Dse4120 Manual PDF

COMPLEX SOLUTIONS
MADE SIMPLE.
DEEP SEA ELECTRONICS PLC

DSE4120
AUTO MAINS FAILURE MODULE
OPERATING MANUAL
DSE Model 4120 Automatic Mains Failure Operators Manual
Deep Sea Electronics Plc

Highfield House
Hunmanby
North Yorkshire
YO14 0PH
ENGLAND
Sales Tel: +44 (0) 1723 890099
Sales Fax: +44 (0) 1723 893303
E-mail: [email protected]
Website: www.deepseaplc.com
DSE Model 4120 Control System Operators Manual

Deep Sea Electronics Plc
All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any
medium by electronic means or other) without the written permission of the copyright holder except in accordance with the
provisions of the Copyright, Designs and Patents Act 1988.
Applications for the copyright holders written permission to reproduce any part of this publication should be addressed to Deep
Sea Electronics Plc at the address above.
Any reference to trademarked product names used within this publication is owned by their respective companies.
Deep Sea Electronics Plc reserves the right to change the contents of this document without prior notice.
057-023 4120 OPERATING MANUAL ISSUE 2.1
18/06/2007 JR
TABLE OF CONTENTS
Section
Page
INTRODUCTION .............................................................................................. 4
CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION. ........ 4
OPERATION .................................................................................................... 5
3.1
3.2
3.3
AUTOMATIC MODE OF OPERATION ............................................................................... 5

MANUAL OPERATION ....................................................................................................... 6
EXERCISE SCHEDULER.................................................................................................... 8
PROTECTIONS ................................................................................................ 9
4.1
4.2
WARNINGS ......................................................................................................................... 9
SHUTDOWNS ...................................................................................................................... 9
DESCRIPTION OF CONTROLS .................................................................... 10
FRONT PANEL CONFIGURATION ............................................................... 12

6.1
6.2
ACCESSING THE FRONT PANEL CONFIGURATION EDITOR .................................... 12

EDITING THE CONFIGURATION ..................................................................................... 12
CONFIGURATION TABLES .......................................................................... 13
INSTALLATION INSTRUCTIONS .................................................................. 17

8.1
8.2
8.3
8.4
8.5
PANEL CUT-OUT .............................................................................................................. 17

COOLING........................................................................................................................... 18
UNIT DIMENSIONS ........................................................................................................... 18
FRONT PANEL LAYOUT .................................................................................................. 20
REAR PANEL LAYOUT .................................................................................................... 20
ELECTRICAL CONNECTIONS ...................................................................... 21

9.1
9.2
CONNECTION DETAILS................................................................................................... 21
CONNECTOR FUNCTION DETAILS ................................................................................ 22
10
SPECIFICATION ......................................................................................... 23
11
COMMISSIONING ....................................................................................... 24
11.1
PRE-COMMISSIONING ................................................................................................. 24
12
FAULT FINDING ......................................................................................... 25
13
TYPICAL WIRING DIAGRAM ..................................................................... 26
14
SOLID STATE OUTPUTS ........................................................................... 27
15
APPENDIX .................................................................................................. 28
15.1
ALTERNATIVE WIRING TOPOLOGIES ....................................................................... 28
15.1.1 TWO PHASE TWO WIRE........................................................................................... 28
15.1.2 SINGLE PHASE TWO WIRE ...................................................................................... 28
15.2
PUSH BUTTONS ........................................................................................................... 30
15.3
ALARM / SHUTDOWN INDICATIONS .......................................................................... 30
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1 INTRODUCTION
The DSE 4120 automatic mains failure module has been primarily designed to monitor the mains (utility) supply,
starting the generator automatically should it fall out of limits, transferring the load automatically to the generator.
Once the mains (utility) has returned the load is automatically transferred back to the mains (utility) and the
generator cooled down before it stops. If required the generator can be started and stopped manually.
The DSE 4120 module has a built in LCD hours counter, which displays the number of hours that the generator
has run, to the nearest 1/10 hour.
The DSE 4120 module monitors the mains (utility) supply indicating the status of the mains via an LED. Additionally
the module monitors the engine, indicating that the generator is running via an LED. There are a further 8 LEDs
indicating fault conditions and 2 LEDs indicating whether the mains (utility) or generator is supplying the load.
When a fault is detected the generator is automatically shut down, giving a true first up fault condition.
The customer using the modules front panel configuration editor can alter selective operational sequences, timers
and alarm trips.
The module is housed in a fully enclosed robust plastic case for front panel mounting, offering a high IP rating of 56
with the optional gasket. Connections to the module are via locking plug and sockets.
2 CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION.
NOTE:
Highlights an essential element of a procedure to ensure correctness.
CAUTION!
Indicates a procedure or practice which, if not strictly observed, could result

in damage or destruction of equipment.
WARNING!
Indicates a procedure or practice, which could result in injury to personnel

or loss of life if not followed correctly.
Deep Sea Electronics Plc owns the copyright to this manual, which cannot
be copied, reproduced or disclosed to a third party without prior written
permission.
Compliant with BS EN 60950 Low Voltage Directive
Compliant with BS EN 50081-2 EMC Directive
Compliant with BS EN 50082-2 EMC Directive
UL Registered Component for USA & Canada
Year 2000 Compliant
18/06/2007 JR
3 OPERATION
The following description details the sequences followed by a module containing the standard factory
configuration. Always refer to your configuration source for the exact sequences and timers observed by any
particular module in the field.
FIG 1
3.1
AUTOMATIC MODE OF OPERATION
This mode is activated by pressing the

action.
pushbutton. An LED indicator beside the button confirms this
Should the mains (utility) supply fall outside the configurable limits for longer than the period of the delay start
timer, the mains (utility) is healthy indicator will extinguish. Additionally, while in AUTO mode, the remote start input
is monitored.
Whether the start sequence is initiated by mains (utility) failure, or by remote start input, the follow sequence is
followed :
To allow for short term mains supply transient conditions or false remote start signals, the Start Delay timer is
initiated. After this delay, if the pre-heat output option is selected then the pre-heat timer is initiated and the
corresponding auxiliary output (if configured) will energise.
NOTE:- If the mains supply returns within limits, (or the Remote Start signal is removed if the start
sequence was initiated by remote start) during the Start Delay timer, the unit will return to a stand-by
state.
After the above delays the Fuel Solenoid is energised, then one second later, the Starter Motor is engaged.
18/06/2007 JR
The engine is cranked for a 10 second period. If the engine fails to fire during this cranking attempt then the starter
motor is disengaged for the 10 second rest period. Should this sequence continue beyond the 3 cranking attempts,
the start sequence will be terminated and Fail to Start
fault will be displayed.
When the engine fires, the starter motor is disengaged and locked out at 20 Hz measured from the Alternator
output. Rising oil pressure can also be used to disconnect the starter motor, however it cannot be used for
underspeed or overspeed detection.
After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine
Temperature, Under-speed and any delayed Auxiliary fault inputs to stabilise without triggering the fault.
NOTE:- The safety on time (used for delayed alarms) is pre set to 12 seconds and can not be
changed.
Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to stabilise before
accepting the load.
If the remote start is being used and has been configured to Remote start is on load, or the mains (utility) has
failed, the load will be transferred to the generator.
NOTE:-A load transfer will not be initiated until the Oil Pressure has risen. Thus preventing
excessive wear on the engine.
On the return of the mains supply, (or removal of the Remote Start signal if the set was started by remote signal),
the Stop delay timer is initiated, once it has timed out, the load is transferred back to the mains (utility). The
Cooling timer is then initiated, allowing the engine a cooling down period off load before shutting down. Once the
Cooling timer expires the Fuel Solenoid is de-energised, bringing the generator to a stop.
Should the mains supply fall outside limits again (or the Remote Start signal be re-activated) during the cooling
down period, the load will be immediately transferred to the generator.
3.2
MANUAL OPERATION
To initiate a start sequence in MANUAL, press the
pushbutton.
NOTE:- There is no Start Delay in this mode of operation.

If the pre-heat output option is selected this timer is then initiated and the auxiliary output selected is energised.
After the above delay the Fuel Solenoid is energised, then the Starter Motor is engaged.
The engine is cranked for a 10 second period. If the engine fails to fire during this cranking attempt then the starter
motor is disengaged for the 10 second rest period. Should this sequence continue beyond the 3 cranking attempts,
the start sequence will be terminated and Fail to Start
fault will be displayed.
When the engine fires, the starter motor is disengaged and locked out at 20 Hz measured from the Alternator
output. Rising oil pressure can also be used to disconnect the starter motor, however it cannot be used for
underspeed or overspeed detection.
After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High Engine
Temperature, Under-speed and any delayed Auxiliary fault inputs to stabilise without triggering the fault.
changed.
18/06/2007 JR
Once the engine is running, the Warm Up timer, if selected, is initiated, allowing the engine to stabilise before it
can be loaded.
The generator will run off load, unless the mains (utility) supply fails or a Remote Start on load signal is applied, at
which point the load will be transferred to the generator.
The generator will continue to run on load regardless of the state of the mains (utility) supply or remote start input
until the Auto mode is selected.
If Auto mode is selected and the mains supply is healthy with the remote start on load signal not active, then the
Remote Stop Delay Timer begins, after which the load is transferred to the mains (utility). The generator will then
run off load allowing the engine a cooling down period.
Selecting STOP (O) de-energises the FUEL SOLENOID, bringing the generator to a stop.
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3.3
EXERCISE SCHEDULER
Available in module versions V1.3 and higher.

The exercise scheduler is used to give a 30-minute test run every seven days. The starting time is configurable and
repeated every week, but the run duration is fixed at 30 minutes.
The scheduler is configured as follows:
Press and hold the

button. After 6 seconds, the LED beside the Auto button will extinguish. This
sets the exercise run time to the current time.
Release the
button, the LED beside the Auto button will illuminate to show that the module is in
Auto mode. The exercise period will begin.
After 30minutes, the set will stop; the same 30 minute exercise period will be repeated on a 7 day cycle so long
as the module is in the Auto mode.
When the exercise timer is set, the Auto LED will blink every 3 seconds. To cancel the timer, press and hold
the
button for 6 seconds, the Auto LED will extinguish to show the timer has been cancelled and
will return to steady operation once the Auto button is released. Removing DC power from the module will also
reset the exercise timer.
NOTE:If remote start mode is configured to off load then the exercise run will be OFF-LOAD.
If remote start mode is configured to on load then the exercise run will be ON-LOAD regardless of
the state of the mains (utility) supply.
NOTE:- If the Mains (utility) supply fails during the exercise run, the set will take load and the
exercise timer is cancelled.
NOTE:- If remote start input is active, the set will continue to run beyond the end of the exercise
time as the set is then under the control of the remote start input.
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4 PROTECTIONS
The module will indicate that an alarm has occurred by illuminating the relevant LED.
4.1
WARNINGS
Warnings are used to warn the operator of an impending fault

BATTERY CHARGE FAILURE, if the module does not detect a voltage from the warning light terminal on the
icon will illuminate. (Either 8 Volts or 16 Volts depending on the configuration
auxiliary charge alternator, the
of Nominal DC Voltage).
Inputs 1 and 2 can be configured as warnings or shutdowns. The relevant icon will be illuminated when the input is
active.
4.2
SHUTDOWNS
Shutdowns are latching and stop the generator. The alarm must be cleared and the fault removed to reset the
module. In the event of a shutdown the appropriate icon will be illuminated
NOTE:- The alarm condition must be rectified before a reset will take place. If the alarm condition
remains it will not be possible to reset the unit (The exception to this is the Low Oil Pressure alarm and
similar delayed alarms, as the oil pressure will be low with the engine at rest). Any subsequent
warnings or shutdowns that occur will be displayed steady, therefore only the first-up shutdown will
appear flashing.
changed.
FAIL TO START, if the engine does not fire after the pre-set 3 attempts at starting, a shutdown will be initiated.
icon will illuminate.
The
LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low oil pressure
switch after the Safety On timer has expired, a shutdown will occur.
The
HIGH ENGINE TEMPERATURE, if the module detects that the engine coolant temperature has exceeded the high
engine temperature switch after the Safety On timer has expired, a shutdown will occur.
The
OVERSPEED, if the engine speed exceeds the pre-set trip (14% above the nominal frequency) a shutdown is
initiated. Overspeed is not delayed, it is an immediate shutdown.
The
NOTE:- During the start-up sequence the overspeed trip level is extended to 24% above the normal
frequency for the duration of the safety timer to allow an extra trip level margin. This is used to prevent
nuisance tripping on start-up.
UNDERSPEED, if the engine speed falls below the pre-set trip (20% of the nominal frequency) after the Safety On
timer has expired, a shutdown is initiated.
The
Inputs 1 and 2 can be configured as warnings or shutdowns. The relevant icon will be illuminated when the input is
active
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5 DESCRIPTION OF CONTROLS
The following section details the function and meaning of the various controls on the module.
Auxiliary Input 1
Low Oil
High Coolant
Over
Under
Charge Alt
Fail To Start
Active
Pressure Temperature
Speed
Speed
Failure
Shutdown
Warning /
Shutdown
Shutdown
Shutdown
Shutdown
Warning
Shutdown
Stop Mode
Manual Mode
Automatic Mode And Indicator

LED
FIG 2A
10
18/06/2007 JR
Auxiliary Input 2
Active
Warning /
Shutdown
Tamperproof LCD Hours

Counter. Displaying Hours
and Tenths of Hours when
fuel solenoid is energised.
Mains Indication
LED. Lit when
The Mains Is
Healthy
Close Mains Output

LED. On When The
Mains Is Required
To Be On Load
Close Generator
Output LED. On When
The Generator Is
Required To Be On
Load
Generator available LED.

On When The Generator
Is Available For Loading.
FIG 2B
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11
6 FRONT PANEL CONFIGURATION

The DSE 4120 module is fully configurable from the front panel. There is no requirement for a PC / Laptop or
software.
6.1
ACCESSING THE FRONT PANEL CONFIGURATION EDITOR

With the unit in Stop
mode, Configuration Mode is selected by operation of a small switch on the rear
bottom edge of the PCB. This is partially hidden to prevent accidental operation.
Switch In Normal Mode
6.2
Switch in Configuration Mode
Once Configuration Mode is selected, the Auto LED will commence rapid flashing and all normal operation is
suspended.
EDITING THE CONFIGURATION
pushbutton can be used to select the LED code that corresponds to the required function. The 5
The Stop
left-hand LEDs will form the code. See configuration table over leaf.
pushbutton will allow the user to change the associated value. The 3 right-hand LEDs inform
The Manual
the user of the current setting for the chosen function. See configuration table over leaf.
When the required parameters are displayed, pressing the Auto

and the process is repeated for each function change.
When configuration is complete, the Configuration Mode Selector Switch should be returned to the Normal
position.
12
18/06/2007 JR
button will save the new setting
7 CONFIGURATION TABLES
! 1
! 2
Value (Default in Bold)
{
{
{
0 Seconds
O
{
{
5 Seconds
O
{
{
10 Seconds
O
O
{
15 Seconds
O
{
{
20 Seconds
O
O
{
30 Seconds
O
O
{
60 Seconds
O
O
O
180 Seconds
Used to pre-heat the engine prior to cranking. The output is active for the duration of the setting, prior to cranking.
Function
Pre-heat Timer
{
{
{
0 Seconds
O
{
{
5 Seconds
O
{
{
10 Seconds
O
O
{
15 Seconds
O
{
{
20 Seconds
O
O
{
30 Seconds
O
O
{
60 Seconds
O
O
O
180 Seconds
Used to give a delay between activating the remote start input, or a mains failure and actually starting the engine.
Start Delay
{
{
{
0 Seconds
O
{
{
5 Seconds
O
{
{
10 Seconds
O
O
{
15 Seconds
O
{
{
20 Seconds
O
O
{
30 Seconds
O
O
{
60 Seconds
O
O
O
180 Seconds
Used to give a delay between the mains returning and the system switching the load back to the mains. Used to ensure
that the mains is steady before this action is executed.
Stop Delay
Mains Return Delay
{
{
{
0 Seconds
O
{
{
5 Seconds
O
{
{
10 Seconds
O
O
{
15 Seconds
O
{
{
20 Seconds
O
O
{
30 Seconds
O
O
{
60 Seconds
O
O
O
180 Seconds
Used for the control of the engine stop solenoid. When the engine is to be stopped, the Energise To Stop output
becomes active, closing the stop solenoid (fuel valve). When the engine comes to rest, the stop solenoid will remain
energised for the period of the Energise To Stop Timer, to ensure the engine has come to a complete stop.
Energise to Stop
Hold Timer
{
{
{
0 Seconds
O
{
{
5 Seconds
O
{
{
10 Seconds
O
O
{
15 Seconds
O
{
{
20 Seconds
O
O
{
30 Seconds
O
O
{
60 Seconds
O
O
O
180 Seconds
Delay between the engine being available for use and the closure of the generator load-switching device to allow time
for the engine to warm before being loaded. This occurs after the 12 second safety on timer.
Warm-up Timer
{
{
{
0 Seconds
O
{
{
5 Seconds
O
{
{
10 Seconds
O
O
{
15 Seconds
O
{
{
20 Seconds
O
O
{
30 Seconds
O
O
{
60 Seconds
O
O
O
180 Seconds
Delay between opening the generator load-switching device and stopping the engine to allow time for the engine to
cool down before being stopped. This is particularly useful when used in conjunction with turbo-charged engines.
Cooling Timer
18/06/2007 JR
13
FUNCTIONS AND CONFIGURATION TABLE

Function
Nominal Frequency
! 1
! 2

50 Hz (O/S +14% /
Overshoot +24%)
60 Hz (O/S +14% /
Overshoot +24%)
The systems nominal frequency. Either 50 Hz or 60 Hz

{
HET Switch Contact
Crank disconnect on
Oil Pressure
{
{
{
12V DC (CF 8V)
O
{
{
24V DC (CF 16V)
The generator battery voltage. Either 12 Volts or 24 Volts. It is used for the charge alternator failure level.
Nominal DC Voltage
{
{
{
Close on Fault
O
{
{
Open on Fault
Configuration for the oil pressure switch. Either to close to battery negative on a fault, or open on a fault.
LOP Switch Contact
{
{
{
Close on Fault
O
{
{
Open on Fault
Configuration for the coolant temperature switch. Either to close to battery negative on a fault, or open on a fault.
{
Disabled
Enabled (2 Second
Delay)
If this is enabled, the starter motor will disconnect 2 seconds after the oil pressure switch detects oil pressure.
NOTE:- Not suitable for all generators, due to the different monitoring points on lubrication systems.
O
O
O
{
{
{
{
{
Underspeed
Disabled
Detection
O
{
{
Enabled (U/S 20%)
If this is enabled, the unit will shut down the generator if the frequency falls below 20% of the nominal frequency.
O
O
O
{
{
Remote start
{
{
{
Remote start
function
O
{
{
Simulated mains
Programmable input can be configured to one of the following.
Remote start If the input is active the generator will be started and stopped if the input is deactive. Mains fail is
allways active.
Simulated mains If the input is active the generator will not start in the event of a mains failure. E.G. if the
generator is supporting a non 24 hour operation, a 24 hour timer can be used to prevent a mains failure from
starting the generator and taking load.
Remote start on load
(ignore if simulated
mains)
Remote start is off

load
Remote start is on load
O
{
{
The remote start input can be configured to one of the following.
Remote start is off load The generator will start and run off load when the remote start input is active.
Remote start is on load The generator will start and the load transferred to the generator when the remote start
is active.
14
18/06/2007 JR

Function
Auxiliary Input 1
Function
! 1
! 2

Immediate Warning
Close on Fault
Immediate Warning
Open on Fault
Immediate Shutdown
Close on Fault
Immediate Shutdown
Open on Fault
Delayed Warning
Close on Fault
Delayed Warning
Open on Fault
Delayed Shutdown
Close on Fault
Delayed Shutdown
Open on Fault
Programmable input, can be configured to on of the following
Immediate warning close on fault If the input is activated at any time the unit will alarm and energise the
common warning and common alarm output.
Immediate warning open on fault If the input is deactivated at any time the unit will alarm and energise the
Immediate shutdown close on fault If the input is activated at any time the generator will be shutdown and
energise the common warning and common shutdown output. The generator can not be started.
Immediate shutdown open on fault If the input is deactivated at any time the generator will be shutdown and
Delayed warning close on fault If the input is activated and the saftey time has elapsed the unit will alarm and
energise the common warning and common alarm output.
Delayed warning open on fault If the input is deactivated and the saftey time has elapsed the unit will alarm and
Delayed shutdown close on fault If the input is activated and the saftey time has elapsed the generator will be
shutdown and energise the common warning and common shutdown output.
Delayed shutdown open on fault If the input is deactivated and the saftey time has elapsed the generator will be
Auxiliary Input 2
Function
O
{
Immediate Warning
Close on Fault
Immediate Warning
Open on Fault
Immediate Shutdown
Close on Fault
Immediate Shutdown
Open on Fault
Delayed Warning
Close on Fault
Delayed Warning
Open on Fault
Delayed Shutdown
Close on Fault
Delayed Shutdown
Open on Fault
Programmable input, can be configured to on of the following
Immediate warning close on fault If the input is activated at any time the unit will alarm and energise the
Immediate warning open on fault If the input is deactivated at any time the unit will alarm and energise the
Immediate shutdown close on fault If the input is activated at any time the generator will be shutdown and
Immediate shutdown open on fault If the input is deactivated at any time the generator will be shutdown and
Delayed warning close on fault If the input is activated and the saftey time has elapsed the unit will alarm and
Delayed warning open on fault If the input is deactivated and the saftey time has elapsed the unit will alarm and
Delayed shutdown close on fault If the input is activated and the saftey time has elapsed the generator will be
Delayed shutdown open on fault If the input is deactivated and the saftey time has elapsed the generator will be
18/06/2007 JR
15

Function
Auxiliary Output 1
Function
! 1
! 2

Not used
Pre-heat
Load Transfer
Common Warning
Common Shutdown
System in Auto
Common Alarm
Energise to Stop
Programmable output can be configured to one of the following.
Pre-heat. - The output is energised for the period of pre-heat time prior to cranking and between the cranking
attempts.
Load Transfer. - The output is active after the saftey timer has elapsed.
Common warning. - The output is active if there are any warning alarm active.
Common shutdown - The output is active if there are any shutdown alarms active.
System in auto. - The output is active when the system is in automatic mode.
Common Alarm. - The output is active if there is any alarm condition.
Energise to stop. - The output is energised when the engine is required to stop (normal or fault conditions) and will
remain energised for the period of the Energise To Stop Timer, to ensure the engine has come to a complete
stop.
Auxiliary Output 2
Function
Not used
Pre-heat
Load Transfer
Common Warning
Common Shutdown
System in Auto
Common Alarm
Energise to Stop
Programmable output can be configured to one of the following.
Pre-heat. - The output is energised for the period of pre-heat time prior to cranking and between the cranking
attempts.
Load Transfer. - The output is active after the saftey timer has elapsed.
Common warning. - The output is active if there are any warning alarm active.
Common shutdown - The output is active if there are any shutdown alarms active.
System in auto. - The output is active when the system is in automatic mode.
Common Alarm. - The output is active if there is any alarm condition.
Energise to stop. - The output is energised when the engine is required to stop (normal or fault conditions) and will
remain energised for the period of the Energise To Stop Timer, to ensure the engine has come to a complete
stop.
Mains Under
Voltage
(Trip / Return)
60V / 70V
70V / 80V
O
{
{
80V / 90V
O
O
{
90V / 100V
O
{
{
120V / 140V
O
O
{
140V / 160V
O
O
{
160V / 180V
O
O
O
180V /200V
If for example 180/200 is selected the generator will be started and the load transferred if any phase falls below 180V
with respect to the neutral for the duration of the delay start timer. The load will be transferred back to mains when the
mains voltage returns to 200V or higher for the duration of the mains return timer. (The system must be in Auto)
NOTE: - All the outputs are solid state, rated at 1.2 Amps and switch to battery negative when
active.
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18/06/2007 JR
8 INSTALLATION INSTRUCTIONS
The model DSE 4120 Module has been designed for front panel mounting. Fixing is by 2 clips for easy assembly.
8.1
PANEL CUT-OUT
98mm
(3.9)
154mm
(6.1)
FIG 3
Maximum panel thickness 8mm (0.3)
In conditions of excessive vibration the module should be mounted on suitable anti-vibration mountings.
18/06/2007 JR
17
8.2
COOLING
The module has been designed to operate over a wide temperature range -30 to +70 C. Allowances should be
made for the temperature rise within the control panel enclosure. Care should be taken NOT to mount possible
heat sources near the module unless adequate ventilation is provided. The relative humidity inside the control
panel enclosure should not exceed 95%.
8.3
UNIT DIMENSIONS
FIG 4
18
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FIG 4B
FIG 4C
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19
8.4
FRONT PANEL LAYOUT
8.5
REAR PANEL LAYOUT
FIG 5
FIG 6
20
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9 ELECTRICAL CONNECTIONS
Connections to the Module are via plug and sockets.
9.1
CONNECTION DETAILS
The following describes the connections and recommended cable sizes to the 2 plugs and sockets on the rear of
the Module. See rear panel layout FIG 6.
PIN
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
DESCRIPTION
DC Plant Supply Input
(-ve)
DC Plant Supply Input
(+ve)
Fuel relay Output
Start relay Output
Auxiliary Output relay 1
Auxiliary Output relay 2
Charge Fail Input/ Excitation
Output
Low Oil Pressure Input
High Engine Temp Input
Auxiliary Input 1
Auxiliary Input 2
Remote Start Input
Mains loading Relay
Normally Open contact
Generator loading Relay
Normally Open contact
Functional Earth
Mains L1
Voltage Monitoring Input
Mains L2
Mains L3
Mains N
Alternator Input L1
Alternator Input N
CABLE
SIZE
1.0mm
NOTES
Connected to plant battery negative
1.0mm
Connected to plant battery positive

(Recommended Fuse 2A)
Used to operate the fuel relay.
Used to operate the cranking relay.
Configurable output.
Configurable output.
Must NOT be connected to plant supply
negative if not used.
Switch to negative.
Switch to negative.
Switch to negative.
Switch to negative.
Switch to negative.
Used to close the mains
contactor / breaker
Used to close the generator
contactor / breaker
Connect to a good clean earth point
Connect to Mains L1 supply (AC)
(Recommend 2A Fuse Max.)
Connect to Mains N supply (AC)
1.0mm
1.0mm
Do not connect if not used. (2A Fuse)

Do not connect if not used.
1.0mm
1.0mm
1.0mm
1.0mm
1.0mm
1.0mm
0.5mm
0.5mm
0.5mm
0.5mm
0.5mm
1.0mm
1.0mm
1.0mm
1.0mm
1.0mm
1.0mm
NOTE:- For single phase mains monitoring the neutral should be connected to terminal 19, L1 should
be connected to terminals 16,17 and 18.
NOTE:- For two phase mains monitoring the L2 should be connected to terminal 19, L1 should be
connected to terminals 16,17 and 18. The voltage between the two phases must not exceed 305 Volts.
NOTE:- All the outputs are solid state, rated at 1.2 Amps and switch to battery negative when active.
18/06/2007 JR
21
9.2
CONNECTOR FUNCTION DETAILS
The following describes the functions of the 3 connectors on the rear of the module. See rear panel layout FIG 5.
PIN
No
1
2
3
4
5
6
7
8
10
11
12
13
14
15
16
17
18
19
20
21
22
DESCRIPTION
DC Supply -ve. System DC negative input. (Battery Negative).
DC Supply +ve. System DC positive input. (Battery Positive).
Fuel Relay output. Plant Supply negative from pin 1. Used to control the fuel
solenoid or engine fuel control system.
Starter Relay output. Plant Supply negative from pin 1. Used to control the Starter
Motor.
Auxiliary Relay output 1. Plant Supply negative from pin 1. Configurable output, see
configuration tables for options available.
Auxiliary Relay output 2. Plant Supply negative from pin 1. Configurable output, see
configuration tables for options available.
Charge Fail input / Excitation output. Supplies excitation to the Plant Battery
Charging Alternator, also an input for the Charge Fail detection circuitry.
Low Oil Pressure input. This is a negative switched input, it is possible to calibrate
the input to be a normally closed signal or a normally open signal. This input is
used to signal to the module that the oil pressure is low.
High Engine Temperature input. This is a negative switched input, it is possible to
calibrate the input to be a normally closed signal or a normally open signal. This
input is used to signal to the module that the engine temperature is high.
Auxiliary input 1. This is a negative switched configurable input, see configuration
tables for options available. It is possible to configure the input to be a normally
closed signal or a normally open signal.
Auxiliary input 2. This is a negative switched configurable input, see configuration
tables for options available. It is possible to configure the input to be a normally
closed signal or a normally open signal.
Remote Start input. This is a negative switched input, which will start the generator
when Auto is selected. This input can be configured as a simulated mains, to
prevent the generator from starting in the event of a mains failure.
Mains loading relay. Plant Supply negative from pin 1. Normally open. This output
closes when the mains (utility) has failed, energising a slave relay which should
open the mains (utility) switching device.
Generator loading relay. Plant Supply negative from pin 1. Normally open. This
output closes when the generator is available for loading, energising a slave relay
which should close the generator switching device.
Functional Earth - Ensure connection to a good clean earth point.
Mains L1 voltage monitoring input. Connect to mains L1 supply
Mains Neutral input. Connect to mains N supply.
Generator L1 sensing input. Connect to alternator L1 output.
Generator N sensing input. Connect to alternator N output.
18/06/2007 JR
10 SPECIFICATION
DC Supply
Cranking Dropouts
Typical Standby Current

Max. Operating Current
Alternator / Mains (Utility) Input
Range
Single phase 2 wire system
3Phase 4Wire System
Alternator / Mains (Utility) Input
Frequency
Start Relay Output
Fuel Relay Output
Auxiliary Relay Outputs
Dimensions
Panel cutout
Charge Fail / Excitation Range
Operating Temperature Range
Electromagnetic Compatibility
Electrical Safety
Cold Temperature
Hot Temperature
Humidity
Vibration
Shock
Applicable Standards
8.0 to 35 V Continuous.
Able to survive 0 V for 50mS, providing supply was at least 10 V before
dropout and supply recovers to 5V. This is achieved without the need
for internal batteries.
TBA. mA at 12 V. TBA. mA at 24 V.
TBA. mA at 12 V. TBA. mA at 24V
15V AC - 277 V AC (ph-N) (+20%)

15V AC - 277 V AC (ph-N) 3 Phase 4wire (+20%)
50Hz - 60 Hz at rated engine speed
1.2 Amp DC at supply voltage.
154mm x 98mm ( 6.1 x 3.9) Maximum panel thickness 8mm (0.3)
12 Volts = 8 Volts CF 24 Volts = 16 Volts CF
-30 to +70C
BS EN 50081-2 EMC Generic Emission Standard (Industrial)
BS EN 50082-2 EMC Generic Immunity Standard (Industrial)
BS EN 60950 Safety of I.T. equipment, including electrical business
equipment.
BS EN 60068-2-1 to -30 oC
BS EN 60068-2-2 to +70oC
BS2011-2-1 to 93% RH @ 40C for 48 Hours
BS EN60068-2-6
10 sweeps at 1 octave/minute in each of 3 major axes.
5Hz to 8Hz @ +/-7.5mm constant displacement
8Hz to 500Hz @ 2gn constant acceleration
BS EN 60068-2-27
3 Half sine shocks in each of 3 major axes
15gn amplitude, 11mS duration
Compliant with BS EN 60950 Low Voltage Directive
Compliant with BS EN 50081-2: 1992 EMC Directive
Compliant with BS EN 61000-6-4: 2000 EMC Directive
Compliance to European Legislation
18/06/2007 JR
23
11 COMMISSIONING
11.1 PRE-COMMISSIONING
Before the system is started, it is recommended that the following checks are made:1) The unit is adequately cooled and all the wiring to the module is of a standard and rating compatible with the
system.
2) The unit DC supply is fused and connected to the battery and that it is of the correct polarity.
3) To check the start cycle operation take appropriate measures to prevent the engine from starting (disable the
operation of the fuel solenoid). After a visual inspection to ensure it is safe to proceed, connect the battery
supply. Select MANUAL, the unit start sequence will commence.
4) The starter will engage and operate for the pre-set crank period. After the starter motor has attempted to start
the engine for the pre-set number of attempts the LCD will display its icon indicating; Failed to start
Select the STOP/RESET position to reset the unit.
5) Restore the engine to operational status (reconnect the fuel solenoid), again select MANUAL, this time the
engine should start and the starter motor should disengage automatically. If not then check that the engine is
fully operational (fuel available, etc.) and that the fuel solenoid is operating. The engine should now run up to
operating speed. If not and an alarm is present, check the alarm condition for validity, then check input wiring.
The engine should continue to run for an indefinite period.
6) Select AUTO on the front panel, the engine will run for the pre-set cooling down period, then stop. The
generator should stay in the standby mode. If not check that there is not a signal present on the Remote start
input and that the mains (utility) supply is healthy and available.
7) Initiate an automatic start by supplying the remote start signal or failing the mains (utility) supply. The start
sequence will commence and the engine will run up to operational speed. Once the generator is available a
load transfer will take place, the Generator will accept the load. If not, check the wiring to the Generator
switching device.
8) Remove the remote start signal and/or ensure the mains (utility) supply is healthy, the return sequence will
start. After the pre-set time period, the load will be removed from the generator. The generator will then run for
the pre-set cooling down period, then shutdown into its standby mode.
9) If despite repeated checking of the connections between the 4120 and the customers system, satisfactory
operation cannot be achieved, then the customer is requested to contact the factory for further advice on:INTERNATIONAL TEL: +44 (0) 1723 890099
INTERNATIONAL FAX: +44 (0) 1723 893303
E-mail: [email protected]
Website : www.deepseaplc.com
24
18/06/2007 JR
12 FAULT FINDING
SYMPTOM
Unit is inoperative
Unit shuts down
Low oil Pressure fault operates
after engine has fired
High engine temperature fault
operates after engine has fired.
Shutdown fault operates
Warning fault operates
Fail to Start is activated after preset number of attempts to start
Continuous starting of generator
when in AUTO
Generator fails to start on receipt
of Remote Start signal or mains
(utility) supply failure.
Pre-heat inoperative
Starter motor inoperative
Fuel solenoid inoperative
Engine runs but generator will not

take load
POSSIBLE REMEDY
Check the battery and wiring to the unit. Check the DC supply. Check the DC
fuse.
Check DC supply voltage is not above 35 Volts or below 9 Volts
Check the operating temperature is not above 70 C. Check the DC fuse.
Check engine oil pressure. Check oil pressure switch and wiring. Check
switch polarity is correct (i.e. Normally Open or Normally Closed).
Check engine temperature. Check switch and wiring. Check switch polarity is
correct (i.e. Normally Open or Normally Closed).
Check relevant switch and wiring of fault indicated by the illuminated LED.
Check configuration of input.
Check relevant switch and wiring of fault indicated by the illuminated LED.
Check configuration of input.
Check wiring of fuel solenoid. Check fuel. Check battery supply. Check battery
supply is present on the Fuel output of the module. Refer to engine manual.
Check that mains (utility) supply is healthy and check that its protection fuses
are in place and are not blown.
Check that there is no signal present on the Remote Start input.
If remote start fault, check signal is on Remote Start input. Confirm that the
input is configured to be used as Remote Start.
Check wiring to engine heater plugs. Check battery supply. Check battery
supply is present on the Pre-heat output of module. Check pre-heat has been
selected in your configuration.
Check wiring to starter solenoid. Check battery supply. Check battery supply
is present on the Starter output of module. NB all the outputs are negative
switching.
Check wiring to fuel solenoid. Check battery supply. Check battery supply is
present on the fule output of module. NB all the outputs are negative
switching.
Check that the output is working, NB all outputs are negative switching.
NOTE:- The above fault finding is provided as a guide check-list only. As it is possible for the
module to be configured to provide a wide range of different features always refer to the source of your
module configuration if in doubt.
NOTE:- All the outputs are solid state, rated at 1.2 Amps and switch to battery negative when active.
18/06/2007 JR
25
13 TYPICAL WIRING DIAGRAM
26
18/06/2007 JR
14 SOLID STATE OUTPUTS

DSEs utilisation of Solid State Outputs gives many advantages, the main points being:
No Moving Parts
Fully Overload / Short Circuit Protected.
Smaller dimensions hence lighter in weight and more cost effective than conventional relays.
Lower power consumption, hence increased reliability.
The main difference from conventional outputs is that solid state outputs switch to negative (ve) when active. This
type of output is normally used with an automotive or plug in relay.
Solid state output from DSE m odule

Fuel Solenoid
(+ term inal)
eg. T erm inal 3 of 4120 - FUEL

* O bserve polarity when using
rela ys fitted with integral diodes!
Battery positive (+)
A
B
C
D
Solid State Output

from DSE Module Pin
3
Automotive
relay Pin
86
85
30
87
8 Pin Plugin relay
Function
7
2
1
3
Fuel Output
To Positive supply via fuse
To Positive supply via fuse
To Fuel Solenoid
Example of relay pins connected to DSE solid state output to drive a fuel solenoid.
See overleaf for overall typical wiring diagram
NOTE:- The Close Mains Relay should be NORMALLY CLOSED when de-energised for fail safe
reasons. Should the DC supply fail the mains will always be available. The output from the DSE solid
state output when energised, will OPEN the relay therefore isolating the mains supply.
18/06/2007 JR
27
15 APPENDIX
15.1 ALTERNATIVE WIRING TOPOLOGIES
15.1.1 TWO PHASE TWO WIRE
15.1.2 SINGLE PHASE TWO WIRE

28
18/06/2007 JR
18/06/2007 JR
29
15.2 PUSH BUTTONS

Display
Description
Stop/Reset
Manual mode
Auto mode
15.3 ALARM / SHUTDOWN INDICATIONS

Display
Description
Low Oil Pressure
High Coolant Temperature
Overspeed
Underspeed
Fail to start (Over-crank)
Charge Fail
30
!1
Auxiliary Alarm input 1 (Warning or Shutdown)
!2
Auxiliary Alarm input 2 (Warning or Shutdown)
18/06/2007 JR

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COMPLEX SOLUTIONS

DEEP SEA ELECTRONICS PLC

DSE Model 4120 Automatic Mains Failure Operators Manual

Deep Sea Electronics Plc

DSE Model 4120 Control System Operators Manual

057-023 4120 OPERATING MANUAL ISSUE 2.1

DSE Model 4120 Automatic Mains Failure Operators Manual

CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION. ........ 4

AUTOMATIC MODE OF OPERATION ............................................................................... 5

DESCRIPTION OF CONTROLS .................................................................... 10

FRONT PANEL CONFIGURATION ............................................................... 12

ACCESSING THE FRONT PANEL CONFIGURATION EDITOR .................................... 12

CONFIGURATION TABLES .......................................................................... 13

INSTALLATION INSTRUCTIONS .................................................................. 17

PANEL CUT-OUT .............................................................................................................. 17

ELECTRICAL CONNECTIONS ...................................................................... 21

FAULT FINDING ......................................................................................... 25

TYPICAL WIRING DIAGRAM ..................................................................... 26

SOLID STATE OUTPUTS ........................................................................... 27

057-023 4120 OPERATING MANUAL ISSUE 2.1

DSE Model 4120 Automatic Mains Failure Operators Manual

2 CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION.

Highlights an essential element of a procedure to ensure correctness.

Indicates a procedure or practice which, if not strictly observed, could result

Indicates a procedure or practice, which could result in injury to personnel

057-023 4120 OPERATING MANUAL ISSUE 2.1

DSE Model 4120 Automatic Mains Failure Operators Manual

AUTOMATIC MODE OF OPERATION

This mode is activated by pressing the

pushbutton. An LED indicator beside the button confirms this

057-023 4120 OPERATING MANUAL ISSUE 2.1

DSE Model 4120 Automatic Mains Failure Operators Manual

fault will be displayed.

To initiate a start sequence in MANUAL, press the

NOTE:- There is no Start Delay in this mode of operation.

fault will be displayed.

057-023 4120 OPERATING MANUAL ISSUE 2.1

DSE Model 4120 Automatic Mains Failure Operators Manual

057-023 4120 OPERATING MANUAL ISSUE 2.1

DSE Model 4120 Automatic Mains Failure Operators Manual

Available in module versions V1.3 and higher.

Press and hold the

057-023 4120 OPERATING MANUAL ISSUE 2.1

DSE Model 4120 Automatic Mains Failure Operators Manual

Warnings are used to warn the operator of an impending fault

icon will illuminate.

icon will illuminate.

icon will illuminate.

DSE Model 4120 Automatic Mains Failure Operators Manual

Automatic Mode And Indicator

057-023 4120 OPERATING MANUAL ISSUE 2.1

Tamperproof LCD Hours

DSE Model 4120 Automatic Mains Failure Operators Manual

Close Mains Output

Generator available LED.

057-023 4120 OPERATING MANUAL ISSUE 2.1

DSE Model 4120 Automatic Mains Failure Operators Manual

6 FRONT PANEL CONFIGURATION

ACCESSING THE FRONT PANEL CONFIGURATION EDITOR