Deep Sea Electronics PLC: 555 Operators Manual

DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual
Deep Sea Electronics Plc
555 Operators Manual
Author – Miles Revell
Deep Sea Electronics Plc

Highfield House
Hunmanby Industrial Estate
North Yorkshire
YO14 0PH
ENGLAND
Tel +44 (0) 1723 890099
Fax +44 (0) 1723 893303
Email : [email protected]
555 OPERATING MANUAL ISSUE 5 04/04/02 MR 1

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2 555 OPERATING MANUAL ISSUE 5 04/04/02 MR

TABLE OF CONTENTS
Section Page
INTRODUCTION................................................................................................................................ 5
CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION. ...................................... 6
1. OPERATION ............................................................................................................................... 7
1.1 CONTROL ........................................................................................................................... 7
FIG 1 .................................................................................................................................... 7
1.2 NORMAL MANUAL OPERATION ....................................................................................... 7
1.3 AUTOMATIC (MAINS FAILURE/REMOTE) OPERATION .................................................. 9
1.4 TEST (SIMULATE MAINS FAILURE) OPERATION.......................................................... 12
2. PROTECTIONS ........................................................................................................................ 15
VIEWING ALARMS ............................................................................................................... 16
2.1 WARNINGS ....................................................................................................................... 17
2.2 SHUTDOWNS ................................................................................................................... 18
2.3 ELECTRICAL TRIPS ......................................................................................................... 20
2.4 PRE-ALARMS AND OPTIONS .......................................................................................... 20
3. DESCRIPTION OF CONTROLS............................................................................................... 21
3.1 LCD DISPLAY.................................................................................................................... 21
VIEWING THE INSTRUMENT AND EVENT LOG PAGES.......................................................... 22
SYNCHROSCOPE OPERATION (IF FITTED) ......................................................................... 23
OPERATOR CONFIGURATION MODE....................................................................................... 24
POWER UP LCD DISPLAY.......................................................................................................... 26
3.2 LED INDICATORS.................................................................................................................. 28
3.3 CONTROL PUSH-BUTTONS................................................................................................. 29
3. INSTALLATION INSTRUCTIONS............................................................................................. 31
3.1 PANEL CUT-OUT .............................................................................................................. 31
FIG 3 .................................................................................................................................. 31
3.2 COOLING........................................................................................................................... 31
3.3 UNIT DIMENSIONS ........................................................................................................... 31
FIG 4 .................................................................................................................................. 31
3.4 FRONT PANEL LAYOUT .................................................................................................. 32
FIG 5 .................................................................................................................................. 32
3.5 REAR PANEL LAYOUT ..................................................................................................... 32
FIG 6 .................................................................................................................................. 32
4. ELECTRICAL CONNECTIONS ................................................................................................ 33
4.1 CONNECTION DETAILS................................................................................................... 33
PLUG “A” 13 WAY .................................................................................................................... 33
PLUG “B” 17 WAY .................................................................................................................... 33
PLUG “C” 4 WAY ...................................................................................................................... 34
PLUG “D” 11 WAY .................................................................................................................... 34
PC CONFIGURATION INTERFACE CONNECTOR ................................................................ 35
EXPANSION INTERFACE CONNECTOR................................................................................ 35
4.2 CONNECTOR FUNCTION DETAILS ................................................................................ 36
PLUG “A” 13 WAY .................................................................................................................... 36
PLUG “B” 17 WAY .................................................................................................................... 37
PLUG “C” 4 WAY ...................................................................................................................... 38
PLUG “D” 11 WAY .................................................................................................................... 38
5. SPECIFICATION....................................................................................................................... 39
6. COMMISSIONING .................................................................................................................... 40
6.1 PRE-COMMISSIONING...................................................................................................... 40
7. FAULT FINDING ....................................................................................................................... 41
8. TYPICAL WIRING DIAGRAMS................................................................................................. 42
9 FACTORY DEFAULT CONFIGURATION..................................................................................... 44

10. ICONS AND LED IDENTIFICATION .....................................................................................46

10.1 ICON DESCRIPTIONS .........................................................................................................46
10.2 LED IDENTIFICATION DIAGRAM ........................................................................................47
10.3 SENDER WIRING RECOMMENDATIONS ..........................................................................47
11. NAVIGATION CHART............................................................................................................49
12. APPENDIX .............................................................................................................................50
12.1 55X IDMT TRIPPING CURVES (TYPICAL) ......................................................................50
12.2 55X SHORT CIRCUIT TRIPPING CURVES (TYPICAL)................................................51
12.3 USING THE 55X MODULE WITH ACB’S .............................................................................52
12.4 OUTPUT EXPANSION..........................................................................................................53
12.4.1 RELAY OUTPUT EXPANSION (157).............................................................................53
12.4.2 LED OUTPUT EXPANSION (548) .................................................................................53
12.5 INPUT EXPANSION..............................................................................................................53
13. SYNCHRONISING NOTES ...................................................................................................54
13.1 CHECK SYNC VERSIONS ........................................................................................54
13.2 AUTO SYNC VERSIONS ......................................................................................54

13.2.1 GOVERNOR AND AVR CONTROL USING INTERNAL RELAYS DIRECTLY..............55
TYPICAL CONNECTIONS.....................................................................................................55
MODULE CONFIGURATION SETTING FOR 555 AUXILIARY RELAYS .............................55
13.2.2 GOVERNOR AND AVR CONTROL USING INTERNAL RELAYS TO DRIVE
MOTORISED/ELECTRONIC POTENTIOMETER. ...................................................................56
13.2.3 GOVERNOR AND AVR CONTROL USING P122 DIGITAL RESISTANCE MODULES57
13.2.4 DIRECT GOVERNOR CONTROL AND AVR CONTROL USING P122 DIGITAL
RESISTANCE MODULES .........................................................................................................58

INTRODUCTION
The DSE 555 Module, has been designed to allow the OEM to meet most of the industry’s complex
specifications. 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.
The DSE 555 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 555 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 32-Bit Micro-processor contained within the module allows for a range of complex
features to be incorporated as standard;
• Full Multi-lingual LCD display (including non-western character fonts).

• Up to eight different languages held on-board the module.
• True RMS voltage monitoring.
• Optional Power measurement facility.
• Optional Communications capability (RS485 or RS232 including GSM/SMS functions)
• Optional Check Sync capability
• Optional Automatic Sync capability
• Fully configurable inputs for use as alarms or a range of different functions.
• Extensive range output functions using built in relay outputs or relay expansion available .
Selective operational sequences, timers and alarm trips can be altered by the customer via a PC
using the P810 For Windows ™ software and 810 interface
Access to critical operational sequences and timers for use by qualified engineers, are barred by a
security code. Module access is barred by PIN code. Limited operator selections, such as
display language, can be changed from the module 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.

CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION.
Highlights an essential element of a procedure to ensure

NOTE: correctness.
Indicates a procedure or practice which, if not strictly observed,

CAUTION!: could result in damage or destruction of equipment.
Indicates a procedure or practice which could result in injury to

WARNING!: personnel or loss of life if not followed correctly.
Indicates facility is only available on V2.00 or later modules. If in

doubt check ‘V’ number on power up display.
Indicates facility is only available on V3.00 or later modules. If in

doubt check ‘V’ number on power up display.
Deep Sea Electronics Plc owns the copyright to this manual, which
ã cannot be copied, reproduced or disclosed to a third party without
prior written permission.

1. OPERATION
1.1 CONTROL
Control of the DSE 555 module is via push-buttons mounted on the front of the module with
STOP/RESET, MANUAL, START, AUTO, TEST and ALARM MUTE 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. Details of their operation is detailed
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.
Deep Sea Electronics plc

Model 555
i
O I AUTO
FIG 1
1.2 NORMAL MANUAL OPERATION
Operation Detail
To initiate a start sequence, press the ‘Manual’ push-
button.
The LED above the button will illuminate and the LCD MANUAL MODE
display will briefly indicate:

Operation Detail
The LED above the button will illuminate and the LCD GENERATOR AT REST
display will then indicate:
Then, press and hold the START push-button, once the

module has commenced the start sequence the button
may then be released. (However, it is possible to configure
the module such the start-button must be held pressed to Ι
maintain engine cranking until disconnect speed is reached -
Refer to your configuration Source)
The LED above the button will illuminate and the LCD START
If the pre-heat output option is configured, the Pre-heat PRE-HEATING

timer is then initiated, and the auxiliary output selected is
energised. 00:09
After the pre-heat timer has expired the module will de- PRE-HEATING
energise the pre-heat output and commence engine
starting; the following sequence occurs. 00:00
The Fuel Solenoid is energised, then after a 1 second FUEL ON
delay the Starter Motor is engaged
The engine is cranked for the duration of the crank timer CRANKING ATTEMPT.1
00:08
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 terminating cranking, along with options of Charge alternator voltage and oil pressure.
If a Magnetic Pick-up is utilised it is also possible to configure the module so that if the starter motor
fails to engage on the first attempt, the starter relay will be de-energised and the a second attempt
to engage will be made. For further details on this function please refer to the P810 for Windows™
configuration manual.
Operation Detail
Should the engine not fire on the first attempt and the CRANK REST. 1
crank timer expires, the module will rest the starter for
the duration of the crank rest timer. 00:04
Once this has expired the module will once again CRANKING ATTEMPT 2
attempt to start the engine.
00:07
This will be repeated until either the engine fires or the pre-set number of attempts to start have
been completed…
Operation Detail
In this instance the module will indicate a ‘Fail to start’ SHUTDOWN
alarm.
FAILED TO START
NOTE:- Should a ‘Fail to start’ alarm occur the

module must be placed into STOP/RESET mode by
pressing the STOP/RESET PUSHBUTTON. O
Determine why the engine failed to fire before
making any further attempts to start.

If the engine start is successful, the following sequence occurs:-
Operation Detail
After the starter motor has disengaged, the Safety On WAITING FOR SAFETY
timer is activated.
ON 00:08
This timer allows Oil Pressure, High Engine Temperature, Underspeed, Undervolts, Charge Fail
and any delayed Auxiliary fault inputs to stabilise without triggering the fault.
Operation Detail
Once the engine is running and the Safety on timer has GENERATOR AVAILABLE IN
expired, full fault protection is made available. MANUAL
Pressing the STOP/RESET PUSHBUTTON will de-
energise the Fuel Solenoid and bring the engine to rest.
O
The LCD screen will acknowledge the button press… STOP/RESET
While the engine runs down the module will start it’s ‘Fail STOPPING
to stop’ timer.
00:24
If the engine is still running when the ‘Fail to stop’ Timer SHUTDOWN
expires the module will alarm.
FAIL TO STOP
Should the engine come to rest within the time allowed GENERATOR AT REST
by the fail to stop timer the screen will revert to …
NOTE:- The Load Transfer Output will not normally become active during a ‘Manual’
start. However, if the ‘Remote Start’ input is activated once the engine is running then the
Load Transfer Output will be activated and remain active until the engine is stopped.
1.3 AUTOMATIC (MAINS FAILURE/REMOTE) OPERATION
Operation Detail
If the module is placed in ‘AUTO’ mode by pressing the
‘AUTO’ PUSHBUTTON, it will monitor the auxiliary
inputs for a ‘REMOTE START’ signal. In addition the AUTO
module will monitor the incoming AC mains supply.
The LCD display will briefly indicate AUTO MODE
The LCD display will then indicate GENERATOR AT REST

Should the ‘REMOTE START’ signal be detected, or the Mains supply become outside of
acceptable limits, the following sequence will occur…
The module will start its ‘Start Delay’ timer, this is used START DELAY
to ensure that the start event is really required and not
just a momentary transient signal. 00:09
Once this timer has expired the module will continue with its normal start sequence as detailed
below. Should the remote start signal be removed or the mains return to within limits during either
the start delay timer or pre-heat timer, the module will terminate its start sequence and return to its
standby ‘AUTO‘ state until such time as a start is signalled again.
Operation Detail
If the pre-heat output option is configured, then the pre- PRE-HEATING
heat timer is then initiated, and the auxiliary output
selected is energised. 00:09
00:06
to engage will be made. For further details on this function please refer to the P810 For Windows™
configuration manual.
Operation Detail
00:07
been completed…
Operation Detail
alarm.
FAIL TO START


Operation Detail
timer is activated.
ON 00:09
and any delayed Auxiliary fault inputs to stabilise without triggering the fault. Once the engine is
running and the safety on timer has expired, full fault protection is made available.
Operation Detail
Once the generator is running at the correct speed and WARMING UP
up to voltage the Warm-up timer is then initiated
00:08
Should the remote start signal be removed or the mains return to within limits during either of the
cranking or warm-up timers, the module will terminate its normal auto start sequence will initialise
its ‘Cooling Timer’ and eventually return to its standby ‘AUTO‘ state until such time as a start is
signalled again.
Operation Detail
After the warm-up timer has expired the module will GENERATOR AVAILABLE
open the mains contactor relay.
IN AUTO
After a short transfer delay to allow the mains contactor GENERATOR AVAILABLE
to open the generator contactor will close.
The generator in now up and running and is selected to supply the load.
Operation Detail
Should the remote start signal be removed, or the mains GENERATOR AVAILABLE
return the module will first initiate a return timer to
ensure that it is safe to stop the generator. 00:06
Should the remote start input become active again or the mains fall outside of acceptable limits
again within this time the module will continue to run the generator on load and ignore the
fluctuating remote start signal or mains supply until such time as it remains in-active for the duration
of the stop delay timer.
Once the return timer has expired, the module will de-energise the Load Transfer output.
Operation Detail
The module will then commence its cooling timer, this COOLING DOWN
allows the engine to run off load to ensure that it has
adequately cooled before being brought to a standstill. 2:34
Once the cooling timer has expired the module will de- STOPPING
energise the fuel solenoid and the engine will be
brought to rest. 00:27
FAIL TO STOP
Should the engine come to rest within the time allow by GENERATOR AT REST
the fail to stop timer the screen will revert to

Note:- It is possible that the module has been configured to perform regular
exercise runs automatically. This may be used to exercise the engine periodically in
standby applications or to assist in peak-lopping arrangements. Therefore even though
the remote start input is not active and the mains supply is healthy, it is possible that if the
system is in the ‘Auto’ mode the engine may start unexpectedly if a scheduled run is
configured to occur.
WARNING!:- Before commencing work on the generating set it is important to take

steps to ensure that a scheduled run cannot start the engine unexpected. The system
should at a minimum be taken out of the ‘Auto’ mode and ‘Stop’ selected. Depending on
the nature of the work to be performed - further steps to ensure safety while working may
be necessary.
1.4 TEST (SIMULATE MAINS FAILURE) OPERATION
Operation Detail
To place the module into ‘TEST’ mode press ‘TEST’
PUSHBUTTON. This mode is used to simulate an
automatic start and will start the generator and transfer
the load.
The LCD display will briefly indicate TEST MODE
The LCD display will then indicate GENERATOR AT REST
Then, press and hold the START push-button, once the

module has commenced the start sequence the button
may then be released. (However, it is possible to configure
the module such that the start-button must be held pressed to Ι
maintain engine cranking until disconnect speed is reached -
Refer to your configuration Source)
The LED above the button will illuminate and the LCD START
If the pre-heat output option is configured, the Pre-heat PRE-HEATING

timer is then initiated, and the auxiliary output selected is
energised. 00:09
00:08
to engage will be made. For further details on this function please refer to the 810 configuration
manual.

Operation Detail
00:07
been completed…
Operation Detail
alarm.
FAIL TO START

Operation Detail
timer is activated.
ON 00:09
and any delayed Auxiliary fault inputs to stabilise without triggering the fault. Once the engine is
running and the safety on timer has expired, full fault protection is made available.
Operation Detail
Once the generator is running at the correct speed and WARMING UP
up to voltage the Warm-up timer is then initiated
00:08
After the warm-up timer has expired the module will GENERATOR AVAILABLE IN
energise it’s Load Transfer Output. MANUAL
The generator in now up and running and is selected to supply the load. To test the generator
stopping sequence press the ‘Auto’ pushbutton.
Operation Detail
If the module is placed in ‘AUTO’ mode by pressing the
‘AUTO’ PUSHBUTTON, it will monitor the auxiliary
inputs for a ‘REMOTE START’ signal. In addition the AUTO
module will monitor the incoming AC mains supply.
The LCD display will briefly indicate AUTO MODE
Should the remote start signal not be present, or the GENERATOR AVAILABLE
mains is within limits,the module will first initiate a return
timer to ensure that it is safe to stop the generator. 00:06

Should the remote start input become active again within this time the module will continue to run
the generator on load and ignore the fluctuating remote start signal until such time as it remains in-
active for the duration of the stop delay timer.
Once the return timer has expired, the module will de-energise the Load Transfer output.
Operation Detail
The module will then commence its cooling timer, this COOLING DOWN
allows the engine to run off load to ensure that it has
adequately cooled before being brought to a standstill. 2:34
Once the cooling timer has expired the module will de- STOPPING
energise the fuel solenoid and the engine will be
brought to rest. 00:27
FAIL TO STOP
Should the engine come to rest within the time allow by GENERATOR AT REST
the fail to stop timer the screen will revert to

2. PROTECTIONS
The module will indicate that an alarm has occurred in several ways;
The Audible Alarm will sound. This can be silenced by

pressing the ‘Mute’ button
The “Common alarm” LED will illuminate(Warning =

Steady, Shutdown = Flashing [steady when Muted])
The LCD display will jump from the ‘Information page’ to
display the Alarm Page and the LED above the page
icon will illuminate
The LCD will the display ALARM
Followed by the appropriate alarm text SHUTDOWN

LOW OIL PRESSURE
If no alarms are present the LCD will display the following message and will then return to the
‘Information Display’ page;
NO ALARM PRESENT
i
The LCD will display multiple alarms E.g. “High Engine Temperature shutdown”, “Emergency Stop”
and “Low Coolant Warning” alarms have been triggered. These will automatically scroll round in
the order that they occurred;
ALARM
SHUTDOWN
HIGH ENGINE TEMP
SHUTDOWN
EMERGENCY STOP
WARNING
LOW COOLANT LEVEL

It is also possible to manually scroll to display the different alarms;
Initial display >>>>>>> ALARM
Pressing the DOWN button the LCD will SHUTDOWN

then show…
HIGH ENGINE TEMP
Pressing the DOWN button again the SHUTDOWN
LCD will then show…
EMERGENCY STOP
Pressing the DOWN button again the WARNING
LOW COOLANT LEVEL
Pressing the DOWN button again the ALARM
Pressing the UP button the LCD will WARNING

then show…
etc, etc, etc. LOW COOLANT LEVEL
VIEWING ALARMS
If the module is operating in the normal ‘INFORMATION PAGE’ display any alarm condition will
automatically be displayed.
Jumps to >>>
i
If the user is viewing instrumentation, e.g.
Then the alarm page will not automatically be

displayed and must be viewed by the operator.
To view an alarm operate the page button to move to

the ‘Alarm’ page.
To clear an alarm the original triggering conditions must

be removed before the alarm can be reset. Alarms are
reset by pressing the ‘Stop/Reset’ pushbutton.
O

2.1 WARNINGS
Warnings are non-critical alarm conditions and do not affect the operation of the generator system,
they serve to draw the operators attention to an undesirable condition.
BATTERY CHARGE FAILURE, if the module does not detect a voltage from the warning light
terminal on the auxiliary charge alternator, the module will display ‘WARNING CHARGE ALT
FAILURE’ on the LCD. The COMMON ALARM LED will also illuminate.
BATTERY LOW VOLTAGE, if the module detects that the plant DC supply has fallen below the low
volts setting level , the module will display ‘WARNING LOW BATTERY VOLTAGE’ on the LCD.
The COMMON ALARM LED will also illuminate.
BATTERY HIGH VOLTAGE, if the module detects that the plant DC supply has risen above the
high volts setting level , the module will display ‘WARNING HIGH BATTERY VOLTAGE’ on the
LCD. The COMMON ALARM LED will also illuminate.
OIL PRESSURE SENDER/SWITCH, the module can be configured to only attempt to crank the
engine if the Oil Pressure is initially low, (engine at rest, not running). The module will display ‘FAIL
TO STOP’ on the LCD. The COMMON ALARM LED will also illuminate.
LOW OIL PRESSURE, if the module detects that the engine oil pressure has fallen below the low
oil pressure pre-alarm level after the Safety On timer has expired, a warning alarm will occur. The
LCD will indicate ‘WARNING LOW OIL PRESSURE’ and the COMMON ALARM LED will
illuminate.
HIGH ENGINE TEMPERATURE, if the module detects that the engine coolant temperature has
exceeded the high engine temperature pre-alarm level after the Safety On timer has expired, a
warning alarm will occur. The LCD will indicate ‘WARNING HI COOLANT TEMP.’ and the
COMMON ALARM LED will illuminate.
OVERSPEED, if the engine speed exceeds the pre-alarm level a warning is initiated. The LCD will
indicate ‘WARNING OVERSPEED’ and the COMMON ALARM LED will illuminate.
UNDERSPEED, if the engine speed falls below the pre-alarm level after the Safety On timer has
expired, a warning alarm is initiated. The LCD will indicate ‘WARNING UNDERSPEED’ and the
GENERATOR HIGH FREQUENCY, if the module detects a generator output frequency in excess
of the pre-alarm level a warning is initiated. The LCD will indicate ‘WARNING GEN HIGH
FREQUENCY’ and the COMMON ALARM LED will illuminate.
GENERATOR LOW FREQUENCY, if the module detects a generator output frequency below the
pre-alarm level after the Safety On timer has expired, a warning is initiated. The LCD will indicate
‘WARNING GEN LOW FREQUENCY’ and the COMMON ALARM LED will illuminate.
GENERATOR HIGH VOLTAGE, if the module detects a generator output voltage in excess of the
pre-alarm level a warning is initiated. The LCD will indicate ‘WARNING GEN HIGH VOLTAGE
WARNING’ and the COMMON ALARM LED will illuminate.
GENERATOR LOW VOLTAGE, if the module detects a generator output voltage below the pre-
alarm level after the Safety On timer has expired, a warning is initiated. The LCD will indicate
‘WARNING GEN LOW VOLTAGE WARNING’ and the COMMON ALARM LED will illuminate.
MAINS PHASE SEQUENCE WRONG , if the module detects a generator phase rotation error
a warning is initiated. The LCD will indicate ‘MAINS PHASE SEQ WRONG’ and the COMMON
ALARM LED will illuminate.

MAINTENANCE DUE ALARM, if the engine exceed the allowed running hours or time
between periodic maintenance a warning is initiated. The LCD will indicate ‘MAINTENANCE NOW
DUE’ and the COMMON ALARM LED will illuminate. To clear the alarm a ‘MAINTENANCE
RESET’ must be performed (refer to config source or P810 for Windows software manual for more
detail)
AUXILIARY INPUTS, if an auxiliary input has been configured as a warning the appropriate LCD
message will be displayed and the COMMON ALARM LED will illuminate.
2.2 SHUTDOWNS
Shutdowns are latching and stop the Generator. The alarm must be accepted and 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 the like, 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. The LCD will indicate ‘SHUTDOWN FAIL TO START’ and the COMMON
ALARM and LED will flash.
EMERGENCY STOP, removal of the +ve DC Supply from the Emergency Stop input initiates the
following sequence, firstly it will initiate a controlled shutdown of the Generator and prevent any
attempt to restart the Generator until the Emergency Stop push-button has been reset. Secondly it
removes the +ve DC supply from both the Fuel Solenoid and Starter Solenoid. The LCD will
indicate ‘SHUTDOWN EMERGENCY STOP’ and the COMMON ALARM LED will flash.
NOTE:- The Emergency Stop +Ve 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. The
LCD will indicate ‘SHUTDOWN LOW OIL PRESSURE’ and the COMMON ALARM LED will flash.
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. The LCD will indicate ‘SHUTDOWN HIGH COOLANT TEMP’ and the
COMMON ALARM LED will flash.
OVERSPEED, if the engine speed exceeds the pre-set trip a shutdown is initiated. The LCD will
indicate ‘SHUTDOWN OVERSPEED’ and the COMMON ALARM LED will flash. Overspeed is not
delayed, it is an immediate shutdown.
NOTE:-However 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 P810 for Window™ Configuration 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. The LCD will indicate ‘SHUTDOWN UNDERSPEED’ and the

GENERATOR HIGH FREQUENCY, if the module detects a generator output frequency in excess
of the pre-set trip a shutdown is initiated. The LCD will indicate ‘SHUTDOWN GEN HIGH
FREQUENCY’ and the COMMON ALARM LED will flash. High frequency is not delayed, it is an
immediate shutdown.
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. The LCD will indicate
‘GEN LOW FREQUENCY’ and the COMMON ALARM LED will flash.
GENERATOR HIGH VOLTAGE, if the module detects a generator output voltage in excess of the
pre-set trip a shutdown is initiated. The LCD will indicate ‘GEN HIGH VOLTAGE’ and the
COMMON ALARM LED will flash. High voltage is not delayed, it is an immediate shutdown.
GENERATOR LOW VOLTAGE, if the module detects a generator output voltage below the pre-set
trip after the Safety On timer has expired, a shutdown is initiated. The LCD will indicate ‘GEN LOW
VOLTAGE’ and the COMMON ALARM LED will flash.
OIL PRESSURE SENDER OPEN CIRCUIT, if the module detects a loss of signal from the oil
pressure sender (open circuit) a shutdown is initiated. The LCD will indicate ‘OIL PRESS SENDER
FAULT’ and the COMMON ALARM LED will flash. Sender failure is not delayed, it is an
immediate shutdown.
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 ‘GEN EARTH FAULT’ and the
GENERATOR PHASE SEQUENCE WRONG , if the module detects a generator phase

rotation error a shutdown is initiated. The LCD will indicate ‘GEN PHASE SEQ WRONG’ and the
AUXILIARY INPUTS, if an auxiliary input has been configured as a Shutdown the appropriate LCD
message will be displayed and the COMMON ALARM LED will flash.
= Enhanced Instrumentation Versions only

2.3 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 ‘Load Transfer’ 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.
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’
and the COMMON ALARM LED will flash.
GENERATOR OVER CURRENT, if the module detects a generator output current in excess of the
pre-set trip a shutdown is initiated. The LCD will indicate ‘GEN OVER CURRENT’ and the
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’ and the
AUXILIARY INPUTS, if an auxiliary input has been configured as an Electrical Trip the appropriate
LCD message will be displayed and the COMMON ALARM LED will illuminate.
= Enhanced Instrumentation Versions only
2.4 PRE-ALARMS AND OPTIONS

During module configuration it is possible to select pre-alarm levels for all of the above shutdowns
and electrical trips to give a warning that the trip value is being approached. This allows the
operator to take steps to prevent the shutdown from ultimately occurring by rectifying the triggering
condition.
If the module is fitted with the optional RS232 communication board, then the following alarm is
available:-
MODEM POWER FAULT, if the module detects a modem supply current in excess of 350mA
warning is initiated. The LCD will indicate ‘MODEM POWER FAULT’ and the COMMON ALARM
LED will illuminate. The power supply to the modem will be removed until the alarm is reset.
If the module is fitted with the option of Check Sync or Auto Sync , then the
following alarm is available:-
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’ and the

3. DESCRIPTION OF CONTROLS
The following section details the function and meaning of the various controls on the module.
LCD Display User Configurable

LED's with insert pocket
Up and Down Model 555
Scroll Buttons Common Alarm Indicator
Information Page Indicator
Event Log Page Indicator
Operator Configuration i
Mode Indicator
Page Select Button Alarm Mute Button

O I AUTO
Stop/Reset Button
Mains Instruments Page Indicator
Test Mode Button
Generator Instruments Page Indicator
Start Button Auto Mode Button

Engine Instruments Page Indicator
Manual Mode Button

Alarm Page Indicator
3.1 LCD DISPLAY
INFORMATION PAGE
The LCD display normally indicates the status of the generator such as
‘GENERATOR AT REST’, ‘PRE-HEATING’, ‘GENERATOR AVAILABLE’, etc.
i This is the default display and is always automatically returned to after a pre-set
period of operator inactivity.
ALARM PAGE
The LCD also displays the exact nature of any alarm condition which have
occurred such as ‘SHUTDOWN LOW OIL PRESSURE’. This allows very specific
alarm conditions to be brought to the operators’ attention. Refer to the
‘Protections’ section of this manual for details of how to interact with the alarm
page.
ENGINE INSTRUMENTS PAGE
The LCD displays the various engine parameters such as ‘ENGINE SPEED’, ‘OIL
PRESSURE’, ‘HOURS RUN’, etc.
GENERATOR INSTRUMENT PAGE

The LCD displays the various generator output values such as ‘GENERATOR
VOLTAGE’, ‘GENERATOR CURRENT’, etc. If the enhanced instrumentation
option is fitted the LCD will also display the values of ‘GENERATOR KW’,
‘GENERATOR pF’, ‘GENERATOR KVAr’, etc.
MAINS INSTRUMENT PAGE

The LCD displays the various mains supply values such as ‘MAINS VOLTAGE’,
‘MAINS FREQUENCY’, etc.

EVENT LOG PAGE

In the event of a shutdown alarm occurring the triggering alarm will be recorded in
the Event Log Memory. The Memory will record the last 25 such shutdowns.
Subsequent alarms will then over-write the oldest previous alarm. This feature
allows service engineers arriving on site a detailed look at the recent history of the
gen-set or plant.
VIEWING THE INSTRUMENT AND EVENT LOG PAGES

To view a particular instrument operate the “Page”
button to move to the required page. Each press of the
button will move the page indicator LED along. The
LCD will also indicate the page title.
i.e. To view the Engine Coolant temperature move to the ‘Engine Instruments Page’.
The LCD will display the page title and then will
automatically commence scrolling down the
various instrument . These will automatically
scroll round, 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 after a period of inactivity the module will revert to the ‘Information Page’
ENGINE
INSTRUMENTATION
ENGINE SPEED
1503 RPM
ENG OIL PRESSURE
2.5Bar 56psi
COOLANT TEMP
78deg C 105deg f
BATTERY VOLTAGE
24.5 V
CHARGE ALT VOLTAGE
27.5 V
ENGINE RUN TIME
50H 36M
NUMBER OF STARTS
67
NEXT MAINTENANCE
123 HOURS
It is also possible to manually scroll to display the different instruments, once 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 ‘Information Page’.
NOTE:-This description of operation is also true for the other instrument pages and for
viewing the records in the event log.

Manually Selecting an Instrument

Initial display >>>>>>> ENGINE INSTRUMENTS
Pressing the DOWN button the LCD will ENGINE SPEED

then show…
1503 RPM
Pressing the DOWN button again the ENG OIL PRESSURE
2.5Bar 56psi
Pressing the DOWN button again the COOLANT TEMP
78deg C 105deg f
Pressing the DOWN button again the BATTERY VOLTAGE
24.5 V
Pressing the DOWN button again the CHARGE ALT VOLTAGE
27.5 V
Pressing the UP button the LCD will BATTERY VOLTAGE
then show…
etc, etc, etc. 24.5 V
If the DOWN button is pressed while the LCD display is showing ‘ENGINE RUN TIME’ then the
display will jump round to the top of the page and display the page title; ‘ENGINE INSTRUMENTS’.
Pressing the DOWN button again will then display; ‘ENGINE SPEED’
SYNCHROSCOPE OPERATION (IF FITTED)

Display Detail
Initial stage of Synchronising display will only
show the difference between the Mains Supply and
Hz +2.9 V +0.2 the Generator Output. Here the display is showing a
frequency mis-match of +2.9Hz - The gen-set
frequency is too high and should be reduced
(indicated by the arrow). The voltage is +0.2 volts
high, but is within the limits set for synchronising.
Once the difference between the Mains supply and
the Generator output has been reduced the
Hz +0.9 V +0.2 ‘Synchroscope’ display will become active. The
moving bar will roll from left to right or right to left
depending on the mis-match between the Mains
supply and the generator output. 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
Hz -0.2 V +0.2 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
should be adjusted until the moving bar enters the
centre of the scope.
Once the Mains and the generator are synchronised
the moving bar will be in the centre of the scope and
Hz -0.2 V +0.2 the bar will be ‘locked’ into the synchronising window.
While the bar is ‘locked’ the module will initiate a
breaker close to load the generator onto the Mains.
Should synchronism be broken the moving bar will
pass out of the synchronising window and the
‘locked’ indication will clear.

OPERATOR CONFIGURATION MODE

This configuration mode allows the operator limited customising of the way the module operates.
Operation Detail
To enter the ‘Operator configuration mode’ press both
the UP and DOWN scroll buttons together.
+
The module will enter ‘Operator Configuration mode’
and the ‘Operator configuration mode indicator’ will
illuminate above the PAGE button.
The LCD will then display: CONFIGURATION
To view the different configuration functions press the

PAGE button.
The LCD will then display: LANGUAGE

ENGLISH
Pressing the UP or DOWN Button will then change the
selected language.
or
The LCD will then display the new language: LANGUAGE
FRENCH
Repeat until the required language is displayed. LANGUAGE
GERMAN
To view the next function press the PAGE button.
The LCD will then display: CONTRAST

o ï ■
Pressing the UP or DOWN Button will move the sliding
bar UP (Darker) or DOWN (Lighter) - set this to the
desired position. or
When correct, to view the next function press the PAGE
button.
The LCD will then display: AUTO SCROLL TIME

3.0 Seconds
This is the duration each instrument will be displayed for
during the automatic scrolling. Use the UP and DOWN
buttons to set this to the required value. or
button.

Operation Detail
The LCD will then display: INDICATIONS ON LCD
YES
Digital inputs configured as indications can be viewed on
the LCD by pressing the UP or DOWN button when the
‘Information Page’ is active. To disable this function or
set to ‘NO’ by pressing the UP or DOWN button.
button.
The LCD will then display: ABANDON CHANGES

AND EXIT
To exit the ‘Operator configuration mode’ with-out
storing any changes made press the UP or DOWN
button. or
If you wish to save the changes you have made to the
configuration press the PAGE button.
The LCD will then display: SAVE CHANGES AND

EXIT
To exit the ‘Operator configuration mode’ and store
the changes you have made press the UP or DOWN
button. or
The module will then return to the ‘Information Page’ display and the ‘Operator Configuration
Mode Indicator’ will extinguish.

POWER UP LCD DISPLAY

On application of the DC supply the module LCD will display information about the module.
M550 NS 4W
M S01 C01 V2.00
S C V
Code Letter Meaning Options Detail
M Module Type 550 NS 4W Auto-start Module Variant with no Sync option, 4
wire (3ph+N) connection.
550 CS 4W Auto-start Module Variant with Check Sync
option, 4 wire (3ph+N) connection.
550 AS 4W Auto-start Module Variant with Auto Sync option,
4 wire (3ph+N) connection.
550 NS 3W Auto-start Module Variant with out Sync option, 3
wire (3ph) connection.
550 CS 3W Auto-start Module Variant with Check Sync
option, 3 wire (3ph) connection.
550 AS 3W Auto-start Module Variant with Auto Sync option,
3 wire (3ph) connection.
555 NS 4W Automatic Mains Failure Module Variant with no
Sync option, 4 wire (3ph+N) connection.
555 CS 4W Automatic Mains Failure Module Variant with
Check Sync option, 4 wire (3ph+N) connection.
555 AS 4W Automatic Mains Failure Module Variant with
check Sync option, 4 wire (3ph+N) connection.
555 NS 3W Automatic Mains Failure Module Variant with no
Sync option, 3 wire (3ph) connection.
555 CS 3W Automatic Mains Failure Module Variant with
check Sync option, 3 wire (3ph) connection.
555 AS 3W Automatic Mains Failure Module Variant with Auto
Sync option, 3 wire (3ph) connection.
S System Options 00 Basic Metering Version
01 Enhanced Metering Version
C Custom Options 00 No options fitted
01 RS232 Comms Board Fitted
02 RS485 Comms Board Fitted
09 RS232 Comms Board + Load Share (CAN-bus)
Fitted
10 RS485 Comms Board + Load Share (CAN-bus)
Fitted
13 RS232 Comms Board + Load Share (2x CAN-
bus) Fitted
14 RS485 Comms Board + Load Share(2x CAN-bus)
Fitted

Code Letter Meaning Options Detail

V Software X.XX Details internal firmware revision (FLASH
Version Version)
NOTE:- Some features are only

available on V2.00 or later modules.
Some feature are only available on

V3.00 or later modules.

3.2 LED INDICATORS
COMMON ALARM LED

This LED indicates when an alarm condition is present.
The Alarms Page on the LCD will detail the exact nature
of the alarm.
• ‘OFF’ - no alarm active.
• ‘FLASHING’ - A shutdown alarm is present, but has
not been muted.
• ‘STEADY’ - A warning alarm is present or a
shutdown alarm which has been muted is present.
USER CONFIGURABLE LED’s
These LED 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 user’s equipment -
Such as Battery Charger On or Louver’s 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.

3.3 CONTROL PUSH-BUTTONS

STOP/RESET
This push-button places the module into it’s 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
O
module will automatically instruct the change-over device to un-load 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 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’ push-button.
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.
START
This push-button is used to manually 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
Ι
start. Should it fail on the first attempt it will re-try until either 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 modules 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 it’s ‘Automatic’ mode. This
mode allows the module to control the function of the generator AUTO
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.

TEST
This push-button places the module into it’s ‘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.
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 re-active 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.

3. INSTALLATION INSTRUCTIONS
The model DSE 555 Module has been designed for front panel mounting. Fixing is by 4 spring
loaded clips for easy assembly.
3.1 PANEL CUT-OUT
138.00mm
185.00mm
FIG 3
In conditions of excessive vibration the module should be mounted on suitable anti-vibration
mountings.
3.2 COOLING
The module has been designed to operate over a wide temperature range -30 to +70º C. However
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 93%.
3.3 UNIT DIMENSIONS

All dimensions in mm.
:
144.0mm
137mm 157 ü
808 û
CE
110.0mm 185.0mm
192.0mm
7.5mm Panel Cut-out:138mmx185mm
FIG 4

3.4 FRONT PANEL LAYOUT

Model 555
i
O I AUTO
FIG 5
3.5 REAR PANEL LAYOUT
:
157/548 ü
808 û
CE
FIG 6

4. ELECTRICAL CONNECTIONS
Connections to the Module are via plug and sockets.
4.1 CONNECTION DETAILS

The following describes the connections and recommended cable sizes to the 3 plugs and sockets
on the rear of the Module. See rear panel layout FIG 5.
PLUG “A” 13 WAY

PIN DESCRIPTION CABLE NOTES
No SIZE
1 DC Plant Supply Input 2.5mm
(-ve)
2 DC Plant Supply Input 2.5mm (Recommended Fuse 21A Max.)
(+ve)
3 Emergency Stop Input 2.5mm Plant Supply +ve. Also supplies fuel & start
outputs. (Recommended Fuse 32A Max.)
4 Fuel relay Output 2.5mm Plant Supply +ve from pin 3. 16 Amp rated.
5 Start relay Output 2.5mm Plant Supply +ve from pin 3. 16 Amp rated.
6 Auxiliary Output relay 1 1.0mm Plant Supply +ve. 5 Amp rated.
8 Charge Fail Input/ Excitation 1.0mm Must NOT be connected to plant supply -ve.
Output
9 Auxiliary Input 1 0.5mm Switch to -ve
PLUG “B” 17 WAY

No SIZE
20 Magnetic Pickup Input (+ve) 0.5mm Connect to Magnetic Pickup device
21 Magnetic Pickup Input 0.5mm Connect to Magnetic Pickup device
(-ve)
22 Oil Pressure Input 0.5mm Connect to Oil pressure sender
23 Coolant Temperature Input 0.5mm Connect to Coolant Temperature sender
24 Sender Common Return 0.5mm Return feed for senders**.
25 CT secondary for L1 2.5mm Connect to secondary of L1 monitoring CT
28* CT secondary common 2.5mm Connect to secondary of all monitoring CT’s
29* Neutral CT secondary 2.5mm Connect to Neutral CT secondary and Earth
30 Functional Earth 2.5mm Connect to a good clean earth point
NOTE**:- If using single terminal sender refer to connection diagram. If using earth
return type senders connect return terminals to pin 24 and earth pin 24.

CAUTION!:- Refer to Typical wiring Diagram for 3 CT and 4 CT wiring differences
WARNING!:- Do not disconnect plug ‘B’ when the gen-set is running. Disconnection
will open circuit the secondary of the CT’s and dangerous voltages may then develop.
Always ensure the gen-set is at rest before making or breaking connections to the module.
PLUG “C” 4 WAY

No SIZE
31 Generator L1 Voltage 1.0mm Connect to generator L1 output (AC)
Monitoring Input (Recommend 2A Fuse Max.)
34 Generator Neutral Input 1.0mm Connect to generator Neutral output (AC)
PLUG “D” 11 WAY

No SIZE
35 Generator Loading Relay 2.5mm Connect to generator contactor coil.
Contact
36 Generator Loading Relay 2.5mm Connect to generator contactor coil feed supply.
Contact
37 NOT USED Do not connect.
38 Mains Loading Relay 2.5mm Connect to mains contactor coil feed supply.
Normally Closed Contact
39 Mains Loading Relay 2.5mm Connect to mains contactor coil.
Change-over contact
40 Mains loading Relay Normally 2.5mm Used in conjunction with mains breakers. Not
Open contact required if using mains contactor.
41 NOT USED Do not connect.
42 Mains L1 Voltage Monitoring 1.0mm Connect to Mains L1 supply (AC) (Recommend
Input 2A Fuse Max.)
43 Mains L2 Voltage Monitoring 1.0mm Connect to Mains L2 supply (AC)
Input (Recommend 2A Fuse Max.)
44 Mains L3 Voltage Monitoring 1.0mm Connect to Mains L3 supply (AC)
Input (Recommend 2A Fuse Max.)
45 Mains Neutral Input 1.0mm Connect to Mains Neutral supply (AC)
NOTE:- Screened cable must be used for connecting the Magnetic Pickup, ensuring
that the screen is earthed at one end ONLY.

PC CONFIGURATION INTERFACE CONNECTOR

8-way connector allows connection to PC via 810 configuration interface.
: Module can then be re-configured utilising the P810 for windows™ software.
EXPANSION INTERFACE CONNECTOR

4-way connector allows connection to the 157 relay expansion module or 548
157 ü LED expansion modules. A maximum of 2 relay or LED expansion modules
808 û may be connected in series to this port.
Auto-sync versions of the 55x can also control the P122 digital
resistance module via this port. These can be fitted in addition the any 157 relay modules required.
See caution note below.
CAUTION!:- Do not connect the 808 configuration interface to this port, as it in not
possible to use the 808 software to configure the 555 module.
When used in conjunction with the P122 Digital Resistance Modules,

only P157 Relay Expansion modules with Part Number 81xxxxx MUST
CAUTION!: be used. Please refer to the relevant 55x Manuals for details.

4.2 CONNECTOR FUNCTION DETAILS

The following describes the functions of the 4 connectors on the rear of the module. See rear panel
layout FIG 5.
PLUG “A” 13 WAY

PIN DESCRIPTION
No
1 DC Supply -ve. System DC negative input. (Battery Negative).
2 DC Supply +ve. System DC positive input. (Battery Positive).
3 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. Positive Supply also removed from Starter and Fuel therefore only a
single pole Emergency Shutdown button is required.
4 Fuel Relay output. Plant Supply +ve from pin 3. Used to control the fuel solenoid or engine
fuel control system.
5 Starter Relay output. Plant Supply +ve from pin 3. Used to control the Starter Motor.
6 Auxiliary Relay output 1. Plant Supply +ve. Configurable output, see Calibration Manual for
options available.
options available.
8 Charge Fail input / Excitation output. Supplies excitation to the Plant Battery Charging
Alternator, also an input for the Charge Fail detection circuitry.
9 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.

PLUG “B” 17 WAY

PIN DESCRIPTION
No
options available.
options available.
20 Magnetic Input +ve. An AC signal from the magnetic pickup +ve for speed sensing.
21 Magnetic Input -ve. An AC signal from the magnetic pickup -ve for speed sensing.
22 Oil Pressure sensing input. Connect to resistive type oil pressure sender. Refer to
connection diagram for details.
23 Coolant Temperature sensing input. Connect to resistive type coolant temperature sender.
Refer to connection diagram for details.
24 Sender Common connection. Return feed from sender units - refer to connection diagram
for details.
25 Generator L1 current transformer connection.
26 Generator L2 current transformer connection. If single phase is used do not connect this
pin.
27 Generator L3 current transformer connection. If single phase is used do not connect this
pin.
28* Generator current transformer common connection.
29* Generator current transformer Neutral connection and CT earth connection.
30 Functional Earth - Ensure connection to a good clean earth point.
CAUTION!:- Refer to Typical wiring Diagram for 3 CT and 4 CT wiring differences
WARNING!:- Do not disconnect plug ‘B’ when the gen-set is running. Disconnection
will open circuit the secondary of the CT’s and dangerous voltages may then develop.
Always ensure the gen-set is at rest before making or breaking connections to the module.

PLUG “C” 4 WAY

PIN DESCRIPTION
No
31 Generator L1 sensing input. Connect to alternator L1 output.
32 Generator L2 sensing input. Connect to alternator L2 output. If using single phase only do
not connect this terminal.
33 Generator L3 sensing input. Connect to alternator L3 output. If using single phase only do
not connect this terminal.
34 Generator N sensing input. Connect to alternator N output.
PLUG “D” 11 WAY

PIN DESCRIPTION
No
35 Generator Loading Relay, Normally open, Volts free contacts to 36. Used to connect to
Generator contactor or circuit breaker.
36 Generator Loading Relay , Normally open, Volts free contacts to 35. Used to connect to
Generator contactor or circuit breaker.
37 DO NOT USE
38 Mains Loading Relay, Normally Closed Change-over, Volts free contacts to 39 Used to
connect to Mains contactor or circuit breaker.
39 Mains Loading Relay, Change-over, Volts free contacts to 38 and 40. Used to connect to
Mains contactor or circuit breaker.
40 Mains Loading Relay, Normally open Change-over, Volts free contacts to 39. Used to
connect to Mains contactor or circuit breaker.
41 DO NOT USE
42 Mains L1 sensing input. Connect to Mains L1 supply.
43 Mains L2 sensing input. Connect to Mains L2 supply. If using single phase only do not
connect this terminal.
44 Mains L3 sensing input. Connect to Mains L3 supply. If using single phase only do not
connect this terminal.
45 Mains N sensing input. Connect to Mains N supply.

5. SPECIFICATION
DC Supply 9.0 to 35 V Continuous.
Cranking Dropouts Able to survive 0 V for 50 mS, providing supply was at least
10 V before dropout and supply recovers to 5V .This is
achieved without the need for internal batteries.
Max. Operating Current 513mA at 12 V. 263 mA at 24 V.
Max. Standby Current 370 mA at 12 V. 210 mA at 24 V
Typical Standby Current 363mA at 12 V. 190 mA at 24 V.
Alternator Input Range 15V - 277(ph-N) 3 Phase 4wire AC (+20%)
Alternator Input Frequency 50 - 60 Hz at rated engine speed (Minimum 15V AC Ph-N)
Magnetic Input Range (if fitted) +/- 0.5 V to 70 V Peak
Magnetic Input Frequency 10,000 Hz (max) at rated engine speed.
Start Relay Output 16 Amp DC at supply voltage.
Fuel Relay Output 16 Amp DC at supply voltage.
Auxiliary Relay Outputs 5 Amp DC at supply voltage.
Dimensions 192 X 144 X 138
Charge Fail / Excitation Range 0 V to 35 V
Operating Temperature Range -30 to +70°C
CT Burden 2.5VA
CT Secondary 5A
CT Class Class 1 Recommended (Basic Instrumentation)
Class 1 Required (Enhanced Instrumentation)
Mains Input Voltage Range 15V - 277(ph-N) 3 Phase 4wire AC (+20%)
Mains Input Frequency 50 - 60 Hz (Minimum 15V AC Ph-N)
Mains / Gen Loading Relays 8 Amp AC RMS rated
Electromagnetic Compatibility BS EN 50081-2 EMC Generic Emission Standard (Industrial)
BS EN 50082-2 EMC Generic Emission Standard (Industrial)
Electrical Safety BS EN 60950
Cold Temperature BS EN 60068-2-1 to -30 oC
Hot Temperature BS EN 60068-2-2 to +70oC
Humidity BS2011-2-1 to 93% RH@40oC for 48 Hours
Vibration BS EN60068-2-6
10 sweeps at 1 octave/minute in each of 3 major axes.
5Hz to 8Hz @ +/-7.5mm constant displacement
8Hz to 500Hz @ 2gn constant acceleration
Shock BS EN 60068-2-27
3 Half sine shocks in each of 3 major axes
15gn amplitude, 11mS duration

6. COMMISSIONING
6.1 PRE-COMMISSIONING
Before the system is started, it is recommended that the following checks are made:-
6.1. The unit is adequately cooled 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 (+ve)
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, 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 that the engine is fully
operational (fuel available, etc.) and that the fuel solenoid is operating. The engine should
now run up to operating speed. If not, and an alarm is present, check the alarm condition for
validity, then check input wiring. The engine should continue to run for an indefinite period. 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 timed out.
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 it’s standby mode.
6.7. If despite repeated checking of the connections between the 555 and the customer’s system,
satisfactory operation cannot be achieved, then the customer is requested to contact the
factory for further advice on:-
INTERNATIONAL TEL: 44 (0) 1723 377566

INTERNATIONAL FAX: 44 (0) 1723 354453
E-mail: [email protected]

7. FAULT FINDING
SYMPTOM POSSIBLE REMEDY

Unit is inoperative Check the battery and wiring to the unit. Check the DC
supply. Check the DC fuse.
Unit shuts down Check DC supply voltage is not above 35 Volts or below 9
Volts
Check the operating temperature is not above 55 °C.
Check the DC fuse.
Unit locks out on Emergency Stop 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.
Intermittent Magnetic Pick-up sensor Ensure that Magnetic pick-up screen is only connected at
fault one end, if connected at both ends this enables the screen
to act as an aerial and will pick up random voltages.
Low oil Pressure fault operates after Check engine oil pressure. Check oil pressure
engine has fired 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 555 Module.
High engine temperature fault Check engine temperature. Check switch/sender and
operates after engine has fired. wiring. Check configured polarity (if applicable) is correct
(i.e. Normally Open or Normally Closed) or that sender is
compatible with the 555 Module.
Shutdown fault operates Check relevant switch and wiring of fault indicated on LCD
display. Check configuration of input.
Warning fault operates Check relevant switch and wiring of fault indicated on LCD
display. Check configuration of input.
Fail to Start is activated after pre-set Check wiring of fuel solenoid. Check fuel. Check battery
number of attempts to start supply. Check battery supply is present on the Fuel output
of the module. Check the speed sensing signal is present
on the 555 inputs. Refer to engine manual.
Continuous starting of generator Check that there is no signal present on the “Remote Start”
when in AUTO input. Check configured polarity is correct.
Generator fails to start on receipt of Check Start Delay timer has timed out. If remote start fault,
Remote Start signal or under mains check signal is on “Remote Start” input. Confirm input is
failure conditions. configured to be used as “Remote Start”.
Pre-heat inoperative 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.
Starter motor inoperative 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 +Ve.
Engine runs but generator will not Check Warm up timer has timed out. Ensure generator
take load 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.

8. TYPICAL WIRING DIAGRAMS

(With No Neutral CT fitted)
LOAD
L1 L2 L3 N
Current
Transformers
ALTERNATOR MAINS
Generator Mains
F F F G Contactor Contactor M F F F
Electrical Interlock
Optional 157 Relay

Expansion Board
25 26 27 29 34 33 32 31 36 35 40 39 38 42 43 44 45 (Maximum 2 off)
Generator Loading Mains Loading FCC68 - 4 Way
Relay Relay
Internal Emergency Stop
FCC68 - 8 Way 810

20 21 22 24 23 9 10 11 12 13 14 15 16 17
Configuration
1 2 3 5 4 8 6 7 18 19 30
4 Safety Earth Connection
Must be connected to
the Safety Earth
Oil Temp
F F Sender Sender
MPU NOTE:-
When connected to a
completed Panel / Gen-set
5 Real-time diagnostic display
This Ground connection must be is available
on the engine block and must
be a sound electrical connection 6
to the sender bodies.
The wire to Terminal 24 must not 7
be used to provide a ground 8
connection to any other device
9
Configurable inputs

(With Neutral CT fitted)

LOAD
L1 L2 L3 N
Current
Transformers
ALTERNATOR MAINS
Generator Mains
F F F G Contactor Contactor M F F F
Optional 157 Relay

Expansion Board
25 26 27 29 28 34 33 32 31 36 35 40 39 38 42 43 44 45 (Maximum 2 off)
Generator Loading Mains Loading FCC68 - 4 Way
Relay Relay
Internal Emergency Stop
FCC68 - 8 Way 810

20 21 22 24 23 9 10 11 12 13 14 15 16 17
Configuration
1 2 3 5 4 8 6 7 18 19 30
4
Safety Earth Connection
Must be connected to
the Safety Earth
Oil Temp
F F Sender Sender
MPU NOTE:-
When connected to a
completed Panel / Gen-set
5 Real-time diagnostic display
This Ground connection must be is available
on the engine block and must
be a sound electrical connection 6
to the sender bodies.
The wire to Terminal 24 must not 7
be used to provide a ground 8
connection to any other device
9
Configurable inputs

9 FACTORY DEFAULT CONFIGURATION

Edit 5xx for Windows. Configuration for 550 module. Edit 5xx for Windows. Configuration for 550 module.
Page 1 of 3 Page 2 of 3
Configuration description Configuration description
1 Default Factory Settings 1 Default Factory Settings
2 Miles Revell 2 Miles Revell
3 17/6/99 3 17/6/99
4 4
Created by - Miles Revell on 29/06/99 Created by - Miles Revell on 29/06/99
Filename - 550a Filename - 550a
Miscellaneous settings LED Settings
Display load transfer state No 1 Lit Output not used
Display indications on LCD No 2 Lit Output not used
Use oil pressure for engine at rest Yes 3 Lit Output not used
Start button must be held down to crank No 4 Unlit Output not used
Alarm prior to starting engine No Timer Settings
Fast loading Yes Starting timers
All warnings are latched No Start delay 05s
Alternator fitted Yes poles 4 Pre-heat 00s
Magnetic pickup fitted No Pre-heat bypass 00s
Module language English Cranking time 10s
Immediate mains dropout No Crank rest time 10s
Mains Fail detection Yes Manual crank limit 30s
Input settings Smoke limit 00s
Low oil pressure input VDO match, 0-10 bar Smoke limit off 00s
High coolant temp input VDO match, 120 degC Safety on delay 10s
Trip Restore Overspeed overshoot 00s
Low oil pressure pre-alarm 17.0 PSI 18.0 PSI Load timers
Low oil pressure shutdown 15.1 PSI Warming up time 05s
High coolant temp pre-alarm 115 DegC 110 DegC Breaker close pulse 00.0s
High coolant temp shutdown 120 DegC Breaker trip pulse 00.0s
Digital inputs Contactor feedback has not been enabled
1 Remote start Close to activate Stopping timers
2 User configured Auxiliary Input 2 Close to activate Warning Always active Return delay 30s
3 User configured Auxiliary Input 3 Close to activate Warning Active from safety on Cooling time 30s
4 User configured Auxiliary Input 4 Close to activate Shutdown Always active ETS solenoid hold 00s
5 User configured Auxiliary Input 5 Close to activate Shutdown Active from safety on Fail to stop delay 30s
6 User configured Auxiliary Input 6 Close to activate Electrical trip Always active Other timers
7 User configured Auxiliary Input 7 Close to activate Electrical trip Active from safety Battery low volts delay 01m 00s
on Battery high volts delay 01m 00s
8 User configured Auxiliary Input 8 Close to activate Indication Always active LCD auto scroll timer 02s
9 Panel lock Close to activate LCD page timer 05m 00s
Output Settings
Module relays
1 Energise Preheat (during pre-heat timer)
2 Energise Common alarm
3 Energise Close generator
4 Energise System in auto mode
5 De-energise Close Mains
6 Energise Close Generator
Expansion A
1 Energise Output not used
Expansion B

Edit 5xx for Windows. Configuration for 550 module.Page 3 of 3 Mains Settings
Configuration description Trip Restore
1 Default Factory Settings Under volts trip 184 V 207 V
2 Miles Revell Over volts trip 276 V 253 V
3 17/6/99 Under frequency trip 450 V 480 V
4 Over frequency trip 550 V 520 V
Created by - Miles Revell on 29/06/99
Filename - 550a
Generator Settings
Voltage and frequency settings Trip Restore
Under volts pre-alarm 196 V 207 V
Under volts trip 184 V
Over volts pre-alarm 265 V 253 V
Over volts trip 276 V
Under frequency pre-alarm 42.0 Hz 45.0 Hz
Under frequency trip 40.0 Hz
Over frequency pre-alarm 55.0 Hz 52.0 Hz
Over frequency trip 57.0 Hz
Power settings Trip Curve Action
Delayed over current 100 % 36 Electrical trip
Short circuit 3.0 pu 6 Shutdown
Earth fault 0.10 pu 1000 Shutdown
Reverse power 100 KW Shutdown
Engine Settings
Crank disconnect
Crank dis' from generator freq. 21.0 Hz
Check oil pressure prior to starting Yes
Speed settings Trip Restore
Plant battery settings Trip Restore
Under volts warning 8.0 V 9.0 V
Over volts warning 33.0 V 32.0 V

10. ICONS AND LED IDENTIFICATION

10.1 ICON DESCRIPTIONS
Symbol Meaning Description
Stop/Reset Stop the generator and reset any alarm conditions.
Refer to Section 1 of this Manual.
Start Start the generator (if in an appropriate mode).
I
Auto The controller will automatically start the generator
when given a remote start command.
Manual The controller will start the generator under manual
control. (Separate Start command may be
necessary)
Common Alarm An alarm condition has been detected.
(Warning = Steady, Shutdown = Flashing)
Mains Failure Simulation On AMF modules this is used to simulate a mains
(Test) failure event. (On load test)
Alarm Mute Silences the audible warning device.
Lamp Test Causes all indicating LED’s to illuminate to test for

correct operation
Engine Instruments Instruments page for engine details such as Oil
pressure, Engine temperature.
Generator Instruments Instruments page for generator details such as

frequency and voltage
Mains Instruments Instruments page for mains supply details such as

frequency and voltage.
Event Log Details recorded history of generator operation.

10.2 LED IDENTIFICATION DIAGRAM
LED1
Model 555 LED2
LED3
LED4
i
O I AUTO
10.3 SENDER WIRING RECOMMENDATIONS
Using Earth return (single wire) senders
Connection name Terminal 22 24 23

Oil pressure 22 55x / 560
Coolant temperature 23 module
Sender common 24
NOTE:- . It is important that terminal 24 ( 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.

Using insulated return (two wire) senders
Connection name Terminal 22 24 23

Oil pressure 22 55x / 560
Coolant temperature 23 module
Sender common 24
NOTE:- . It is important that terminal 24 ( sender common ) is soundly connected to an

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

11. NAVIGATION CHART

555 MODULE PAGE NAGIVATION CHART
Information Page Alarm Page Engine Instruments Page Generator Instruments Page MAINS INSTRUMENTS page Event Log page
With no Alarm
Normally displays operating states
LCD Indication 1 Alarm No Alarm Present Engine Speed Gen L1-N L2-N L3-N MAINS L1-N L2-N L3-N Logged EVENT 1
1500 RPM V 234 236 234 V 234 236 234
LCD Indication 2 Alarm Text 1 Oil Pressure Gen L1-2 L2-3 L3-1 MAINS L1-2 L2-3 L3-1 LOGGED EVENT 2
2.5 Bar 56PSI V 412 414 415 V 412 414 415 etc
LCD Indication 3 ALarm Text 2 Coolant Temp Gen L1 L2 L3 MAINS

Etc .... 78 Deg C 105 Deg F A 45 48 43 Hz 51.2
LCD Indication 4 Battery Voltage Gen EARTH CURRENT

ETC.... 24.5V A 0.0 MAINS PHASE SEQ.
L1 L2 L3
Modules with-out enhanced
instrumentation
CHARGE ALT Voltage Gen
27.5V Hz 51.2
Modules with enhanced instrumentation only
Engine Run Time Gen L1 L2 L3 Gen

50H 34M Kw 45 48 43 KWh 56
+ Gen Total Gen

Number of Starts KW 47 KVAH 43
CONFIGURATION Page 24
Gen L1 L2 L3 Gen
LANGUAGE
KVA 34 37 33 KVARH 47
ENGLISH UK Next Maintenance Due
274Hours
Gen Total Gen Phase Sequence

CONTRAST
KVA 42 L3 L2 L1
o ï n
Modules with Sync. Check option fitted
Gen L1 L2 L3
AUTO SCROLL TIME Hz -0.2 V +0.2
Pf 0.82 0.78 0.84
3.0 SECONDS
Gen Average
INDICATIONS ON LCD
YES pf 0.82
Gen L1 L2 L3
ABANDON CHANGES
KVAR 34 37 33
AND EXIT
Gen Total
SAVE CHANGES
KVAr 37
AND EXIT

12. APPENDIX
12.1 55X IDMT TRIPPING CURVES (TYPICAL)
55x Delayed over-current protection
1000000
100000
10000
Tripping time in seconds
1000
100
10
1
1 2 3
Current as a multiple of the trip-point setting
At default setting of t = 36

12.2 55X SHORT CIRCUIT TRIPPING CURVES (TYPICAL)
Model 55x Short circuit & Earth fault curves for a 3 phase fault @ 50 Hz
100000
Curve 8200
10000
Curve 6800
Detection time in milliseconds
Curce 5600
Curve 4700
Curve 3900
Curve 3300
Curve 2700
Curve 2200
Curve 1800
Curve 1500
Curve 1200
1000
Curve 1000
100
1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2
Current as a multiple of the trip-point setting

12.3 USING THE 55X MODULE WITH ACB’S

The standard configuration allows the 55x module to be connected to contactors and the like.
However, it may be required to connect the to 55x module to breakers such as ACB’s, etc. If so the
following connection scheme is recommended as considered a ‘fail-safe’ method.
Output 6 Output 5
Configure as: De-Energise - Close Mains Configure as: Energise - Close Generato
Closing Supply Closing Supply
Output 4 Output 3
Configure as: Energise - Trip Mains 38 Configure as: De-Energise - Trip Generator 36
Internal DC Supply Internal DC Supply

55x Module
19 39 40 18 35
Tripping Supply UV Coil Supply
DC Slave Mains Closing DC Slave Generator

Relay Coil Relay Closing Coil
*Or use DC trip Coil *Or use DC trip Coil
Mains Shunt Generator

Trip Coil Undervolts Coil

12.4 OUTPUT EXPANSION

There are several methods of output expansion available for the 55x module:-
12.4.1 RELAY OUTPUT EXPANSION (157)

An expansion module is available, which connects to the configuration socket, and enables the 55x
to use eight additional relays on the 157 relay module, providing Volt-free contacts for customer
connection. A maximum of 2 off 157 relays modules can be connected, there are identified as ‘A’
and ‘B’ and give a total of 16 extra relay outputs.
CAUTION!:- When used in conjunction with the P122 Digital Resistance Modules, only
P157 Relay Expansion modules with Part Number 81xxxxx MUST be used. The digital
resistance requires a different set of data commands to operate and the 55x module will
change the data output by the 808 port to suit the P122 when selected. The older P157
relay modules (Part No. 80xxxxx) will only function if the P122 module is not configured for
use by the 555.
Refer to technical data sheet on the 157 relay module for further details.
12.4.2 LED OUTPUT EXPANSION (548)

An expansion module is available, which connects to the configuration socket, and enables the 55x
to use eight additional LED’s on the 548 module, providing remote LED’s indication up to 50 metres
away. A maximum of 2 off 548 LED modules can be connected, there are identified as ‘A’ and ‘B’
and give a total of 16 extra LED outputs.
use by the 555.
Refer to technical data sheet on the 548 LED module for further details.
It is possible to use a mix of 157 and 548 modules to give both relay and LED expansion if required
(Please refer to our Technical Support department for details.).
12.5 INPUT EXPANSION

It is possible to increase the number of monitored inputs available by utilising a DSE 54x Protection
Expansion/Annunciator. Please refer to our Technical department for details.

13. SYNCHRONISING NOTES
13.1 CHECK SYNC VERSIONS

A special version of the module provides the function of Check Sync relay and
Synchroscope display. 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 Sync.
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.
13.2 AUTO SYNC VERSIONS
A special version of the module provides the function of Automatic synchronising. The
module features all the functions associated with the Check sync version and in addition it
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 Auto-sync 55x module provides the ability to control the generator by adjusting the speed
(frequency) and voltage being output. Several method of providing this control are available. The
following pages give typical examples of interfacing with the engine governor and alternator AVR.
Refer to the P810 software manual for further details.
NOTE:- To verify if your particular 55x module has any of the above special features
fitted please refer to page 26 for the Power Up LCD display information.

13.2.1 GOVERNOR AND AVR CONTROL USING INTERNAL RELAYS DIRECTLY.
This scheme uses the 55x modules own internal relays to control the speed and voltage output. It
is only possible to use this system of control if the Governor or AVR in question supports speed
up/speed down and volts up/volts down via control input.
CAUTION!:- It is essential to use only the modules own internal relays for this type of
control (Auxiliary outputs 1-4). Use of the 157 relay expansion module outputs to do the
same could result in instability due to the much slower response of the 157 expansion
modules control relays.
TYPICAL CONNECTIONS
(See Note 1) Interposing

Relay
555 Module
Governor
Aux 1 Speed Up
+Ve
(See Note 1) Interposing Speed Down
Aux 2 Relay
Aux 3
Aux 4
Actuator

Relay
AVR
Volts Up
(See Note 1) Interposing Volts Down

Relay
To Alternator
Note 1:- Interposing relay should connect to recommended polarity and voltage for
Governor/AVR input. Refer to Governor or AVR manufacturer for details.
MODULE CONFIGURATION SETTING FOR 555 AUXILIARY RELAYS

Aux 1 Energise Speed Raise Relay
Aux 2 Energise Speed Lower Relay
Aux 3 Energise Voltage Raise Relay
Aux 4 Energise Voltage Lower Relay

13.2.2 GOVERNOR AND AVR CONTROL USING INTERNAL RELAYS TO DRIVE

MOTORISED/ELECTRONIC POTENTIOMETER.
This scheme uses the 55x modules own internal relays to control the speed and voltage output via
an external motorised or electronic potentiometer. It is only possible to use this system of control if
the Governor or AVR in question supports speed or voltage control via an external potentiometer.
CAUTION!:- It is essential to use only the modules own internal relays for this type of
control (Auxiliary outputs 1-4). Use of the 157 relay expansion module outputs to do the
same could result in instability due to the much slower response of the 157 expansion
modules control relays.
TYPICAL CONNECTIONS

Relay
555 Module Governor

Potentiometer
(See Note 2)
Aux 1 Resistance Up
+Ve
(See Note 1) Interposing Resistance Down Speed Trim
Aux 2 Relay
Aux 3
Aux 4
Actuator

Relay
Potentiometer AVR
(See Note 2)
Resistance Up
(See Note 1) Interposing Resistance Down Volts Trim

Relay
To Alternator
potentiometer input. Refer to potentiometer manufacturer for details.
Note 2:- The Potentiometer output should be a suitable resistance as recommended by
the Governor/AVR manufacturer.

Aux 3 Energise Voltage Raise Relay
Aux 4 Energise Voltage Lower Relay

13.2.3 GOVERNOR AND AVR CONTROL USING P122 DIGITAL RESISTANCE

MODULES
This scheme uses the 55x modules to control the speed and voltage output via the P122 (Governor
and AVR) digital resistance boxes. This devices gives a simple modular approach to solving the
problem of interfacing to the Governor and AVR. This also negates the need to fit interposing
relays and motorised potentiometers and have the additional benefit of leaving the modules own
internal relays available for other functions. It is only possible to use this system of control if the
Governor or AVR in question supports speed or voltage control via an external potentiometer.
use by the 555.
use by the 555.
TYPICAL CONNECTIONS
555 Module Governor

P122 Digital
Resistance
Aux 1 AVR
+Ve Speed Trim
Governor
Aux 2
To Interface/Exp.
Aux 3
To Controller
Aux 4
Actuator
P122 Digital AVR

Resistance
AVR
Governor Volts Trim
To Interface/Exp.
P808 Port on 555 To Controller
To Alternator
CAUTION :- The P122 digital resistance output should be a suitable resistance as

recommended by the Governor/AVR manufacturer. This should be specified on ordering
from DSE.
The P122 digital resistance has a selector switch for AVR or Governor connection, this
should be set to the correct position, otherwise auto-sync control will not be possible.
Refer to the diagram above.

13.2.4 DIRECT GOVERNOR CONTROL AND AVR CONTROL USING P122 DIGITAL
RESISTANCE MODULES
This scheme uses a mixture of the possible control options from the 55x modules to control the
speed and voltage output via the P122 (Governor and AVR) digital resistance boxes. This method
gives a cost effective solution to interfacing to the Governor and AVR. It is only possible to use this
system of control if the Governor supports speed up/down inputs and the AVR in question supports
voltage control via an external potentiometer.
use by the 555.
When used in conjunction with the P122 Digital Resistance Modules, only P548 Relay
Expansion modules with Part Number 81xxxxx MUST be used. The digital resistance
requires a different set of data commands to operate and the 55x module will change the
data output by the 808 port to suit the P122 when selected. The older P548 relay modules
(Part No. 80xxxxx) will only function if the P122 module is not configured for use by the 555.
TYPICAL CONNECTIONS
Relay
555 Module
Governor
Aux 1 Speed Up
+Ve
(See Note 1) Interposing Speed Down
Aux 2 Relay
Aux 3
Aux 4
Actuator
P122 Digital AVR

Resistance
AVR
Governor Volts Trim
To Interface/Exp.
P808 Port on 555 To Controller
To Alternator
CAUTION :- The P122 digital resistance output should be a suitable resistance as

recommended by the AVR manufacturer. This should be specified on ordering from DSE.
The P122 digital resistance selector switch for AVR or Governor connection, should be set
to the correct position. Refer to the diagram above.
Governor input. Refer to Governor manufacturer for details.


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DSE Model 555 Automatic Mains Failure Control and Instrumentation System Operators Manual

Deep Sea Electronics Plc

555 Operators Manual

Author – Miles Revell

Deep Sea Electronics Plc

555 OPERATING MANUAL ISSUE 5 04/04/02 MR 1

<<< THIS PAGE INTENTIONALLY BLANK >>>

2 555 OPERATING MANUAL ISSUE 5 04/04/02 MR

555 OPERATING MANUAL ISSUE 5 04/04/02 MR 3

10. ICONS AND LED IDENTIFICATION .....................................................................................46

13.1 CHECK SYNC VERSIONS ........................................................................................54

13.2 AUTO SYNC VERSIONS ......................................................................................54

4 555 OPERATING MANUAL ISSUE 5 04/04/02 MR

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

555 OPERATING MANUAL ISSUE 5 04/04/02 MR 5

CLARIFICATION OF NOTATION USED WITHIN THIS PUBLICATION.

Highlights an essential element of a procedure to ensure

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

Indicates a procedure or practice which could result in injury to

Indicates facility is only available on V2.00 or later modules. If in

Indicates facility is only available on V3.00 or later modules. If in

6 555 OPERATING MANUAL ISSUE 5 04/04/02 MR

Deep Sea Electronics plc

555 OPERATING MANUAL ISSUE 5 04/04/02 MR 7

Then, press and hold the START push-button, once the

If the pre-heat output option is configured, the Pre-heat PRE-HEATING

NOTE:- Should a ‘Fail to start’ alarm occur the

8 555 OPERATING MANUAL ISSUE 5 04/04/02 MR

If the engine start is successful, the following sequence occurs:-

The LCD screen will acknowledge the button press… STOP/RESET

1.3 AUTOMATIC (MAINS FAILURE/REMOTE) OPERATION

The LCD display will briefly indicate AUTO MODE

The LCD display will then indicate GENERATOR AT REST

555 OPERATING MANUAL ISSUE 5 04/04/02 MR 9

NOTE:- Should a ‘Fail to start’ alarm occur the

10 555 OPERATING MANUAL ISSUE 5 04/04/02 MR

If the engine start is successful, the following sequence occurs:-

555 OPERATING MANUAL ISSUE 5 04/04/02 MR 11

WARNING!:- Before commencing work on the generating set it is important to take

1.4 TEST (SIMULATE MAINS FAILURE) OPERATION

The LCD display will briefly indicate TEST MODE

The LCD display will then indicate GENERATOR AT REST

Then, press and hold the START push-button, once the

If the pre-heat output option is configured, the Pre-heat PRE-HEATING

12 555 OPERATING MANUAL ISSUE 5 04/04/02 MR

NOTE:- Should a ‘Fail to start’ alarm occur the

If the engine start is successful, the following sequence occurs:-

The LCD display will briefly indicate AUTO MODE

555 OPERATING MANUAL ISSUE 5 04/04/02 MR 13

14 555 OPERATING MANUAL ISSUE 5 04/04/02 MR

The Audible Alarm will sound. This can be silenced by

The “Common alarm” LED will illuminate(Warning =

The LCD will the display ALARM

Followed by the appropriate alarm text SHUTDOWN

555 OPERATING MANUAL ISSUE 5 04/04/02 MR 15

It is also possible to manually scroll to display the different alarms;

Initial display >>>>>>> ALARM

Pressing the DOWN button the LCD will SHUTDOWN

Pressing the UP button the LCD will WARNING