COMPLEX SOLUTIONS

MADE SIMPLE.

DEEP SEA ELECTRONICS PLC

DSE5520
AUTOMATIC MAINS FAILURE
CONTROL MODULE
OPERATING MANUAL

DSE Model 5520 Automatic Mains Failure Control and Instrumentation System 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 5520 Control and Instrumentation 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.

1 BIBLIOGRAPHY
1.
2.
3.

IEEE Std C37.2-1996 IEEE Standard Electrical Power System Device Function Numbers and Contact
Designations. Institute of Electrical and Electronics Engineers Inc. ISBN 1-55937-879-4
Diesel generator handbook. L.L.J.Mahon. ISBN 0-7506-1147-2
On-Site Power Generation. EGSA Education Committee. ISBN 0-9625949-3-8

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TABLE OF CONTENTS
Section
1
2

BIBLIOGRAPHY .............................................................................................. 2
INTRODUCTION .............................................................................................. 6
2.1
2.2

Page

CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION. ..........................7

ICON DESCRIPTIONS.........................................................................................................7

OPERATION .................................................................................................... 8
3.1
CONTROL ............................................................................................................................8
3.2
AUTOMATIC OPERATION .................................................................................................9
3.2.1
MAINS FAILURE ...........................................................................................................9
3.2.2
REMOTE START IN ISLAND MODE..........................................................................11
3.2.3
REMOTE START ON LOAD .......................................................................................13
3.3
MANUAL OPERATION......................................................................................................15
3.4
TEST OPERATION ............................................................................................................17

PROTECTIONS .............................................................................................. 19
4.1
4.2
4.3
4.4
4.5

WARNINGS ........................................................................................................................19
ANALOGUE PRE-ALARMS ..............................................................................................23
SHUTDOWNS ....................................................................................................................26
ELECTRICAL TRIPS .........................................................................................................30
ROCOF / VECTOR SHIFT .................................................................................................32

DESCRIPTION OF CONTROLS .......................................................................... 33

4.6
TYPICAL LCD DISPLAY SCREENS.................................................................................33
4.6.1
TYPICAL STATUS DISPLAY ......................................................................................33
4.6.2
TYPICAL INSTRUMENT DISPLAY ............................................................................34
4.6.3
TYPICAL ALARM DISPLAY ........................................................................................34
4.6.4
TYPICAL EVENT DISPLAY ........................................................................................35
4.6.5
VIEWING THE INSTRUMENT AND EVENT LOG PAGES ........................................36
4.6.6
SYNCHROSCOPE OPERATION ...............................................................................37
4.7
COMPLETE INSTRUMENTATION LIST ...........................................................................38
4.7.1
BASIC INSTRUMENTATION ......................................................................................38
4.7.2
ENHANCED ENGINE INSTRUMENTATION .............................................................38
4.8
ACCESSING THE FRONT PANEL CONFIGURATION EDITOR .....................................39
4.8.1
ENTERING THE CONFIGURATION EDITOR PIN NUMBER ....................................39
4.8.2
EDITING VALUES.......................................................................................................40
4.8.3
LIST OF ADJUSTABLE PARAMETERS (MAIN CONFIGURATION EDITOR) .........41
4.8.4
LIST OF ADJUSTABLE PARAMETERS (APPLICATION EDITOR) ..........................42
4.9
DISPLAY EDITOR .............................................................................................................43
4.9.1
EDITING DISPLAY EDITOR CONFIGURATION VALUES ......................................43

LED IDENTIFICATION AND FRONT PANEL LAYOUT ................................ 45

5.1

CONFIGURABLE LED IDENTIFICATION DIAGRAM ......................................................45

LED INDICATORS AND LOGO INSERT ....................................................... 46

CONTROL PUSH-BUTTONS ........................................................................ 47

INSTALLATION INSTRUCTIONS.................................................................. 50
8.1
8.2
8.3

PANEL CUT-OUT ..............................................................................................................50

COOLING ...........................................................................................................................50
UNIT DIMENSIONS ...........................................................................................................50

ELECTRICAL CONNECTIONS...................................................................... 51
9.1
CONNECTION DETAILS ...................................................................................................51
9.1.1
PLUG A 8 WAY.........................................................................................................51
9.1.2
PLUG B 11 WAY.......................................................................................................51
9.1.3
PLUG C 9 WAY ........................................................................................................52
9.1.4
PLUG D 3 WAY ........................................................................................................52
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9.1.5
PLUG E 5 WAY ........................................................................................................ 52
9.1.6
PLUG F 8 WAY ........................................................................................................ 53
9.1.7
PLUG G 4 WAY ........................................................................................................ 53
9.1.8
PLUG H 12 WAY ...................................................................................................... 53
9.1.9
PC CONFIGURATION INTERFACE CONNECTOR .................................................. 54
9.1.10 EXPANSION INTERFACE CONNECTOR ................................................................. 54
9.2
CONNECTOR FUNCTION DETAILS................................................................................ 55
9.2.1
PLUG A 8 WAY ........................................................................................................ 55
9.2.2
PLUG B 11 WAY ...................................................................................................... 55
9.2.3
PLUG C 9 WAY ........................................................................................................ 56
9.2.4
PLUG D 3 WAY ........................................................................................................ 56
9.2.5
PLUG E 5 WAY ........................................................................................................ 57
9.2.6
PLUG F 8 WAY ........................................................................................................ 57
9.2.7
PLUG G 4 WAY ........................................................................................................ 57
9.2.8
PLUG H 12 WAY ...................................................................................................... 58
9.3
ENGINE CONTROL UNIT INTERFACE ........................................................................... 59

10

SPECIFICATION .........................................................................................60

11

COMMISSIONING .......................................................................................62

11.1.1 PRE-COMMISSIONING ............................................................................................. 62

11.2
BYPASSING ALARMS AT STARTUP .......................................................................... 63
11.3
COMMISSIONING SCREENS ....................................................................................... 63
11.3.1 SCREEN 1 .................................................................................................................. 63
11.3.2 SCREEN 2 .................................................................................................................. 63
11.3.3 SCREEN 3 .................................................................................................................. 63
11.3.4 SCREEN 4 .................................................................................................................. 63

12

FAULT FINDING ..........................................................................................64

13

TYPICAL WIRING DIAGRAM .....................................................................65

14

FACTORY DEFAULT CONFIGURATION ...................................................66

15

SENDER WIRING RECOMMENDATIONS ..................................................70

15.1.1
15.1.2

16

USING EARTH RETURN (SINGLE WIRE) SENDERS. ............................................ 70

USING INSULATED RETURN (TWO WIRE) SENDERS. ......................................... 71

APPENDIX ...................................................................................................72

16.1
5520 IDMT TRIPPING CURVES (TYPICAL)................................................................. 72
16.2
5510 SHORT CIRCUIT TRIPPING CURVES (TYPICAL) ............................................. 72
16.3
ACCESSORIES ............................................................................................................. 73
16.3.1 OUTPUT EXPANSION ............................................................................................... 73
RELAY OUTPUT EXPANSION (157).................................................................................... 73
LED OUTPUT EXPANSION (548) ........................................................................................ 73
16.3.2 INPUT EXPANSION (P130/P540/P541) .................................................................... 73
16.4
COMMUNICATIONS OPTION ....................................................................................... 74
16.4.1 DESCRIPTION ........................................................................................................... 74
16.4.2 PC TO CONTROLLER (DIRECT) CONNECTION ..................................................... 74
16.4.3 MODEM TO CONTROLLER CONNECTION ............................................................. 74
16.4.4 RS485 LINK TO CONTROLLER ................................................................................ 75
TYPICAL BUILDING MANAGEMENT SCHEME USING RS485 MONITORING ................. 76
16.4.5 MODBUS................................................................................................................. 76
16.5
IEEE C37.2 STANDARD ELECTRICAL POWER SYSTEM DEVICE FUNCTION
NUMBERS .................................................................................................................................... 77
16.6
ENCLOSURE CLASSIFICATIONS ............................................................................... 79
IP CLASSIFICATIONS .......................................................................................................... 79
NEMA CLASSIFICATIONS ................................................................................................... 80

12.

SYNCHRONISING NOTES ..........................................................................81

16.6.1 CHECK SYNC ............................................................................................................ 81
16.6.2 AUTO SYNC ............................................................................................................... 81
16.6.3 LOAD CONTROL ....................................................................................................... 81
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MAINS CT ..............................................................................................................................81
16.6.4 TYPICAL PEAK LOPPING SYSTEM ..........................................................................82

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2 INTRODUCTION
The DSE 5520 Module has been designed to allow the OEM to meet demand for increased
capability within the industry. It has been primarily designed to allow the user to start and stop the
generator and if required, transfer the load to the generator either manually or automatically, or in
the event of the module detecting a mains failure. The user also has facility to view all the system
operating parameters via the LCD display.
Utilising the inbuilt synchronising, volts matching and paralleling functions, the 5520 can also be
used to parallel with the mains supply for no break return, peak lopping or power import / export
functionality and load control.
The DSE 5520 module monitors the incoming AC mains supply for under or over voltage / under or
over frequency and instructs the generating set to start and to supply the load.
The DSE 5520 module also monitors the engine, indicating the operational status and fault
conditions; automatically shutting down the engine and giving a true first-up fault condition of an
engine failure by a flashing COMMON ALARM LED. Exact failure mode information is indicated by
the LCD display on the front panel.
The powerful Micro-processor contained within the module allows for a range of enhanced
features to be incorporated as standard;

Full Multi-lingual LCD displays (including non-western character fonts).

True RMS voltage monitoring.
Power measurement instrumentation.
Communications capability (RS485 or RS232 including GSM/SMS functions)
Check Sync capability
Automatic Sync capability
Load control capability
Fully configurable inputs for use as alarms or a range of different functions.
Extensive range of output functions using built in relay outputs or relay expansion available.
CAN instrumentation and diagnostics when connected to a compatible CAN (electronically
controlled) engine controller.

Selective operational sequences, timers and alarm trips can be adjusted by the customer via the
integral front panel configuration editor.
Comprehensive configuration is made using the 5xxx For Windows software and 810 interface
module
Access to critical operational sequences and timers for use by qualified engineers, can be barred
by a security code. Module access can also be barred by PIN code. Selected parameters can be
changed from the modules front panel.
The module is housed in a robust plastic case suitable for panel mounting. Connections to the
module are via locking plug and sockets.

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2.1

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!

2.2

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.

ICON DESCRIPTIONS

Symbol

Meaning
Stop/Reset

Description
Stop the generator and reset any alarm conditions.

Start

Start the generator (if in an appropriate mode).

The controller will automatically start the generator
when given a remote start command.
The controller will start the generator under manual
control. (Separate Start command may be necessary)

Auto
Manual
Mains Failure Simulation
(Test)

On AMF modules, this is used to simulate a mains

failure event. (On-load test)

Alarm Mute

Silences the audible warning device.

Information

Changes the display to another page

Up

Selects the previous item on the page

Down

Selects the next item on the page

Close mains load switching device (manual mode
only)
Close generator load switching device (manual mode
only)
Edit or save current selection (configuration mode
only)

Close mains
Close generator

9
+
-

Accept
Increase

Increase current selection (configuration mode only)

Decrease

Decrease current selection (configuration mode only)

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3 OPERATION
3.1

CONTROL

Control of the DSE 5520 module is via push buttons mounted on the front of the module with
STOP/RESET, MANUAL, TEST, AUTO, LAMP TEST and ALARM MUTE and START functions.
For normal operation, these are the only controls which need to be operated. The smaller push
buttons are used to access further information such as engine instruments and load switching
operations. Detail of their operation is covered later in this document.
The following descriptions detail the sequences followed by a module containing the standard
factory configuration. Always refer to your configuration source for the exact sequences and
timers observed by any particular module in the field.

CAUTION: - The module may instruct an engine start event due to external
influences. Therefore, it is possible for the engine to start at any time without warning.
Prior to performing any maintenance on the system, it is recommended that steps are
taken to isolate DC supplies and remove the battery.

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3.2

AUTOMATIC OPERATION

3.2.1

MAINS FAILURE

This mode of operation is used to ensure continuity of supply to critical loads during a mains failure
condition. This is the normal mode of operation when installed on a standby generator.
NOTE: - If a digital input configured to panel lock is active, changing module modes

will not be possible. Viewing the instruments

and
are NOT affected by panel
lock. If panel lock is active the Panel lock indicator (if configured) illuminates.

This mode is activated by pressing the

will illuminate to confirm this operation.

pushbutton. An LED indicator beside the button

Should the mains (utility) supply fall outside the configurable limits for longer than the period of the
mains transient delay timer, the mains (utility) available GREEN indicator LED extinguishes.
To allow for short term mains supply transient conditions, 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 during the Start Delay timer, the unit
will return to a stand-by state.
After the above delays have expired the Fuel Solenoid (or enable ECU output if configured) is
energised, then one second later, the Starter Motor is engaged.
NOTE:- If the unit has been configured for CAN Bus, compatible ECUs will receive
the start command via CAN Bus. Refer to the Manual CAN and DSE Wiring. Part No. 057004 for more information on utilising DSE modules with electronically controlled engines.
The engine is cranked for a pre-set time. If the engine fails to fire during this cranking attempt then
the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond
the set number of attempts, the start sequence will be terminated and Fail to Start fault will be
displayed.
Alarm
Shutdown
Fail to start
When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency
measured from the alternator output. Alternatively, a Magnetic Pickup mounted on the flywheel
housing can be used for speed detection (This is selected by PC using the 5xxx series
configuration software). Rising oil pressure can also be used to disconnect the starter motor;
however it cannot be used for underspeed or overspeed detection.
NOTE:- If the unit has been configured for CAN Bus, speed sensing is via CAN Bus.

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After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure,
High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to
stabilise without triggering the fault.
Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to
stabilise before accepting the load.
After the Warm-up timer has expired then the module will transfer the load from the failed mains
supply to the generator output. It will observe the following sequence. The Mains
Contactor/Breaker will be instructed to open and after a short delay (transfer delay), the
Generator Contactor/Breaker will be instructed to close.
The generator will then supply the requirements of the load.
NOTE:-A load transfer will not be initiated until the Oil Pressure has risen. This
prevents excessive wear on the engine.
When the mains supply returns, the Stop delay timer is initiated. Once it has expired, the set is
synchronised and paralleled with the mains supply. The system remains in this condition until
expiry of the Parallel run timer. Once this has expired, the module will ramp the remaining load
from the generator to mains supply. The Generator Contact/Breaker will open and 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.
During the parallel run, the module can be configured to either run at a fixed level output, or to
maintain an output in relation to the load level on the mains. For full details of these mode please
refer to the manual The Guide to sync and load share Pt1
Should the mains supply fall outside limits once again the set will return on load.
NOTE: - When synchronising is enabled, the mains supply is checked before closing
any load switching device. If the supply is live, synchronising will take place before any
closure takes place.

NOTE: - Synchronising can be disabled if the application does not require this
function. Contact your genset supplier in the first instance for further details.

10

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3.2.2

REMOTE START IN ISLAND MODE

This mode of operation is used to start the set in response to an external start requirement from
another device. It may also be used to provide continuity of supply during expected black out
events.
NOTE:- If a digital input configured to panel lock is active, changing module modes

will not be possible. Viewing the instruments

and
are NOT affected by panel
lock. If panel lock is active the Panel lock indicator (if configured) illuminates.

This mode is activated by pressing the

will illuminate to confirm this operation.

pushbutton. An LED indicator beside the button

If the remote start in island mode input activates, the Remote Start Active indicator (if configured)
illuminates.
To allow for false remote start signals, the Start Delay timer is initiated. After this delay, if the preheat output option is selected then the pre-heat timer is initiated and the corresponding auxiliary
output (if configured) will energise.
NOTE:- If the Remote Start signal is removed during the Start Delay timer, the unit
will return to a stand-by state.
After the above delays, the Fuel Solenoid (or enable ECU output if configured) is energised, and
then one second later, the Starter Motor is engaged.
NOTE: - If the unit has been configured for CAN Bus, compatible ECUs will receive
the start command via CAN Bus. Refer to the Manual CAN and DSE Wiring. Part No. 057004 for more information on utilising DSE modules with electronically controlled engines.
The engine is cranked for a pre-set time. If the engine fails to fire during this cranking attempt then
the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond
the set number of attempts, the start sequence will be terminated and Fail to Start fault will be
displayed.
Alarm
Shutdown
Fail to start

When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency
measured from the alternator output. Alternatively, a Magnetic Pickup mounted on the flywheel
housing can be used for speed detection (This is selected by PC using the 5xxx series
configuration software). Rising oil pressure can also be used to disconnect the starter motor;
however, it cannot be used for underspeed or overspeed detection.
NOTE: - If the unit is configured for CAN Bus, speed sensing is via CAN Bus.

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After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure,
High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to
stabilise without triggering the fault.
Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to
stabilise before accepting the load.
NOTE: - A load transfer will not be initiated until the Oil Pressure has risen. This
prevents excessive wear on the engine.
The Generator will first be instructed to synchronise with the mains supply before closing the
Generator Contact/Breaker and transferring load from mains to generator until the generator is
supplying the required amount of power (adjustable using 5xxx configuration software).
When the supplies have been in parallel for the duration of the parallel run time, the load will
ramp off the mains supply and onto the generator. The Mains Contactor/Breaker will be
instructed to open.
The generator will then supply the requirements of the load.
When the remote start signal is removed, the Stop delay timer is initiated. Once it has expired, the
set is synchronised and paralleled with the mains supply.
The system remains in this condition until expiry of the Parallel run timer. Once this has expired,
the module will ramp the remaining load from the generator to mains supply.
The Generator Contact/Breaker will open and 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.
NOTE: - Synchronising can be disabled if the application does not require this
function. Contact your generating set supplier in the first instance for further details.

NOTE: - The internal Scheduler can be configured to operate they system in the
same manner as described for the Remote start input. Please refer to the 5xxx
Configuration Software manuals for full details on the feature.

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3.2.3

REMOTE START ON LOAD

This mode of operation is used to start the set in response to rising load levels on the mains supply
(if configured).
NOTE: - If a digital input configured to panel lock is active, changing module modes

will not be possible. Viewing the instruments

and
are NOT affected by panel
lock. If panel lock is active the Panel lock indicator (if configured) illuminates.

This mode is activated by pressing the

will illuminate to confirm this operation.

pushbutton. An LED indicator beside the button

Should the load level on the mains supply exceed a pre-set level the module will initiate a start
sequence.
To allow for short duration load surges, the Start Delay timer is initiated. After this delay, if the preheat output option is selected then the pre-heat timer is initiated and the corresponding auxiliary
output (if configured) will energise.
NOTE: - If the load level returns below the pre-set level during the Start Delay timer,
the unit will return to a stand-by state.
After the above delays, the Fuel Solenoid (or enable ECU output if configured) is energised, and
then one second later, the Starter Motor is engaged.
NOTE: - If the unit has been configured for CAN Bus, compatible ECUs will receive
the start command via CAN Bus. Refer to the Manual CAN and DSE Wiring. Part No. 057004 for more information on utilising DSE modules with electronically controlled engines.
The engine is cranked for a pre-set time. If the engine fails to fire during this cranking attempt then
the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond
the set number of attempts, the start sequence will be terminated and Fail to Start fault will be
displayed.
Alarm
Shutdown
Fail to start

When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency
measured from the alternator output. Alternatively, a Magnetic Pickup mounted on the flywheel
housing can be used for speed detection (This is selected by PC using the 5xxx series
configuration software). Rising oil pressure can also be used to disconnect the starter motor;
however, it cannot be used for underspeed or overspeed detection.
NOTE: - If the unit is configured for CAN Bus, speed sensing is via CAN Bus.

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After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure,
High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to
stabilise without triggering the fault.
Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to
stabilise before accepting the load.
After the Warm-up timer has expired then the module will transfer the load from the mains supply
to the generator output. It will observe the following sequence.
The Generator will first be instructed to synchronise with the mains supply. Once these are
matched, the Generator Contact/Breaker will be instructed to close.
The load will then be ramped from the Mains to the appropriate level on the generator.
The generator will then supply the requirements of the load.
NOTE: - A load transfer will not be initiated until the Oil Pressure has risen. This
prevents excessive wear on the engine.
When the remote start on load input is removed, the Stop delay timer is initiated. Once this timer
has expired, the module will ramp the load from the generator to mains supply. The Generator
Contact/Breaker will open and 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.
During the parallel run, the module can be configured to either run at a fixed level output, or to
maintain an output in relation to the load level on the mains.
NOTE: - When synchronising is enabled, the mains supply is checked before closing
any load switching device. If the supply is live, synchronising will take place before any
closure takes place.

NOTE: - Synchronising can be disabled if the application does not require this
function. Contact your genset supplier in the first instance for further details.

NOTE: - The load level mode of operation relies on a Current Transformer (CT) fitted
to the mains feed of the system. This is then used for measurement of the mains current
used in the load level calculations.

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3.3

MANUAL OPERATION

Manual mode is used to allow the operator to control the operation of the generator, and to provide
fault finding and diagnostic testing of the various operations normally performed during Automatic
mode operation.
NOTE: - If a digital input configured to panel lock is active, changing module modes

will not be possible. Viewing the instruments

and event logs
is NOT affected by
panel lock. If panel lock is active the Panel lock indicator (if configured) illuminates.
MANUAL, mode is selected by pressing the

pushbutton. An LED besides the button will

illuminate to confirm this operation. When the START (I) button is operated, the module will initiate
the start sequence.
NOTE: - There is no Start Delay in this mode of operation.
If the pre-heat output option has been selected, this timer will be initiated and the auxiliary output
selected energised.
After the above delay, the Fuel Solenoid (or ECU output if configured) is energised, and then one
second later, the Starter Motor is engaged.
NOTE:- If the unit is configured for CAN Bus, compatible ECUs will receive the start
command via CAN Bus. Refer to the Manual CAN and DSE Wiring. Part No. 057-004 for
more information on utilising DSE modules with electronically controlled engines.
The engine is cranked for a pre-set time. If the engine fails to fire during this cranking attempt then
the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond
the set number of attempts, the start sequence will be terminated and Fail to Start will be
displayed.
Alarm
Shutdown
Fail to start

When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency
measured from the Alternator output. Alternatively, a Magnetic Pickup mounted on the flywheel
housing can be used for speed detection (This is selected by PC using the 5xxx series
configuration software). Rising oil pressure can also be used to disconnect the starter motor;
however, it cannot be used for underspeed or overspeed detection.
NOTE: - If the unit is configured for CAN Bus, speed sensing is via CAN Bus.
After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure,
High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to
stabilise without triggering the fault.
Once the engine is running, the Warm Up timer (if selected) is initiated, allowing the engine to
stabilise before it can be loaded. Once the warm up timer has expired, the generator is then
available to go on load and the Generator Available LED will illuminate on the front panel.
The generator will run off load unless:
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1. The mains supply fails,

2. A Remote Start on load signal is applied, or an on-load run is configured in the scheduler.
3. The

Close Generator button is pressed.

If any of the above signals are received, the generator is synchronised and paralleled with the
mains supply (if available).
During the parallel run, the module can be configured to either run at a fixed level output, or to
maintain an output in relation to the load level on the mains. For full details of these mode please
refer to the manual The Guide to sync and load share Pt1
Parallel operation:
Close Generator button is pressed again while in parallel, then the module will
If the
transfer the load fully to the generators, removing the load from the mains supply. This will be
achieved by ramping the load from the parallel operating level to the generator. The Mains
Contactor/Breaker will then be opened. Pressing the
Close Mains button will cause the
module to re-synchronise the generator with the mains supply and then return to parallel
operation.
If the
Close Mains button is pressed while in parallel, the module will open the generator
load switching device, transferring the load fully to the mains supply.
If Auto mode is selected and the mains supply is healthy, and the remote start on load signal not
active, and the scheduler is not calling for a run, then the Return Delay Timer will start.
Once this has expired then the module will exit parallel operation and will ramp the load back to
the mains supply. It will then open the Generator Contactor/Breaker. The generator will then run
off load allowing the engine a cooling period.
Selecting STOP (O) de-energises the FUEL SOLENOID, bringing the generator to a stop.
WARNING: - Operation of the STOP button in any mode will stop the generator
operation and return the load switching system to a safe state. This operation may lead
to loss of supply to the load. It is recommended that the STOP button is only operated
once the generator is OFF LOAD and the mains is supplying the load.

NOTE: - Synchronising can be disabled if the application does not require this
function. Contact your genset supplier in the first instance for further details. If
synchronising is disabled the system will always perform an open transition when
switching the load from the mains to the generator or when returning to the mains. The
parallel run stages of the sequence are not used when operating in this way.
NOTE: - When synchronising is enabled, the mains supply is checked before closing
any load switching device. If the supply is live, synchronising will take place before any
closure takes place.

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3.4

TEST OPERATION

Test operation is used to perform a full on load test sequence to allow for diagnosis of faults.
Alternatively, it may also be used to provide continuity of supply during expected black out events,
peak lopping or peak shaving during high tariff periods.
NOTE: - If a digital input configured to panel lock is active, changing module modes

will not be possible. Viewing the instruments

and event logs
is NOT affected by
panel lock. If panel lock is active the Panel lock indicator (if configured) illuminates.
TEST mode is initiated by pressing the

pushbutton. An LED besides the button will illuminate

to confirm this operation. When the START (I) button is operated, the module will initiate the start
sequence.
NOTE: - There is no Start Delay in this mode of operation.
If the pre-heat output option has been selected, this timer will initiate and the auxiliary output
selected will be energised.
After the above delay, the Fuel Solenoid (or ECU output if configured) is energised, and then one
second later, the Starter Motor is engaged.
NOTE: - If the unit has been configured for CAN Bus, compatible ECUs will receive
the start command via CAN Bus. Refer to the Manual CAN and DSE Wiring. Part No. 057004 for more information on utilising DSE modules with electronically controlled engines.
The engine is cranked for a pre-set time. If the engine fails to fire during this cranking attempt then
the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond
the set number of attempts, the start sequence will be terminated and Fail to Start will be
displayed.
Alarm
Shutdown
Fail to start

When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency from
the Alternator output. Alternatively, a Magnetic Pickup mounted on the flywheel housing can be
used for speed detection (This is selected by PC using the 5xxx series configuration software).
Rising oil pressure can also be used to disconnect the starter motor; however, it cannot be used
for underspeed or overspeed detection.
NOTE: - If the unit has been configured for CAN Bus speed sensing is via CAN Bus.
After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure,
High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to
stabilise without triggering the fault.

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Once the engine is running, the Warm Up timer, if selected is initiated, allowing the engine to
stabilise before accepting the load.
After the Warm-up timer has expired then the module will transfer the load from the mains supply
to the generator output. It will observe the following sequence.
The Generator will first be instructed to synchronise with the mains supply. Once these are
matched the Generator Contact/Breaker will be instructed to close.
The load will then be ramped from the Mains to the appropriate level on the generator.
It will remain in this state whilst in the TEST mode.
If the module has an active remote start in island mode input or the internal scheduler has been
configured for island mode then the parallel run time will activate. When this expires, the load will
ramp off the mains supply and onto the generator. The Mains Contactor/Breaker will be
instructed to open
The generator will then supply the requirements of the load.
NOTE:-A load transfer will not be initiated until the Oil Pressure has risen. This
prevents excessive wear on the engine.
The system will then remain in this mode of operation until a different mode is selected. It is
recommended that

mode is used to cancel the TEST mode.

When
mode is selected the Stop delay timer is initiated. Once it has expired, the set is
synchronised and paralleled with the mains supply. The system remains in this condition until
expiry of the Parallel run timer. Once this has expired the module will ramp the remaining load
from the generator to mains supply. The Generator Contact/Breaker will open and 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.
During the parallel run the module can be configured to either run at a fixed level output, or to
maintain an output in relation to the load level on the mains. For full details of these mode please
refer to the manual The Guide to sync and load share Pt1

NOTE:- When synchronising is enabled, the mains supply is checked before closing
any load switching device. If the supply is live, synchronising will take place before any
closure takes place.

NOTE:- Synchronising can be disabled if the application does not require this
function. Contact your genset supplier in the first instance for further details.

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4 PROTECTIONS
When an alarm is present the Audible Alarm will sound and the Common alarm LED (if configured)
will illuminate.
The audible alarm can be silenced by pressing the Mute button
The LCD display will jump from the Information page to display the Alarm Page
Alarm
Warning
Low oil pressure

The type of alarm. Shutdown or warning

The nature of alarm, e.g. Low oil
pressure.

The LCD will display multiple alarms e.g. High Engine Temperature shutdown, Emergency Stop
and Low Coolant Warning alarms that may have been triggered. These will automatically scroll
round in the order that they occurred.
In the event of a warning alarm the LCD will display the appropriate text. If a shutdown then occurs
the module will again display the appropriate text.
Example:Alarm
Shutdown
High coolant temp
Followed by.
Alarm
Shutdown
Emergency stop
Followed by.
Alarm
Warning
Low coolant level
The unit will scroll through
all active alarms in a
continuous loop.
Alarm
Shutdown
High coolant temp

Generator available
L-N 229v
0A
L-L 400v

50.0Hz

pf 0.00

0KW

4.1

If no alarms are present the LCD

will display this default page.

WARNINGS
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Warnings are non-critical alarm conditions and do not affect the operation of the generator system.
They draw the operators attention to an undesirable condition.
In the event of an alarm the LCD will jump to the alarms page and scroll through all active
warnings and shutdowns.
BATTERY CHARGE FAILURE, will be displayed if the module does not detect a voltage from the
warning light terminal on the auxiliary charge alternator.
Alarm
Warning
Charge alt failure

BATTERY LOW VOLTAGE will be displayed if the module detects that the plant DC supply has
fallen below the low volts setting level. The Battery Low Voltage alarm is delayed by the Low DC
Volts Delay timer.
Alarm
Warning
Low battery voltage

BATTERY HIGH VOLTAGE will be displayed if the module detects that the plant DC supply has
risen above the high volts setting level. The Battery High Voltage alarm is delayed by the High DC
Volts Delay timer.
Alarm
Warning
High battery voltage

FAIL TO STOP, will be displayed if the module detects the engine is still running when the Fail to
stop timer expires.
Alarm
Fail to stop

NOTE:- Fail to Stop could indicate a faulty oil pressure sender - If engine is at rest
check oil sender wiring and configuration.

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AUXILIARY INPUTS, auxiliary inputs can be user configured and will display the message as
configured in the module.
Example
Alarm
Warning
Bearing temp high

LOW FUEL LEVEL, will be displayed if the fuel level detected by the fuel level sender falls below
the low fuel level setting.
Alarm
Warning
Low fuel level

LOW ENGINE TEMPERATURE, if the module detects that the engine coolant temperature has
fallen below the low engine temperature pre-alarm setting leve, a warning will occur. Alarm
Warning Low Coolant Temp will be displayed.
Alarm
Warning
Low Coolant Temp

GENERATOR FAILED TO OPEN, if the module requests the generator contact/breaker to open it
will monitor the auxiliary contacts for feedback that this has happened. If the feedback does not
confirm the action within the Generator breaker open timer, then the following alarm will occur.
Alarm
Warning
Gen failed to open

MAINS FAILED TO CLOSE, if the module requests the mains contact/breaker to close it will
monitor the auxiliary contacts for feedback that this has happened. If the feedback does not
confirm the action within the Mains breaker close timer, then the following alarm will occur.
Alarm
Warning
Mains failed to close

MAINS FAILED TO OPEN, if the module requests the mains contact/breaker to open it will monitor
the auxiliary contacts for feedback that this has happened. If the feedback does not confirm the
action within the Mains breaker open timer, then the following alarm will occur.
Alarm
Warning
Mains failed to open

MAINTENANCE DUE , The module can be configured to monitor either engine running hours or
absolute time, or both. Should either of these values exceed the pre-set service interval the
following alarm will occur..
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Alarm
Warning
Maintenance Due
The following alarms are only applicable if synchronising is enabled:
FAILED TO SYNCHRONISE, if the module cannot synchronise within the timer allowed by the
Synchronising timer a warning is initiated. The LCD will indicate FAILED TO SYNC .
Alarm
Warning
Failed to synchronise

GENERATOR PHASE SEQUENCE WRONG, if the module detects a bus phase rotation error a
warning is initiated. The LCD will indicate GEN PHASE SEQ WRONG .
Alarm
Warning
Gen phase Seq Wrong

MAINS PHASE SEQUENCE WRONG, if the module detects a MAINS phase rotation error a
warning is initiated. The LCD will indicate MAINS PHASE SEQ WRONG.
Alarm
Warning
Mains phase Seq Wrong

NEGATIVE PHASE SEQUENCE, if the module detects an imbalance in the load current of each
phase above a pre-set level, then the following warning will occur.
Alarm
Warning
Negative phase
Sequence

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4.2

ANALOGUE PRE-ALARMS

The following alarms are termed pre-alarms as they pre warn the operator of a potentially more
serious alarm condition. For instance, if the engine temperature rises past the pre alarm level, a
warning condition will occur to notify the operator. If the temperature falls below this level, then the
alarm ceases and the set will continue to run as normal. However if the temperature continues to
rise until the coolant temperature trip point is reached, the warning is escalated and a high coolant
temperature shutdown is initiated.
LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low
oil pressure pre-alarm setting level after the Safety On timer has expired, a warning will occur.
Alarm Warning Low Oil Pressure will be displayed.
Alarm
Warning
Low oil pressure

HIGH ENGINE TEMPERATURE, if the module detects that the engine coolant temperature has
exceeded the high engine temperature pre-alarm setting level after the Safety On timer has
expired, a warning will occur. Alarm Warning High Coolant Temperature will be displayed.
Alarm
Warning
High coolant temp

OVERSPEED, if the engine speed exceeds the pre-alarm trip a warning is initiated. Alarm Warning
Overspeed will be displayed. It is an immediate warning.
Alarm
Warning
Overspeed

UNDERSPEED, if the engine speed falls below the pre-set pre-alarm after the Safety On timer has
expired, a warning is initiated. Alarm Warning Underspeed will be displayed.
Alarm
Warning
Underspeed

GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the
pre-set trip a warning is initiated. Alarm Warning High Current will be displayed. If this high current
condition continues for an excess period of time, then the alarm is escalated to a shutdown
condition. For further details of the high current alarm, please see High Current Shutdown Alarm.
Alarm
Warning
Over current

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GENERATOR HIGH FREQUENCY, if the module detects a generator output frequency in excess
of the pre-set pre-alarm, a warning is initiated. Alarm Warning High frequency will be displayed, it
is an immediate warning.
Alarm
Warning
Gen high frequency
GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the
pre-set pre-alarm after the Safety On timer has expired, a warning is initiated. Alarm Warning Low
Frequency will be displayed
Alarm
Warning
Gen low frequency

GENERATOR HIGH VOLTAGE, if the module detects a generator output voltage in excess of the
pre-set pre-alarm, a warning is initiated. Alarm Warning High voltage will be displayed, it is an
immediate warning.
Alarm
Warning
Gen high voltage
GENERATOR LOW VOLTAGE, if the module detects a generator output voltage below the preset pre-alarm after the Safety On timer has expired, a warning is initiated. Alarm Warning Low
Voltage will be displayed.
Alarm
Warning
Gen low voltage

CAN ECU ERROR, If the module is configured for CAN Bus instruments and receives
an error message from the engine control unit, Can ECU error is shown on the
modules display and a warning alarm is generated.
Example
Alarm
Can ECU error
Exhaust high
temperature

24

The display will alternate

between the text display
and the manufacturers
error codes

Alarm
Can ECU error
SPNnnnnnnn
FMInnnnnnn

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INSUFFICIENT CAPACITY, if the module is configured to limit the import Kw on the mains supply,
variations in the load levels will be matched by increasing the Kw on the generator. Should the
load level increase to a sufficient demand that the generator is giving 100% of its rating. Further
increases in demand will need to be met by increasing the Kw on the mains supply as the
generator cannot supply any more. The system will issue the warning alarm to indicate that it can
no longer regulate the Kw present on the mains until the total load level is reduced.
Alarm
Warning
Insufficient Capacity

LOSS OF EXCITATION, the module will monitor the KVAr present on the generator. Should this
exceed a pre-set amount of negative VAr this indicates a possible loss of excitation on the
alternator. The following alarm will then be generated.
Alarm
Warning
Loss of Excitation

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4.3

SHUTDOWNS

Shutdowns are latching and stop the Generator. The alarm must be cleared and the fault removed
to reset the module.
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).
FAIL TO START, if the engine does not fire after the pre-set number of attempts has been made a
shutdown will be initiated. Alarm Shutdown Fail To Start will be displayed.
Alarm
Shutdown
Fail to start

EMERGENCY STOP, removal of the positive DC Supply from the Emergency Stop input will
initiate a shutdown of the Generator and prevent any attempt to restart the Generator until the
Emergency Stop push-button has been reset. Additionally it removes the positive DC supply from
both the Fuel Solenoid and Starter Solenoid.
Alarm Shutdown Emergency Stop will be displayed.
Alarm
Shutdown
Emergency stop

NOTE:- The Emergency Stop positive signal must be present otherwise the unit will
shutdown.
LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low
oil pressure trip setting level after the Safety On timer has expired, a shutdown will occur. Alarm
Shutdown Low Oil Pressure will be displayed.
Alarm
Shutdown
Low oil pressure

HIGH ENGINE TEMPERATURE, if the module detects that the engine coolant temperature has
exceeded the high engine temperature trip setting level after the Safety On timer has expired, a
shutdown will occur. Alarm Shutdown High Engine Temperature will be displayed.
Alarm
Shutdown
High coolant temp

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OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated. Alarm
Shutdown Overspeed will be displayed. Overspeed is not delayed, it is an immediate shutdown.
Alarm
Shutdown
Overspeed

NOTE:-During the start-up sequence the overspeed trip logic can be configured to
allow an extra trip level margin. This is used to prevent nuisance tripping on start-up Refer to the 55xx series configuration software manual under heading Overspeed
Overshoot for details.
UNDERSPEED, if the engine speed falls below the pre-set trip after the Safety On timer has
expired, a shutdown is initiated. Alarm Shutdown Underspeed will be displayed.
Alarm
Shutdown
Underspeed
GENERATOR HIGH FREQUENCY, if the module detects a generator output frequency in excess
of the pre-set trip a shutdown is initiated. Alarm Shutdown High Frequency will be displayed, it is
an immediate shutdown.
Alarm
Shutdown
Gen high frequency
GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the
pre-set trip after the Safety On timer has expired, a shutdown is initiated. Alarm Shutdown Low
Frequency will be displayed.
Alarm
Shutdown
Gen low frequency
GENERATOR HIGH VOLTAGE, if the module detects a generator output voltage in excess of the
pre-set trip a shutdown is initiated. Alarm Shutdown High Volts will be displayed, it is an
immediate shutdown.
Alarm
Shutdown
Gen high voltage
GENERATOR LOW VOLTAGE, if the module detects a generator output voltage below the preset trip after the Safety On timer has expired, a shutdown is initiated. Alarm Shutdown Low Volts
will be displayed.
Alarm
Shutdown
Gen low voltage

NOTE:-Generator voltage and frequency alarms can be delayed by the Gen

Transient ignore timer. This is to prevent nuisance tripping when applying or removing
load on the generator.

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OIL PRESSURE SENDER OPEN CIRCUIT, if the module detects a loss of signal from the oil
pressure sender (open circuit) a shutdown is initiated. Alarm Shutdown Sender Fault will be
displayed. Sender failure is not delayed, it is an immediate shutdown.
Alarm
Shutdown
Oil press sender fault

MAGNETIC PICKUP OPEN CIRCUIT, if the module detects a problem with the connection to the
magnetic pickup (open circuit) a shutdown is initiated. MPU failure is not delayed, it is an
immediate shutdown.
Alarm
Shutdown
MPU open circuit

AUXILIARY INPUTS, if an auxiliary input has been configured as a shutdown the appropriate
message will be displayed as configured by the user.
Alarm
Shutdown
Bearing temp high

LOSS OF SPEED SIGNAL, if the speed sensing signal is lost during cranking, a shutdown is
initiated. Alarm Shutdown Loss of Speed Signal will be displayed.
Alarm
Shutdown
Loss of speed signal

NOTE:- This will only occur if the magnetic pickup speed sensing signal is lost during
cranking or during the safety on timer. If the signal is lost during normal operation the
Generator will shutdown with an Under-speed alarm.

CAN DATA FAIL, If the module is configured for CANbus operation and does not detect
data on the engine CANbus datalink, a shutdown will occur and Can data fail is shown on
the modules display.
Alarm
Shutdown
Can data fail

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CAN ECU FAIL, If the module is configured for CANbus operation and receives a fail
message from the engine control unit, the engine is shutdown and Can ECU fail is
shown on the modules display.
Example
Alarm
Can ECU fail
Fuel pressure low

The display will alternate

between the text display
and the manufacturers
error codes

Alarm
Can ECU fail
SPNnnnnnnn
FMInnnnnnn

NOTE: - If the CAN message is a manufacturers specific code, it may not be

displayed as text. If this is the case, the display will show the generic manufacturers
code only, which must be cross-referenced with the engine manufacturers literature.
Please contact the engine manufacturer for further assistance.
The above displays show a standard J1939 based system. Other manufacturers
systems supported by the module work in a similar way though the exact detail may
vary from those illustrated.
Example
Alarm
Can ECU fail
SPNnnnnn
FMInnnn
GENERATOR EARTH FAULT, if the module detects a generator earth fault current in excess of
the pre-set trip a shutdown is initiated. The LCD will indicate EARTH FAULT. This alarm is
configurable between Warning, Shutdown and Electrical Trip. Shutdown is the factory default
setting.
Alarm
Shutdown
Earth Fault

AIR FLAP CLOSED, if the module detects feedback to indicate that the engine air intake flap is
closed a shutdown alarm will be initiated.
Alarm
Shutdown
Air flap closed

NEGATIVE PHASE SEQUENCE, if the module detects an imbalance in the load current of each
phase above a pre-set level, then the following shutdown will occur.
Alarm
Shutdown
Negative phase
Sequence

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4.4

ELECTRICAL TRIPS

Electrical trips are latching and stop the Generator but in a controlled manner. On initiation of the
electrical trip condition the module will de-energise the Close Generator Output to remove the
load from the generator. Once this has occurred the module will start the Cooling timer and allow
the engine to cool off-load before shutting down the engine. The alarm must be accepted and
cleared and the fault removed to reset the module.
AUXILIARY INPUTS, if an auxiliary input has been configured as an electrical trip the appropriate
message will be displayed as configured by the user.
Example
Alarm
Electrical trip
Output breaker tripped
The following alarms are configurable between Warning, Shutdown and Electrical Trip. Electrical
Trip is the factory default setting.
GENERATOR HIGH CURRENT, if the module detects a generator output current in excess of the
pre-set trip a warning is initiated. This warning will continue for a period of time depending upon
the level of overload that the generator is subjected to and the configuration setting for Generator
High Current in the 5xxx series configuration software.
Alarm
Shutdown
High current trip

For instance, the factory default settings for Generator High Current allow for a loading of the
generator to 110% for one hour. That is to say if the generator load level exceeds the trip point by
10%, a warning alarm will occur while the overload condition exists. If the load level does not drop
to normal levels within one hour, the breaker is opened and set is cooled down and stopped.
NOTE:- Higher overload levels will result in a faster acting shutdown condition. For
instance with the factory default configuration, an overload level twice that of the trip
level (typically 200%) will result in a Generator High Current shutdown condition after 36
seconds.
For details of the relationship between the overload and the shutdown time, please see
the Appendix section of this manual.
GENERATOR REVERSE POWER, if the module detects a generator reverse power current in
excess of the pre-set trip a shutdown is initiated. The LCD will indicate GEN REVERSE POWER.
Alarm
Electrical trip
Gen Reverse Power
GENERATOR SHORT CIRCUIT, if the module detects a generator fault current in excess of the
pre-set trip a shutdown is initiated. The LCD will indicate GEN SHORT CIRCUIT.
Alarm
Electrical trip
Gen Short Circuit

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MAINS REVERSE POWER, the module will monitor the amount of power being exported to the
mains supply. If this is above the setting for the export power level alarm then the following will be
displayed.
Alarm
Electrical trip
Mains Reverse Power

LOSS OF EXCITATION, the module will monitor the KVAr present on the generator. Should this
exceed a pre-set amount of negative VAr this indicates a possible loss of excitation on the
alternator. The following alarm will then be generated.
Alarm
Electrical trip
Loss of Excitation

NEGATIVE PHASE SEQUENCE, if the module detects an imbalance in the load current of each
phase above a pre-set level, then the following trip will occur.
Alarm
Electrical trip
Negative phase
Sequence
INSUFFICIENT CAPACITY, if the module is configured to limit the import Kw on the mains supply,
variations in the load levels will be matched by increasing the Kw on the generator. Should the
load level increase to a sufficient demand that the generator is giving 100% of its rating. Further
increases in demand will need to be met by increasing the Kw on the mains supply as the
generator cannot supply any more. The system will issue the trip to indicate that it can no longer
regulate the Kw present on the mains until the total load level is reduced.
Alarm
Electrical trip
Insufficient Capacity

GENERATOR FAILED TO CLOSE, if the module requests the generator contact/breaker to close
it will monitor the auxiliary contacts for feedback that this has happened. If the feedback does not
confirm the action within the Generator breaker close timer, then the following trip will occur.
Alarm
Electrical trip
Gen failed to close

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4.5

ROCOF / VECTOR SHIFT

When configured to run in parallel with the mains (utility) supply, the module monitors for ROCOF /
Vector shift trips according to the modules configuration settings. This is included within the
module and will detect failure of the mains supply during parallel operation with the generator.
NOTE:- This protection operates only when in parallel with the mains supply and is
disabled at all other times.
Should either of these alarms operate, the module will perform either a controlled shutdown
(electrical trip) of the generator or will instigate the mains failure function. This operation must be
manually reset :
1) Press
button. The engine will stop if it is still running and the alarm is cleared.
2) Activate digital input configured to Clear ROCOF/Vector shift if this has been provided.
3) Press
and
button together and hold for 5 seconds. The ROCOF/Vector shift
instrument is displayed and all peak hold values are reset, clearing the ROCOF/Vector
shift alarm.
Alarm
Electrical Trip
Mains ROCOF

Alarm
Electrical Trip
Mains Vector Shift

Alarm
Electrical Trip
Mains Decoupling
Low Frequency

Alarm
Electrical Trip
Mains Decoupling
High Frequency

Alarm
Electrical Trip
Mains Decoupling
Low Voltage

Alarm
Electrical Trip
Mains Decoupling
High Voltage
For details on activating and configuring the ROCOF/Vector shift protection you are referred to the
5xxx for Windows configuration software manual.
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DESCRIPTION OF CONTROLS
The following section details the function and meaning of the various controls on the module.

4.6

TYPICAL LCD DISPLAY SCREENS

4.6.1

TYPICAL STATUS DISPLAY

Status
Mains available

Indicates that the module is in Automatic and that the mains is on

load (closed). The unit will respond to either a mains failure or an
active remote start.

Auto mode

Status
Cranking attempt
2
00.06
Auto mode

Indicates that the module is in automatic and that a start sequence

has been initiated, either by a mains failure or remote start input.
The module is attempting to crank the generator.

Generator available
L-N 229v
L-L 400 v
Pf 0.00

0A
50.0hz
0KW

If no alarms are present the LCD will display this default page.

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4.6.2

TYPICAL INSTRUMENT DISPLAY

Engine oil pressure

6.2 Bar
90 Psi
620 KPa

The display of the engine oil pressure

Coolant temperature

74 C
165 F

The display of the engine coolant temperature

Generator Amps

L1
L2
L3

50A
52A
50A

4.6.3

The display of all three generator line currents.

TYPICAL ALARM DISPLAY

Alarm
Warning
Low oil pressure

The module is warning that the engine oil pressure has fallen below
a pre set level. The generator is not shutdown.

Alarm
Shutdown
Low oil pressure

The oil pressure has fallen below a second pre set value and has
shutdown the generator.

Alarm
Warning
Low battery Volts

34

The module is warning that the battery voltage is below a pre set
value.

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4.6.4

TYPICAL EVENT DISPLAY

Event log

1
On the 17th January 2005 at 16:29 the unit detected a mains failure
condition

17 Jan 2005 16:29:49

Mains failure

Event log

On the 8th September 2004 at 20:10. The emergency stop button

was pressed and the generator was shutdown.

On the 7th September 2004 at 08:46, the unit detected that the
generator output volts exceeded pre-set trip level and has

8 Sep 2004 20:10:05

Emergency stop

Event log
7 Sep 2004 08:46:00
Over Volts
Shutdown

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4.6.5

VIEWING THE INSTRUMENT AND EVENT LOG PAGES

To view a particular instrument, operate the Page button to move to the required
page.
The LCD will display the page title and then will automatically commence scrolling down the
various instruments. On reaching the last instrument, the LCD display will then jump back to the
page title and resume scrolling down the page. This sequence will be repeated until either the user
moves off the page or an alarm condition occurs. In the case of the latter the module will jump to
the alarm page to show the relevant alarm details.
Engine speed

0 RPM
Engine oil pressure

6.2 Bar
90 Psi
620 KPa
Coolant temperature

74 C
165 F
Etc.
and
buttons. Once
It is also possible to scroll to display the different instruments using the
selected the instrument will remain on the LCD display until the user selects a different instrument
or page, or after a period of inactivity, the module will revert to the Status page.
NOTE:-This description of operation is also true for the other instrument pages and
for viewing the records in the event log.

NOTE:- The factory default setting is to show all instruments in a single list. It is
possible to change this configuration to a page style display using the 5xxx
configuration software. When configured to the page style, the instruments are grouped
into separate pages i.e. Engine instruments, Gen instruments, Mains instruments.

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4.6.6

SYNCHROSCOPE OPERATION

(When enabled)
Display

Hz +2.9

V +0.2

Hz +0.9

V +0.2

Hz -0.2

V +0.2

Hz -0.2

V +0.2

Detail
Initial stage of Synchronising display will only show
the difference between the Mains Supply and the
Generator Output. Here the display is showing a
frequency mismatch of +2.9Hz - The genset
frequency is too high (indicated by the arrow) and
should be reduced. The voltage is +0.2 volts high, but
is within the limits set for synchronising.
Once the difference between the Mains and the
Generator frequency has been reduced, the
Synchroscope display will become active. The
moving bar will roll from one side to the other showing
the phase of the two supplies. The area in the centre
of the scope indicates the set limits for synchronising
to occur.
Synchronising will only occur when both the
Frequency and the voltage differences are within
acceptable limits - Indicated by Tick marks on the
top of the display. Then the moving bar display will
show the phase difference. The engine speed will be
automatically adjusted, altering the phase, until the
moving bar enters the centre of the scope.
Once the Mains and generator supplies are
synchronised, the module will initiate a breaker close
signal to load the generator onto the Mains. Should
synchronism be broken the moving bar will pass out
of the synchronising window.

Note:-On the start of the synchronising process and if the display is still on the status
page, the module will automatically switch to the Synchroscope page. Once the system
enters one of the ramping states, the ramp progress will also be displayed on the screen.

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4.7
4.7.1

COMPLETE INSTRUMENTATION LIST

BASIC INSTRUMENTATION

Engine Speed
Engine Oil pressure
Coolant temperature
Fuel level
Battery voltage/Charge alt volts
Engine run time/Number of starts
Next maintenance (if enabled)
Generator volts (L1-N, L2-N, L3-N)
Generator volts (L1-L2, L2-L3, L3-L1)
Generator Hz
Generator Amps (L1,L2,L3)
Generator earth current
Generator kW (L1,L2,L3)
Generator total kW
Generator kVA (L1,L2,L3)
Generator total kVA
Generator pf (L1,L2,L3)
Generator average pf
Generator kVAr (L1,L2,L3)
Generator total kVAr
Generator kWh/Generator kVAh/Generator kVArh
Generator phase sequence
Synchroscope (when enabled)
Mains volts (L1-N, L2-N, L3-N)
Mains volts (L1-L2, L2-L3, L3-L1)
Mains Hz
Mains Amps
Mains total kW
Mains total kVA
Mains average pf
Mains total kVAr
Mains phase sequence

4.7.2

ENHANCED ENGINE INSTRUMENTATION

(When supported by the electronic engine ECU)

Engine oil temperature
Coolant pressure
Inlet manifold temperature
Exhaust temperature
Turbo pressure
Fuel pressure
Fuel consumption
Total fuel used

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4.8

ACCESSING THE FRONT PANEL CONFIGURATION EDITOR

This configuration mode allows the operator limited customising of the way the module operates.
Operation
To enter the configuration mode press both the INFO
and STOP buttons together.

4.8.1

Detail

ENTERING THE CONFIGURATION EDITOR PIN NUMBER

The configuration editor contains two sections.

Main configuration editor (for site adjustable or commissioning parameters)
Application editor (to allow installation engineers to make application changes).
The Application Editor is designed to allow the module to be configured for different
applications without needing to re-configure the module settings. This makes it particularly
suitable for applications where the generator would be used in a number of different roles,
specifically in Rental or mobile type applications.
If the module PIN number has been set, the PIN number request is then shown. The configuration
cannot be viewed or changed until the PIN number is correctly entered.
Enter either the main PIN or the application PIN.
If no PIN has been set, then skip to the next section.
NOTE: - The Application Editor must be enabled first in order to make it accessible
from the modules fascia. This is done by setting a PIN (number) for the modules main
front panel editor, using the 5xxx for Windows PC configuration software.
Enter pin

****

Enter pin

1***
Enter pin

12**

Enter pin

123*

The first * is flashing. Press + or buttons to adjust it to the correct

value for the first digit of the PIN number.
Press 9 when the first digit is correctly entered.

The second * is now flashing. Press + or buttons to adjust it to the

correct value for the second digit of the PIN number.
Press 9 when the second digit is correctly entered.

The third * is now flashing. Press + or buttons to adjust it to the

correct value for the third digit of the PIN number.
Press 9 when the third digit is correctly entered.

The fourth * is now flashing. Press + or buttons to adjust it to the

correct value for the fourth digit of the PIN number. Press 9 when
the fourth digit is correctly entered.

NOTE:- When 9 is pressed after editing the final PIN digit, the PIN is checked for
validity. If the number is not correct, the editor is automatically exited. To retry you must
re-enter the editor as described above.

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4.8.2

EDITING VALUES

If the PIN number has not been set, or has been correctly entered :
Operation
The LCD will then display:

Detail

CONFIGURATION

To view the different configuration functions press the + or - buttons.

The LCD will then display:

CONFIGURATION
Oil Pressure
Pre-alarm
1.30 Bar

18 PSI

130 kPa

Pressing the 9 button will enter edit mode :

The parameter being changed will flash.
Pressing + or buttons will change the parameter to the
desired value.

CONFIGURATION
Oil Pressure
Pre-alarm
1.30 Bar

18 PSI

130 kPa

Press 9 to save the change. The parameter will stop flashing as the edit mode is exited.
To view the different configuration functions press the + or - buttons.
to select between day, month, year, hours and minutes.
For date and time editing only: press
To exit the Operator configuration mode save your
current value change if you havent already done so
(press 9 to exit the flashing edit mode), then press
Stop/Reset to exit configuration mode.

The module will then return to the Status Page display.

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4.8.3

LIST OF ADJUSTABLE PARAMETERS (MAIN CONFIGURATION EDITOR)

(Factory default settings are shown in bold italicised text)

Section

Parameter as shown on display

Values

Input settings

Oil Pressure Pre Alarm

Oil Pressure Shutdown
High Coolant Temp Pre Alarm
High Coolant Temp Shutdown
Low Coolant Temp Alarm
Low Fuel Level Alarm
Mains Transient Delay
Generator Transient Delay
Start Delay
Pre Heat Time
Crank Time
Crank Rest Time
Safety On Delay
Overspeed Overshoot Delay
Warm Up Time
Transfer Delay
Return Delay
Cooling Run Time
Fail To Stop Delay
Low Battery Delay
High Battery Delay
Gen Reverse Power Delay
Mains Under Voltage Alarm
Mains Over Voltage Alarm
Mains Under Frequency Alarm
Mains Over Frequency Alarm
Generator Under Voltage Shutdown
Generator Under Voltage Pre Alarm
Generator Nominal Voltage
Generator Over Voltage Pre Alarm
Generator Over Voltage Shutdown
Generator Under Frequency Shutdown
Generator Under Frequency Pre Alarm
Generator Nominal Frequency
Generator Over Frequency Pre Alarm
Generator Over Frequency Shutdown
Generator Over Current Trip
Generator Short Circuit Trip
Generator Reverse Power Trip
Earth Fault Trip
Engine underspeed shutdown
Engine underspeed Pre-alarm
Engine Overspeed pre alarm
Engine Overspeed shutdown
Overspeed Overshoot
Plant Battery Under Volt Alarm
Plant Battery Over Volt Alarm
Charge Alternator Failure Alarm
Language

0 bar -4bar (1.17bar)

0 bar -4bar (1.03bar)
80C -140C (115C)
80C -140C (120C)
67C -137C (disabled)
0%-100% (disabled)
0-10s (2s)
0 -10s (0s)
0 -60m (5s)
0 -60m (0s)
0 -60s (10s)
0-60s (10s)
0-30s (10s)
0-10s (0s)
0-60m (0s)
0-10s (0.75s)
0 -60m (30s)
0-60m (60s)
0-30s (30s)
0-10m (1m)
0-10m (1m)
0-30s (2s)
50V-360V ph-N (184V)
50V-360V ph-N (277V)
0Hz -75Hz (45Hz)
0Hz -75Hz (55Hz)
50V-360V ph-N (184V)
50V-360V ph-N (196V)
52V-330V(230V)
50V-360V ph-N (265V)
50V-360V ph-N (277V)
0Hz -75Hz (40Hz)
0Hz -75Hz (42Hz)
0Hz 74Hz (50Hz)
0 -75Hz (55Hz)
0 -75Hz (57Hz)
100-200% full load rating (100%)
50%-300% full load rating (200%)
0%-200% full load rating (35kW)
1%-100% full load rating (10%)
0-5995RPM (disabled)
1-5996RPM (disabled)
2-5999RPM (disabled)
3-6000RPM (disabled)
0-10 (0%)
0-24V (10V)
0-24V (30V)
0-24V (6V)
ENGLISH, OTHERS
(see note below)
Enable/Disable
Enable/Disable
3 phase, 4wire
Single phase, 2 wire
3 phase, 3 wire
2 phase, 2wire L1& L2
3 phase, 4 wire ED
2 phase 2 wire L1 & L3
300-600A (500A)
Enable/Disabled

Timers

Mains

Generator

Engine

Languages
Application settings

Alternative Frequency
Alternative voltage
AC System

Generator Full load rating

Droop
Contrast
Date and Time
Auto Scroll Time
Generator CT Primary Rating
Generator CT Secondary Rating
Mains CT Primary Rating
Mains CT Secondary Rating
Generator Control Full kW rating
Generator Control Full kVAr rating
Load ramp rate
Load Parallel Power
Load Power Factor

dd mmm yyyy hh:mm

0-10s (2.0s)
5-6000A (600A)
1A / 5A
5-6000A (600A)
1A/ 5A
1-5000kW (345kW)
1-5000kVAr (258kW)
0.1-100% (3%)
0-100% (50% 172Kw)
01-1.00-01 (1.00pf)

NOTE:- More comprehensive module configuration is possible using the 5xxx series
PC configuration software in conjunction with the P810 PC interface. Please contact us
for further details.
NOTE:- Languages are subject to change as the modules are updated. Please
contact us for the list of latest supported languages.

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4.8.4

LIST OF ADJUSTABLE PARAMETERS (APPLICATION EDITOR)

(Factory default settings are shown in bold italicised text)

Section

Parameter as shown on display

Values

Display

Language

ENGLISH, OTHERS

Application settings

Alternative Frequency
Alternative voltage
AC System

Generator Full load rating

Droop

(see note below)

Enable/Disable
Enable/Disable
3 phase, 4wire
Single phase, 2 wire
3 phase, 3 wire
2 phase, 2wire L1& L2
3 phase, 4 wire ED
2 phase 2 wire L1 & L3
300-600A (500A)
Enable/Disabled

Contrast

Date and Time

Auto Scroll Time
Generator CT Primary Rating
Generator CT Secondary Rating
Mains CT Primary Rating
Generator Control Full kW rating
Generator Control Full kVAr rating
Load ramp rate
Load Parallel Power
Load Power Factor

dd mmm yyyy hh:mm

0-10s (2.0s)
5-6000A (600A)
1A / 5A
1A/ 5A
1-5000kW (345kW)
1-5000kVAr (258kW)
0.1-100% (3%)
0-100% (50% 172Kw)
01-1.00-01 (1.00pf)

NOTE:- More comprehensive module configuration is possible using the 5xxx series
PC configuration software in conjunction with the P810 PC interface. Please contact us
for further details.
NOTE:- Languages are subject to change as the modules are updated. Please
contact us for the list of latest supported languages.

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4.9

DISPLAY EDITOR

The Display Editor is user to make changes to display language, contrast and run priority mode.
Operation
To enter the Display Editor press both the UP and
DOWN buttons together.

4.9.1

Detail

EDITING DISPLAY EDITOR CONFIGURATION VALUES

Operation
The LCD will then display:
Software version is shown for your convenience. This is
the version of firmware within the 5510 controller.

Detail

CONFIGURATION
Contrast

l
Software version x.xx

To change the value for the displayed parameter press either the
ordecrease the value.

To view the different configuration functions press the

The LCD will then display:

buttons to increase

button.

CONFIGURATION
Language
English (United Kingdom)
Software version x.xx

To change the value for the displayed parameter press either the
decrease the value.

To view the different configuration functions press the

The LCD will then display:

buttons to increase of

button.

CONFIGURATION
Enable commissioning
Screens? No
Software version x.xx

To change the value for the displayed parameter press either the
buttons to increase of
decrease the value.
For details on the commissioning screens see the section elsewhere in this manual.
To view the different configuration functions press the

button.

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CONFIGURATION
Override starting
alarms? No

The LCD will then display:

Software version x.xx

To change the value for the displayed parameter press either the
buttons to increase of
decrease the value.
When override starting alarms is enabled (yes) it allows alarms to be overridden during the start
process by holding the start button. This allows (for instance) the AVR / Governor to be adjusted
without the engine being shutdown on under volts or overfrequency etc.
This operation is a one off operation, the function is automatically changed back to No and must
be manually enabled if it is required once more.
To view the different configuration functions press the
The LCD will then display:

button.

CONFIGURATION
Abandon Changes
And exit
Software version x.xx

To exit the editor without saving changes press either of the

To save changes press the

The LCD will then display:

buttons.

button.

CONFIGURATION
Save changes
and exit
Software version x.xx

To exit the editor and save any changes press either of the

To return to the beginning of the list press the

buttons.

button.

The module will then return to the Status Page display.

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5 LED IDENTIFICATION AND FRONT PANEL LAYOUT

5.1

CONFIGURABLE LED IDENTIFICATION DIAGRAM

LED 1
LED 2
LED 3
LED 4

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6 LED INDICATORS AND LOGO INSERT

USER CONFIGURABLE LEDs
These LEDs can be configured by the user to indicate any one of 100+ different functions based
around the following: INDICATIONS - Monitoring of a digital input and indicating associated functioning users
equipment - Such as Battery Charger On or Louvre Open, etc.
WARNINGS and SHUTDOWNS - Specific indication of a particular warning or shutdown
condition, backed up by LCD indication - Such as Low Oil Pressure Shutdown, Low
Coolant level, etc.
STATUS INDICATIONS - Indication of specific functions or sequences derived from the
modules operating state - Such as Safety On, Pre-heating, Panel Locked, Generator
Available, etc.
These LEDs are annunciated using a removable insert card. Additionally the modules logo can be
changed to suit generator manufacturers requirements. This can be used for instance to give
custom branding to the module, or even include the service telephone number.
DSE have produced the insert card creator software, shipped with the DSE SoftwareCD to ease
the production of text and logo insert cards to suit your application.

Removal and insertion of the LED text insert card

Removal and insertion of the Logo insert card

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7 CONTROL PUSH-BUTTONS
STOP/RESET
This push-button places the module into its Stop/reset mode. This will
clear any alarm conditions for which the triggering criteria have been
removed. If the engine is running and this push-button is operated, the
module will automatically instruct the changeover device to unload the
generator (Load transfer becomes in-active (if used)). The fuel supply
will be removed and engine will be brought to a standstill. Should a
remote start signal be present while operating in the Stop/reset mode,
a remote start will not occur.
MANUAL
This push-button is used to allow manual control of the generator
functions. Entering this mode from any other mode will initially not cause
any change of operating state, but allows further push-buttons to be used
to control the generator operation. For example, once in Manual mode it
is possible to manually start the engine by using the START pushbutton. If the engine is running off-load in the Manual mode and a
remote start signal becomes present, the module will automatically
instruct the change-over device to place the generator on load (Load
transfer becomes active (if used)). Should the remote start signal then
be removed the generator will remain on load until either the
STOP/RESET or AUTO push buttons are operated.
This button is also the - button when in the configuration editor mode. It
is used to move through the different parameters or to decrease the value
being edited.
START
This push-button is used to start the engine. The module must first be
placed in the MANUAL mode of operation. The START button should
then be operated. The engine will then automatically attempt to start.
Should it fail on the first attempt either it will re-try until the engine fires or
the pre-set number of attempts have been made. To stop the engine the
STOP/RESET button should be operated. It is also possible to configure
the module such that the start push-button must be held to maintain
engine cranking.
NOTE:-Different modes of operation are possible - Please refer
to your configuration source for details.
AUTO
This push-button places the module into its Automatic mode. This
mode allows the module to control the function of the generator
automatically. The module will monitor the remote start input and once a
start condition is signalled the set will be automatically started and placed
on load (Load transfer becomes active (if used)). If the starting signal is
removed, the module will automatically transfer the load from the
generator and shut the set down observing the stop delay timer and
cooling timer as necessary. The module will then await the next start
event. For further details, please see the more detailed description of
Auto Operation earlier in this manual.
This button is also the 9 button when in the configuration editor mode. It
is used to edit the displayed parameter or to save the new value when
editing a value.

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TEST
This push-button places the module into its Test mode. This mode is
used to test the function and timing of the generator start and load
sequence. The mode is initiated by pressing the Start Button and the
set will be automatically started and placed on load. The set will run on
load continuously. To test the off-loading and stopping sequence return
the set to the Auto mode, the module will automatically transfer the load
from the generator and shut the set down observing the stop delay timer
and cooling timer as necessary. The module will then await the next
start event. For further details, please see the more detailed description of
Test Operation earlier in this manual.
This button is also the + button when in the configuration editor mode. It
is used to move through the different parameters or to increase the value
being edited.
ALARM MUTE
This push-button is used to silence the internal alarm sounder and also
any external sounder devices fed from the audible alarm output. Any
further alarm conditions will reactivate the sounder. Once the alarm has
been muted and investigated, it may then be cleared.
Refer to the Protections section of this manual for details.
When the Alarm Mute is operated a Lamp test function will also be
implemented and all LED indicators will be illuminated.
TRANSFER TO GENERATOR
This push button is used to control the closure of the generator load
switching device and has three modes of operation :
1. Synchronising is NOT enabled. Pressing this button when the
generator is running off load and in MANUAL mode, the mains load
switch is opened. After a delay (load transfer time), the generator load
switch is closed. Further presses of this button will have no effect.
2. Synchronising is enabled. Pressing this button when the generator is
running and in MANUAL mode, the 5520 controller will volts match
and synchronise with the mains supply. The generator load switch is
then closed in parallel with the mains supply.
3. Synchronising is enabled. Pressing this button when the generator is
running in parallel with the mains supply and in MANUAL mode, will
open the mains load switch and after a delay (load transfer time), the
mains load switch is opened (transferring the load to the generator
supply).
NOTE: - This button is only active in MANUAL mode.

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TRANSFER TO MAINS
This push button is used to control the closure of the mains load switching
device and has three modes of operation :
1. Synchronising is NOT enabled. Pressing this button when the
generator is running on load and in MANUAL mode, the generator
load switch is opened. After a delay (load transfer time), the mains
load switch is closed. Further presses of this button will have no
effect.
2. Synchronising is enabled. Pressing this button when the generator is
running on load and in MANUAL mode, the 5520 controller will volts
match and synchronise with the mains supply. The generator load
switch is then closed in parallel with the mains supply.
3. Synchronising is enabled. Pressing this button when the generator is
in MANUAL mode and running in parallel with the mains supply will
open the generator load switch, transferring the load back to the
mains supply only.
NOTE: - This button is only active in MANUAL mode.

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8 INSTALLATION INSTRUCTIONS
The model DSE 5520 Module has been designed for front panel mounting. Fixing is by 4 clips for
easy assembly.

8.1

PANEL CUT-OUT

160.00mm
(6.3)

220.00mm
(8.7)
Maximum panel thickness 8mm (0.3)
In conditions of excessive vibration, the module should be mounted on suitable anti-vibration
mountings.

8.2

COOLING

The module has been designed to operate over a wide temperature range -30 C to +70C.
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

Panel cut-out 220mm x 160mm ( 8.7 x 6.3)

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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 8 plugs and sockets
on the rear of the Module.

9.1.1
PIN
No
1

PLUG A 8 WAY
DESCRIPTION

CABLE
SIZE
2.5mm

DC Plant Supply Input

(Negative)
DC Plant Supply Input
(Positive)
Emergency Stop Input

4
5
6
7
8

Fuel relay Output

Start relay Output
Auxiliary Output relay 1
Auxiliary Output relay 2
Auxiliary Output relay 3

2.5mm
2.5mm
1.0mm
1.0mm
1.0mm

9.1.2

PLUG B 11 WAY

PIN
No
9
10
11
12
13
14
15
16
17
18
19

DESCRIPTION
Charge Fail Input/ Excitation
Output
Auxiliary Input 1
Auxiliary Input 2
Auxiliary Input 3
Auxiliary Input 4
Auxiliary Input 5
Auxiliary Input 6
Auxiliary Input 7
Auxiliary Input 8
Auxiliary Input 9
Functional Earth

NOTES

2.5mm

(Recommended Fuse 20A Max.)

2.5mm

Plant Supply positive. In addition, supplies fuel &

start outputs. (Recommended Fuse 32A Max.)
Plant Supply positive from pin 3. 16 Amp rated.
Plant Supply positive from pin 3. 16 Amp rated.
Plant Supply positive 5 Amp rated.
Plant Supply positive 5 Amp rated.
Plant Supply positive 5 Amp rated.

CABLE
SIZE

NOTES

1.0mm

Must NOT be connected to plant supply negative

0.5mm
0.5mm
0.5mm
0.5mm
0.5mm
0.5mm
0.5mm
0.5mm
0.5mm
2.5mm

Switch to negative
Switch to negative
Switch to negative
Switch to negative
Switch to negative
Switch to negative
Switch to negative
Switch to negative
Switch to negative
Connect to system earth

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9.1.3
PIN
No
20
21
22
23

PLUG C 9 WAY
DESCRIPTION
Magnetic pickup screen
Magnetic pickup
Magnetic pickup
Electronic Engine ECU
Screen
Electronic Engine ECU H
Electronic Engine ECU L
Unused
Unused
Unused

24
25
26
27
28

CABLE
SIZE

NOTES

0.5mm
0.5mm
0.5mm
0.5mm

Connect at module end only!

Connect to magnetic pickup device
Connect to magnetic pickup device
Connect screen at one end only

0.5mm
0.5mm

120 impedance CAN cable

120 impedance CAN cable
Do not connect
Do not connect
Do not connect

NOTE:- Screened cable must be used for connecting the Magnetic Pickup, ensuring
that the screen is earthed at one end ONLY.

NOTE:- Screened 120 impedance cable specified for use with CAN must be used for
the electronic engine link.

9.1.4
PIN
No
29
30
31

PLUG D 3 WAY
DESCRIPTION
RS485 SCREEN
RS485 B
RS485 A

CABLE
SIZE
0.5mm
0.5mm
0.5mm

NOTES
Screen for RS485
120 impedance RS485 cable
120 impedance RS485 cable

NOTE:- Screened 120 impedance cable specified for use with RS485 must be used.

9.1.5
PIN
No
32
33
34
35
36

PLUG E 5 WAY
DESCRIPTION
Governor output B
Governor output A
Unused
AVR output B
AVR output A

CABLE
SIZE
0.5mm
0.5mm
0.5mm
0.5mm

NOTES
Connect to governor for speed/load control
Connect to governor for speed/load control
Do not connect
Connect to governor for volts/VAr control
Connect to governor for volts/VAr control

NOTE:- It is recommended to use screened cable for the Governor and AVR output
connections.

NOTE:- For details of connections to governors / AVRs refer to the DSE Guide to
Synchronising Part 2.

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9.1.6
PIN
No
37
38
39
40
41
42
43
44

9.1.7
PIN
No
45
46
47
48

9.1.8
PIN
No
49
50
51
52
53
54
55
56
57
58
59
60

PLUG F 8 WAY
DESCRIPTION
Mains Loading Relay
Normally Closed Contact
Mains Loading Relay
Normally Closed Contact
Generator Loading Relay
Normally Open Contact
Generator Loading Relay
Normally Open Contact
Mains volts L1
Mains volts L2
Mains volts L3
Mains volts N

CABLE
SIZE

NOTES

2.5mm

Connect to mains contactor coil feed supply.

2.5mm

Connect to mains contactor coil.

2.5mm

Connect to generator contactor coil feed supply.

2.5mm

Connect to generator contactor coil.

1.0mm
1.0mm
1.0mm
1.0mm

Connect to Mains L1
Connect to Mains L2
Connect to Mains L3
Connect to Mains N

PLUG G 4 WAY
DESCRIPTION
Generator volts L1
Generator volts L2
Generator volts L3
Generator volts N

CABLE
SIZE
1.0mm
1.0mm
1.0mm
1.0mm

NOTES
Connect to Generator L1
Connect to Generator L2
Connect to Generator L3
Connect to Generator N

PLUG H 12 WAY
DESCRIPTION
CT Secondary for
generator L1
CT Secondary for
generator L2
CT Secondary for
generator L3
Generator CT secondary
common
CT Secondary for
generator N
CT Secondary for mains
L1
Mains CT secondary
common
Not used
Low oil pressure sender
Coolant temperature
sender
Fuel level sender
Sender common

CABLE
SIZE
2.5mm
2.5mm
2.5mm
2.5mm
2.5mm

NOTES
Connect to secondary of generator L1
monitoring CT
Connect to secondary of generator L2
monitoring CT
Connect to secondary of generator L3
monitoring CT
Connect to secondary of all monitoring CTs

1.0mm
1.0mm

Connect to secondary of generator N (earth

fault) monitoring CT
Connect to secondary of mains L1
monitoring CT
Connect to secondary of mains monitoring
CT
Do not connect
Connect to low oil pressure sender
Connect to Coolant temperature sender

1.0mm
1.0mm

Connect to Fuel level sender

Connect to sender common

2.5mm
2.5mm

WARNING!:- Do not disconnect this plug when the gen-set is running. Disconnection
will open circuit the secondary of the CTs and dangerous voltages may then develop.
Always ensure the gen-set is at rest before making or breaking connections to the
module.

NOTE*:- If using single terminal senders refer the Appendix section entitled Sender
wiring recommendations elsewhere in this manual.

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9.1.9

PC CONFIGURATION INTERFACE CONNECTOR

8-way connector allows connection to PC via 810
configuration interface. Module can then be re-configured
utilising the 5xxx for Windows software.

9.1.10 EXPANSION INTERFACE CONNECTOR

4-way connector allows connection to the 130 input
expansion, 157 relay expansion module or 545/548 LED
expansion modules.
A maximum of 2 relay or LED expansion modules may be
connected in series to this port.
CAUTION! - Do not connect the 808 configuration interface to this port, as it is not
possible to use the 808 software to configure the 5520 module.

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9.2

CONNECTOR FUNCTION DETAILS

The following describes the connections and recommended cable sizes to the 8 plugs and sockets
on the rear of the Module.

9.2.1

PLUG A 8 WAY

PIN No
1
2
3

4
5
6
7
8

9.2.2
PIN
No
9
10

11

12

13

14

15

16

17

18

19

DESCRIPTION
DC Supply negative. System DC negative input. (Battery Negative).
DC Supply positive. System DC positive input. (Battery Positive).
Emergency Stop input. Internally linked to Starter and Fuel outputs. If this input is not
connected to positive the module will be locked out and if the engine is running it will
shutdown immediately. The Positive Supply is also removed from Starter and Fuel
therefore only a single pole Emergency Shutdown button is required.
Fuel Relay output. Plant Supply positive from pin 3. Used to control the fuel solenoid or
engine fuel control system.
Starter Relay output. Plant Supply positive from pin 3. Used to control the Starter Motor.
Auxiliary Relay output 1. Plant Supply positive Configurable output, see Calibration
Manual for options available.
Auxiliary Relay output 2. Plant Supply positive Configurable output, see Calibration
Manual for options available.
Auxiliary Relay output 3. Plant Supply positive Configurable output, see Calibration
Manual for options available.

PLUG B 11 WAY
DESCRIPTION
Charge Fail input and Excitation output. Supplies excitation to the Plant Battery Charging
Alternator, also an input for the Charge Fail detection circuitry.
Auxiliary input 1. This is a negative switched configurable input, see Calibration Manual for
options available. It is possible to configure the input to be a normally closed signal or a
normally open signal.
Auxiliary input 2. This is a negative switched configurable input, see Calibration Manual for
options available. It is possible to configure the input to be a normally closed signal or a
normally open signal.
Auxiliary input 3. This is a negative switched configurable input, see Calibration Manual for
options available. It is possible to configure the input to be a normally closed signal or a
normally open signal.
Auxiliary input 4. This is a negative switched configurable input, see Calibration Manual for
options available. It is possible to configure the input to be a normally closed signal or a
normally open signal.
Auxiliary input 5. This is a negative switched configurable input, see Calibration Manual for
options available. It is possible to configure the input to be a normally closed signal or a
normally open signal.
Auxiliary input 6. This is a negative switched configurable input, see Calibration Manual for
options available. It is possible to configure the input to be a normally closed signal or a
normally open signal.
Auxiliary input 7. This is a negative switched configurable input, see Calibration Manual for
options available. It is possible to configure the input to be a normally closed signal or a
normally open signal.
Auxiliary input 8. This is a negative switched configurable input, see Calibration Manual for
options available. It is possible to configure the input to be a normally closed signal or a
normally open signal.
Auxiliary input 9. This is a negative switched configurable input, see Calibration Manual for
options available. It is possible to configure the input to be a normally closed signal or a
normally open signal.
Functional earth

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9.2.3

PLUG C 9 WAY

PIN
No

DESCRIPTION

20
21

Magnetic pickup screen

Magnetic Input positive. An AC signal from the magnetic pickup positive for speed
sensing.
Magnetic Input negative. An AC signal from the magnetic pickup negative for speed
sensing.
Electronic Engine ECU Screen
Electronic Engine ECU H. For connection to the Engine ECU terminal H
Electronic Engine ECU L. For connection to the Engine ECU terminal L
Unused
Unused
Unused

22
23
24
25
26
27
28

NOTE:- Screened cable must be used for connecting the Magnetic Pickup, ensuring
that the screen is earthed at one end ONLY.
NOTE:- Screened 120 impedance cable specified for use with CAN must be used for
both the Electronic engine link and the Multiset comms link

9.2.4
PIN
No
29
30
31

PLUG D 3 WAY
DESCRIPTION
RS485 SCREEN
RS485 B. For connection to other RS485 controllers in a multidrop RS485 communications
system.
RS485 A. For connection to other RS485 controllers in a multidrop RS485 communications
system.

NOTE:- Screened 120 impedance cable specified for use with RS485 must be used.

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9.2.5

PLUG E 5 WAY

PIN
No

DESCRIPTION

32

Governor output B. For connection to electronic speed governors for synchronising and load
sharing.
Governor output A. For connection to electronic speed governors for synchronising and load
sharing.
Unused
AVR output B. For connection to automatic voltage regulators for volts matching and VAr
sharing.
AVR output A. For connection to automatic voltage regulators for volts matching and VAr
sharing.

33
34
35
36

NOTE:- It is recommended to use screened cable for the Governor and AVR output
connections.
NOTE:- For details of connections to governors and AVRs refer to the DSE Guide to
Synchronising Part 2.

9.2.6

PLUG F 8 WAY

PIN
No

DESCRIPTION

37

Mains Loading Relay, Normally closed. Volts free contacts to 38. Used to connect to Mains
contactor or circuit breaker.
Mains Loading Relay, Normally closed. Volts free contacts to 37. Used to connect to Mains
contactor or circuit breaker.
Generator Loading Relay, Normally open. Volts free contacts to 40. Used to connect to
generator contactor or circuit breaker.
Generator Loading Relay, Normally open. Volts free contacts to 39. Used to connect to
generator contactor or circuit breaker.
Mains volts L1. Used for sensing the voltage and frequency of mains L1.
Mains volts L2. Used for sensing the voltage and frequency of mains L2.
Mains volts L3. Used for sensing the voltage and frequency of mains L3.
Mains volts N. Used for sensing the mains voltage and frequency.

38
39
40
41
42
43
44

9.2.7
PIN
No
45
46
47
48

PLUG G 4 WAY
DESCRIPTION
Generator volts L1. Used for sensing the voltage and frequency of generator L1.
Generator volts L2. Used for sensing the voltage and frequency of generator L2.
Generator volts L3. Used for sensing the voltage and frequency of generator L3.
Generator volts N. Used for sensing the voltage and frequency of the generator output.

CAUTION!:- Refer to Typical wiring Diagram for different wiring topologies.

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9.2.8

PLUG H 12 WAY

PIN
No
49
50
51
52
53
54
55
56
57
58
59
60

DESCRIPTION
CT Secondary for generator I1 (s2)
CT Secondary for generator I2 (s2)
CT Secondary for generator I3 (s2)
Generator CT secondary common (s1)
CT Secondary for generator IN
CT Secondary for Mains L1 (s2)
CT Secondary for Mains L1 (s1)
Not used
Low oil pressure sender
Coolant temperature sender
Fuel level sender
Sender common

Used for sensing generator output Current

for metering of Amps, KW, KVA and KVAr.
Provides protection for Overcurrent, reverse
power, earth fault and also load sharing.
Used to provide current sensing on the
mains supply for metering and import/export
control
If using single terminal senders refer the
Appendix section entitled Sender wiring
recommendations elsewhere in this manual.

WARNING!:- Do not disconnect this plug when the genset is running. Disconnection
will open circuit the secondary of the CTs and dangerous voltages may then develop.
Always ensure the genset is at rest before making or breaking connections to the
module.

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9.3

ENGINE CONTROL UNIT INTERFACE

The module is capable of interfacing with the ECU fitted to electronically injected engines. Different
manufacturers engines utilise various different interfaces and protocols. As this is a rapidly
developing area we recommend checking with DSE Support as to which engines are currently
supported.
The module will monitor the engines operating parameters such as engine speed, oil pressure,
engine temperature (among others) in order to closely monitor and control the engine. The data
that is gathered by the engine controller is then transmitted on an industry standard
communications interface. This allows generator controllers such as the DSE 55xx range to access
these engine parameters with no physical connection to the sensor device.
Utilising the technology present on the engine in this way gives less connections to the engine,
higher reliability and better diagnosis of engine related problems.
NOTE:- For further details for connections to electronic engines refer to the manual
CAN and DSE Wiring. Part No. 057-004

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10 SPECIFICATION
DC Supply

Alternator Input

Bus and mains Input

CTs

Magnetic Pickup

Relay outputs

60

Continuous voltage rating :

8V to 35V
Cranking dip protection :
Able to survive 0V for 50mS, providing supply was at least 10V before dropout and supply
recovers to 5V. This is achieved without the need for internal batteries
Charge Fail/ Excitation:
0V to 35V fixed power source 25W
Max. Standby Current:
375mA at 12V. 200mA at 24V.
Max. Operating Current:
460mA at 12V. 245mA at 24V
Range:
5V - 277(ph-N) (+20%) 50Hz - 60Hz (Minimum 15V AC Ph-N)
Accuracy:
1% of full scale True RMS sensing
Supported topologies:
3 Phase 4wire Wye
3 phase 3 wire Delta
3 phase 3 wire Edison Delta
Single phase 2 wire
2 Phase 3wire L1 & L2
2 Phase 3 wire L1 & L3
Range:
15V - 277(ph-N) (+20%) 50Hz - 60 Hz
Accuracy:
1% of full scale True RMS sensing
Supported topologies:
3 Phase 4wire Wye
3 phase 3 wire Delta
3 phase 3 wire Edison Delta
Single phase 2 wire
2 Phase 3wire L1 & L2
2 Phase 3 wire L1 & L3
Burden:
0.5VA
Primary rating:
1A - 6000A (user selectable)
Secondary rating:
1A or 5A secondary (user selectable)
Accuracy of measurement:
1% of full load rating (when using 0.5% or better CTs with 5A secondary winding) Lower class CTs
will reduce the overall accuracy of the reading.
Recommendations:
Class 1 required for instrumentation
Protection class required if using for protection.
Voltage range :
+/- 0.5V minimum (during cranking) to 70V Peak
Frequency range:
10,000 Hz (max)
Fuel:
16 Amp DC at supply voltage
Start:
16 Amp DC at supply voltage
Auxiliary outputs 1,2,3:
5 Amp DC at supply voltage
Output 4 (Generator loading relay)
Voltage free, normally open, 8 Amp 250V AC RMS rated
Output 5 (Mains loading relay)
Voltage free, normally closed, 8 Amp 250V AC RMS rated

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Dimensions

Electrical Safety
/Electromagnetic
Compatibility
Environmental

Overall:
240mm x 172 mm x 57mm
(9 x 6 x 2 )
Panel cut-out:
220mm x 160mm
( 8.7 x 6.3)
Max panel thickness 8mm ( 0.3)
BS EN 60950 Safety of information technology equipment, including electrical business equipment
BS EN 61000-6-2 EMC Generic Emission Standard (Industrial)
BS EN 61000-6-4 EMC Generic Emission Standard (Industrial)
BS EN 60068-2-1 Cold Temperature
-30C
BS EN 60068-2-2 Hot Temperature
+70C
BS2011-2-1 Humidity
93% RH@40C for 48 Hours
BS EN60068-2-6 Vibration
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 Shock
3 Half sine shocks in each of 3 major axes
15gn amplitude, 11mS duration
BS EN 60529 Degrees of protection provided by enclosures:
IP55 (Front of module when module is installed into the control panel with the optional sealing
gasket).
IP42 (front of module when module is installed into the control panel WITHOUT being sealed to
the panel)
NEMA Rating (Approximate)
12 (Front of module when module is installed into the control panel with the optional sealing
gasket).
2 (front of module when module is installed into the control panel WITHOUT being sealed to the
panel)

Product Certification

C
European CE approved.

BS EN 2002/95/EC
Restriction of Hazardous
Substances
(RoHS)

US

UL approved
C-UL / CSA approved.

BS EN 2002/96/EC
Waste Electrical and
Electronic Equipment (WEEE)

Russia and other CIS

countries approved

CAN interface certified by

MTU for use with MDEC
engines

Relevant Company
Certification

BS EN ISO 9001:2000
Applicable to Design,
marketing, assembly, service
and repair of electronic control
modules
In line with our policy of continual development, Deep Sea Electronics, reserve the right to change specification without notice.

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11 COMMISSIONING
11.1.1 PRE-COMMISSIONING
Before the system is started, it is recommended that the following checks are made:6.1. The module has adequate cooling and all the wiring to the module is of a standard and rating
compatible with the system.
6.2. The unit DC supply is fused and connected to the battery and that it is of the correct polarity.
6.3. The Emergency Stop input is wired to an external normally closed switch connected to DC
positive.
NOTE:- If Emergency Stop feature is not required link this input to the DC Positive.
The module will not operate unless either the Emergency Stop is fitted correctly OR Pin 3
is connected to DC positive (positive)
6.1. 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. Press the MANUAL pushbutton, and then
press the START pushbutton for a short time. The unit start sequence will commence.
6.2. 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
Shutdown Failed to start. Press the STOP/RESET pushbutton to reset the unit.
6.3. Restore the engine to operational status (reconnect the fuel solenoid), again select
MANUAL and operate the START pushbutton, this time the engine should start and the
starter motor should disengage automatically. If not, then check the engine is 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. It will be
possible at this time to view the engine and alternator parameters - refer to the Description
of Controls section of this manual.
6.4. 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.
6.5. Initiate an automatic start by supplying the remote start signal. 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 Contactor Coil (if used). Check the Warming timer has expired.
6.6. Remove the remote start signal, 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.
6.7. Further details on synchronising and load sharing can are found in the DSE Guide to Load
Share system Design and Commissioning and the DSE Guide to Synchronising and load
sharing Part1 and Part2.
6.8. If despite repeated checking of the connections between the 5520 and the customers
system, satisfactory operation cannot be achieved, then the customer is requested to contact
the factory for further advice on:Should you have any queries arising from this manual please contact our Technical Department:

INTERNATIONAL TEL: +44 (0) 1723 890099

INTERNATIONAL FAX: +44 (0) 1723 893303
E-mail: [email protected]
Web: http://www.deepseaplc.com

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11.2 BYPASSING ALARMS AT STARTUP

When override starting alarms is enabled using the Display Editor, it allows alarms to be
overridden during the start process by holding the start I button. This allows (for instance) the AVR
/ Governor to be setup without the engine being shutdown on under volts or underfrequency etc.
This operation is a one off operation, the function is automatically changed back to No and must
be manually enabled if it is required once more.
The alarms that are overridden during this time are : Undervolts shutdown, Overvolts shutdown,
underfrequency shutdown, underspeed shutdown.
The pre-alarms remain active to give attention to the operator that an alarm is active, the set will
continue to run to allow the operator to adjust the set to nominal speed / voltage.
NOTE:- Overfrequency and Overspeed are NOT disabled when this function is
activated.

11.3 COMMISSIONING SCREENS

Commissioning screens are available to both aid the commissioning process and also to give
additional information about the synchronising and load sharing process.
These screens can be enabled and disabled in the modules display editor.

11.3.1 SCREEN 1
L-N
Amps
Pf
Gov

0V
0A
0.00
0.0%

kW
KVAr
kW
Avr

0
0
0.0%
0.0%

Average L-N Voltage and total kW

Maximum Amps and total kVAr
Average power factor and % of full load kW
Levels of analogue governor / AVR outputs.

0.0%
0.0%
5.0%
0.0%

Target and actual % of full load kW

Target and actual % of full load kVAr
Average power factor and ramp position.
Levels of analogue governor / AVR outputs.

11.3.2 SCREEN 2
Tgt
Tgt
pf
Gov

0.0%
0.0%
0.0
0.0%

kW
KVAr
Ramp
Avr

11.3.3 SCREEN 3
GA
G pf
G kW
G kVAr

0
0.0
0
0

MA
M pf
M kW
M kVAr

0
0.0
0
0

Maximum generator Amps, Mains Amps

Average generator power factor, Mains power factor
Total generator kW, mains kW
Total generator kVAr, mains kVAr

11.3.4 SCREEN 4
M Tgt
M Tgt
Pf
Gov

0
0
0.0
0.0%

kW
kVAr
Ramp
Avr

0
0
0.0%
0.0%

Mains target and Mains actual kW

Mains target and Mains actual kVAr
Mains power factor and Mains ramp position
Levels of analogue governor / AVR outputs

NOTE:- Some of the items may be removed from the commissioning screens if they
are not applicable to the module configuration.

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12 FAULT FINDING
SYMPTOM
Unit is inoperative
Unit shuts down

Unit locks out on Emergency Stop

Intermittent Magnetic Pick-up sensor

fault
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 pre-set
number of attempts to start

Continuous starting of generator

when in AUTO
Generator fails to start on receipt of
Remote Start signal or under mains
failure conditions.
Pre-heat inoperative

Starter motor 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.
If an Emergency Stop Switch is not fitted, ensure that a
positive is connected to the Emergency Stop input. Check
emergency stop switch is functioning correctly. Check
Wiring is not open circuit.
Ensure that Magnetic pick-up screen is only connected at
one end, if connected at both ends this enables the screen
to act as an aerial and will pick up random voltages.
Check engine oil pressure. Check oil pressure
switch/sender and wiring. Check configured polarity (if
applicable) is correct (i.e. Normally Open or Normally
Closed) or that sender is compatible with the 5520 Module.
Check engine temperature. Check switch/sender and
wiring. Check configured polarity (if applicable) is correct
(i.e. Normally Open or Normally Closed) or that sender is
compatible with the 5520 Module.
Check relevant switch and wiring of fault indicated on LCD
display. Check configuration of input.
Check relevant switch and wiring of fault indicated on LCD
display. 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. Check the speed sensing signal is present
on the 5520 inputs. Refer to engine manual.
Check that there is no signal present on the Remote
Start input. Check configured polarity is correct.
Check Start Delay timer has expired. If remote start fault,
check signal is on Remote Start input. Confirm 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. Ensure that the Emergency Stop input is at
positive.
Check Warm up timer has expired. Ensure generator load
inhibit signal is not present on the module inputs.

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.

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13 TYPICAL WIRING DIAGRAM

NOTE:- When not fitting the neutral CT, terminal 53 is the CT common and earth.
Terminal 52 is not used.

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14 FACTORY DEFAULT CONFIGURATION

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15 SENDER WIRING RECOMMENDATIONS

15.1.1 USING EARTH RETURN (SINGLE WIRE) SENDERS.

59

57

60

58

Fuel level

Oil
Pressure

EARTH

Coolant
temperature

NOTE:- . It is important that terminal 60 ( sender common ) is soundly connected to

an earth point on the ENGINE BLOCK, not within the control panel and must be a sound
electrical connection to the sender bodies.

NOTE:- . If you use PTFE insulating tape on the sender thread when using earth
return senders, ensure you do not insulate the entire thread as this will prevent the
sender body from being earthed via the engine block.

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15.1.2 USING INSULATED RETURN (TWO WIRE) SENDERS.

59

57

60

58

Fuel
level

Oil
Pressure

EARTH

Coolant
temperature

NOTE:- . It is important that terminal 60 (sender common) is soundly connected to an

earth point on the ENGINE BLOCK, not within the control panel.

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16 APPENDIX
16.1 5520 IDMT TRIPPING CURVES (TYPICAL)

16.2 5510 SHORT CIRCUIT TRIPPING CURVES (TYPICAL)

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16.3 ACCESSORIES
16.3.1 OUTPUT EXPANSION
There are several methods of output expansion available for the 55xx range of modules: RELAY OUTPUT EXPANSION (157)
An expansion module is available, which connects to the configuration socket, and enables the
55xx to use eight additional relays, providing Volt-free contacts for customer connection. A
maximum of two of these units can be used give 16 independent volt-free contacts.
The 157s need to be identified as module A and module B
Refer to technical data sheet on the 157 relay module for further details.

LED OUTPUT EXPANSION (548)

An expansion module is available, which connects to the configuration socket, and enables the
55xx to use the eight additional LEDs on the 548 module, providing remote LEDs indication. A
maximum of two of these units can be used give 16 independent remote LEDs.
The 548s need to be identified as module A and module B
Refer to technical data sheet on the 548 LED modules for further details.
It is possible to use a mix of 157 and 548 modules to give both relay and LED expansion if
required.

16.3.2 INPUT EXPANSION (P130/P540/P541)

It is possible to increase the number of monitored inputs available by utilising either:

DSE P130 input expansion.

540 / 541 Protection Expansion/Annunciator.

Please refer to the relevant product documentation for further details.

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16.4 COMMUNICATIONS OPTION

16.4.1 DESCRIPTION
The 5xxx series configuration software allows the 5520 controller to communicate with a PC. The
computer can be connected to the module either directly, via a modem (RS232)* or via an RS485
link**.
The operator is then able to remotely control the module, starting or stopping the generator,
selecting operating modes, etc. The various operating parameters (such as output volts, oil
pressure, etc.) on the remote generator can also be viewed.
The information contained in this manual should be read in conjunction with the appropriate
module documentation. This manual only details the operation of the communications software
and how it should be used. The operation of the module is detailed in its own relevant manual.
NOTE: - *If modem communications is a requirement, then it is important to order the
correct 5520 module with the RS232 communications board fitted. This provides a 9-way
D-type connector suitable for connection to the modem. Please refer to the comms
section of this manual for details of how the system should be configured.
**If RS485 communications is required, then it is important to order the correct 5510
module with the RS485 communications board fitted. This provides a 3-way terminal
block for connection of the RS485 link.

16.4.2 PC TO CONTROLLER (DIRECT) CONNECTION

To connect a 5510 to a modem the following items are required: Any 5520 Module (RS232 or RS485)
5xxx series configuration software (Supplied on DSE software
CD).
P810 interface (USB or RS232 as required)

16.4.3 MODEM TO CONTROLLER CONNECTION

To connect a 5520 to a modem the following items are required:

5520 Module with RS232 Communications Interface

Compatible RS232 Modem (PSTN or GSM)
Suitable connection leads
Power supply for the modem
5xxx series configuration software (Supplied on DSE software CD).
Access to a PSTN Line or GSM network.

CAUTION! - The modem must be powered from a suitably stabilised supply,

preferably supplied with the modem (see below). Failure to ensure continuity of supply
will result in communication difficulties at such times as Mains failure or during cranking.
An uninterruptible power supply arrangement is recommended (AC or DC depending on
modem power requirement).
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16.4.4 RS485 LINK TO CONTROLLER

The RS485 enabled 5520 modules are able to communicate with a PC or other RS485 enabled
device over a standard RS485 connection. Typical uses of RS485 are:

Direct connection to a remote PC running the Link5000 software. RS485 is capable of

communication over a distance of 1.2km where suitable 120 RS485 cable is installed.
Connection to a building management to allow mains, generator and engine parameters/alarm
conditions to be displayed along with information from other devices (air conditioning, fire
alarm system etc).

Typical connections of
RS485 PC system
(master) to RS485 DSE
controller (slave)

NOTE: - The RS485 system will comprise of one MODBUS master (typically a PC) and
up to 31 MODBUS slaves. The 5520 modules are always MODBUS slave devices. To
ensure correct operation a suitable 120 terminal resistor must be fitted to each end of
the RS485 connection bus.

Caution! - The A and B lines of the 485 network should be terminated at each end
with a 120 resistor.
Some RS485 devices (PC cards in particular) are already fitted with a terminating
resistor. However if they are not installed as an end of line device then such
terminating resistors must be removed. Other RS485 devices may be fitted with a
switchable resistor, again this must be switched out if the device is not installed as an
end of line device.

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TYPICAL BUILDING MANAGEMENT SCHEME USING RS485 MONITORING

CAUTION! -. RS485 cabling must be 120 impedance cable, specified for use with
RS485. 120 terminating resistors must be fitted to the first and last devices on the bus.
Some PC RS485 cards are already fitted with this resistor, and in this case should not be
fitted externally. If in doubt, consult the supplier of your PC RS485 card.
If the 5520 controller is the last device on the bus, then its RS485 connection must be
suitably terminated with a 120 resistor as detailed in the specification laid out in the
RS485 standard.
Recommended cable BELDEN 9841 120 RS485 cable.
DSE part number 016-030.

NOTE: - The RS485 output uses MODBUS protocol. It is possible to use third party
software to monitor and control the 5520 module via this protocol.
Please refer to Deep Sea Electronics Plc for details.

16.4.5 MODBUS
The RS485 output uses Modbus communications protocol. This uses a master-slave technique
to communicate. Only the Master can initiate a packet transaction, called a query. When
appropriate the slave (5520 Module) responds to the query and provides the information requested
by the master.
All supported data can be read and written as specified in the register table (documentation is
available from Deep Sea Electronics Plc.).
When the 5520 Module receives a query it will respond by either supplying the requested register
data or performing the requested action. A slave device (the 5520 module) will never initiate
communications on the Modbus link. The 5520 can only be configured as a slave device. The
Master can only query individual slaves. Refer to the Modbus protocol document for more
details.
Refer to the Link5000plus Manual for further details on communications expansion.
NOTE:- 5560 controller only available with RS485 communications.

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16.5 IEEE C37.2 STANDARD ELECTRICAL POWER SYSTEM DEVICE

FUNCTION NUMBERS
The DSE 5520 contains many protection devices and functions, which are listed in detail in the
following sections.
Functions and protections provided corresponding to IEEE C37.2 (1996) system device numbers
are listed below.
Overall, the 5520 is designated as 11 - Multifunction device and includes the following protections
and functions:
Device
2

time delay starting

or closing relay

checking or
interlocking relay

stopping device

12 overspeed device
14 underspeed device
15

speed or frequency
matching device

18

accelerating or
decelerating device

synchronizing or
25 synchronism-check
relay
27 undervoltage relay
30 annunciator relay
31

separate excitation
device

32

directional power
relay

reverse-phase or
46 phase-balance
current relay
48

incomplete
sequence relay

50

instantaneous
overcurrent relay

51

ac time overcurrent
relay

Description
A device that functions to give a desired amount of time delay before or
after any point of operation in a switching sequence or protective relay
system, except as specifically provided by device functions 48, 62, 79, and
82.
A device that operates in response to the position of one or more other
devices or predetermined conditions in a piece of equipment or circuit, to
allow an operating sequence to proceed, or to stop, or to provide a check
of the position of these devices or conditions for any purpose.
A control device used primarily to shut down equipment and hold it out of
operation. (This device may be manually or electrically actuated, but it
excludes the function of electrical lockout [see device function 86] on
abnormal conditions.)
A device, usually direct connected, that operates on machine overspeed.
A device that functions when the speed of a machine falls below a
predetermined value.
A device that functions to match and hold the speed or frequency of a
machine or a system equal to, or approximately equal to, that of another
machine, source, or system.
A device that is used to close or cause the closing of circuits that are used
to increase or decrease the speed of a machine.
A synchronizing device produces an output that causes closure at zerophase angle difference between two circuits. It may or may not include
voltage and speed control. A synchronism-check relay permits the
paralleling of two circuits that are within prescribed limits of voltage
magnitude, phase angle, and frequency.
A device that operates when its input voltage is less than a predetermined
value.
A nonautomatically reset device that gives a number of separate visual
indications upon the functioning of protective devices and that may also be
arranged to perform a lockout function.
A device that connects a circuit, such as the shunt field of a synchronous
converter, to a source of separate excitation during the starting sequence.
A device that operates on a predetermined value of power flow in a given
direction such as reverse power flow resulting from the motoring of a
generator upon loss of its prime mover.
A device in a polyphase circuit that operates when the polyphase currents
are of reverse-phase sequence or when the polyphase currents are
unbalanced or when the negative phase-sequence current exceeds a
preset value.
A device that generally returns the equipment to the normal or off position
and locks it out if the normal starting, operating, or stopping sequence is
not properly completed within a predetermined time.
A device that operates with no intentional time delay when the current
exceeds a preset value.
A device that functions when the ac input current exceeds a predetermined
value, and in which the input current and operating time are inversely
related through a substantial portion of the performance range.
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A device that is used to close and interrupt an ac power circuit under

normal conditions or to interrupt this circuit under fault or emergency
conditions.
turning gear
A device either electrically operated, controlled, or monitored that functions
engaging device
to cause the turning gear to engage (or disengage) the machine shaft.
A device that operates when the power factor in an ac circuit rises above
power factor relay
or falls below a predetermined value.
A device that operates when its input voltage exceeds a predetermined
overvoltage relay
value.
A device that imposes a time delay in conjunction with the device that
time-delay stopping
initiates the shutdown, stopping, or opening operation in an automatic
or opening relay
sequence or protective relay system.
A device that operates at a given pressure value or at a given rate of
pressure switch
change of pressure.
A device with two-positions that in one position permits the closing of a
permissive control circuit breaker, or the placing of a piece of equipment into operation, and in
device
the other position, prevents the circuit breaker or the equipment from being
operated.
A device that operates at a given level value, or on a given rate of change
level switch
of level.
A device other than an annunciator, as covered under device function 30,
alarm relay
that is used to operate, or that operates in connection with, a visual or
audible alarm.
phase-angle
A device that functions at a predetermined phase angle between two
measuring relay
voltages, between two currents, or between voltage and current.
A device that responds to the frequency of an electrical quantity, operating
frequency relay
when the frequency or rate of change of frequency exceeds or is less than
a predetermined value.
automatic selective
A device that operates to select automatically between certain sources or
control or transfer
conditions in equipment or that performs a transfer operation automatically.
relay
A device that trips and maintains the associated equipment or devices
lockout relay
inoperative until it is reset by an operator, either locally or remotely.
A device that functions to regulate a quantity or quantities, such as voltage,
current, power, speed, frequency, temperature, and load, at a certain value
regulating device
or between certain (generally close) limits for machines, tie lines, or other
apparatus.

52 ac circuit breaker
54
55
59
62
63

69

71
74
78
81

83
86

90

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16.6 ENCLOSURE CLASSIFICATIONS

IP CLASSIFICATIONS
BS EN 60529 Degrees of protection provided by enclosures

First Digit

Second digit

Protection against contact and ingress of solid objects

Protection against ingress of water

No protection

No protection

Protected against ingress solid objects with a

diameter of more than 50 mm. No protection against
deliberate access, e.g. with a hand, but large
surfaces of the body are prevented from approach.

Protection against dripping water falling vertically. No

harmful effect must be produced (vertically falling
drops).

Protected against penetration by solid objects with a

diameter of more than 12 mm. Fingers or similar
objects prevented from approach.

Protection against dripping water falling vertically.

There must be no harmful effect when the equipment
(enclosure) is tilted at an angle up to 15 from its
normal position (drops falling at an angle).

Protected against ingress of solid objects with a

diameter of more than 2.5 mm. Tools, wires etc. with
a thickness of more than 2.5 mm are prevented from
approach.

Protection against water falling at any angle up to 60

from the vertical. There must be no harmful effect
(spray water).

Protected against ingress of solid objects with a

diameter of more than 1 mm. Tools, wires etc. with a
thickness of more than 1 mm are prevented from
approach.

Protection against water splashed against the

equipment (enclosure) from any direction. There must
be no harmful effect (splashing water).

Protected against harmful dust deposits. Ingress of

dust is not totally prevented but the dust must not
enter in sufficient quantity to interface with
satisfactory operation of the equipment. Complete
protection against contact.

Protection against water projected from a nozzle

against the equipment (enclosure) from any direction.
There must be no harmful effect (water jet).

Protection against ingress of dust (dust tight).

Complete protection against contact.

Protection against heavy seas or powerful water jets.

Water must not enter the equipment (enclosure) in
harmful quantities (splashing over).

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NEMA CLASSIFICATIONS
NOTE: - There is no direct equivalence between IP / NEMA ratings. IP figures shown
are approximate only.
1

Provides a degree of protection against contact with the enclosure equipment and against a limited amount of
falling dirt.

IP30
2

Provides a degree of protection against limited amounts of falling water and dirt.

IP31
3

Provides a degree of protection against windblown dust, rain and sleet; undamaged by the formation of ice on
the enclosure.

IP64
3R

Provides a degree of protection against rain and sleet:; undamaged by the formation of ice on the enclosure.

IP32
4 (X)

Provides a degree of protection against splashing water, windblown dust and rain, hose directed water;
undamaged by the formation of ice on the enclosure. (Resist corrosion).

IP66
12/12K

Provides a degree of protection against dust, falling dirt and dripping non corrosive liquids.

IP65
13

Provides a degree of protection against dust and spraying of water, oil and non corrosive coolants.

IP65

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12. SYNCHRONISING NOTES

Optionally, the 5520 controller can be configured to synchronise, volts match and parallel with the
mains supply. This facility can be used to supply a fixed amount of power to the load and/or mains
supply or provide no-break (closed transition) transfers to and from the generator supply.
Additionally, with the addition of the optional Mains CT, the module can be used to automatically
start the set upon rising mains load and use the generator set to keep the mains load below an
adjustable level.

16.6.1 CHECK SYNC

(If enabled)
The module will control the operation of the load-switching device to allow parallel operation with
the mains supply only when the two supplies are in Synchronism. These functions can be used to
provide manual Peak lopping/ Peak shaving and short duration no-break or bump-less transfers
back to the mains supply following a mains failure.
Refer to the 5xxx software manual for further details.

16.6.2 AUTO SYNC

(If enabled)
The module provides control signals to the Engine Governor and the Alternator AVR to control the
speed and voltage output from the generating set.
These functions can be used to provide peak lopping/ peak shaving (without load share control)
and true no-break or bump-less transfers back to the mains supply following a mains failure.
The 5xxx module provides the ability to control the generator by adjusting the speed (frequency)
and voltage being output. Several methods of providing this control are available. The following
pages give a schematic overview of the interface with the engine governor and alternator AVR.
Refer to the 5xxx software manual for further details.

16.6.3 LOAD CONTROL

(If enabled)
The module features all the functions associated with the Check sync and autosync features and in
addition it provides control signals to the Engine Governor and the Alternator AVR while in parallel
with the mains (utility) supply to provide soft loading (load ramping) and control the amount of load
(kW and kVAr) supplied by the generating set.
These functions can be used to provide peak lopping / peak shaving and true no-break or bumpless transfers back to the mains supply following a mains failure.
MAINS CT
Mains current monitoring is included as standard to allow (optional) automatic starting of the set on
rising load levels to allow true peak lopping / shaving, ramping of the load from the mains to the set
and vice versa and more.
Refer to the 5xxx software manual for further details.

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16.6.4 TYPICAL PEAK LOPPING SYSTEM

For further details on this subject, you are referred to the Deep Sea Electronics Guide to
Synchronising and Load Sharing Parts 1 and 2.

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