Starting System DS-102 Series 200 Elmatik AS P.O.Box 309 NO-3471, Slemmestad T - +47 31 28 37 83 F - +47 31 28 37 93 www.elmatik.no post@elmatik.no
CONTENT 1. INTRODUCTION 3 2. TECHNICAL SPECIFICATIONS 4 3. OPERATIONAL DESCRIPTION 6 3.1 General 3.2 Manual Starting Procedure 3.3 Starting failure 7 3.4 Alarms and Safety actions 3.5 Automatic Start / Stop 3.6 Normal Stop 4. TECHNICAL DESCRIPTION 9 4.1 The TACHO Card 4.2 The Start / Stop Card 12 4.3 The Alarm / Shut-down Card 16 5. GENERAL ARRANGEMENT 19 6. CUT-OUTS 20 2
1. INTRODUCTION Diesel starter DS-102 Series 200 is a control system, designed to enable manual and automatic control and supervision of Diesel engines. The system has the following functions: - Manual START and STOP. - Automatic START and STOP. - 4 separate channels for initiating Automatic shut-down. - Detection and Indication of RPM. - Choice of 1, 2, 3 starting attempts. - Adjustable Starting - time. - Adjustable Stopping - time. - Adjustable Blocking time for lubricating oil pressure - Outputs (potential free change over contacts) for: 1. Alarm for Shut-down. 2. Running indication. 3. Alarm Low voltage. 4. Alarm blocking of lubricating oil pressure. - Extra: 6-Channel alarm system. (Optional) 3
2. TECHNICAL SPECIFICATIONS - System arrangement: All circuitry is built on plug-in type printed cards and mounted in a self contained unit which is taking care of all necessary operational functions. MOS integrated circuits are used extensively to ensure a high degree of reliability. - Permissible Ambient temperature: 0 o 60 o C. - Duration Starting signal: 10 45 sec. (adjustable) - Number of Starting attempts: 1, 2, 3, (Selective *) - Duration Stop signal: 10 55 sec. (adjustable) - Duration Alarm blocking: 8 45 sec. (adjustable) - Tachometer type: Magnetic Transducer Type EMP 9 (others possible). - Tacho input frequency: 50 10.000 pulses/sec. - Accuracy RPM indicator: +/- 2% FSD. - External RPM indicator: Moving coil meter 1 ma FSD. - Sensors for Auto Shut-down: Normally open contact. 4
TECHNICAL SPECIFICATIONS continued - External signal contacts: Change-over contacts for: - Alarm Auto Shut-down - Running Indication - Alarm Low voltage - Alarm blocking - Auto control - Max. Rating: 2Amp. - Power demand: Nominal voltage: 24 Vdc Limit values: 18 36 Vdc Current consumption: 0.3 Amp 5
3. OPERATIONAL DESCRIPTION 3.1 General Viewed from left to right the Control Panel of DS-102 is divided into the following units: a) The Tacho Card (D-201-x) The card supervises starting procedures, RPM etc. of the Diesel set. It comprises indicating lights for obtained started speed (STARTED) and running speed (RUNNING). The card also supplied with three push-buttons used for reading and adjusting the three set points for STARTED, RUNNING, as well as OVER-SPEED. b) The Start / Stop Card (D-202-x) This card executes the various start and stop orders as they are initiated, either from the control unit itself, or from a remote control position. The card contains indicating lights for START and STOP showing the order which has been given. c) The Alarm / Shut-down Card (D-203-x) The card takes care of the safety requirement and will give alarm and automatic shu-down of the set for certain faults. The card has lamps for low lubricating oil pressure (LUB OIL PRESS. LOW), high cooling water temperature (COOL WATER TEMP. HIGH) as well as for high RPM (OVERSPEED). In addition to a spare alarm channel the card is also supplied with an indicating light, informing of whether the equipment is blocked for further startup procedures. d) The Meter unit This unit contains the RPM meter as well as the main control push-buttons for START, AUTO and STOP. 6
3.2 Manual Starting Procedure Manual start of the diesel set is initiated by pressing the START button. The indicator for START will light, and the starting solenoid (or the starting motor) will be energized. The indicator for STOP will be turned off. When the set reaches ignition speed (usually set to 20%) the indicating light for STARTED will be turned on. The starting solenoid (starting motor) is then de-energized. As the Diesel set approaches running speed the indicator light for RUNNING will become alight (usually set to 80%). Approximately 40 sec. after start, the indicating lamp RESTART BLOCKED will light up. At normal running conditions the following indicators are therefore turned ON: 3.3 Starting failure START STARTED RUNNING RESTART BLOCKED (after 40 sec.) One can pre-selected 1, 2, or 3 starting attempts. If a starting failure should take place, up to two extra starting attempts will be executed before the indicator lamp RESTART BLOCKED is turned on, indicating that the system will not perform any more starting attempts before the blocking is reset. RESTART BLOCKED is reset by pressing the STOP push-button. NOTE! During normal running, RESTART BLOCKED will be alight after 40 sec., and shall in this case of course not be reset by means of the STOP push-button. 7
3.4 Alarms and Safety actions The following system faults will initiate alarm, light up the corresponding lamp on the control panel and lead to automatic shut-down: - Low lubricating oil pressure (LUB OIL PRESS LOW) - High cooling water temperature (COOL WATER TEMP. HIGH) - High RPM (OVERSPEED) In each case the system must be reset by pressing the STOP pushbutton before a new starting attempt can be initiated. If the fault still remains, alarm and auto shut-down will again be initiated. 3.5 Automatic Start / Stop The system is set to remote control by pressing the AUTO push-button. The STOP and START indicating lamps on the Start /Stop card (D-202- x) indicate the operation order received from the remote control position. 3.6 Normal Stop Normal stop of the diesel set is achieved by pressing the STOP pushbutton, thus energizing the stop solenoid. During normal conditions only the STOP indicator lamp should be alight. 8
4. TECHNICAL DESCRIPTION 4.1 The Tacho Card (D-201-x) Fig. 2. D-201-x: Functions and external connections. 9
The Tacho generator is a pulse generating type, and the pulse rate is proportional to the engine speed. The Tacho generator is connected to pins 31 and 32 via terminals 38 and 39. the frequency to voltage will change the pulse signal to a DC voltage signal proportional to the engine speed. The DC voltage signal is fed to three different comparators units for the STARTED, RUNNING and OVERSPEED functions. The STARTED output signal is fed to card D-202-x via pin 8. the output signal for RUNNING operates relay change-over contacts connected to terminal 24,25 and 26 on Terminal Board L2 (C 510A). The output signal from the comparator for OVERSPEED is fed via terminal 7 to the alarm and auto shut-down circuits on card D- 203-x. The set points for all comparators can be adjusted by means of screwdriver controls (15 turn potis) at the front of the card. The procedure is as follows: Press the control push-button for the desired function, Adjust the corresponding screwdriver control until RPM- Meter indicates the desired value. The equipment is normaly supplied from the manufacturer with the following preset values: STARTED 20% RUNNING 80% OVERSPEED 115% 10
RPM Adjust Fig. 3. D-201-x: Tacho Card The frequency to voltage converter is also feeding a signal to a voltage to current converter, driving the RPM indicator M1 as well as a possible external indicator. The frequency to voltage converter is adjusted by the manufacturer and should not be re-adjusted unless absolutely needed to do so. The Tacho-card is also supervising the supply voltage. A relay contact will operate when the voltage drops below 18 volts. The contact is connected to terminals 21, 22 and 23 on Terminal Board L2 (C 510A) via pins 4, 5 and 6. 11
4.2 The Start / Stop Card (D-202-x) Fig. 4. D-202-x Functions and external connections. 12
Starting and stopping on the Diesel set is normally performed by means of the START and STOP push-buttons on the front panel. Starting and stopping can also be automatic, e.g. from an isolating relay operating by mains failure or similar. When automatic operation is to take place the AUTO push-button on the front panel must be pressed. The START, AUTO and STOP push-buttons are interlocked such that only one can be pressed at a time. Orders for START or STOP are executed by giving the pins 16 respectively 15 zero potential. When the AUTO push-button is pressed, the Diesel set will start when 24V dc is supplied to pins 6 and 7. The Diesel set will stop when the voltage is removed. The card may also be equipped with a latching relay to accept impulse Start and Stop (see drawing). Start time Adjust. Stop time Adjust. Fig. 5. D-202-x: The Start / Stop Card. 13
A starting order will set the memory. The START indicator will light up, and start order will be fed via RESTART COUNTER CONTROL to the START STOP CONTROL, to the START EXITATION and the START RELAY which operates the Diesel set s starting system. The Diesel starter can be arranged to give 1, 2 or 3 starting attempts. This is made by the maker as specified. The starting periods are usually adjusted between 10 and 15 seconds. If the Tacho Card (D-201-x) senses that ignition speed ( STARTED) has been reached the starting-relay will be de exitated. Fig. 5. shows card D-202-x and in particular the adjusting potentiometers for Starting and Stopping Time. The time duration for each starting attempt can be adjusted between 10 and 45 seconds. The potentiometers have been set by the maker, and re adjustments are normally not necessary. If the Diesel set does not start, the system will perform the predetermined number of starting attempts. If the set still has not started, the RESTART COUNTER CONTROL will block any further starting attempts. The indicator lamp RESTART BLOCKED will be turned on. The circuits for restart blocking will be activated approximately 40 seconds after a normal start of the Diesel set. The indicator lamp RESTART BLOCKED will therefore be alight after a normal start has taken place. This has been done as a safety measure if irregularities should occur in the engine speed measuring system. A stop order will set the memory in opposite direction. The START lamp will go out and the STOP lamplight up. The STOP relay will be energizes via the START STOP CONTROL and the STOP EXITATION unit, thus activating the Diesel set s stop solenoid. 14
The stopping time can be adjusted on a separate potentiometer (see fig. 5.). The stopping time is the time when the STOP relay remains energized after the RPM of the Diesel set has fallen below the STARTED level. The maker has usually set this time to about 15 seconds. In order to avoid overheating of the stop solenoid the total energizing time is in any case limited to max. 55 seconds. Orders for automatic Shutdown will be generated in the Alarm-/Shut-down Card for certain faults. These signals are fed from pin 26 on the Alarm-/Shut-down card to pin 20 on the Start / Stop Card. Such signals will operate the START STOP CONTROL and the STOP EXITATION unit and stop the Diesel set in the same way as described above. New start-up attempts are blocked until the system has been reset, by operating the STOP push-button. 15
4.3 The Alarm-/Shut-down Card (D-203-x) Fig. 6. D-203-x: Functions and external connections. 16
The card comprises the following 4 alarm channels: - Lubrication Oil Pressure, Low: The pressure transducer is connected to terminals 15 and 16 on the Terminal Board (D 510A) Strip L2. - Cooling Water Temperature, High: The temperature transducer is connected to terminals 19 and 20 on Terminal Board (D 510A) Strip L2. - OVERSPEED: The signal is obtained from pin 7 on the Tacho Card (D-201-x) and fed to pin 12 on the Alarm-/Shut-down Card (D-203-x). - SPARE: The alarm initiator might be connected to terminals 17 and 18 on Terminal Board (D 510A) Strip L2. If one of the above alarms are initiated, a corresponding alarm light on the front panel will be turned on. At the same time a common Shutdown channel will be activated. The signal is fed from pin 26 to pin 20 on the Start / Stop card. A common external alarm circuit is activated by means of a relay contact connected to terminals 9, 10 and 11 on Terminal Board (D 510A) Strip L2 (corresponding to pins 18, 19 and 20 on the card.). When an alarm and shut-down has taken place, the system must be reset before the Diesel set again can be started. This is obtained by pressing the STOP push-button. The card is supplied with a blocking relay which can be used for suppressing alarms etc. in external circuits. The change-over contact is connected to terminals 12, 13 and 14 on Terminal Board (C 510A) Strip L2, (corresponding to pins 14, 15 and 16 on the card.). 17
The Alarm-/Shut-down function for Lubrication Oil Pressure, Low is blocked internally when the Diesel set is stopped. The blocking is automatically cancelled about 8 seconds after the starting relay is deenergized after start and the memory has stored an order for start. Lub. Oil Block time Adjust Fig. 7. D-203-x: Alarm-/Shut-down Card 18
GENERAL ARRANGEMENT 19
CUT OUTS Height: Width: 177 mm 278 mm Settings: Serial No.: 979 RPM : 1800 Z : 126 100% : 3780 Hz Start : Min. Stop :_Min. Block : Min. Started:_300 Run :_1000 Overspeed : 2070 Spare parts: Order no.: Description: 100043 D-201-x Tacho Card. 100044 D-202-x Start / Stop Card 100045 D-203-x Alarm-/ Shut-down Card 100045L D-203-xL Alarm-/ Shut-down Card w/latching relay 100053 D-204-x Main back plane (Mother board) 100054 D-205 Control panel w/meter gauge and buttons 100058 D-607-x Alarm Card (Optional) 100049 DA-605-x Alarm back plane (Optional) 100048 Extension Card D-607 Only (To take measurements) 100050 Cable D-Sub 15 DS-102-200 (Optional) 1.5m 100055 Cable D-Sub 37 DS-102-200 Main flat cable 1.5m 100051 Cable IDC-14 DS-102-200 20cm. 100037 C 510A Terminal Board Strip L2 100038 C 610A Terminal Board Strip L3 (Optional) 100056 Push-buttons (Used in the control panel) 100057 RPM Panel meter (Used in the control panel) Items marked Optional are items used with DS-102-200 systems equipped with the extra Alarm section. -ooo- 20