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053-083 ISS 1

D E E P S E A E L E C T R O N I C S

SYNC LOCK INSTALLATION INSTRUCTIONS

Description The DSE7570 Sync Lock Controller has been designed for manual connection and disconnection from the mains/utility supply. The Sync Lock Controller provides a user friendly zero-sync/phase locking solution that is integrated easily with generators controlled by the DSE7510 Load Share module. With forward and backward synchronising with the mains/utility supply, the DSE7570 is ideal for temporary generator installations. Where access is restricted, the DSE Sync Lock Interface is used to provide up to a maximum distance of 200 m between the DSE7570 Sync Lock Controller and the DSE7510 Load Share module. The DSE7570 Sync Lock Controller is supplied in a robust case (IP67 when closed, IP65 when open in use) and interface box with connections to the DSE7510 controlled generator. Typical Applications • Generator hire • Local sub-station maintenance, service and repairs • Emergency power provision • Temporary power solutions

Dimensions SyncLock Case 406 mm x 330 mm x 174 mm (16.0 " x 13.0 " x 6.9 ") Expansion box 122 mm x 120 mm x 55 mm (4.8 ” x 4.7 ” x 2.2 ”)

Interface box cable 1 m (3 ft) supplied, extension possible. SyncLock Control extension cable Maximum 200 m (666 ft)

Deep Sea Electronics Plc. Tel:+44 (0)1723 890099

Fax: +44 (0)1723 893303

Email: [email protected] Web: www.deepseaplc.com

Deep Sea Electronics inc. Phone: +1 (815) 316-8706 Fax: +1 (815) 316- 8708 TOLL FREE (USA only)

Tel: 1 866 636 9703 Email: [email protected]

Web: www.deepseausa.com

Connections DSE 7570 Sync Lock DSE 7510

generator controller

Mains and Generator Sensing Connections Mains and Generator sensing cables are manufactured as follows : Connection Signal Plug details Part

number Manufacturer

CN2 L1 Connector Hood 10426500 Contact Connectors CN3 L2 Connector Insert 10432000 Contact Connectors CN4 L3 CN5 N It is recommend to terminate the sensing cables with fused crocodile clips. Suitable parts are Silvertronic Part No 126065/Black + Part No.125041/Black and Silvertronic Part No 126024/Green + Part No.125041/Green.

Control Cable Extension Should it be necessary to extend the control cable between the Sync Lock device and Interface Box, this is achieved as below (maximum of 200 m using Belden 9843 cable). The extension is ‘straight through’ (ie 1-1, 2-2, 3-3, 4-4, 5-5, 6-6, 7-7) with one end male, the other female. Parts list (Manufacturer Contact Connectors)

Female End Male End Description Qty Part Description Qty Part no Hood 1 10426500 Hood 1 10429500 Insert 1 11251500 Insert 1 11250500 Pins 7 13163500 Pins 7 13162500

Control cable (1.5m supplied)

customer extension possible

Mains Sensing Generator Sensing

Interface Box*

*Connections from interface box to DSE7510 controller supplied (1.5m)

DSEPOWER®

Document Number 057-133

Author: Tony Manton

DSE Model 7570 operator manual

057-133 7570 Operator Manual Issue 2 08/12/10 AM 2

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 7570 operator manual

© Deep Sea Electronics Plc All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means or other) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988. Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to Deep Sea Electronics Plc at the address above. The DSE logo and the names DSEUltra, DSEControl, DSEPower, DSEExtra, DSEMarine and DSENet are UK registered trademarks of Deep Sea Electronics PLC. Any reference to trademarked product names used within this publication is owned by their respective companies. Deep Sea Electronics Plc reserves the right to change the contents of this document without prior notice. Amendments since last publication Amd. No. Comments

Clarification of notation used within this publication.

NOTE:

Highlights an essential element of a procedure to ensure correctness.

CAUTION!

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

WARNING!

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



TABLE OF CONTENTS Section Page 1 BIBLIOGRAPHY........................................................................................... 4

1.1 INSTALLATION INSTRUCTIONS ................................................................................. 4 1.2 TRAINING GUIDES ..................................................................................................... 4 1.3 MANUALS .................................................................................................................. 4

2 INTRODUCTION........................................................................................... 5

3 DESCRIPTION OF CONTROLS.................................................................... 7 3.1 VIEWING THE INSTRUMENTS.................................................................................... 8

4 OPERATION ................................................................................................ 9 4.1 STARTING THE SYSTEM ........................................................................................... 9 4.2 FORWARD SYNC TO MAINS SUPPLY ........................................................................ 9 4.3 PROCEED TO ISLAND OPERATION ......................................................................... 10 4.4 BACK SYNC TO MAINS ............................................................................................ 10



1 BIBLIOGRAPHY This document refers to and is referred to by the following DSE publications which can be obtained from the DSE website www.deepseaplc.com 1.1 INSTALLATION INSTRUCTIONS Installation instructions are supplied with the product in the box and are intended as a ‘quick start’ guide only. DSE PART DESCRIPTION 053-052 DSE7510 Installation Instructions 1.2 TRAINING GUIDES Training Guides are produced to give ‘handout’ sheets on specific subjects during training sessions. DSE PART DESCRIPTION 056-047 Fail to close and out of sync 1.3 MANUALS DSE PART DESCRIPTION 057-088 DSE7510 Operator Manual 057-119 DSE7500 Series Configuration Software Manual



2 INTRODUCTION This document details the installation and operation requirements of the DSE8680 bus tie controller, part of the DSEPower® range of products. The manual forms part of the product and should be kept for the entire life of the product. If the product is passed or supplied to another party, ensure that this document is passed to them for reference purposes. This is not a controlled document. You will not be automatically informed of updates. Any future updates of this document will be included on the DSE website at www.deepseaplc.com DSE7570 controller is compatible with DSE7510 generator controllers. The DSE7570 Sync Lock Controller has been designed for manual connection and disconnection from the mains/utility supply. The Sync Lock Controller provides a user friendly zero-sync/phase locking solution that is integrated easily with generators controlled by the DSE7510 Load Share module. With forward and backward synchronising with the mains/utility supply, the DSE7570 is ideal for temporary generator installations. Where access is restricted, the DSE Sync Lock Interface is used to provide up to a maximum distance of 200 m between the DSE7570 Sync Lock Controller and the DSE7510 Load Share module. Typical applications for the DSE7570 are: • Generator hire • Local sub-station maintenance, service and repairs • Emergency power provision • Temporary power solutions The user also has the facility to view the system operating parameters via the LCD display. The powerful ARM microprocessor contained within the module allows for incorporation of a range of complex features: • Text based LCD display (supporting multiple languages). • True RMS Voltage, Current and Power monitoring. • Fully configurable inputs for use as alarms or a range of different functions. Using a PC in conjunction with the DSE810 interface and 75xx Configuration software allows alteration of selected operational sequences, timers and alarms. A robust plastic case houses the module. Connections are via locking plug and sockets.



3 DESCRIPTION OF CONTROLS The following section details the function and meaning of the various controls and connections on the DSE7570 module.

To DSE7510 controller

Generator sensing

Mains sensing

Check Sync indicator

DC Supply indicator

Check Sync audible indicator



3.1 VIEWING THE INSTRUMENTS It is possible to scroll to display the different pages of information by repeatedly operating the next

page button.

Menu navigation buttons

Status and instrumentation display

Control buttons. See section entitled ‘Operation’ for details.



4 OPERATION

NOTE:- The generator controller MUST be version 12.11 or above to provide the Sync Lock feature.

4.1 STARTING THE SYSTEM

To show correct connection of the system, the generator controller displays Sync Lock on it’s screen.

4.2 FORWARD SYNC TO MAINS SUPPLY

1.Connect mains and generator sensing cables to the respective supplies.

Take care to ensure connection to the correct phases.

2. Connect control cable to the generator interface box

3. Press DC ON button to energise the system

4. Press to begin the sequence. The generator is automatically placed into Auto Mode and started by the Sync Lock device.

6. Press to Forward Sync the set with the mains supply. The synchroscope screen appears in the Sync Lock display, a duplicate of the generator’s synchroscope.

Trouble Shooting Operation of the “Sync Lock” message and Communication LED along with placing the 7510 automatically into AUTO mode depends upon the following:

1) 7510 must be version 12.11 or above. 2) MSC link must be correctly connected and terminated

with 120 ohm resistor at the 7510 end. 3) Control cable must be correctly connected to the

7570 sync lock device. 4) Any extension to the Control cable must be made in

Belden 9843 cable. Any extension to the interface box connection to the 7510 MSC link must be made in Belden 9841 cable.

COMMUNICATION LED illuminates

Trouble Shooting Inability to sync with the mains supply could be caused by a number of possibilities:

1) Measure the mains load first. Then set this amount (or a little below it) into the running editor of the system. This instructs the generator how much power to produce when it parallels with the mains supply.

2) Failure of the Control Cable connection to the MSC link of the 7510 controller.

3) Incorrect setup of the generator set / generator controller. See ‘DSE Four Steps to Synchronising’ for a checklist of items to test.

4) If the mains supply has varying frequency and/or voltage, the generator may be difficult to synchronise as it is trying to match a ‘moving target’.

5. Enter the running editor and select the amount of power that the set is to produce when in parallel. Usually this amount is close to the mains load.



4.3 PROCEED TO ISLAND OPERATION

4.4 BACK SYNC TO MAINS

7. Enter the Running Editor and Use increase and decrease load buttons to adjust the generator to take the whole load, minimising load on the mains supply. Remove the mains fuses in order L3 then L2 and finally L1. The generator is now in island mode solely providing power to the load.

8. Press after removing the final mains fuse (L1).

9. And remove the control cable to cease the forward sync part of the operation.

10. Connect mains and generator sensing cables to the respective supplies. Take care to ensure connection to the correct phases.

The Sync Lock device identifies the state of the system and continues with the generator running in island mode and the “Mains Failed Mode” LED illuminated.

Trouble Shooting

1) Change the generator load power in small steps. 2) Take care not to place too much load on the

generator. If you increase the load too far, excess power will be exported to the mains supply!

3) If the set is not instructed to take enough load, it will take a ‘load hit’ when the mains fuses are removed.

4) When you are happy that most of the load is being supplied by the generator, remove the fuses and move to island mode.



13. Press to begin the back sync operation, The Sync Lock device instructs the generator to synchronise with the mains supply and ‘hold’ the supplies in sync. This operation will take a short while, the check sync lamp and audible sounder activate to show when the supplies are in sync. Once held in sync, replace the mains fuses in order L1 then L2, then L3. Don’t hesitate during the fuse replacement and proceed to step 11 immediately after replacing the final fuse (L3)

11. Connect control cable to the generator interface box

12. Press DC ON button to energise the system

14. Press AFTER replacing ALL THREE mains fuses. This instructs the generator to ramp down and open the breaker. The set will then cool down and stop.

COMMUNICATION LED illuminates and ‘Sync Lock’ appears on the screen of the generator controller.

Trouble Shooting Operation of the “Sync Lock” message and Communication LED along with placing the 7510 automatically into AUTO mode depends upon the following:

1) MSC link must be correctly connected and terminated with 120 ohm resistor at the 7510 end.

2) Control cable must be correctly connected to the 7570 sync lock device. Any extension to the Control cable must be made in Belden 9843 cable.

3) Any extension to the interface box connection to the 7510 MSC link must be made in Belden 9841 cable.

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DSE7570REMOTE SYNC LOCK CONTROLLER

DSEGenset

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VOLTS

GENERATORSENSING

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DC POWER SUPPLY 8-35V

MAINS (UTILITY) SENSING

ISSUE 1

7

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DSE7570 DATA LINK

7570 7510

DSE��®

The DSE7570 Sync Lock Controller has beendesigned for manual connection anddisconnection from the mains (utility) supply.

The Sync Lock Controller provides a user-friendly zero-sync/phase locking solution,that is easily integrated with generatorscontrolled by the DSE7510 or DSE8610 LoadShare module. With forward and backwardsynchronising with the mains/utility supply,the DSE7570 is ideal for temporary generatorinstallations.

Where access is restricted, the DSE SyncLock Interface is used to provide up to amaximum distance of 200 m between theDSE7570 Sync Lock Controller and theDSE7510 or DSE8610 Load Share module.

DSE7570REMOTE SYNC LOCK CONTROLLER

FEATURES

ENVIRONMENTAL TESTING STANDARDS

ELECTRO-MAGNETIC COMPATIBILITYBS EN 61000-6-2EMC Generic Immunity Standard for the Industrial EnvironmentBS EN 61000-6-4EMC Generic Emission Standard for the Industrial Environment

ELECTRICAL SAFETYBS EN 60950Safety of Information Technology Equipment, including Electrical Business Equipment

TEMPERATUREBS EN 60068-2-1Ab/Ae Cold Test -30 oCBS EN 60068-2-2Bb/Be Dry Heat +70 oC

VIBRATIONBS EN 60068-2-6Ten sweeps in each of three major axes5 Hz to 8 Hz @ +/-7.5 mm, 8 Hz to 500 Hz @ 2 gn

HUMIDITYBS EN 60068-2-30Db Damp Heat Cyclic 20/55 oC@ 95% RH 48 HoursBS EN 60068-2-78Cab Damp Heat Static 40 oC@ 93% RH 48 Hours

SHOCKBS EN 60068-2-27Three shocks in each of three major axes15 gn in 11 mS

DEGREES OF PROTECTIONPROVIDED BY ENCLOSURESBS EN 60529IP67 - When case is closed.

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VOLTS

GENERATORSENSING

VOLTS

DC POWER SUPPLY 8-35V


ISSUE 1

COMPREHENSIVE FEATURE LIST TO SUIT A WIDE VARIETYOF GEN-SET HIRE APPLICATIONS

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DEEP SEA ELECTRONICS PLC UKHighfield House, Hunmanby Industrial Estate, Hunmanby YO14 0PHTELEPHONE +44 (0) 1723 890099 FACSIMILE +44 (0) 1723 893303EMAIL [email protected] WEBSITE www.deepseaplc.com

DEEP SEA ELECTRONICS INC USA3230 Williams Avenue, Rockford, IL 61101-2668 USATELEPHONE +1 (815) 316 8706 FACSIMILE +1 (815) 316 8708EMAIL [email protected] WEBSITE www.deepseausa.com

055-085/11/10 (3) US

KEY BENEFITS• Provides a user-friendly zero-

sync/phase locking solution, idealfor temporary generatorinstallations, including forwardand backward synchronising withthe mains (utility)

• No-break removal and return ofmains (utility) fuses

• Interface provides applicationflexibility where access is limited

TYPICAL APPLICATIONS• Generator hire• Local sub-station maintenance,

service and repairs• Emergency power provision• Temporary power solutions

RELATED MATERIALSTITLE PART NO’SDSE7570 Installation Instructions 053-083DSE7570 Operator Manual 057-132DSE7510 Data Sheet 055-065DSE123 Data Sheet 055-044DSE8610 Data Sheet 055-083

SPECIFICATION

DC SUPPLYCONTINUOUS VOLTAGE RATING8 V to 35 V Continuous

CRANKING DROPOUTSAble to survive 0 V for 50 mS, providing supply was at least 10 V before dropout and supply recovers to 5 V. This is achieved without the need for internal batteries.LEDs and backlight will not be maintained during cranking.

MAXIMUM OPERATING CURRENT150 mA at 12 V, 80 mA at 24 V

MAXIMUM STANDBY CURRENT50 mA at 12 V, 30 mA at 24 V

MAINS (UTILITY) VOLTAGE RANGE15 V - 333 V AC (L-N)

FREQUENCY RANGE3.5 Hz to 75 Hz

GENERATORVOLTAGE RANGE 15 V - 333 V AC (L-N)

FREQUENCY RANGE3.5 Hz to 75 Hz

DIMENSIONSSYNC LOCK CASE406 mm x 330 mm x 174 mm(16.0" x 13.0" x 6.9")

INTERFACE BOX(To be ordered separately)122 mm x 120 mm x 55 mm(4.8” x 4.7” x 2.2”)

SYNC LOCK INTERFACE EXTENSION CABLE (NOT AVAILABLE FROM DSE)3 pair twisted individually screened cableMaximum 200 m (666 ft)

OPERATING TEMPERATURE RANGE-30°C to +70°C

STORAGE TEMPERATURE RANGE-40°C to +80°C

DSE7570 SYNC LOCK CONTROLLER

FEATURES

Registered in England & Wales No.01319649VAT No.316923457

Deep Sea Electronics Plc maintains a policy of continuous development and reserves the right to changethe details shown on this data sheet without prior notice. The contents are intended for guidance only.

INTERFACE BOX*

DSE7510/DSE8610 GENERATOR CONTROLLER

DSE7570SYNC LOCK

GENERATOR SENSING

CONTROL CABLE(1.5m supplied)

customer extension possible*Connections from interface box to

DSE7510 / DSE8610 controller supplied(1.5m)


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