DEEP SEA

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057-070 Issue 1 26/07/2006 CWG 057-070 Issue 1 26/07/2006 CWG 11

Introduction to Generators and DSE generator

controllers

Author: - Colin Greenfield Author: - Colin Greenfield

Deep Sea Electronics Plc Deep Sea Electronics Plc

Highfield House Highfield House Hunmanby Hunmanby North Yorkshire North Yorkshire YO14 0PH YO14 0PH England England Tel: Tel: +44 (0) 1+44 (0) 1723 890099723 890099 Fax: +44 (0) 1723 893303 Fax: +44 (0) 1723 893303 email:

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Deep Sea Electronics Plc Deep Sea Electronics Plc Highfield House Highfield House Hunmanby Hunmanby North Yorkshire North Yorkshire YO14 0PH YO14 0PH ENGLAND ENGLAND Sales Tel: Sales Tel: +44 (0) +44 (0) 1723 8900991723 890099 Sales Fax: +44 (0) 1723 893303 Sales Fax: +44 (0) 1723 893303 E-mail

E-mail [email protected]@Deepseaplc.com

Website

Website www.deepseaplc.comwww.deepseaplc.com

Introduction to Generators and DSE generator controllers Introduction to Generators and DSE generator controllers © Deep Sea Electronics Plc

All rights reserved. No part of this publication may be reproduced in any material form (includingbe reproduced in any material form (including photocopying or storing in any medium by electronic means

photocopying or storing in any medium by electronic means or other) without the written permission ofor other) without the written permission of the copyright holder except in accordance with the provisions

the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Actof the Copyright, Designs and Patents Act 1988.

1988.

Applications for the copyright holder’s written permission to reproduce any

Applications for the copyright holder’s written permission to reproduce any part of this publication shouldpart of this publication should be addressed to Deep Sea Electronics Plc at the address above.

be addressed to Deep Sea Electronics Plc at the address above.

Any reference to trademarked product names used within this publication is

Any reference to trademarked product names used within this publication is owned by their respectiveowned by their respective companies.

companies.

Deep Sea Electronics Plc reserves the right to change the

Deep Sea Electronics Plc reserves the right to change the contents of this document without priorcontents of this document without prior notice.

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1 1 WHAT

WHAT IS

IS A

A GENERATOR

GENERATOR SET?

SET?

•

• A generator set is the combination of and engine to create power andA generator set is the combination of and engine to create power and an alternator to change that power into electricity.

an alternator to change that power into electricity.

•

• The engine turns a shaft that in turn is The engine turns a shaft that in turn is connected to the alternator. Thisconnected to the alternator. This turning of the alternator creates the electrical power.

turning of the alternator creates the electrical power.

•

• As there are different types of power all over the As there are different types of power all over the world, differentworld, different generator sets are built to create different forms of electrical power. generator sets are built to create different forms of electrical power.

•

• In England the power is 230v at 50Hz the same as is supplied fromIn England the power is 230v at 50Hz the same as is supplied from your sockets at home. In the United States of America this power is your sockets at home. In the United States of America this power is usually 110v at 60Hz.

usually 110v at 60Hz.

•

• Where ever in the world the generator set is built Where ever in the world the generator set is built for, the followingfor, the following diagram shows the general parts and construction of

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2 2 WHAT

WHAT IS

IS A

A GENERATOR

GENERATOR CONTROLLER?

CONTROLLER?

•

• A generator controller is a device used to monitor, start and stop aA generator controller is a device used to monitor, start and stop a generator.

generator.

•

• Just like any other engine, your car for example, a generator set has aJust like any other engine, your car for example, a generator set has a number of things that

number of things that must be monitored and checked during normalmust be monitored and checked during normal operation.

operation.

•

• Some of the items that are monitored are oil Some of the items that are monitored are oil pressure, enginepressure, engine temperature, fuel level among others.

temperature, fuel level among others.

•

• Also just like when you are starting your car you need to control theAlso just like when you are starting your car you need to control the start and fuel inputs to the engine. These are controlled with automatic start and fuel inputs to the engine. These are controlled with automatic switches called relays.

switches called relays.

•

• Unlike your car, a generator must also check the output of theUnlike your car, a generator must also check the output of the alternator. This will be in voltage, current and frequency. These alternator. This will be in voltage, current and frequency. These connections allow the controller to monitor the output to ensure the connections allow the controller to monitor the output to ensure the generator is operating correctly and

generator is operating correctly and is not overloaded.is not overloaded.

•

• The reason for all this checking is that normally a generator will be in The reason for all this checking is that normally a generator will be in aa separate building but unlike your car, no one will be available to check separate building but unlike your car, no one will be available to check these settings. In your car you would be there when driving to switch off these settings. In your car you would be there when driving to switch off the engine if there was a problem.

the engine if there was a problem.

•

• The below diagram shows different parts The below diagram shows different parts of an engine and generatorof an engine and generator

with the monitor and main control links to the DSE module. with the monitor and main control links to the DSE module.

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3 3 WHAT

WHAT IS

IS A

A MANUAL

MANUAL START

START UNIT?

UNIT?

•

• A manual start unit is the simplest form of A manual start unit is the simplest form of electronic generatorelectronic generator controller and is one step above a ‘pull start’ generator.

controller and is one step above a ‘pull start’ generator.

•

• This device is almost identical to the controls in your car. The deviceThis device is almost identical to the controls in your car. The device usually has a key and button to start the generator.

usually has a key and button to start the generator.

•

• If your mains power fails and you need to use generator power, youIf your mains power fails and you need to use generator power, you have to turn the key, to start the generator manually.

have to turn the key, to start the generator manually.

•

• The 701, 511, 512 and 501 are modules of this type. They only haveThe 701, 511, 512 and 501 are modules of this type. They only have basic controls to monitor items such as oil pressure and engine

basic controls to monitor items such as oil pressure and engine temperature.

temperature.

•

• The manual start unit is ideal for stand alone functions and portableThe manual start unit is ideal for stand alone functions and portable generator sets as these would normally have personnel to start and generator sets as these would normally have personnel to start and stop the generator. Examples of this are the generators often seen at stop the generator. Examples of this are the generators often seen at roadworks. roadworks.

501

701

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4 4 WHAT

WHAT IS

IS AN

AN AUTOMATIC

AUTOMATIC OR

OR REMOTE

REMOTE START

START UNIT?

UNIT?

•

• An automatic start module has all the same features as a manual startAn automatic start module has all the same features as a manual start

•

• The unit is capable of receiving a start signal from an external source.The unit is capable of receiving a start signal from an external source. This could be a start switch located inside the factory where the

This could be a start switch located inside the factory where the generator is sited for instance.

generator is sited for instance.

•

• The unit can also be set to start automatically when the mains power orThe unit can also be set to start automatically when the mains power or some other input is given to the module.

some other input is given to the module.

•

• These types of module are often used with an automatic transfer switchThese types of module are often used with an automatic transfer switch discussed later.

discussed later.

•

• 5510, 550, 4110, 703, 521 are examples of this type of module. They5510, 550, 4110, 703, 521 are examples of this type of module. They

still have only basic controls but have the advantage of being able to still have only basic controls but have the advantage of being able to receive a start signal from an external source.

receive a start signal from an external source.

4110

550

521

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5 5 WHA

WHAT

T IS

IS AN

AN AUTOMA

AUTOMATIC

TIC TRANSFE

TRANSFER

R SWITCH?

SWITCH?

•

• An automatic transfer switch (ATS) is different to a generator controllerAn automatic transfer switch (ATS) is different to a generator controller as it only monitors the mains and generator power but does not start as it only monitors the mains and generator power but does not start the engine.

the engine.

•

• The unit normally sits in a monitor panel and has connections to theThe unit normally sits in a monitor panel and has connections to the generator controller.

generator controller.

•

• When the mains power fails the ATS gives a command to the generatorWhen the mains power fails the ATS gives a command to the generator controller to start the generator set.

controller to start the generator set.

•

• Once the generator set is up and running the ATS then switches overOnce the generator set is up and running the ATS then switches over the power from mains to generator.

the power from mains to generator.

•

• The ATS will then check the mains to see when the power returns.The ATS will then check the mains to see when the power returns.

•

• Once the power returns the ATS will switch over to the mains and thenOnce the power returns the ATS will switch over to the mains and then tell the generator to stop.

tell the generator to stop.

•

• 705, 530 and 4130 modules are ATS 705, 530 and 4130 modules are ATS units.units.

530

705

704

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6 6 WHA

WHAT

T IS

IS AN

AN AUTOMA

AUTOMATIC

TIC MAINS

MAINS F

FAILURE

AILURE UNIT?

UNIT?

•

• An automatic mains failure An automatic mains failure (AMF) module combines the automatic start(AMF) module combines the automatic start module with an automatic transfer switch.

module with an automatic transfer switch.

•

• The module will monitor the mains and generator power like an ATSThe module will monitor the mains and generator power like an ATS but added to this is the ability for

but added to this is the ability for the module to control the generator asthe module to control the generator as well.

well.

•

• The module works like an auto start module in operation. TheThe module works like an auto start module in operation. The difference being it can create its own start input from

difference being it can create its own start input from conditions it canconditions it can monitor.

monitor.

•

• The AMF module is normally The AMF module is normally used when a backup power system isused when a backup power system is required for a site.

required for a site.

•

• Our own factory has an AMF panel for backup power if the mainsOur own factory has an AMF panel for backup power if the mains

power fails. power fails.

•

• The 5320, 5220, 5120, 555 and The 5320, 5220, 5120, 555 and 704 are examples of AMF systems.704 are examples of AMF systems.

704

555

555 5220

5220

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7 7 WHA

WHAT

T IS

IS SYNCHRON

SYNCHRONISING

ISING AND

AND LOAD

LOAD SHARING

SHARING?

?

•

• A synchronising and load share unit is the ultimate generator controller.A synchronising and load share unit is the ultimate generator controller. •

• They come in many forms including allowing up to 16 generators to beThey come in many forms including allowing up to 16 generators to be combined together and even providing power to the

combined together and even providing power to the national gridnational grid electricity system.

electricity system. •

• The synchronising and load sharing module can also be The synchronising and load sharing module can also be used inused in

conjunction with a ‘mains controller’ to monitor the mains and act as an conjunction with a ‘mains controller’ to monitor the mains and act as an ATS for all the generator sets.

ATS for all the generator sets. •

• 5510 and 550 are modules capable of 5510 and 550 are modules capable of providing multiple generator setproviding multiple generator set systems.

systems. •

• 5520, 555 and 557 are single set controllers to allow one generator to5520, 555 and 557 are single set controllers to allow one generator to act as mains backup and synchronise with the

act as mains backup and synchronise with the mains supply.mains supply. •

• 5560 and 556 are mains controller 5560 and 556 are mains controller and ATS modules.and ATS modules. •

• DSE’s own onsite backup power system uses synchronising and loadDSE’s own onsite backup power system uses synchronising and load sharing to allow three generator sets to start up automatically (upon sharing to allow three generator sets to start up automatically (upon mains failure) or manually (before mains failure) to power the factory. mains failure) or manually (before mains failure) to power the factory. These generators then all connect together on a

These generators then all connect together on a common wiring. Thiscommon wiring. This is then connecte

is then connected ‘en block’ d ‘en block’ to the factory, suppto the factory, supplying our power whelying our power whenn there is a power cut. The advantage of this system is that when the there is a power cut. The advantage of this system is that when the power required by the factory is reduced, then the system can stop one power required by the factory is reduced, then the system can stop one or more of the three generators, thereby saving fuel. If

or more of the three generators, thereby saving fuel. If the power thenthe power then rises again it can start the generator again and connect it to the

rises again it can start the generator again and connect it to the otherother two. two.

550

556

550

556 5510

5560

5510

5560

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057-070 Issue 1 26/07/2006 CWG

057-070 Issue 1 26/07/2006 CWG 1111

8 8 WHA

WHAT

T ARE

ARE P808, P810,

P808, P810, CONFIG

CONFIGURA

URATION

TION AND

AND

COMMUNICATIONS SOFTWARE?

•

• Take a look at road going trucks and see how many different typesTake a look at road going trucks and see how many different types there are. As the engines used on generating sets are made by the there are. As the engines used on generating sets are made by the same manufacturers (ie Volvo, Scania, Cummins), you can

same manufacturers (ie Volvo, Scania, Cummins), you can imagineimagine there are many engine types

there are many engine types used on generator sets.used on generator sets.

•

• To allow all our generator controllers to be able to operate with To allow all our generator controllers to be able to operate with asas many engines and generators as possible we have settings i

many engines and generators as possible we have settings in then the controller that can be changed by the customer.

controller that can be changed by the customer.

•

• These settings can then be saved on a These settings can then be saved on a computer and sent to thecomputer and sent to the module as a configuration file.

module as a configuration file.

•

• The 5xxx, 42xx and other software allows The 5xxx, 42xx and other software allows the customer to set the customer to set thesethese parameters and read and write them to a module.

parameters and read and write them to a module.

•

• The software can connect to the module by a cable to a computer. TheThe software can connect to the module by a cable to a computer. The small ‘box’ that allows the computer to connect to the module is the 810 small ‘box’ that allows the computer to connect to the module is the 810 or 808 interface.

or 808 interface.

808

Used for ‘older’ DSE products Used for ‘older’ DSE products such as 520, 530, 560 etc such as 520, 530, 560 etc

Configuration Software

810

Used for ‘newer’ DSE

Used for ‘newer’ DSE products such as 5200products such as 5200 series, 5300 series, 5500 series etc.

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9 9 WHA

WHAT

T ARE

ARE RS232

RS232 AND

AND RS485?

RS485?

•

• RS232 is a connection from the module that allows the unit to talk tRS232 is a connection from the module that allows the unit to talk to ao a modem.

modem.

•

• Once connected to a modem the Once connected to a modem the module can send SMS textmodule can send SMS text

messages, dial a phone number and can be called up to check on the messages, dial a phone number and can be called up to check on the status of the set.

status of the set.

•

• This connection can also be used to This connection can also be used to connect to the configurationconnect to the configuration software to allow the unit to have settings changed.

software to allow the unit to have settings changed.

•

• RS485 allows the module to be connected on a cable to many otherRS485 allows the module to be connected on a cable to many other devices. These devices can be other controllers, building management devices. These devices can be other controllers, building management systems and computers.

systems and computers.

RS485 multiple generator set link RS485 multiple generator set link

RS232 fixed line modem and GSM

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057-070 Issue 1 26/07/2006 CWG

057-070 Issue 1 26/07/2006 CWG 1313

10 WHA

10 WHAT IS

T IS CAN?

CAN?

•

• CAN is a communication link, similar to the previous types, but isCAN is a communication link, similar to the previous types, but is designed to pass information very quickly and securely between a designed to pass information very quickly and securely between a generator and the controller.

generator and the controller.

•

• The system passes all the information on The system passes all the information on oil pressure, engineoil pressure, engine temperature, fuel consumption, engine speed and much more. temperature, fuel consumption, engine speed and much more.

•

• The offshoot of this is that a controller using CAN only requires a two-The offshoot of this is that a controller using CAN only requires a two-wire connection to the engine.

wire connection to the engine.

•

• If you compare that to the picture earlier in If you compare that to the picture earlier in this publication (see below)this publication (see below) the advantages of reduced wiring can be

the advantages of reduced wiring can be seen.seen.

•

• The controller can even start and stop the engine with the CAN link byThe controller can even start and stop the engine with the CAN link by just telling the engine to start and stop. This is

just telling the engine to start and stop. This is similar to the controlsimilar to the control your computer has over your printer telling it to print

your computer has over your printer telling it to print and stop printingand stop printing remotely.

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DEEP SEA

Introduction to Generators and DSE generator

Introduction to Generators and DSE generator

controllers

controllers

Table of Contents

Table of Contents

1

1 WHAT

WHAT IS

IS A

A GENERATOR

GENERATOR SET?

SET?

2

2 WHAT

WHAT IS

IS A

A GENERATOR

GENERATOR CONTROLLER?

CONTROLLER?

3

3 WHAT

WHAT IS

IS A

A MANUAL

MANUAL START

START UNIT?

UNIT?

501

501

701

701

4

4 WHAT

WHAT IS

IS AN

AN AUTOMATIC

AUTOMATIC OR

OR REMOTE

REMOTE START

START UNIT?

UNIT?

4110

4110

550

550

521

521

5

5 WHA

WHAT

T IS

IS AN

AN AUTOMA

AUTOMATIC

TIC TRANSFE

TRANSFER

R SWITCH?

SWITCH?

530

530

705

705

704

704

6

6 WHA

WHAT

T IS

IS AN

AN AUTOMA

AUTOMATIC

TIC MAINS

MAINS F

FAILURE

AILURE UNIT?

UNIT?

704

704