parameters allow the configuration of the block for energy inversion (of course, only if the board version is that with the power measurement). The first one allows the configuration of a threshold expressed in kW. If such parameter is zero the block is disabled. The second one allows the configuration of the filtering time for that block (in seconds). The block is activated if the active power measured has a negative sign and if it exceeds the P52 threshold for the P53 time. The block involves the immediate shutdown of
DST4600A Operating Manual - 24/10/03 - page 27
EAAM002010I.doc the generator set (even in manual). Both parameters are not displayed if the board doesn’t have the power measurement option.
5.1.13 Parameter P55 This parameter allows the configuration of a minimum threshold for the temperature of the engine’s cooling water for the supply permission. Of course, to use this parameter the analogue temperature sensor must be connected to the board. If the sensor exists and the parameter P55 is different from 0, when the water temperature exceeds the threshold (after the generator set is in the window) the power changeover can be switched on the generator, whether or not the time set through the parameter P06 has passed. Then if you want to be sure of engine heating, set P06 with a high time value and set P55 with the wanted engine temperature value.
5.1.14 Parameters P56-P60 These parameters are used to configure and enable the LOW POWER STATUS signal function. From software release EB02200080037, they can also be used to configure the max power protection, alternatively to LOW POWER function. Please see paragraph 10.6 for a complete description.
5.1.15 Parameter P61 This parameter is a bit-managed one. Each 1 bit enables a function and each 0 bit disables a function. Each bit corresponds to a value. The parameter must be set with the result obtained by summing the values associated to the bits you wish to put at 1. 8 bits are available: Bit Value
Description
0
1
Enable terminal 14 “INPUT A” to acquire KG status
1
2
If this bit is 0, terminal 12 “INPUT C” has the EXTERNAL OVERSPEED function. If the bit is 1 the terminal is used to acquire the KR status
2
4
Enable data call on event function
3
8
Enable special command sequences for VOLVO engine EDC
4
16
Enable generator set Time Lock function (only if Real Time Clock option is installed)
5
32
Enable KR close failure protection function.
6
64
Enable execution of data calls or SMS when mains is missing (even if mains sensor is external)
7
128
Select the function related to parameters P56-P60. If set, the max power protection function is selected, if not set the low power signaling function is selected.
The bit 3 of this parameter enables some special functions related to Volvo engines. These functions are available from SW 08.00.21. These functions are: •
The stop in excitation command duration is fixed to two seconds. The time set in parameter P09 is used again for activation of F21 block (engine not stopped)
•
The block “OVER-SPEED” (from terminal 12) can be activated only if engine is running (it is ignored if engine is stopped).
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5.1.16 Parameter P62 P62 is used to configure the serial port baud rate. This setting is valid for all the selected protocol. It is possible to select the following values: •
3
300 bps
•
6
600 bps
•
12
1200 bps
•
24
2400 bps
•
48
4800 bps
•
96
9600 bps
•
192
19200 bps
5.1.17 Parameter P63 The “byte frame” of the serial communication link is defined by P63. The valid values and associated meanings are the followings: •
0
1 start bit, 8 data bits, no parity, 1 stop bit
•
1
1 start bit, 8 data bits, no parity, 2 stop bit
•
2
1 start bit, 8 data bits, even parity, 1 stop bit
•
3
1 start bit, 8 data bits, even parity, 2 stop bit
•
4
1 start bit, 8 data bits, odd parity, 1 stop bit
•
5
1 start bit, 8 data bits, odd parity, 2 stop bit
5.1.18 Parameter P64 Starting from SW version 08.00.18, this parameter set the rate of the analogue data collection for the internal record system database. The set value is used for the analogue data to be written in the fast database. The set value multiply by 30 is the rate used for the slow database. See par. 10.8 for this function description.
5.1.19 Parameters P68 and P69 These parameters (starting from SW version 08.00.23) allow setting the voltage measure transform ratio. That is useful in case GENERATOR and/or MAINS voltages are connected to the board by means of measuring transformers. In this way, it is possible to measure input voltage up to 1000V. If the voltage value to be shown will be greater then 1000V, the message “E—“ will be displayed instead (overflow indication). Transformers shall have a secondary winding of about 400V. Primary winding shall be chosen according to the nominal operating voltage of the system. Generator set input and Mains input can be work with different nominal voltage. The transformer ratio must be set in thousandths of secondary/primary turns ratio, being 1000 the value for 1 : 1 transformer. For example: transformer 690/400 V Value for P68 and/or P69 id ((400 / 690) * 1000)
à 580
For example: transformer 690/440 V
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EAAM002010I.doc Value for P68 and/or P69 id ((440 / 690) * 1000)
à 638
If Power Option equips your board, be caution in transformer choice. In this case care that the phase lag introduced will be negligible. For best performance use measure transformer or at lest 30VA transformer designed for the nominal voltage at no-load. That’s should minimize also harmonic distortion.
5.1.20 Parameters P70, P71 and P73 These parameters represent a time. They are in the format hh.mm (hours. minutes), two digits for hours and two digits for minutes. They are modifiable as other parameters but only valid values are accepted by the board (for example, by pressing button “F1” from 00.59 the value become 01.00).
5.1.21 Parameters P72 and P74 These parameters allow enabling periodic functions in specific day of the week. Bit Value
Description
0
1
Sunday
1
2
Monday
2
4
Tuesday
3
8
Wednesday
4
16
Thursday
5
32
Friday
6
64
Saturday
7
128
Reserved
Days related to Values used to obtain the programmed parameter have the specific function (Generator set periodic test and Generator set Time Lock) enabled. These parameters are valid only if the Real Time Clock option is installed and according to bit 4 of P61.
5.1.22 Parameter P76 This parameter configures the time dependant over-current protection performed by the board. This protection works on a threshold set by the parameter P16. The P16 value is a percent of the maximum TA current, set by parameter P17. For example, if you set P17 to 500 and P16 to 80 the threshold is: 500A * 80% = 400 A Parameter P76 is a time, expressed in seconds. If its value is 0, the protection must act immediately (the current must be greater then the threshold for at least 4 seconds). If its value is different from 0, the protection acts whit a delay that is inverse proportional to the amount of over-current. The time set by P76 parameter is the protection delay if the current is the threshold multiplied by 1.41. In the example above, the protection acts after the P76 time if the current is: 400 * 1.41 = 566 A The protection acts in a lower time if current is greater then 566A and in a higher time if current is smaller then 566. The protection doesn’t act if current is smaller then 400 A.
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The implemented function is known as Extremely Inverse I t.
Intervention time 1000
) s d n o c e s ( e m i t n o i t n e v r e t n I
100
10
1
0,1 1
10 Multiple of I
The graphic shows the trend of the intervention time related to multiples of over-current threshold, with P76 set to 60 seconds.
5.1.23 Parameter P77 This parameter configures the short-circuit protection performed by the board. First, you have to enable the over-current protection by setting the P16 parameter to anything but not 0. In this way, the maximum nominal current ( Imax) is known: Imax = (P17 * P16) / 100 Then you have to set in parameter P77 the short-circuit threshold, expressed as a percent on Imax. In this way the short-circuit current (Isc) is known: Isc = (Imax * P77) / 100 Finally you have to set P76 to a value greater then 0 (if not, the short-circuit protection is not enabled). Till to software release EB02200080036, the protection was activated immediately when the current become greater than the threshold Isc (the BLOCK “F16” is issued). From software release EB02200080037, the protection is activated when the current become greater than the threshold Isc consecutively for the time specified by parameter P78. P78 resolution is 0.1 seconds and even the value 0 is allowed (meaning instantaneous activation). This function is disabled if P76 or P16 are set to 0.
5.1.24 Parameter P79 This parameter is a bit-managed one. Each 1 bit enables a function and each 0 bit disables a function. Each bit corresponds to a value. The parameter must be set with the result obtained by summing the values associated to the bits you wish to put at 1. 8 bits are available: Bit Value
Description
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5.2
Bit Value
Description
0
1
If set, the blocks OVERLOAD, OVERCURRENT and SHORT CIRCUIT are managed as “deactivation”, that is the engine is cooled before stopping it.
1
2
If set, warning “F13” is subjected to mains presence status.
2
4
If set, when switching from AUTO or TEST to MAN the load is connected to KR (or, for /P, the KG breaker is opened)
3
8
If set, the board sends SMS or makes data calls when mains become present.
4
16
If set, the “shutdown block” is enabled (valid from 00.40 revision).
5
32
-
6
64
-
7
128
-
Activation of the PROGRAMMING Procedure To enter the PROGRAMMING procedure, switch the key selector to PROG. After about half a second, the display “MULTIFUNCTION” shows the message “PXX” (where XX represents the number of the displayed parameter) and the display “V” shows the current value of the parameter. Starting from SW version 08.00.24 both displays “V” and “A” are used to show the parameter values. “A” shows units, tens and hundreds, “V” shows thousands. The first time you enter the PROGRAMMING procedure since the board turn on the parameter P01 will be displayed. The next time it will be displayed the last parameter displayed the previous time. The indicator “L1/L2” is turned off. By entering the programming in this way you can view the parameters’ value but you can’t change it. If on the contrary you wish to change the value of one or more parameters, switch the key selector to any position except “PROG”, then press “MODE / ACK” and keeping it pressed switch the key selector to PROG. After half a second, the front panel looks as described above but with the indicator “L1/L2” turned on to indicate the possibility of change.
5.3
Quitting the PROGRAMMING procedure To quit the PROGRAMMING procedure, simply switch the key selector to any position except PROG. The parameters are stored in the non-volatile memory as soon as they are changed, therefore there’s no need of particular cautions before quitting the programming procedure.
5.4
Selecting a Parameter To select a parameter use “F1” e “F2”. Through “F1” you go to the next parameter, through “F2” you go to the previous one. The management of these buttons supports the “AUTOREPEAT” function, that is if you press and soon release one of the buttons “F1” or “F2” you move of only one position in the parameters’ list, while if you keep it pressed you move of one position as soon as you press the button and after 1 second you move of one position every 0.1 seconds. The parameters are displayed cyclically, that is by pressing “F1” you move from the last to the first and vice versa.
5.5
Setting a Parameter When the display “MULTIFUNCTION” shows the wanted parameter (PXX) to change it you need to follow the instructions below:
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Press “MODE / ACK”. The indicator “L1/L2” turns off and “L2/L3” flashes.
2.
Use “F1” and “F2” to change the value. Through “F1” you increase the value, through “F2” you decrease it. The management of these buttons supports the “AUTOREPEAT” function, that is if you press and soon release one of the buttons “F1” or “F2” you move of only one position in the parameters’ list, while if you keep it pressed you move of one position as soon as you press the button and after 1 second you move of one position every 0.1 seconds. If you keep pressed the button for other five seconds, the “AUTOREPEAT” function will add “5” to the value. Again, elapsed other 5 second with the button pressed, it will be added “50” to the value. The parameters are displayed cyclically, that is by pressing “F1” you move from the last to the first and vice versa.
3.
If you wish to cancel the setting in progress press “STOP”. The original value of the parameter is displayed. The indicator “L2/L3” is turned off, while “L1/L2” one is turned on. You are again at point 1.
4.
If you wish to store the set value press “MODE / ACK”. The indicator “L1/L2” turns on and “L2/L3” turns off. The new value is immediately stored in the non-volati le memory. You are again at point 1.
The instructions at point 2 refer to all parameters except P17 (TA ratio) and P62. Some parameters can have values over 999. In those cases, until SW version 08.00.23, the value is displayed divided by 10 (therefore you lose the possibility to set the units) and the indicator “x10” is turned on. Starting from version 08.00.24, the indicator “x10” is no more used (in programming mode) and values are shown on the two displays “V” and “A”. The parameters P25, P34 and P40 are displayed with a decimal. The parameters P70, P71 and P73 are displayed with two decimals.
5.6
Loading the Default Values In the event you think you’ve altered the parameters by mistake or if you wish to start again from the default condition you can load the default values (if you execute this procedure the default values are stored in the non-volatile memory therefore the current parameters are lost). To load the default values enter the programming procedure as if you wish to change the parameters (keep “MODE / ACK” pressed) and then keep pressed at the same time for at least two seconds “F1” and “F2”. After the two seconds the default values will be loaded and the displays “V” and “A” will show the messages “DEF” and “AUL” (DEFAULT) for one second.
5.7
Work Sequence during the programming. When the key selector is switched to “PROG” (with or without the button “MODE / ACK”) the generator set management is aborted. The users are switched on the mains (even if there’s a mains failure), the engine is shut down and all the faults are cancelled. No fault is produced during the programming procedure. But the monitoring of the whole network, of the engine and of the generator remains activated; therefore, after quitting the programming procedure you will immediately get the updated status of the system. Even the status of the indicators KR, KG, ENGINE RUNNING, GENERATOR LIVE and MAINS LIVE is kept updated during the programming procedure.
5.8
Lamp Test during the Programming Procedure.
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EAAM002010I.doc The Lamp Test procedure (testing of all the indicators and displays of the panel and of the board) is not carried out during the programming procedure but when the board is powered. To give the operator the opportunity of executing the test without disconnecting the board, it is possible to execute such test during the programming procedure, but only by a command. Actually, you need to enter the programming procedure in the view mode and then press “STOP”. Until you keep the button pressed all the indicators and displays will turn on.
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6. Faults During the operation of the generator set (but even when it is not running) some faults may occur. The faults can be divided into three categories according to the way the affect the generator set: •
Alarms: faults that are not immediately dangerous for the generator set and for its load, and that therefore allow the generator set to keep on working. They require an operator’s intervention otherwise they could cause a more dangerous fault.
•
Deactivations: these faults are more dangerous for the load that needs to be switched immediately on the mains (even if there’s a mains failure) but they aren’t immediately dangerous for the generator set and/or for the operator: the generator set will have to be stopped in any case but it can be stopped with the standard procedure (cooling cycle, etc.).
•
Blocks: these faults can damage the generator set and sometimes the load, too. When they are activated, the load is immediately switched on the mains (even if there’s a mains failure) and the engine is stopped through the emergency procedure (without the cooling cycle).
Any fault can be activated only if the key selector is on MAN, AUTO or TEST. The alarms can always be activated. There may be more than one alarm at the same time. The deactivation can be activated if in the moment the cause occurs no deactivation or block is present, while one or more alarms can be present. There cannot be two deactivation at the same time. The blocks can be activated only if in the moment the cause occurs no other block is present, while deactivation and/or alarms can be present. As a principle, there cannot be two blocks at the same time, but actually, the blocks “NO FUEL”, “EMERGENCY STOP” and “MANUAL STOP IN AUTO” are an exception since they can be activated even in presence of other blocks When a fault occurs, whatever be its category, the audible alarm is activated (“ALARM OUTPUT”, terminal 16) as well as the corresponding visual signal. Such signal can be an indicator on the front panel (fault area) or a message “FXX” on the display “MULTIFUNCTION”. In the case of an indicator it flashes. The audible alarm stays active for the time programmed through the parameter P54 than it turns off automatically (if P54 is equal to 999 the siren does never turn off automatically, if P54 is equal to 0 the siren never turns on), while the visual signal keeps on flashing until the operator doesn’t ”recognize” it. The “recognition” involves the pressing of “MODE / ACK”. As a consequence, the signal stops flashing and stays turned on and the audible alarm (if still active) is disabled. Once the operator has recognized the alarms, they are automatically cancelled by DST4600A when the corresponding cause ceases to exist. If the alarm is cancelled, the visual signal turns off, too. While the blocks and deactivation can be cancelled only by switching the key selector to “OFF/RESET”.
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6.1
6.2
List of Fxx Codes Code
Description
F01
Generator’s voltage under the minimum threshold (block)
F02
Generator’s voltage over the maximum threshold (block)
F03
Generator’s frequency under the minimum threshold (block)
F04
Generator’s frequency over the maximum threshold (block)
F05
Belt break (block)
F06
Generator’s current over the maximum current (block)
F07
Stop button pressed in automatic (block)
F08
Operating speed not reached (block)
F09
Error in the non-volatile memory (warning)
F10
Alarm from “INPUT B” (terminal 13) (warning)
F11
Energy inversion (block)
F12
Inhibition of generator set use (block)
F13
KR close failure (warning)
F14
KG close failure (warning)
F16
Short-circuit
F21
Shutdown failure (block)
F40
Engine not in thresholds when KG closed (only for asynchronous engine version)
F49
Max power (warning)
F50
Board failure (block)
Alarms
6.2.1 Low oil pressure 6.2.1.1
From dig ital inp ut Disabling Bit 2 of Parameter P39 = 0 Conditions to activate it Engine running from the time set through the parameter P31 Digital input “OIL WARNING” (terminal 08) shorted to ground Fuel solenoid activated. Not existent in asynchronous engine version Filter time 2 seconds Visual signal Quick flashing of the indicator “LOW OIL PRESSURE”
6.2.1.2
From An alogu e Input Disabling
Parameter P47 = 0 and/or parameter P25 = 0
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EAAM002010I.doc Conditions to activate it Engine running from the time set through the parameter P31 Pressure detected by the analogue input “OIL PRESSURE” (terminal 42) lower or equal to the threshold set through the parameter P25 Fuel solenoid activated. Filter time 2 seconds Visual signal Quick flashing of the indicator “LOW OIL PRESSURE”
6.2.2 High Cooling Water Temperature 6.2.2.1
From Digital Input Disabling Conditions for its activation
Filter time Visual signal
6.2.2.2
Bit 0 of the Parameter P39 = 0 Fuel solenoid closed (output “FUEL SOLENOID”, terminal 22 enabled) Digital input “TEMP. WARNING” (terminal 10) shorted to ground 2 seconds Quick flashing of the indicator “TEMPERATURE”
From An alogu e Input Disabling Conditions for its activation
Filter time Visual signal
Parameter P46 = 0 and/or P26 parameter = max Fuel solenoid closed (“FUEL SOLENOID” output, terminal 22 enabled) Temperature detected from the analogue input “TEMPERATURE” (terminal 43) over or equal to the threshold set through the parameter P26 2 seconds Quick flashing of the indicator “TEMPERATURE ”
6.2.3 Starting Battery Fault Disabling Conditions for its activation
Filter time Visual signal
Bit 7 of the Parameter P49 = 0 Starting not in progress (output “START”, terminal 20 not enabled) Battery voltage under 11.8 (or 23.2) V or battery voltage over 15 (or 30) V 40 seconds Slow flashing of the indicator “DISCHARGED”
6.2.4 Minimum Fuel Level in the Tank 6.2.4.1
From Digital Input Disabling Conditions for its activation Filter time Visual signal
6.2.4.2
Bit 6 of the Parameter P39 = 0 Digital input “LOW LEVEL FUEL” (terminal 05) shorted to ground 2 seconds Slow flashing of the indicator “MIN LEVEL”
From An alogu e Input Disabling Conditions for its activation Filter time Visual signal
Parameter P48 =0 and/or parameter P33 = 0 Level detected from the analogue input “FUEL LEVEL” (terminal 45) under or equal to the threshold set through the parameters P33 2 seconds Slow flashing of the indicator “MIN LEVEL”
6.2.5 Maximum Fuel Level in the Tank 6.2.5.1
From Digital Input Disabling
Bit 6 of the parameter P39 = 0
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EAAM002010I.doc Conditions for its activation Filter time Visual signal
6.2.5.2
Digital input “HIGH LEVEL FUEL” (terminal 04) shorted to ground 2 seconds Slow flashing of the indicator “MAX LEVEL”
From An alogu e Input Disabling Conditions for its activation Filter time Visual signal
Parameter P48 =0 and/or parameter P27 = max Level detected from the “FUEL LEVEL” analogue input (terminal 45) over or equal to the threshold set through the parameter P27 2 seconds Indicator “MAX LEVEL” slowly flashing
6.2.6 Auxiliary Alarm Disabling Conditions for its activation Filter time Visual signal
Bit 4 of the Parameter P49 = 0 Digital “INPUT B” (terminal 13) shorted to ground Time set through the parameter P40 Message “F10” on the display “MULTIFUNCTION”
6.2.7 KR close failure Disabling P75 = 0 Conditions for its AUTO o TEST mode. Bit 1 of parameter P61 = 1 (KR status activation connected to INPUT C). KR command active. Filter time Time set through the parameter P75 Visual signal Message “F13” on the display “MULTIFUNCTION” Starting from revision 08.00.24 (not available for /P version and for asynchronous engine version). Setting bit 5 of P61 at 1, it is activated a function that switch the load to Generator set, keeping it running, in case of F13 alarm. Starting from revision 08.00.38, this block may be masked if mains is not present by using bit one of parameter P79.
6.2.8 KG close failure Disabling P75 = 0 Conditions for its AUTO o TEST mode. Bit 0 of parameter P61 = 1 (KG status activation connected to INPUT A). KG command active. Filter time Time set through the parameter P75 Visual signal Message “F14” on the display “MULTIFUNCTION” Starting from revision 08.00.24.
6.2.9 Max power Disabling
Conditions for its activation Filter time Visual signal
Board without power measure option, otherwise Parameter P56 = 0 Parameter P58 = 0 Parameter P56 >= P58 Bit 7 of parameter P61 = 0 Active power higher than P58 threshold (see paragraph 10.6.2) Time set through the parameter P59 Message “F49” on the display “MULTIFUNCTION”
This warning is present only from software release EB02200080037.
6.3
Deactivations
6.3.1 Generator’s Voltage Under Minimum Threshold (“UNDERVOLTAGE”) Disabling
Parameter P13 = 0
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Filter time Visual signal
No deactivation No block Engine running Generator already in the operating window from starting. Shutdown cycle not in progress Fuel solenoid activated With selector on MAN, generator set contactor closed Generator’s voltage under the threshold set through the parameter P13 at least on one phase Not existent in asynchronous engine version Time set through the parameter P24 Message “F01” on the display “MULTIFUNCTION”
6.3.2 Generator’s Frequency Under the Minimum Threshold (“UNDERFREQUENCY”) Disabling Conditions for its activation
Filter time Visual signal
6.4
Parameter P11 = 0 No deactivation No block Engine running Generator already in the window from starting. Shutdown cycle not in progress Fuel solenoid activated With selector on MAN, generator set contactor closed Generator’s frequency under the threshold set through the parameter P11 Not existent in asynchronous engine version Time set through the parameter P23 Message “F03” on the display “MULTIFUNCTION”
Blocks
6.4.1 Emergency STOP Disabling Conditions for its activation Filter time Visual signal
Cannot be disabled “EMERGENCY STOP” input, terminal 03 open 0.5 seconds Indicator “EMERGENCY STOP” slowly flashing
6.4.2 Manual Stop in AUTO Disabling Conditions for its activation Filter time Visual signal
Cannot be disabled Key selector on AUTO or TEST STOP button pressed o external STOP command 0 seconds (immediate) Message “F07” on the display “MULTIFUNCTION”
6.4.3 Fuel END 6.4.3.1
Digit al inp ut Disabling Conditions for its activation Filter time Visual signal
6.4.3.2
Bit 5 of the Parameter P39 = 0 “FUEL END” digital input (terminal 06) shorted to ground 20 seconds Indicator “NO FUEL” slowly flashing
From An alogu e Input Disabling Conditions for its activation Filter time
Parameter P48 = 0 and/or parameter P28 = 0 Level detected from “FUEL LEVEL” (terminal 45) less or equal than the threshold set by means parameter P28 20 seconds
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Indicator “NO FUEL” slowly flashing
6.4.4 Low Oil Pressure 6.4.4.1
From Digital Input Disabling Conditions for its activation
Filter time Visual signal
6.4.4.2
Bit 3 of the Parameter P39 = 0 No block Engine running from the time set through the Parameter P31 Fuel solenoid activated “OIL P. ALARM” digital input (terminal 07) shorted to ground 2 seconds Indicator “LOW OIL PRESSURE” slowly flashing
From An alogu e Input Disabling Conditions for its activation
Filter time Visual signal
Parameter P47 = 0 and/or parameter P34 = 0 No block Engine running from the time set through the parameter P31 Fuel solenoid activated Pressure detected from the “OIL PRESSURE” analogue input (terminal 42) under or equal to the threshold set through the parameter P34 2 seconds Indicator “LOW OIL PRESSURE” slowly flashing
6.4.5 High Cooling Water Temperature 6.4.5.1
From Digital Input Disabling Conditions for its activation
Filter time Visual signal
6.4.5.2
Bit 1 Parameter P39 = 0 No block Fuel solenoid closed (“FUEL SOLENOID output, terminal 22 enabled) “TEMPERAT. ALARM” digital input (terminal 09) shorted to ground 2 seconds Indicator “TEMPERATURE” slowly flashing
From An alogu e Input Disabling Conditions for its activation
Filter time Visual signal
Parameter P46 = 0 and/or parameter P35 = 0 No block Fuel solenoid closed (“FUEL SOLENOID output, terminal 22 enabled) Temperature detected from the “TEMPERATURE” analogue input (terminal 43) over or equal to the threshold set through the parameter P35 2 seconds Indicator “TEMPERATURE” slowly flashing
6.4.6 Non-masked Auxiliary Block Disabling Conditions for its activation Filter time Visual signal
Bit 0 of the Parameter P49 = 0 No block “ALARM 1” digital input (terminal 01) enabled Time set through the parameter P40 “ALARM 1” indicator slowly flashing
6.4.7 Masked Auxiliary Block Disabling
Bit 1 of the Parameter P49 = 0
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Filter time
Visual signal
No block Engine running from the time set through the Parameter P31 Fuel solenoid activated “ALARM 2” digital input (terminal 02) shorted to ground Starting from SW version 08.00.22 this value is set by parameter P.65. In the old version this time was set through the parameter P40 “ALARM 2” (“AUX ALARM”) indicator slowly flashing
6.4.8 Generator’s Voltage Over the Maximum Threshold (“OVERVOLTAGE”) Disabling Conditions for its activation
Filter time Visual signal
Parameter P14 = max No block Engine Running Fuel solenoid activated Generator’s voltage over the threshold set through the parameter P14 at least on one phase Not existent in asynchronous engine version. Time set through the parameter P24 Message “F02” on the display “MULTIFUNCTION”
6.4.9 Generator’s Frequency Over the Maximum Threshold (“OVERFREQUENCY”) Disabling Conditions for its activation
Filter time Visual signal
Parameter P12 = max No block Engine running Fuel solenoid activated Generator’s frequency over the threshold set through the parameter P12 Not existent in asynchronous engine version. Time set through the parameter P23 Message “F04” on the display “MULTIFUNCTION”
6.4.10 Engine Over speed 6.4.10.1
From Digital Input
Disabling Conditions for its activation
Filter time Visual signal
6.4.10.2
Bit 3 of the Parameter P49 = 0 and bit 1 of the parameter P61=0 No block “OVERSPEED” digital input (“INPUT C” terminal 12) shorted to ground. If the VOLVO engine EDC function is enabled (bit 3 of P61, starting from SW release 08.00.21), the engine must be in running state. 0.5 seconds “OVERSPEED” indicator slowly flashing
From Frequenc y
Disabling Conditions for its activation
Filter time Visual signal
P21 parameter = max No block Generator’s Frequency over the threshold set through the parameter P21 Not existent on asynchronous engine version. 0.5 seconds “OVERSPEED” indicator slowly flashing
6.4.11 Overload 6.4.11.1
From Digital Input (“OVERLOA D”)
Disabling
Bit 2 of the Parameter P49 = 0
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No block “OVERLOAD” digital input (terminal 11) shorted to ground Time set through the parameter P40. Starting from 08.00.23 version, a fixed time of 1.5 second is added to the set value. Visual signal “OVERLOAD” indicator slowly flashing Starting from revision 08.00.38, this block may be configured as a “deactivation” by using bit 0 of parameter P79.
6.4.11.2
Fro m Cur rent (“OVERCURRENT”)
Disabling Conditions for its activation
Parameter P16 = 0 and/or P17=0 No block Engine running Generator’s frequency in window Current over the threshold set through the Parameter P16 at least on one phase Filter time 4 seconds if P76 is 0, otherwise the time depends on the amount of over-current and on the value of P76. Visual signal Message “F06” on the display “MULTIFUNCTION” Starting from revision 08.00.38, this block may be configured as a “deactivation” by using bit 0 of parameter P79.
6.4.12 Short circuit Disabling Conditions for its activation
Parameter P16 = 0 and/or P17=0 and/or P76=0 No block Engine running Generator’s frequency in window Current over the threshold set through the Parameter P77 Filter time Immediate until revision EB02200080036, parameter P78 from revision EB02200080037 Visual signal Message “F16” on the display “MULTIFUNCTION” This BLOCK is available from the SW release 08.00.33. Starting from revision 08.00.38, this block may be configured as a “deactivation” by using bit 0 of parameter P79.
6.4.13 Belt Break Disabling Conditions for its activation
Filter time Visual signal
Bit 7 of the Parameter P39 = 0 No block Engine running Shutdown cycle not in progress Voltage measured at the D+WL input (terminals 39-40) under the threshold of 8 (or 16) V. 20 seconds Message “F05” on the display “MULTIFUNCTION”
6.4.14 Operating Speed not reached Disabling Conditions for its activation
Filter time Visual signal
Cannot be disabled No block Selector on AUTO or TEST Engine running Fuel solenoid activated The generator doesn’t get in operating window (for two seconds) within the time limit set through the parameter P32 from the engine start. Immediate Message “F08” on the display “MULTIFUNCTION”
6.4.15 “OVERCRANK” Disabling
Cannot be disabled
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No block Selector on AUTO or TEST Engine not running after P10 starting attempts Immediate “OVERCRANK” indicator slowly flashing
6.4.16 Hardware Hardware fault Disabling Conditions for its activation Filter time Visual signal
Cannot be disabled. No block Detected hardware fault on generator voltage measurement. measurement. Immediate Message “F50“ on the display “MULTIFUNCTION” “MULTIFUNCTION”
6.4.17 Shutdown Failure Disabling Conditions for its activation Filter time Visual signal
From revision 00.00.40 by setting bit 4 of P79 to 0 Shutdown cycle in progress Engine still running after the time limit set through the parameter P09 Immediate Message “F21” on the display “MULTIFUNCTION” “MULTIFUNCTION”
6.4.18 Energy Inversion Disabling Conditions for its activation
Filter time Visual signal
Parameter P52 = 0 and/or Parameter P53 = 0 No block Board configured for power measurement measurement Active power with negative sign and and over the P52 threshold for the P53 time Immediate Message “F11“ on the display “MULTIFUNCTION”
6.4.19 Inhibition of the generator set Use Disabling Conditions for its activation Filter time Visual signal
Cannot be disabled Inhibition activated by serial line or SMS Immediate Message “F12“ on the display “MULTIFUNCTION” “MULTIFUNCTION”
6.4.20 Engine not in thresholds when KG closed Disabling Conditions for its activation
Filter time Visual signal
Cannot be disabled No block Engine running Fuel solenoid activated Shutdown cycle not in progress KG closed “Engine in threshold” input not active for at least 0.5 sec. Immediate Message “F40“ “F40“ on the display display “MULTIFUNCTION” “MULTIFUNCTION”
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7. Operating Sequence 7.1
Definitions
7.1.1 Mains Voltages Status Parameters for the mains management: •
P01: intervention threshold for minimum mains voltage (V)
•
P02: Hysteresis (%)
•
P04: generator generator set intervention delay for mains v oltage failure (s)
•
P05: Mains restoration delay (closing mains contactor from mains present) (s)
•
P15: intervention threshold for maximum mains voltage (V)
Three thresholds are defined in the mains voltage management: •
“Aliv e” mains threshold: threshold: P01 + (((P01 * P02) /100) / 2)
•
“Dead” mains threshold: P01 – (((P01 * P02) / 100) / 2)
•
“OVERVOLTAGE” threshold: P15
Mains is considered “alive” if the voltage on all the existing phases is over of the “alive” mains threshold. It is considered considered “dead” if the voltage on at least one phase is under the “dead” mains threshold. If no phase is under the “dead” mains threshold but at least one of them is under the “alive” mains threshold, the mains keeps the dead/alive status it previously had (hysteresis). If the voltage on at least one phase is over the “OVERVOLTAGE” threshold, threshold, the mains is considered “alive out of window”. Of course the parameter P15 must be over the “alive” mains threshold. In addition, there is the digital input “MAINS SIMULATION” (terminal 24). When such input is enabled, the board wait for time T2 is elapsed before mains is considered “present”. Furthermore, if the board is set to work with an external mains sensor (using only the “MAINS SIMULATION” input and ignoring the mains voltages), when the input “MAINS SIMULATION” is not enabled the mains is immediately considered “absent”. Depending on the SW versions, the delay times related to this input are different. •
Starting from SW version 08.00.22 the parameters P66 and P67 are used to set the Generator set intervention and shutdown on “MAIN SIMULATION” deactivation and activation
•
Starting from SW version 08.00.09 to SW revision 08.00.21 the same parameters used for the delay of the mains control are used (P.04 and P05).
•
Before 08.00.09 version there were no delay time related to this function.
4 status are defined in the mains management: •
Absent:
“dead” or “alive out of window” from a period of time over or equal to T1 (“MAINS LIVE” indicator t urned off)
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Restoring: Restoring:
“alive in window” from a period period of time under T2 (“MAINS (“MAINS LIVE” indicator flashing)
•
Present:
“alive in window” from a period of time over or equal to T2 (“MAINS LIVE” indicator turned on)
•
Outgoing:
“dead” or “alive “alive out of window” window” from a period period of time under under T1 (“MAINS LIVE” indicator flashing)
The T1 and T2 times change according to the position of the key selector and if the engine is running or dead: SELECTOR
ENGINE
T1
T2
AUTO-TEST
Dead
P04
P05
MAN-PROG-OFF
Dead
P04
0s
AUTO-TEST
Running (operatin (operating g speed) 2 s
P05
2
Running (operating speed) 2 s
0s
MAN
1
As you can see, the transitional mains failure is cancelled (2 seconds) with the engine running. In such conditions, as soon as a mains failure occurs, if the selector is on AUTO the users are switched on the generator. In the same way, the transitional mains restoring is cancelled (0 seconds) only if the selector is in OFF-PROG-MAN, to avoid the engine starting or the users’ switching on the generator set if going back to AUTO during the mains restoring.
7.1.2 Generator’s Voltages Status Parameters used in the generator management: •
P02: hysteresis (%)
•
P03: recognition threshold for generator’s generator’s voltage presence (V)
•
P11: protection threshold for minimum generator’s frequency (Hz)
•
P12: protection threshold for maximum generator’s frequency frequency (Hz)
•
P13: protection threshold for minimum generator’s voltage (Hz)
•
P14: protection threshold for maximum generator’s voltage (Hz)
Six thresholds are defined in the generator management: management: •
“Alive” generator threshold: P03 + (((P03 * P02) / 100) / 2)
•
“Dead” generator threshold: P03 – (((P03 * P02) / 100) / 2)
•
“UNDERFREQUENCY” threshold: P11
•
“OVERFREQUENCY” threshold: P12
1
Unusual case: in AUTO mode the engine is dead during the transitional mains restoration only in the event of starting failure.
2
With selector on OFF-PROG the engine is not running.
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“UNDERVOLTAGE” threshold: P13
•
“OVERVOLTAGE” threshold: P14
The generator is considered “alive” if the voltage on all the existing phases is over the “alive” generator threshold. It is considered “dead” if the voltage on at least one of the phases is under the “dead” generator threshold. If no phase is under the “dead” generator threshold but at least one phase is under the “alive” generator threshold, the generator keeps the previous dead/alive status (hysteresis). If the voltage on at least one of the phases is over the “OVERVOLTAGE” threshold, the generator is considered “alive out of window”. Of course, the parameter P14 must be set in order to be over the “alive” mains threshold. If the voltage on at least one of the phases is under the “UNDERVOLTAGE” threshold, the generator is considered “alive out of window”. Of course, the P13 parameter must be set in order to be over the “alive” mains threshold and over the parameter P14. If the generator’s frequency is over the “OVERFREQUENCY” threshold, the generator is considered “alive out of window”. If the generator is alive but its frequency is under the “UNDERFREQUENCY” threshold, the generator is considered “alive out of window”. Of course, the parameter P11 must be under the parameter P12. 4 status are defined in the generator management: •
Absent:
“dead” or “alive out of window” from a period of time over or equal to T1
•
Restoring:
“alive in window” from a period of time under T2
•
Present:
“alive in window” from a period of time over or equal to T2
•
Outgoing:
“dead” or “alive out of window” from a period of time under T1 3
T1 is a fix time of 2 seconds . T2 is a fix time of 0.5 seconds.
7.1.3 Engine Status 7.1.3.1
Definition of Engine Runn ing The engine is defined as “running” if at least one of the following requirements is met:
7.1.3.2
•
Generator’s frequency over the threshold specified through the parameter P42 (only if enabled with bit 6 of the parameter P49)
•
Voltage on all the generator’s phases less than 80 V (not configurable). Starting from version 08.00.23, is used the value of P03 (the default value is c hanged to 80V).
•
Voltage at the D+WL input (terminals 39..40) over the threshold (10 or 20 V according to the nominal voltage of the battery), only if enabled with bit 4 of the parameter P39.
Definitio n of Dead Eng ine The engine is defined as “dead” if all the following requirements are met for at least five seconds:
3
On the DST4600A board this time act only if the generator set contactor is open. If it is closed, wait until the alarms management starts the F01.F04 alarm and then execute the emergency stop cycle.
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7.1. 7.1.3. 3.3 3
•
Generator’s frequency under the threshold specified by the parameter P43 (only if enabled with bit 6 of the parameter P49)
•
Voltage on at least one generator’s phases less than 80 V (not configurable). Starting from version 08.00.23, is used the value of P03 (the default value is changed to 80V).
•
Voltage at the D+WL input (terminals 39..40) under the threshold (3 or 6 V according to the nominal voltage of the battery), only if enabled with bit 4 of the parameter P39.
Starting Request It is a series of many conditions. The most important one is the absence of any block or deactivation. The remaining conditions conditions depend on the key selector status: MAN a) “START” button pressed. AUTO a) Mains status “Absent” “Absent” (and no “MAINS “MAINS SIMULATION”) SIMULATION”) b) “REMOTE TEST” digital input (terminal 46) enabled c)
Periodical Test (if configured configured through through the parameters parameters P18 and and P19)
d) Starting command from RS232 serial line TEST a)
No condition condition (must always start start the engine in TEST TEST mode) mode)
OFF and PROG a) No condition (must never start the engine in TEST mode)
7.1. 7.1.3. 3.4 4
Stop Requests The immediate stop request is given by at least one of the following conditions: a) STOP button b) Presence of any block. c) Selector on OFF or on PROG d) Request from serial line or SMS.
The request of stop with cooling cycle is given by at least one of the t he following conditions: conditions: a) Selector on AUTO and no starting request b) Selector on AUTO or TEST and presence of of a deactivation deactivation
7.2
Shutdown System The control board can be set to work with engines equipped with an excitation shutdown system (usually electromagnet with control on the engine stop lever or electro-valve interrupting interrupting the fuel supply), or dropout shutdown ones ones (standard versions - usually N.C. fuel supply electro-valve or elect ro-magnet unlocking the engine stopping condition). In the first case (EXCITATION SHUTDOWN), the stopping control “STOP SOLENOID” (terminal 18) is activated for the time set with the parameter P09. If the VOLVO engine EDC
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EAAM002010I.doc function is enabled (bit 3 of P.61) is enabled, the “STOP SOLENOID” is driven for a fixed time of 2 seconds. The command is activated at the beginning of of the shutdown phase, phase, stays active for all the set duration and is disabled at the end of the same period. In the second case (DROP-OUT SHUTDOWN), the stopping command takes the meaning of permission to the engine’s running, “FUEL SOLENOID” (terminal 22) is activated with the engine starting command and stays active until the beginning of the stopping command.
7.3
Sequence in “MAN” mode In the MANUAL mode the board DST4600A can receive the engine start/shutdown commands and those for the power changeover from the buttons located on the front panel.
7.3.1 Entering the MANUAL mode When the selector is brought to MANUAL the following operations are executed: •
Keeping of the contactors status. From revision 00.00.39, it is possible to configure the board for switch to mains (bit 2 of P79 parameter).
•
If the engine is being started it is stopped.
•
If a STOP cycle is in progress it is completed.
•
If the engine is cooling, such phase is cancelled and the engine is kept running.
•
The engine is kept running (if it was already running).
7.3.2 Engine Starting To start the generator set in the MANUAL mode press the START button and keep it pressed until the engine is running. The START button is not accepted in presence of deactivation and/or blocks. As a response to this command the board execute the following operations: 1.
It enables the “FUEL SOLENOID” output (terminal (terminal 22). Such output output is automatically removed during the stop cycles or if for 20 seconds the engine is dead.
2.
It disables the “STOP SOLENOID” SOLENOID” output (terminal (terminal 18) (it should should already disabled disabled except if the starting request occurs during a stop cycle), used for the dropout shutdown. shutdown. If engine is already running, the procedure stops here.
3.
If the preheat function for diesel diesel engines is enabled, enabled, it activates the “AUX OUTPUT 1” (terminal15) for the time set with the parameter P20 (if such time is equal to 0 the preheat function is disabled). In this phase the display “MULTIFUNCTION” shows the message “PRE”. At the end of this phase it disable the output and passes to the phase 4 (until SW version 08.00.11 the output “FUEL SOLENOID” were activated only at the end of this phase).
4.
It enables the “START” output (terminal 20) 20) controlling the generator generator set starter. The output is kept enabled until the release of the “START” button or until the engine running recognition. recognition. In this phase the display “MULTIFUNCTION” “MULTIFUNCTION” shows the message “STA”.
For the MANUAL mode no start failure signal is foreseen. The activation sequence is always: “FUEL SOLENOID” (terminal 22), “AUX OUTPUT 1” (PREHEAT OUTPUT) (terminal 15) and then “START” (terminal 20). Thus, it is possible to use this feature to drive an auxiliary output that requires to be activated before the actual start command (use parameter P38 to configure the delay time).
7.3.3 Engine Shutdown To stop the engine in the MANUAL mode press the STOP button. Unlike for the DST4600, it is not necessary to keep the STOP button pressed until the shutdown has taken place:
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EAAM002010I.doc simply press it for a second and the board execute a complete shutdown cycle. That is, it disables the “FUEL SOLENOID” output and it enables the “STOP SOLENOID” one (terminal 18) for the time set with the parameter P09 (if it is enabled the VOLVO engine EDC this time is fixed and of 2 seconds). The MANUAL mode doesn’t foresee any shutdown failure block, except for the automatic shutdown cycles following blocks or deactivation.
7.3.4 Power Change-over Normally, with the board in the MANUAL mode the users are switched on the mains. Only if the engine is running, if the generator is “present” and the delay before the supply has passed - P06 (or if the temperature exceeds the minimum threshold set with P55), the operator has the opportunity to switch them on the generator. To do that, press at the same time “MODE / ACK” and “F1” for one second (such combination is highlighted on the front panel of the board with the indication “MANUAL CHANGE-OVER”. This command works as “toggle”, that is, if the operator gives again the order the users are again switched on the mains. When the users are switched on the generator set, they are automatically switched on the mains if the generator gets “absent” or in presence of deactivations and/or blocks.
7.4
Sequence in “AUTO” mode The control sequence of the generator set in the AUTOMATIC mode develops as follows: 1.
Start requests wait (typically mains failure)
2.
Generator set starting attempts
3.
Generator presence wait
4.
Delay before supply the power
5.
Switching users on the generator
6.
No start requests wait
7.
Users’ switching on the mains
8.
Engine cooling cycle
9.
Engine shutdown cycle.
7.4.1 Start Requests Wait In this phase the engine is dead. The board waits until the mains get “absent” or for at least one of the other start requests (see par.7.1.1).
7.4.2 Engine Starting Attempts. The board tries to start automatically the engine. The number of starting attempts to execute can be programmed through the parameter P10. If, after those attempts, the engine doesn’t start, the start failure block is activated (“OVERCRANK”). Furthermore, the duration of the starting impulse can be set (parameter P08) as well as the delay between two attempts (parameter P38). For each attempt the following operation are executed: 1.
The “FUEL SOLENOID” SOLENOID” output (terminal (terminal 22) is enabled. enabled. Such output output is automatically removed during shutdown cycles or when the engine is dead for 20 seconds.
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The “STOP SOLENOID” output (terminal 18), used for the excitation shutdown, is disabled (it should already be disabled unless the starting request occurs during a stop cycle). If the engine is already running, the procedure stops here.
3.
If the preheat function for diesel engines is enabled the “AUX OUTPUT 1” (terminal 15) is enabled for the time set with the parameter P20 (if such time is equal to 0 the preheat function is disabled). In this phase the display “MULTIFUNCTION” shows the message “PRE”. At the end of this phase the output is disabled passing to phase 2.
4.
The “START” output (terminal 20) controlling the generator set starter, is enabled. The output is kept for the time set with the parameter P08 or until the engine running recognition. In this phase the display “MULTIFUNCTION” shows the message “STA”. If the engine gets started phase 6 will follow, otherwise phase 5 will follow (unless the starting attempts have ended,
5.
The “START” output is disabled and there’s a wait for with the duration set with the parameter P38 During this phase the preheat function for diesel engines is enabled, as well as the “AUX OUTPUT 1” (terminal15) and the display “MULTIFUNCTION” shows the message “PRE”.
6.
Engine running.
The activation sequence is always: “FUEL SOLENOID” (terminal 22), “AUX OUTPUT 1” (PREHEAT OUTPUT) (terminal 15) and then “START” (terminal 20). Thus, it is possible to use this feature to drive an auxiliary output that requires to be activated before the actual start command (use parameter P38 to configure the delay time). Starting from SW version 08.00.12, the activation sequence is always: “FUEL SOLENOID” (terminal 22), “AUX OUTPUT 1” (PREHEAT OUTPUT) (terminal 15) and then “START” (terminal 20). Thus, it is possible to use this feature to drive an auxiliary output that requires to be activated before the actual start command (use parameter P38 to configure the delay time). This sequence is valid also in manual mode. Starting from SW version 08.00.38, the activation sequence is subjected to the engine stopped or the shut down cycle completed conditions.
7.4.3 Generator Waiting In this phase there’s a wait until the generator reaches the operating speed, that is, when the voltages on all the phases and the frequency are within the programmed thresholds (see par. 7.1.2). If this doesn’t take place within the time set with the parameter P32, the block “operating speed not reached” (F08) is activated and the engine will be stopped. In this phase, if the voltage or the frequency exceeds the maximum thresholds, the corresponding blocks are activated (F02 and F04).
7.4.4 Delay before supply the power This phase is just a wait to allow the lubrication and the heating of the generator set before connecting it to the users. The following phase takes place as soon as one of the following requirements is met: § §
After the time set with the parameter P06 has passed since the generator is in window. If the temperature analogue sensor exists, if a minimum threshold for the supply permission has been set (P55 different from 0) and if the temperature is over such threshold.
In this phase the blocks and deactivations F01, F02, F03 and F04 are enabled, while the block F08 is disabled.
7.4.5 Switching users on the Generator In sequential order there are: •
Opening of mains contactor (closed contact at terminals 60-61)
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Change-over wait (set through parameter P22)
•
Closing of generator set contactor (closed contact at terminals 57-58)
Please, consider that the status of each contactor cannot be inverted from the prior command before the time set through the parameter P41 is elapsed from the last command.
7.4.6 No start requests wait The boards waits until the mains gets “present” and all the other start requests get off (see par.7.1.1). Further, the arising of new faults of the generator set is checked.
7.4.7 Switching users to Mains In sequential order there are: •
Opening of the generator set contactor (closed contact at terminals 58-59)
•
Change-over wait (set through parameter P22)
•
Closing of mains contactor (closed contact at terminals 61-62)
Please, consider that the status of each contactor cannot be inverted from the prior command before the time set through the parameter P41 is lapsed from the last command.
7.4.8 Engine Cooling Cycle The engine is kept running after the users’ switching on the mains for a time programmable through the parameter P07. The reason is that the engine cools more quickly by running without supplying then shutting it down.
7.4.9 Engine Shutdown Cycle The shutdown cycle is the following: •
“FUEL SOLENOID” output (terminal 22) disabled
•
“STOP SOLENOID” output (terminal 18) enabled
•
Wait set through parameter P09
•
“STOP SOLENOID” output (terminal 18) disabled. If the VOLVO engine EDC function is enabled (bit 3 of P61), the solenoid is driven only for two seconds but the board waits in any case until P09 is elapsed.
At the end of the cycle, if the engine is still running, the shutdown failure block (“F21”) is activated (anyway the STOP SOLENOID output will not be enabled). Up to revision 08.00.38, the automatic shut down cycle could be aborted if a new start request arises. In some situations, this caused a false F01 or F03 blocks. So, from revision 08.00.39 a new start request can be processed only when the engine is stopped or when the shutdown cycle is terminated.
7.5
Sequence in “TEST” mode The sequence in the TEST mode is fundamentally the same of that in the AUTOMATIC mode, with the following differences: •
The engine is started in any case, independently from the start requests.
•
The users’ switching normally is executed only in case of mains failure. The operator can force it with the same procedure used in the MANUAL mode.
•
The engine is never stopped automatically, except for blocks and/or deactivations.
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EAAM002010I.doc Therefore, the TEST mode can be used to test accurately the generator set without disconnecting the users from the mains, but at the same time assuring the users’ power supply from the generator set in case of mains failure.
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8. Power Measurement The board is able (optionally) to execute the true r.m.s measurements on the generator’ voltages and currents as well as the active, reactive, apparent power and power factor measurements of the system when it is powered by the generator. In addition, it manages an energy meter for the power supplied by the generator set. If the option is present, the generator voltages’ and currents’ true r.m.s. are displayed in the place of the corresponding values measured in the standard version, that is on the displays “V” and “A”. To view the powers press at the same time “MODE / ACK” and “F2” (this combination is highlighted on the front panel of the board with the indication “MODE + F2”: POWER DISPLAY”). In this conditions the “ L1/L2”, “L2/L3” “L3/L1” are all of them turned on and the display “V” shows the power factor, while the display “A” shows the active power. Further, if through the buttons “F1” and “F2” you choose the “MAINS VOLTAGE (Vac) / REACTIVE POWER (kvar)” function, the display “MULTIFUNCTION” shows the reactive power, if you choose the “BATTERY VOLTAGE (V) / APPARENT POWER (kVA)” function, it shows the apparent power. By pressing again the buttons “F2” and “MODE / ACK” at the same time, you’ll go back to the indications of the generator and mains voltages and of the generator current.
8.1
Power Factor The value indicated by the display “V” is the system’s total power factor. It cannot be viewed for each single phase. It is displayed with two decimals. The eventual negative sign associated to this quantity indicates the energy inversion status. This status also refers to the whole system: if one of the phases was in energy inversion, probably it wouldn’t be indicated since globally the system would still supply (NB: actually, it never occurs: if there’s an energy inversion, it is present on all the phases). Further, through the power factor some information on the type of load, inductive or capacitive is given to the operator. This information is provided using the decimal point of the least significant digit of the power factor: when is turned on the load is a capacitive one. In the place of the power factor are displayed three dashes when its value makes no sense, that is in the absence of any current (dead engine or frequency not in window). Furthermore, if the total active power is too low (under 10% of the system’s maximum power), the power factor is forced to one, since its measurement for low current value gets too imprecise.
8.2
Active Power The active power (the system’s total one) is displayed in kW on the display “A” (message “ACTIVE POWER (kW) over the display. If less than 100 kW is displayed with a decimal, if over 1000 kW is displayed in tens of kW, with the indicator “X10” turned on. It is always displayed in module: its sign (that would provide the true information of energy inversion) is associated to the power factor for display problems: if it was displayed associated to the active power one resolution digit would be lost, while by displaying it associated to the power factor it replaces the initial zero (actually the power factor is never 1.00 but always 0.xx). This introduces only a small rounding of the power factor: if it was 1.00 in energy inversion, instead of –1.00 it was displayed as – .99.
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8.3
Reactive Power The reactive power (the system’s total one) is displayed in kvar on the display “MULTIFUNCTION” if the “MAINS VOLTAGE (Vac) / REACTIVE POWER (kvar)” function is selected. If under 100 kvar it is displayed with a decimal, if over 1000 kvar it is displayed in tens of kvar, by turning on the decimal point of the less significant digit to indicate that the value has to be multiplied by 10. It is displayed with its sign, replacing the most significant digit.
8.4
Apparent Power The apparent power (the system’s total one) is displayed in kVA on the display “MULTIFUNCTION”, if the function “BATTERY VOLTAGE (V) / APPARENT POWER (kVA)” is selected. If less than 100 kVA it is displayed with a decimal, if over 1000 kVA it is displayed in tens of kVA, by turning on the indicator “X10”. It is, by definition, always positive, therefore there’s no problem for the display of its sign.
8.5
Energy Meter The energy meter managed by DST4600A counts the energy supplied by the generator set. It has an internal resolution under 100 Wh but it is displayed in kWh. It is updated every second. It is displayed alternatively to the powers by pressing “MODE / ACK” (this procedure is indicated on the front panel of the board with the indication “POWER DISPLAY + MODE: ACTIVE ENERGY”). It uses the displays as follows: §
Display “A”: kWh (indicated by “ACTIVE ENERGY (kWh)”)
§
Display “V”: MWh (indicated by “ACTIVE ENERGY (MWh)”)
§
Display “MULTIFUNCTION”: GWh (indicated by “ACTIVE ENERGY (GWh)”, only two digits, the third one is fix “E”)
If the energy counter exceeds 8 digits (100 GWh), it is saturated to 99.999.999 but is displayed with the decimal point of the less significant digit turned on, to indicate the saturation condition. The energy counter can be reset. The reset procedure is the following one: Ø
By pressing the “F1” and “F2” select the “DATA – HOURS COUNT / START COUNTER” function
Ø
Switch the key selector to OFF_RESET.
Ø
Press at the same time “MODE / ACK” and “START” for 5 seconds. After 5 seconds the counters will be reset. The display does not indicate the reset in any way; therefore the operator has to count the 5 seconds.
The procedure is similar to the other counter reset procedure. The only difference is in the used pushbutton: “START” instead of “STOP”. Until the SW version 08.00.11 the energy meter counter were cleared only together with the hour-counter and with the start-counter.
8.6
Connection caution Be sure that all the TA share the same phase connected to ground and check for the correct phase connection. Otherwise the power measures will be wrong and it’ll possible that the board will issue a reverse power alarm. As a rule, connect terminal 50, 52 and 54 to ground and check that all the TA has the same phase connected to the ground. Then, if the measured power factor is negative, reverse all the TA connection.
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9. Serial Communication The board DST4600A has a serial connector, which can be used to dialog with the board to get all the parameters, the status and the quantities to give the commands.
9.1
Hardware Connections
9.1.1 Direct Connection to a PC To connect a PC or any other equipment to the board DST4600A with a direct serial connection (RS-232) use a 3-wires crossover cable (crossing the TX and RX wires of the two serial ports and joining the grounds). For SW version until 08.00.17: set the parameter P37 (serial address) to 0. In this way you indicate to DST4600A that it doesn’t have to manage an RS-485 external line. For SW version starting from 08.00.18: set a value equal or greater than 10 for P51 to indicate to DST4600A that it doesn’t have to manage an external modem.
9.1.2
Connection to an analogue modem To connect an analogue MODEM to the board DST4600A use a ”one-to-one” cable with 9 wires. Such cable is normally supplied with the modem. For SW version until 08.00.17: set the parameter P37 (serial address) to 0. In this way you indicate to DST4600A that it doesn’t have to manage an RS-485 external line. For SW version starting from 08.00.18: set a value equal or less than 10 for P51 to indicate to DST4600A that it has to manage an external modem.
9.1.3 Connection to a GSM modem To connect a GSM MODEM to the board DST4600A use a ”one-to-one” cable with 9 wires. Such cable is normally supplied with the modem. Connect the antenna to the modem and power it. To power the modem use an additional SICES card to assure a power supply within the limits allowed to the modem and allowing the DST4600A to turn on and off the modem when needed. The additional board has three terminals: two of them have to be connected to the starting battery of the generator set, while the third one to the terminal 36 of the DST4600A (OUTPUT 2). On that terminal there is the turn on/turn off command given by the DST4600A. For SW version until 08.00.17: set the parameter P37 (serial address) to 0. In this way you indicate to DST4600A that it doesn’t have to manage an RS-485 external line. For SW version starting from 08.00.18: set a value less than 10 for P51 to indicate to DST4600A that it has to manage an external modem. Further, set the parameter P37 (serial address) to 0. In this way you indicate to DST4600A that it doesn’t have to manage a communication on a RS-485 network. On the contrary, it is not necessary to indicate expressly that a modem connection is being used: DST4600A automatically execute a self-recognition of what is connected to the serial connector. If the DST4600A recognize the GSM modem, besides the communication protocols that can be used with the other connections, it can use a communication protocol based on SMS (Short Messages). See the special manual (document EAAS0015 revision 01 or following) for the description of the SMS-based communication protocol. Furthermore, the DST4600A provides through the front panel an indication on the quality of the GSM network signal. To get this information switch the key selector on “PROG” and view the parameter P51. The following indicators inform about the signal quality:
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Indicator
Signal Quality
FUEL LEVEL (%)
1st mark GSM signal
TEMPERATURE (°C)
2nd mark GSM signal
OIL PRESSURE (BAR)
3rd mark GSM signal
BATTERY VOLTAGE (V) / APPARENT POWER (kVA)
4th mark GSM signal
9.1.4 Connection to a RS-485 network To connect the board DST4600A to a RS-485 network use an external RS232 converter (supplied by SICES).
ßà RS485
For SW version until 08.00.17: set the parameter P37 (serial address) to a value greater than 0. In this way you indicate to DST4600A that it has to manage an RS-485 external line. For SW version starting from 08.00.18: set a value equal or greater than 10 for P51 to indicate to DST4600A that it doesn’t have to manage an external modem.
9.2
Software Protocols Using the parameter P51 you can configure the DST4600A to use one of the protocols described in this paragraph for the serial communications, with no regard to the type of hardware connection.
9.2.1 DST4600 Protocol It’s a SICES proprietary protocol, very simple and with a MASTER-SLAVE hierarchy. The DST4600A is always the SLAVE of the communication. See the corresponding manual (document EAAS0006 version 01 or following ones) for the protocol documentation. Starting from the 0.05 revision of the DST4600A software, with this protocol it is possible to inhibit the use of the generator set. When the use of the generator set is inhibited the board stops with the “F12” block activated.
9.2.2 MODBUS – RTU Protocol It’s a well-known industrial protocol. The DST4600A implements only the SLAVE version of this protocol. Until version 0.09 it is not available, ask SICES for actual availability of MODBUS protocol.
9.2.3 SMS Protocol See the special manual (document EAAS0015 revision 01 or following ones) for the description of the SMS-based communication protocol. With the 0.05 revision of the DST4600A software, with this protocol it is possible to inhibit the use of the generator set. When the use of the generator set is inhibited the board stops with the “F12” block activated.
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10. Auxiliary Functions 10.1 Automatic recovery from KR close failure Starting from 08.00.24 version, it is possible to avoid black-out due to KR failure. In case of such failure the user power line remains unsupplied if the grid is present. Using this function is possible to guarantee power availability at user level. To use this function the system must be configured as following: •
Connect to “INPUT C” (terminal 12) a signal from KR that will be close to GROUND when KR is close.
•
Enable KR status monitoring at level board setting to 1 bit 1 of P61.
•
Enable F13 alarm (warning) setting a value greater than 0 for P75.
•
Enable the automatic recovery function setting to 1 bit 5 of P61.
•
Set AUTO or TEST mode.
Working with this configuration, if the board doesn’t acknowledge KR closed, after P75 time, issues a “F13” alarm. If bit 5 of P61 is set, the board interrupts cooling down sequence or, if engine is not running, starts the engine and make the Generator set supplying users. At this point the board doesn’t connect the load to the mains (even if it’s acknowledged) until operator performs an appropriate action: •
Up to software release 08.00.24, this operation consists in pressing the key “MODE/ACK” one time.
•
Up to software release 08.00.25 this operation consists in pressing the key “MODE/ACK” twice (the first pressure to switch off the horrn).
•
From software release 08.00.26 this operation consists in setting the MAN mode, manually make the mains supplying users and then set the AUTO mode again.
After these operations, if the board doesn’t acknowledge KR closed, the alarm “F13” is issued again and the procedure is repeated. Starting from SW release 08.00.35, the function has been modified in order to inhibit the engine start (caused by this alarm) if the input “MAINS SIMULATION” (terminal 24) is active and if the board is configured to use the internal mains sensor. If this case, in fact, the “MAINS SIMULATION” is used as “inhibition for automatic intervention“: thus, even this automatic intervention have to be inhibited. If the board doesn’t measures the mains, this input is used as an external mains sensor and so it cannot inhibit this automatic intervention (because it is in case of mains presence that the alarm F13 causes the engine to start). Starting from revision 08.00.38, this block may be masked if mains is not present, by using bit 1 of parameter P79. This mask is useful in plants where the mains breaker is powered by the mains itself. In this situation, when the mains become unavailable, the board immediately acquires the breaker open status. The board needs a lot of seconds in order to start the engine and to close the load on the genset, and so the condition of breaker open while the command is for closure remains for a lot of time. This condition causes the alarm “F13” to be raised. But if the alarm is masked when mains is not present, this false alarm is not raised.
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10.2 Automatic Periodical Test Please see par. 10.7.4
10.3 Fuel Pump You can set the board to control a fuel pump for the automatic filling of the tank. The function can be used only if the fuel level analogue sensor exists. You have to set the two operating threshold: •
P29: fuel level threshold under which the pump is started.
•
P30: fuel level threshold over which the pump is stopped.
The function is enabled if the parameters P29, P30 and P48 are all different from 0 and P29 is lower than P30
10.4 Remote Test With the board in AUTOMATIC mode you can force the generator set start using the “REMOTE TEST” digital input (terminal 46). Until the input stays enabled, the generator set is on (except for deactivations and/or blocks). If in this phase it occurs a mains failure, the users are switched on the generator.
10.5 Remote Signals The following remote signals can be sent: •
“ENGINE RUNNING” (terminal 25): this output is enabled when the engine is running.
•
“GENERAL ALARM” (terminal 26): this output is enabled if at least one alarm is present.
•
“TRIP ALARM” (terminal 27): this output is enabled if at least a deactivation or a block is present.
•
“FUEL ALARM” (terminal 28): this output is enabled if at least one fuel failure is present:
•
-
Minimum fuel level alarm
-
Maximum fuel level alarm
-
Fuel end block
“ENGINE ALARM” (terminal 29): this output is enabled if at least one fault in the engine is present: -
High water temperature alarm
-
Low oil pressure alarm
-
Low battery voltage alarm
-
Shutdown failure alarm
-
Aux. Alarm (“F10”) – starting from SW 08.00.12
-
High water temperature block
-
Low oil pressure block
-
Start failure block
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•
•
-
Non-masked auxiliary block (ALARM1)
-
Masked auxiliary block (ALARM2)
-
Emergency stop
-
Belt break
-
Shutdown failure block (“F21”)
“SPEED ALARM” (terminal 30): this output is enabled if at least one fault relating to the engine’s speed is present: -
High engine speed block (“OVERSPEED”)
-
High generator frequency block (“F04, OVERFREQUENCY”)
-
Low generator frequency deactivation (“F03, UNDERFREQUENCY”)
-
Energy inversion block (“F12”)
“GENERATOR ALARM” (terminal 31): this output is enabled if at least one fault regarding the generator is present: -
Current overload block (“F06, OVERCURRENT”)
-
Contact overload block (“OVERLOAD”)
-
High generator voltage block (“F02, OVERVOLTAGE”)
-
Low generator voltage deactivation (“F01, UNDERVOLTAGE”)
-
Max power warning (“F49, MAX POWER”)
•
“OFF-PROG-MAN” (terminal 32): this output is enabled only if the key selector is on AUTO or on TEST
•
“OFF SELECTION” (terminal 33): this output is enabled only if the key selector is on MAN, AUTO or TEST
Further, you can send the remote signals of the single blocks, deactivations and alarms through the serial interface with the RS 232C device. From the software release 08.00.25 is it possible to order as option the second serial port of DST4600A board. It is then possible to connect to this serial port one expansion board provided with 32 digital outputs or 16 outputs and 16 inputs. The outputs can be used as additional remote signals. See document EAAN0022, release 03 or successive.
10.6 LOW POWER or MAX POWER signaling By using parameters from P56 to P59, it is possible to configure the board for taking some actions related to the active power of the system. These parameters configure two power thresholds and the related filter time. Outside the zone defined by the thresholds (P56 and P58), the board takes some actions. Till to the revision EB02200080036 it could only signal the low power status. From the revision EB02200080037, it can alternatively signal the maximum power status. This function is disabled in the following situations (whatever is the action selected): •
P56 = 0
•
P58 = 0
•
P56 >= P58
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EAAM002010I.doc To select an action, you have to operate with the bit 7 of parameter P61. If not set, the board will signal the low power status, if set the board will signal the maximum power status. This is true from revision EB02200080037, for the previous revisions the only action was the low power signaling. The signal is performed by a digital output (“OUTPUT 1”, terminal 37). The next two paragraphs describe the available actions in details.
10.6.1 Low load status signal. It is possible to use this feature to stop/start one or more external generator connected in parallel. To use this function the following condition shall be met: •
The board must be configured for POWER MEASURAMENT
•
Input “INPUT A” (terminal 14) must be configured to acquire the KG actual status (bit 1 parameter P61=1).
•
“INPUT A” must be acquire the KG actual status
•
Parameters P56 and P58 must have values greater than 0 and P58 must be greater than P56.
•
Bit 7 of parameter P61 must be set to 0 from revision EB02200080037).
This function uses also the parameter P60, in addition to those described in the previous paragraph. Operational procedure: 1.
Generator set not supplying: “OUTPUT 1” is not activated (floating, open circuit). On “INPUT A” (KG status) activation (ground shorted) becomes step 2.
2.
Until P60 time is elapsed, “OUTPUT 1” is still not activated. During P60 time, on “INPUT A” deactivation the procedure returns toward step 1, otherwise, at the end, switches to step 3.
3.
“OUTPUT 1” is driven based on the measured active power: a)
Supplied active power less than P56 threshold throughout P57 time: “OUTPUT 1” is activated.
b)
Supplied active power greater than P58 threshold throughout P59 time: “OUTPUT 1” is deactivated.
c)
If the supplied power value is in the range between P56 and P58 values, “OUTPUT 1” status is not changed from the actual status.
If “INPUT A” is deactivated (KG open) the procedure switches to step 1. NB: this function assumes that the loads are applied to the generators before the time specified by parameter P60 is elapsed. If not, the board assumes to be in a low-load situation and then can deactivate other generators. When the loads will be applied, in the best situation the other generators will be restarted. In the worst situation this generator will be stopped for over-current.
10.6.2 Maximum power. This function is used to have a visible and acoustic signal of the maximum power status. It can be used also for automatically disconnect some of the less important loads from the generator, in order to continue to work in the normal conditions. If the active power is higher than P58 threshold consecutively for P59 time, the maximum power status is set and so the “OUTPUT 1” output and the “F49” warning are activated.
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EAAM002010I.doc If the active power is lower than P56 threshold consecutively for the P57 time, the maximum power status is reset and so the “OUTPUT 1” output and the “F49” warning are deactivated (the “F49” warning is still present on the DST4600A panel if not acknowledged). If the active power is between the P56 and P58 thresholds, the maximum power status and the “OUTPUT 1” output and the “F49” warning are not modified. The “OUTPUT 1” output can be connected to a circuit breaker for automatically disconnect the less important loads. If it is connected to a changeover circuit, the board automatically re-connect the less important loads when the active power back into its nominal range. Comparing the maximum power signal function to the low power signal function, there are the following differences: •
Parameter P60 is not used (and so the function is always enabled).
•
The genset breaker status is not used (and so is not necessary to connect it).
•
The “F49” warning is activated
•
The “OUTPUT 1” output is controlled in the opposite way than in low load function: it is activated if power is greater than P58, while in the low power function it is activated if the power is lower then P56.
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10.7 Real Time Clock option Starting from SW revision 08.00.24, it is possible to install in DST4600A boards a Real Time Clock option (RTC). The option is equipped by a lithium battery that let the watch running also without supply. The expected duration of the battery is quite 10 years. RTC has a full time/date management set of function (hours, minutes, seconds, day, month, year and day of the week). RTC let the board implements the following function: •
Permanent storing of events alongside date and time.
•
Automatic periodical test of generator set at preset time and days of the week.
•
Time Lock of Generator set operation at preset time and days of the week.
10.7.1 How to display Time and Date of RTC If the option is installed and in OFF/RESET mode, pressing STOP pushbutton the RTC display mode is entered. The displays will show hours: •
Display “F”:
hours (00-23)
•
Display “V”:
minutes (00-59)
•
Display “A”:
seconds (00-59)
Pressing “F1” or “F2” the mode will change to date: •
Display “F”:
day (01-31)
•
Display “V”:
month (01-12)
•
Display “A”:
year (00-99)
This mode is outlined by the light on of the dot at the least significant digit of the displays. Pressing again “F1” and “F2” the mode will revert to hour. Pressing STOP again the RTC display mode is exit. From SW release 08.00.35, the displays are blinking if the RTC date/time is not reliable (and so is required that the operator set the correct date/time).
10.7.2 Setting time and date Once in RTC display mode (see previous paragraph), pressing “MODE/ACK” the RTC setting mode is entered. Display “F” will show one of the following messages, while display “A” will show the proper value: •
“SEC”:
seconds (valid value 0 through 59)
•
“MIN”:
minutes (valid value 0 through 59)
•
“HOU”:
hours (valid value 0 through 23)
•
“DAT”:
day of month (valid value 1 through 31)
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“DAY”:
day of week (valid value 0 through 6, 0 is Sunday)
•
“MON”:
month (valid value 1 through 12)
•
“YEA”:
year (valid value 00 through 99)
Using “F1” and “F2” pushbuttons it is possible to select the variable to change. To change a value, work as in programming mode (press “MODE/ACK”, lamp L1/L2 will turn off, L2/L1 will turn on, modify using “F1” and “F2” and then press again “MODE/ACK” to exit change mode). The modified value needs to be explicitly stored. If you press “START” the modified value will be stored, pressing “STOP” the new values will be discarded. In both cases the RTC setting mode is exited. Remember to set the DAY OF WEEK value because it is required for a correct function of some features of RTC option.
10.7.3 Storing time/date into Data Record databases Please see par. 10.8.3
10.7.4 Automatic Periodical Test If your board is equipped by RTC option, it is possible to use two different modes to carry out the periodical test: one based on the RTC value and the other based on elapsed time (standard mode).
10.7.4.1
RTC based perio dic al test To activate this function it is required to: •
Set P73, configuring the time of begin of the test;
•
Set P74, configuring the day of the week when carry out the test (see par. 5.1.21)
•
Set P19, configuring the duration of the test.
If P74 is greater than zero (RTC periodical test enabled), the standard periodical test mode is disabled even if P18 is greater than zero.
10.7.4.2
Standard mo de perio dic al test You can periodically test the operation of the generator set by programming two parameters that allow activating the test sequence on the basis of elapsed time. In particular: •
The parameter P18 determines the cyclical starting period of the generator set.
•
The parameter P19 determines the duration of the test operation of the generator set.
If during the programming you change the value P18 the period count will restart from zero in the moment in which you’ll exit the PROGRAMMING procedure. The automatic periodical test is disabled if at least one of the two parameters is equal to zero or if RTC based periodical test is enabled. If RTC option is not installed it is possible to use only Standard mode periodical test procedure.
10.7.5 Generator set Time Lock function From 08.00.24 SW version and with RTC option installed it is possible to enable the function of the Generator set on time and day bases.
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EAAM002010I.doc This function let you prevent the start of the engine when emergency supply is not required; otherwise you can use this function to start and stop the Generator set at needed time. Three parameters are to be set to enable this function: •
P70: time at which the operation in AUTO mode is enabled;
•
P71: time at which the operation in AUTO mode is disabled;
•
P72: days of the week when the operation is to be enabled;
•
P61: bit 4 to enable this function.
It is possible to configure only one set of enable time and one set of enable days. If P70 is equal to P71 the Generator set will be enabled 24 hours at day but only during the days enabled by P72. When the system is in Time Lock, the display “V” and “A” together will show the message “DISABL”.
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10.8 Data record Starting from SW version 08.00.18 a data record collection function was added to DST4600A boards. SW version 08.00.24 completes the implementation of this function adding non-volatile storing and direct date and time stamp. These features are available only if you have installed the Real Time Clock option. This chapter describes this function.
10.8.1 Databases There are two main types of databases: event databases and analogue data databases. The first type of databases stores the information related to the events that may arise. They can be anomalies, status changes or operator commands or other. When such event arises, the DST4600A board stores the board status alongside the time at which the event occurs. The second type of database, stores the analogue data; they are normally stored on regular time rate. The databases can store a finite number of records, but they have a circular buffer structure: the oldest record is discarded and overwritten by the more recent record. The record index one is always assigned to the oldest record in memory The number of the implemented databases is four; three of them are of the analogue data type, the last one records the events. •
Fast analogue data: the time rate is programmable by the operator with a resolution of one second. The database can store 30 records. This database has the purpose to supply the trend near the event time point. By default, the time rate is 60 seconds, yielding a database time length of 30 minutes.
•
Slow analogue data: the time rate of this database is 30 times more slowly than the fast database. Actually, a new record is written when the fast analogue database is completely rewritten (thus every 30 fast records). It can stores 48 records and has the purpose to supply the slow trend over a greater time window than fast database. By default, it can store two days data.
•
Analogue data linked to event: this data database store analogue data every time that a new event is stored into the event database. The records are linked across the two databases by means time occurrence. It can store 15 records (16 if RTC option is installed).
•
Event: the database can store 15 records (96 if RTC option is installed).
10.8.2 Memory device If RTC option is installed, the databases are stored in non-volatile memory; otherwise they are stored into the DST4600A RAM. This kind of memory is volatile: disconnecting the board from the supply causes the lost of all the data. Please, note that turning the key lock in OFF/RESET let the board supplied and doesn’t cause alone the lost of the data. However, in case RTC option is installed, the data are not directly written in non volatile memory, but they at first written in RAM and transferred in EEPROM when: •
Once time a day (at 01.00);
•
When at least one of RAM databases becomes full;
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When databases are locked (see par. 10.8.6)
•
Moving the key lock in OFF/RESET position
If the board is to be disconnected from power supply, it is good practice to move the key lock switch toward OFF/RESET position before disconnect power supply from the board (battery voltage).
10.8.3 Time and date All time and date information are stored in a 32-bit word. The packaging of information inside the word depends on the availability of RTC option: •
RTC option non-installed: the board doesn’t know the current date and time. For this reason, in the database, it is not stored the absolute time but the time relative to the board power-up. The way this time is obtained let the board to continuously work up to 136 years before wraps the counter. It is possible, for a PC, to read the board relative time, compares it to the proper real time clock and calculates the absolute time of a record.
•
RTC option installed: full real date and time information are stored. It is thus possible store events until 31/12/2063 23:59:59.
10.8.4 Event database This database can gather all the events that may arise during the proper normal working. •
New anomalies
•
Changing in mains status
•
Changing in generator status
•
Changing in mains and generator changeovers status
•
Changing in engine status
•
Start/Stop commands
•
Key lock actions
•
Other
If RTC option is not installed, only event of TYPE 1 are stored, if RTC is installed both TYPE 1 and TYPE 2 events are stored. If event is of TYPE 2*, it is normally not stored, but can be stored if RTC option is present and by setting bit 6 of P61 (enable execution of data calls or SMS if mains is missing). If event is of TYPE 2#, it is normally not stored, but can be stored if RTC option is present and by setting bit 3 of P79 (enable execution of data calls or SMS if mains become present). Each type of event has an identifying code. Code
TYPE Description
1
2
Key lock toward OFF/RESET
2
2
Key lock toward PROG
3
2
Key lock toward MAN
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TYPE Description
4
2
Key lock toward AUTO
5
2
Key lock toward TEST
10
2*
Mains dead
11
2
Mains live, out of range
12
2#
Mains live, in range
13
2
“MAINS SIMULATION” activated
14
2*
“MAINS SIMULATION” deactivated
20
2
Generator dead
21
2
Generator live, out of range
22
2
Generator live, in range
30
2
Command to close the Generator set changeover
31
2
Command to open the Generator set changeover
32
2
Generator set changeover closed
33
2
Generator set changeover open
35
2
Command to close the grid changeover
36
2
Command to open the grid changeover
37
2
Grid changeover closed
38
2
Grid changeover open
40
1
Engine halt
41
2
Engine cranking
42
1
Engine start
43
2
Engine cooling down
44
2
Engine shutting down
50
2
Manual start command
51
2
Manual stop command
52
2
Automatic start command
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TYPE Description
53
2
Automatic stop command
54
2
REMOTE TEST start command
55
2
REMOTE TEST stop command
56
2
Start command by means serial communication
57
2
Stop command by means serial communication
58
2
Periodic test start command
59
2
Periodic test stop command
60
2
Fuel pump on
61
2
Fuel pump off
66
2
RTC Date/Time changed by operator
67
2
Board power up
201
1
Battery low voltage warning
202
1
Fuel low level warning
203
1
Fuel high level warning
204
1
Water high temperature warning
205
1
Oil low pressure warning
206
1
Warning non volatile memory
207
1
Aux. warning
208
1
Warning KR close failure
209
1
Warning KG close failure
210
1
Max power warning
251
1
Oil low pressure block
252
1
Aux. 1 block
253
1
Aux. 2 block
254
1
Emergency stop
255
1
Over crank
256
1
Water high temperature block
257
1
Fuel low level block
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TYPE Description
258
1
Generator low voltage block (F01)
259
1
Generator low frequency block (F03)
260
1
Generator high voltage block (F02)
261
1
Generator high frequency block (F04)
262
1
Over speed
263
1
Overload
264
1
Over current (F06)
265
1
Belt Break (F05)
266
1
Bloc Manual stop in automatic (F07)
267
1
Operating condition failure (F08)
268
1
Fault board (F50)
269
1
Bad stop (F21)
270
1
Reverse Power (F11)
271
1
Generator set Inhibit (F12)
1
Short circuit (F16)
272 273
All the record in the database reports the following information: •
Relative time or real date/time
•
Event code
•
Key lock position (OFF/RESET, PROG, MAN, AUTO, TEST)
•
Engine status (halted, cranking, running, cooling down, shutting down)
•
Generator status (dead, live out of range, live in range)
•
Grid status (dead, live out of range, live in range)
•
Grid and generator changeover commands
•
Digital input status (terminal 1..14, 24, 26)
•
Warning list
•
Blocks and disable list
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EAAM002010I.doc The analogue data related to the event are not stored in the event database. Sometime they are meaningful, for such reason they are stored into an analogue data database linked to the event database. The time field is used to link the two databases.
10.8.5 Analogue data database In spite of fact that there are three different type of analogue data database, their structure is identical. Into the database are recorded only the analogue data, no status are recorded. Each record contains the following information: •
Relative time or real date/time
•
Mains voltage L1-L2 (V)
•
Mains voltage L2-L3 (V)
•
Mains voltage L3-L1 (V)
•
Generator voltage L1-L2 (V)
•
Generator voltage L2-L3 (V)
•
Generator voltage L3-L1 (V)
•
Generator current L1 (A)
•
Generator current L2 (A)
•
Generator current L3 (A)
•
Generator frequency (tenths of Hz)
•
Battery voltage (tenths of V)
•
Oil pressure (tenths of Bar)
•
Water temperature (°C)
•
Fuel level (%)
•
Power factory (multiplied per 100)
•
Active power (tenths of kW)
•
Reactive power (tenths of kvar)
4
1
1
4
If negative, the most significant digit will be replaced by the minus sign.
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Apparent power (tenths of kVA)
10.8.6 Databases lock When a block or disable arise, the updating of the databases are automatically disabled, locking the recorded data. In this way, it is possible to read the data present before the event occurrence. The databases can be unlocked in one of the following ways: •
Moving the key lock switch to OFF/RESET and then moving it away from this position (moving the key in OFF/RESET doesn’t unlock the databases, they are unlocked when the key is moved in PROG or MAN or AUTO or TEST from the OFF/RESET position).
•
By means a serial communication command.
The last solution is useful for remote management of the board when the data call function is used. In this case, when the block arises, the records are locked, the board calls the remote PC that downloads the data and then unlocks the databases. Moreover, it is important, using a remote PC to read the data, that the updating of the databases will be disabled. It is possible to do that also by means a serial communication command. Disabling by remote the updating is important because this function let the PC to read all the data without the record of new data between the readings of two records. If the remote call function is not used, the manual board resetting command unlocks the database and the board can add new records.
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10.9 Data Call and SMS functions The DST4600A board is able to automatically signal some events to a remote computer (data call) and/or to one or more cellular phones (SMS). Up to revision 08.00.38, the choice between data call and SMS were mutually exclusive. From revision 08.00.39, it is possible to send both data call and SMS for each new event. The board uses this function to signal a new event. It can be a block, a deactivation or an alarm. From software release 08.00.28 t his function can also signal status changes. To use this function, it is required a modem connected to the DST4600A. It must be a GSM modem if SMS are required. If you need also data calls, a PC/modem system is required, running a special SW, ready to answer to the board calls.
10.9.1 Setup The data call function setup can be done by means a special PC SW supplied by SICES s.r.l. By means this program it is possible to configure: •
A plant identification string: this string will be sent in each SMS and will be used by the PC in order to select the calling plant when answering an incoming call.
•
New alarm call enable
•
New block or disable call enable
•
Dialing mode (tone or pulse, only for PSTN modem)
•
Up to six-telephone number organized as two groups, the first of four numbers and the second of two numbers. The second group exists only from revision 08.00.38.
•
Number of calls attempt or SMS for the numbers of first group
•
Choice between data call or SMS sending for the numbers of first group
•
Number of calls attempt or SMS for the numbers of second group (this exists only from revision 08.00.38)
•
Choice between data call or SMS sending for the numbers of second group (this exists only from revision 08.00.38)
10.9.2 Data Call Function Enable The data call function must be enabled on the DST4600A board. Even if you have choice the data call function far any group in the configuration program, it is required that you enable directly the function by means the P61 parameters (bit 2 of P61). Please check DST4600A operating manual for how to enable bit 2 of P61 (by default it is enabled). If bit 2 is 0 the function is disabled, otherwise it is enabled. Bit 6 of P61, instead, enables execution of data calls or SMS when mains fails, even if mains sensor is external (this bit is valid from software release 08.00.28). Bit 3 of P79, enables execution of data calls or SMS when mains became present, even if mains sensor is external (this bit is valid from software release 08.00.39).
10.9.3 Description When a new alarm, block or disable arises (from software release 08.00.28 even some status changes), if the GSM modem is ready, the board sends first as many SMS as configured to each existent number of the groups configured for SMS. So the SMS are guarantee for each new event that requires them. However, there is no assurance that a data call is performed for each new alarm or block. This is because all alarms and blocks that are activated when a data calls is performed, are considered acquired from PC when
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EAAM002010I.doc the data call ends. When a new event arises, the board follows this procedure: 1.
The boards send first as many SMS as configured to each existent number of the groups associated with SMS. If no group is associated with SMS or if no number is configured in the group, this step is skipped. Note that up to revision 08.00.38 there was only one group and so if it is assigned to SMS, the data calls were disabled.
2.
The board searches for the first configured number in the groups related to data calls, starting from first group. If no number is configured, the procedure ends, otherwise uses the first found number.
3.
Make the first attempt to call the selected number.
4.
If it gets an answer and at least one valid data transfer from board to PC takes place with the selected protocol, the function ends, the communication stay alive until closed by the PC and the function is ready to wake up at the next event. From revision 08.00.38, the PC has to explicitly acknowledge the data calls in order to stop the procedure (with an apposite ModBus protocol command).
5.
If there isn’t answer or it is impossible to get a valid connection and valid data transfer, then the function searches for another, if present, configured telephone number. If it found the number, wait for a minute and then start from point 3 of this procedure.
6.
If no more number is found or if all the number was already attempted, the function increases the attempt counter. If this value is less or equal to the programmed call attempts, then it waits for a minute and then start from point 2 of this procedure.
7.
If all the attempts are executed without a successful connection and if the event is already set (no local reset has taken place), the procedure wait for 5 minute then start again from point 2 of this procedure. The 5-minute pause has the purpose to let an incoming call to be answered.
10.9.4 PC SW procedure The host PC must execute the following operations to assure that a valid connection and data transaction take place. 1.
It must answer to the incoming call.
2.
It must require to the DST4600A the plant identification string.
3.
On board acknowledgment, it must ask to the board the call reason.
4.
It can read, then, the recorded events and data in order to identify the fault. To do that, it must: a) Sends a database lock command, b) Reads all the data, c)
Unlocks the database
d) Manages the acquired data. e) From revision 08.00.38, it must explicitly acknowledge the data call, in order to stop the procedure on the board.
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10.10 Differences between DST4600A and DST4600A/P Starting from SW revision 08.00.22, the software is no more the same for the two version of the board. The correspondent SW version for the DST4600A/P is 12.05.22.
10.10.1
ALARM2 input for PARALLEL FAULT The input function is specialized for the parallel fault condition. The only difference between DST4600A and DST4600A/P is the default of the P65 (ALARM2 (terminal 02) filter time): for DST4600A/P is 180s instead of 1s.
10.10.2
KR management Now DST4600A/P boards use KR as status for MAINS ALIVE. Enabling the internal MAINS VOLTAGE sensor and connecting the GRID line to the R-S-T input terminal, KR will be deactivated if the MAINS is OK, and otherwise it will be activated. If the internal MAINS VOLTAGE sensor is disabled, KR will be always in deactivated status. The “MAINS SIMULATION” input (terminal 24) will never interfere on KR st atus.
10.10.3
KG management in test operation DST4600A/P boards will drive activated KG during test operation when the Generator set will be ready to supply. This feature is valid for all type of test operation. The operator can manually deactivate KG.
10.10.4
“MAINS SIMULATION” delay time Boards with the new SW version use P66 and P67 values as delay time related to the “MAINS SIMULATION” input status change. DST4600A has default values of 0 for both P66 and P67. DST4600A/P has default value of 2s for P66 and 30s for P67.
10.11 Differences with DST4600A/P for asynchronous engines Starting from SW revision 08.00.39, the software is no more the same for the asynchronous engine version of the board. The correspondent SW version is 29.07.39. This software is built over the DST4600A/P software. This paragraph shows the differences between this new software and the DST4600A/P one.
10.11.1
Generator frequency and voltages The board measures the generator frequency and voltages and shows them on the panel. But it does not use them for any protection and for engine running/stopped detection.
10.11.2
Terminal 8 function In the standard version, this terminal acquires the low oil pressure alarm. In this version, it acquires the engine running status, and so the low oil pressure alarm is disabled.
10.11.3
Terminal 10 function In the standard version, this terminal acquires the high water temperature alarm. In this version, it acquires the “engine in threshold” status, and so the high water temperature alarm is disabled.
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10.11.4
“Engine not in threshold with KG closed” alarm Only for this version, the board can activate a block (“F40”) when the KG is closed and the signal on terminal 10 becomes inactive, with a fixed filter delay of 0.5 seconds.
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11. References 11.1 SMS Protocol for Boards DST4600A and REMOTE SIGNALS Document:
EAAS0015
Revision:
01 or later
11.2 DTS4600-PC Communication Protocol Document:
EAAS0006
Revision:
01 or later
11.3 ModBus protocol implementation for SICES equipment Document:
EAAS0016
Revision:
03 or later
11.4 Remote signal operating manual Document:
EAAS0022
Revision:
03 or later
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12. Annexes NB: these annexes don’t have to be provided to the user. It is meant for internal use. NB: special trained operators must carry out these procedures.
Annex A: SELFTEST Procedure The SELFTEST procedure allows the operator to check the operation of most of the hardware of the board DST4600A. To execute the SELFTEST procedure does not mean to test the board, but it allows finding out any hardware problem without the testing equipment of instruments, such as the oscilloscope or others.
A1
Activating the SELFTEST procedure To activate the SELFTEST procedure, remove the back cover of the board DST4600A. In the board’s central area you’ll see the microprocessor (it is the bigger integrated circuit in the board). Looking at the board with the terminal box upwards (terminals 47-48-49), near the right bottom corner of the microprocessor there’s a three-contact bridge marked “TEST”. In the normal operation the central contact and the one nearest to the microprocessor must be connected, to activate the SELFTEST you need to connect the central one and the one farther from the microprocessor. Now you can turn on the board. The normal procedure for the board’s initialization is carried out, including the “LAMP TEST” (turning on all the indicators and displays of the front panel). At the end of this phase, the display “MULTIFUNCTION” will show three question marks “???” for about two seconds to indicate that the board is going to execute a procedure different from the normal working one. At the end of this phase the SELFTEST procedure is executed.
A2
Quitting the SELFTEST procedure. To quit the SELFTEST procedure and go back to the normal operation power down the board and connect the central contact of the bridge described in paragraph 0 with the contact nearest to the microprocessor. Then you can power the board again and use it to control the generator set.
A3
Main functions of the SELFTEST procedure The test of the various hardware parts of the board is divided into 5 blocks that can be selected with the five positions of the key selector on the front panel. The display “MULTIFUNCTION” shows a message indicating the current position of the key selector, in order to allow the recognition of the hardware problems on the same selector. It follows a general description of the test procedures that are executed for each of the selector’s positions. •
Selector on “OFF/RESET”: test of the digital inputs and of the buttons of the front panel.
•
Selector on “PROG.”: test of the analogue inputs
•
Selector on “MAN.”: test of the non-volatile memory (EEPROM)
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A4
•
Selector on “AUTO”: test of the digital outputs
•
Selector on “TEST”: test of the indicators and displays of the f ront panel.
SELFTEST with selector on “OFF/RESET” The “MULTIFUNCTION” display shows the message “OFF”. Display “A” is used to show the communication serial port test result and display “B” is used to show the digital inputs and pushbuttons status. To execute the serial port test, it is required to place a loop-back connector into JG. The following picture shows the loop-back connection diagram.
Sending data and verifying the received data, the test software checks both the TX and RX channels. What’s more, the DTR and DSR signal lines are also checked. If the serial port is working fine, no messages are displayed on display “A”, otherwise one of the following messages are shown: •
“Er1”:
no data received, maybe a TX or RX problem.
•
“Er2”:
received data have format error (overrun, parity or framing)
•
“Er3”:
transmitted data is not equal to the received data
•
“Er4”:
there is DSR and DTR signals level mismatch
Only one error is shown, the priority is from “Er1” toward “Er2” In this part of the SELFTEST procedure you test also the digital inputs. Display “V” shows a code referring to the active digital input or to the button pressed. For the digital inputs, the number displayed is that of the corresponding terminal. For the buttons is a number over or equal to 100, whose meaning can be derived from the following table.
Code
Description
01
“ALARM1” (“EXTERNAL SHUTDOWN”) digital input
02
“ALARM2” (“AUX. ALARM”) digital input
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Description
03
“EMERGENCY STOP” digital input
04
“HIGH LEVEL FUEL” digital input
05
“LOW LEVEL FUEL” digital input
06
“FUEL END” digital input
07
“OIL P. ALARM” digital input
08
“OIL WARNING” digital input
09
“TEMPERAT. ALARM” digital input
10
“TEMP. WARNING” digital input
11
“OVERLOAD” digital input
12
“INPUT C” digital input
13
“INPUT B (F10)” digital input
14
“INPUT A” digital input
24
“MAINS SIMULATION” digital input
46
“REMOTE TEST” digital input
101
“F1” button
102
“F2” button
103
“MODE / ACK” button
104
“STOP” button
105
“START” button
NB: the digital input “EMERGENCY STOP” (terminal 03) is considered active when the corresponding terminal is not closed on the battery negative (that is when the contact connected to that terminal is open). This is because normally the emergency buttons has closed contacts that open when the button is pressed. As a consequence, if you execute this part of the SELFTEST procedure without connecting anything to the terminal 03, the “VOLT” display will show the code of that input, that is 03. If there are two or more active inputs or buttons at the same time, the priority for the selection of the code to display is made according to the above table. The first position in the table has the first priority, while the last one has the minimum priority. Therefore, if for instance the “MAINS SIMULATION” input and the “F1” button are active at the same time, the display “V” will show “24” that is the code corresponding to the “MAINS SIMULATION” digital input.
A5
SELFTEST with selector on “PROG.” The “MULTIFUNCTION” display will show the message “PRO”. In this part of the procedure the analogue inputs are tested. Through the buttons “F1” and “F2“ select one of the analogue inputs. The display “V” shows a message identifying the selected analogue input and the display “A” shows the value associated to that input. Here follows a table describing the analogue inputs that can be tested by this procedure.
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Message
M.U.
Fractional Digits
Description
“Fr”
Hz
1
Generator set frequency
“1-2”
Volt
0
Phase-to-phase voltage between the phases L1 and L2 of the generator (terminals 63 – 65)
“2-3”
Volt
0
Phase-to-phase voltage between the phases L2 and L3 of the generator (terminals 65 – 67)
“3-1”
Volt
0
Phase-to-phase voltage between the phase L3 and L1 of the generator (terminals 67 – 63)
“C 1”
Ampere
0
Current supplied by the phase L1 of the generator (terminals 50-51)
“C 2”
Ampere
0
Current supplied by the phase L2 of the generator (terminals 52-53)
“C 3”
Ampere
0
Current supplied by the phase L3 of the generator (terminals 54-55)
“R-S”
Volt
0
Phase-to-phase voltage between the phases R and S of the mains (terminals 70 – 72)
“S-T”
Volt
0
Phase-to-phase voltage between the phases S and T of the mains (terminals 72 – 74)
“T-R”
Volt
0
Phase-to-phase voltage between the phases T and R of the mains (terminals 74 – 70)
“BAT”
Volt
1
Generator set starting battery (terminals 47-48 / 49 – 48)
“S P”
Bar
1
Oil pressure (terminals 42 – 41)
“S T”
°C
0
Cooling water temperature (terminals 43 – 41)
“S L”
%
0
Fuel level (terminals 45 – 41)
“ENG”
Volt
1
Voltage on terminals 39 – 40 used for the recognition of the engine running or to determine the block for belt break
voltage
Current value is always displayed in AMPERE units. The format may differ depending on P17 parameter (TA value). •
P17 < 10:
value is displayed with 2 decimal digits.
•
P17 >= 10: value is displayed with 1 decimal digit.
•
P17 >= 100: value is displayed without any decimal digits. If the value is greater than 999 A, it is divided for 10 and the x10 lamp is light on.
As already stated, you can use the buttons “F1” and “F2” to select an analogue input. With the button “F1” you move along the above table downwards, while with the button “F2” you
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EAAM002010I.doc move upwards. The management of these buttons supports the “AUTOREPEAT” function, that is by pressing and soon releasing the “F1” or “F2” buttons you move of one position each time, while by keeping it pressed you move of one position as soon as you press the button and after one second you move of one position every 0.1 seconds. The scanning of the positions is cyclic, that is by pressing “F2” you move from the last to the first and vice versa. In this phase do not use the buttons “START”, “STOP” and “MODE / ACK”. By pressing them you’ll view different information from the analogue input value on the display “A”. Such information is not relevant for the operator.
A6
SELFTEST with selector on “MAN” The “MULTIFUNCTION” display shows the message “MAN”. In this part of the SELFTEST procedure you test the non-volatile memory of the board (EEPROM). To test the non-volatile memory the SELFTEST procedure writes it with known values and then it read it again to check if writing and reading work correctly. This involves that all the data stored in the memory (calibration values of the analogue inputs, programming parameters, operating hours of the generator set) are lost. Do not execute this part of the SELFTEST procedure if you don’t wish to lose those data (you have then to redo a complete calibration of the board). To start the memory test pressing the START button is not enough. The test consists in writing and read again each byte of the memory. The written value is casual (it is the value of an internal timer of the microprocessor frozen in the moment of it is written). When you turn on the board in normal mode, after the execution of the EEPROM test and after the initialization phase, the display “MULTIFUNCTION” will show the message “F09” or the message “INI”. Both indicate that the content of the non-volatile memory is not valid and that therefore the default values have been loaded. SW version until 08.00.23 The display “A” indicates the address of the byte you are testing (NB: the usual EEPROM contains 2048 byte while the “A” can only show numbers ranging from 0 to 999: the addresses between 1000 and 1999 are displayed as 0.999 and the addresses between 2000 and 2048 as 0.48. Normally the display “V” does not display anything. If the test fails even on one byte only, the message “ERR” is displayed. SW version greater than 08.00.23 If RTC option is installed, non-volatile memory is greater than the standard 2048 byte. Thus both “A” and “V” displays are used to show the tested address If the test fails even on one byte only, the message “ERR” is displayed on “V” display.
A7
SELFTEST with selector in “AUTO” The “MULTIFUNCTION” display shows the message “AUT”. In this part of the SELFTEST procedure you test the digital outputs. They are enabled one by one every second. The display “A” is not used, while the display “V” shows a code associated to the digital output currently enabled. That code corresponds to the terminal associated to the output.
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Code
Description
15
“AUX OUTPUT 1” digital output (glow plug)
16
“ALARM OUTPUT” digital output (siren)
17
“AUX OUTPUT 2” digital output (fuel loading pump)
18
“STOP SOLENOID” digital output (excitation shutdown)
20
“START” digital output (starter)
22
“FUEL SOLENOID” digital output (fuel electro valve, drop-out shutdown)
25
“ENGINE RUNNING” digital output
26
“GENERAL ALARM” digital output (or blocks and deactivations)
27
“TRIP ALARM” digital output (or alarms)
28
“FUEL ALARM ” digital output (or fuel blocks)
29
“ENGINE ALARM” digital output (or engine blocks)
30
“SPEED ALARM” digital output (or frequency blocks and deactivations)
31
“GENERATOR ALARM” digital output (or generator blocks and deactivations)
32
“OFF-PROG-MAN” digital output
33
“OFF SELECTION” digital output
36
“OUTPUT 2” digital output
37
“OUTPUT 1” digital output
57
“MAINS” contactor digital output
60
“GEN” contactor digital output
Until SW revision 08.00.23, the tested output was automatically changed at fixed rate of 1 second. Starting from revision 08.00.24 it is up to the operator to change the output in test: pressing any pushbutton does that.
A8
SELFTEST with selector on “TEST” In this part of the SELFTEST procedure you test all the indicators and displays on the front panel. The indicators are all turned on and the displays show “888” with all the decimal points turned on, in order to identify any turned off indicator or display segment. Of course, no message referring to the key position is shown on the “MULTIFUNCTION” display. By means of the board pushbuttons, is possible to make specific test on signal lamps and displays. •
“MODE/ACK” pushbutton: all signal lamps and displays will be turned off. Then each segment of “MULTIFUNCTION” display will then light in sequence one at time.
•
“STOP” pushbutton: all signal lamps and displays will be turned off. Then each segment of “V” display will then light in sequence one at time.
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