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Manual
DCP-10
Genset Controller
Summary of Contents for FG Wilson DCP-10
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Page 1
Manual DCP-10 Genset Controller… -
Page 2
DCP-10 The interpretation of the Symbol: WARNING: A WARNING indicates a potentially hazardous situation which, if not avoided, could result in death, serious personal injury or property damage. CAUTION: A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in damage to equipment or property. -
Page 3
DCP-10 WARNING: Read this entire manual pertaining to the work to be performed before installing, operating, or servicing this controller. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage. The engine or other type of prime mover should be equipped with an… -
Page 4: Table Of Contents
DCP-10 Contents 1. Description…………………………………………………………………………………………………… 2. Outline Dimension Drawings and Controller Wiring………………………………………………… 3. Panel Operation…………………………………………………………………………………………… 4. Installation Guide………………………………………………………………………………………… 5. Control and Operation Instruction……………………………………………………………………… 6. Measure and Display Data……………………………………………………………………………… 7. Pre-alarm and Shutdown Alarm………………………………………………………………………… 8. Parameter Settings……………………………………………………………………………………… 9. LCD Display and Menu System……………………………………………………………………………
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Page 5: Description
DCP-10 1. Description The DCP-10 is an Automatic Controller for generator. When running in “AUTO” mode, it starts the Genset after receiving remote start signal and on failure automatically stops the Genset. The generator’s controlling procedure and protection parameters can be modified, which fully meets the Genset’s requirements of automatic start, stop control and basic protection.
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Page 6: Outline Dimension Drawings And Controller Wiring
DCP-10 2. Outline Dimension Drawings and Controller Wiring 2.1 Following Details: Module Dimensions W120mm×H102mm Panel Cutout W110mm×H92mm Thickness D48mm (without connection) Page 2/27…
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Page 7
DCP-10 2.2 Terminal Connections: Pin no. Function Description Signal 1mm² GEN. V input 0-300Vac L1-N 1mm² GEN. V input 0-300Vac L2-N 1mm² GEN. V input 0-300Vac L3-N 1mm² GEN. Neutral Not used Not used 2.5mm² I1 Gen current input 0-5A 2.5mm²… -
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DCP-10 2.3 Typical Wiring Diagram Fuse protection with a rating of 0.5A must be provided externally to the Controller. Page 4/27… -
Page 9: Panel Operation
DCP-10 3. Panel Operation The operation panel consists of 3 sections: LCD display indicating measurement parameters, LED indicator for common failure, and push buttons for Genset and selection of control modes. The LCD circularly displays different measuring parameters. When failure occurs, LCD displays the corresponding fault icon.
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Page 10: Installation Guide
DCP-10 4. Installation Guide 4.1 The cutout dimensional drawing installed on panel as above attached. The controller is fixed by 2 special fittings. The shock-proof equipment must be mounted if the enclosure is mounted on Genset or other heavy vibrant device. A readily accessible disconnect device shall be incorporated external to the equipment.
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Page 11: Control And Operation Instruction
DCP-10 5. Control and Operation Instruction 5.1 Operation Mode Setting: The controller has 2 modes: AUTO and MANUAL. Operation Description Press and hold the “AUTO” button for 2sec, the LED above the button is illuminated; the controller is running in “AUTO” mode.
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Page 12
DCP-10 NOTE: While cranking, engine ignites. The start motor will power off when the output frequency of generator reaches the preset value (configurable crank cutout value), or if there are one of the following conditions occur: A. Generator’s voltage reaches 80% of rated voltage;… -
Page 13
DCP-10 Stop Failure: When cool down times out, the fuel relay opens and the timer for Stop delay begins. When it times out, if controller detects that the voltage and frequency of generator or oil pressure of engine are greater than the preset values, the Fail to stop LED illuminates and the LCD displays Fail to stop. -
Page 14
DCP-10 5.5 Idle function: For idle function configure one of the configurable outputs as idle. Refer to the flow chart 5.7 for start and stop for idle control flows. 5.6 Preheat function: For Preheat function, configure one of the configurable outputs as Preheat. The controller has 3 selectable preheat control modes as below: Mode 1 —… -
Page 15
DCP-10 5.7 Flow chart for start and stop T1－ start delay T4－ safety-on delay T2－ crank time T5－ idle time T3－ pre-heat time T6－ stop delay NOTE: If T4 is longer than T5, low oil pressure protection is ignored during T5. -
Page 16: Measure And Display Data
DCP-10 6. Measure and Display Data Gen phase voltage L1-N L2-N L3-N Gen line voltage L1-L2 L2-L3 L3-L1 Generator current I1 I2 I3 Generator frequency Hz Engine speed RPM (signal derived from generator frequency) Engine oil pressure BAR / PSI (signal from engine LOP sensor) Engine coolant temperature ℃/℉…
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Page 17: Pre-Alarm And Shutdown Alarm
DCP-10 7. Pre-alarm and Shutdown Alarm 7.1 Pre-alarm (Warning) NOTE: (Pre-alarms are non-critical failure conditions and do not affect the operation of the generator system, they serve for drawing the operators’ attention to an undesirable condition so they can remove it to ensure continuous running of the system.
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Page 18
DCP-10 OVER CURRENT: if any phase output current of generator exceeds the “over current pre-alarm” after the safety-on timer has expired, common failure LED indicator flashes. For example, “over current pre-alarm” preset as: 850A, when any phase output current of generator exceeds this value, LCD flashing high value icon for corresponding phase: GEN. -
Page 19
DCP-10 7.2 Shutdown Alarm NOTE: (shutdown alarm failures immediately lock out the system and stop the Genset. The failure must be removed and the controller reset before restarting the Genset.) Shutdown Alarm / Description LCD Display START FAILURE: if engine does not fire after the preset number of crank attempt has been made, the Shutdown alarm LED illuminates. -
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DCP-10 Code Table for Failure: Name Code Name Code CHARGE FAILURE ENGINE HIGH TEMP BATT. UNDER VOLT OVER SPEED BATT. OVER VOLT UNDER SPEED START FAILURE OVER CURRENT STOP FAILURE GEN. OVER VOLT EMERGENCY STOP GEN. UNDER VOLT LOW OIL PRESS… -
Page 21: Parameter Settings
DCP-10 8. Parameters Setting 8.1 System Parameters: Items Preset Value Range CT ratio 1-2000 VT ratio 1.0-100.0 Rated ph-voltage 45-9999Vac 1,3 (3 for 3 phase 4 wire, 1 for signal AC voltage phase 2 wire) Startup mode 0-1 / 0 (MAN) / 1 (AUTO)
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Page 22
DCP-10 8.3 Engine Parameters: Items Preset Value Range Pair of poles Fuel mode 0-1 / 0(NC) / 1 (NO) T-sensor type 0-15 / 0 (not used) P-sensor type 0-15 / 0 (not used) Start delay 0-300 S Crank attempt 3 times… -
Page 23
DCP-10 8.5 Calibration Menu: Items Preset Value Range ±10.0% GEN. V1 offset ±10.0% GEN. V2 offset ±10.0% GEN. V3 offset ±10.0% Current I1 offset ±10.0% Current I2 offset ±10.0% Current I3 offset ±10.0% Pressure offset ±10.0% Temperature offset ±10.0% Batt. V offset 8.6 The optional items for P/T-sensor:… -
Page 24
DCP-10 Datcon 7 bar: P(Bar) 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0 P(PSI) R(Ω) Murphy 7 bar: P(Bar) 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0 P(PSI) R(Ω) Pre-set 1: 10.0 P(Bar) 14.5 29.0 43.5 58.0… -
Page 25
DCP-10 Datcon: T(℃) T(℉) R(Ω) Murphy: T(℃) T(℉) 1029 R(Ω) PT100: -100 T(℃) -148 T(℉) R(Ω) Pre-set 1: T(℃) T(℉) R(Ω) Pre-set 2: T(℃) T(℉) R(Ω) Pre-set 3: T(℃) T(℉) R(Ω) Pre-set 4: T(℃) T(℉) R(Ω) Type 12： ： ： ：… -
Page 26
DCP-10 LOP switch low level is active HET switch low level is active Emergency stop low level is active Remote start signal low level is active Reserved low level is active Gen Aux. Switch closed low level is active Low fuel level… -
Page 27: Lcd Display And Menu System
DCP-10 9. LCD Display and Menu System Using a backlit TN type LCD to display data and information. After pressing any push button the backlight will automatically turn off in a preset time. In normal operating status, you can set the page scroll time to circularly display each page of measuring data.
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Page 28
DCP-10 9.2 Setting running parameters For example: (setting CT ratio at 1000/5, then CT should be configured as 200) Operation Description Press and hold “ ” 2sec, enter into parameters setting menu, then LCD displays: press “ ”, then LCD displays: Press “… -
Page 29
DCP-10 For example: (resume parameters of controller to factory default) Operation Description Press and hold “ ” 2sec, enter into parameter settings menu, then LCD displays: Press “ ” 8 times, then LCD displays: press “ ” prompted enter password, then key in password: (2213) Press “… -
Page 30: Preparation Before Starting The Controller
DCP-10 10. Preparation before Starting the Controller 10.1 Make sure the controller is correctly installed to meet the ambient requirements. 10.2 Confirm all wiring connections of the controller meet the correct electric specification and corresponding to “2.3 typical wiring diagram”. Ensure the correct polarity of the DC supply source and that it has been protected by an external fuse.
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Page 31: Technical Specification
DCP-10 11. Technical Specification DC working power Voltage range: 12V/24V (8-35V continuous) Cranking drop outs: 0V for 100mS, assuming dc supply was at least 10V before dropout and recovers to 5V Max. operating current: @12V 180mA, @24V 90mA Standby current: TBA AC input voltage: phase voltage15-300Vac RMS (AC frequency≥40 Hz)
DCP-10
The interpretation of the Symbol:
WARNING:
A WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death, serious personal injury or property
damage.
CAUTION:
A CAUTION indicates a potentially hazardous situation which, if not
avoided, could result in damage to equipment or property.
NOTE:
A NOTE provides other helpful information that does not fall under the
warning or caution categories.
I
Table of Contents for FG Wilson DCP-10:
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DCP-10 Page 15/27 7.2 Shutdown Alarm NOTE: (shutdown alarm failures immediately lock out the system and stop the Genset. The failure must be removed and the controller reset before restarting the Genset.) Shutdown Alarm / Description LCD Display START FAILURE: if engine does not fire after the preset number of crank attempt has been made, the Shutdown alarm LED illuminates. LCD displays
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DCP-10 Page 2/27 2. Outline Dimension Drawings and Controller Wiring 2.1 Following Details: Module Dimensions W120mm×H102mm Panel Cutout W110mm×H92mm Thickness D48mm (without connection)
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DCP-10 Page 25/27 For example: (resume parameters of controller to factory default) Operation Description Press and hold “ ” 2sec, enter into parameter settings menu, then LCD displays: Press “ ” 8 times, then LCD displays: press “ ” prompted enter password, then key in password: (2213) Press “ ” to recov
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DCP-10 II WARNING: Read this entire manual pertaining to the work to be performed before installing, operating, or servicing this controller. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage. The engine or other type of prime mover shou
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DCP-10 Page 5/27 3. Panel Operation The operation panel consists of 3 sections: LCD display indicating measurement parameters, LED indicator for common failure, and push buttons for Genset and se
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DCP-10 Page 8/27 NOTE: While cranking, engine ignites. The start motor will power off when the output frequency of generator reaches the preset value (configurable crank cutout value), or if there are one of the following conditions occur: A
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DCP-10 Page 20/27 Datcon 7 bar: Murphy 7 bar: Pre-set 1: Pre-set 2: Pre-set 3: Pre-set 4: Type 11： ：： ： HET sensor parameter addendum： VDO 120℃ ℃℃ ℃: VDO 150℃ ℃℃ ℃: P(Bar) 0.0 0.7 1.4 2.1
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DCP-10 Page 26/27 10. Preparation before Starting the Controller 10.1 Make sure the controller is correctly installed to meet the ambient requirements. 10.2 Confirm all wiring connections of the controller meet the correct electric specification and corresponding to “2.3 typical wirin
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DCP-10 Page 17/27 8. Parameters Setting 8.1 System Parameters: NO. Items Preset Value Range 1.1 CT ratio 100 1-2000 1.2 VT ratio 1.0 1.0-100.0 1.3 Rated ph-voltage 220 45-9999Vac 1.4 AC voltage 2 1,3 (3 for 3 phase 4 wire, 1 for signal phase 2 wi
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DCP-10 Page 14/27 OVER CURRENT: if any phase output current of generator exceeds the “over current pre-alarm” after the safety-on timer has expired, common failure LED indicator flashes. For example, “over current pre-alarm” preset as: 850A, w
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DCP-10 Page 16/27 Code Table for Failure: Name Code Name Code CHARGE FAILURE ENGINE HIGH TEMP BATT. UNDER VOLT OVER SPEED BATT. OVER VOLT UNDER SPEED START FAILURE OVER CURRENT STOP FAILURE GEN. OVER VOLT EMERGENCY STOP GEN. UNDER VOLT
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DCP-10 Page 19/27 8.5 Calibration Menu: NO. Items Preset Value Range 5.1 GEN. V1 offset ±10.0% 5.2 GEN. V2 offset ±10.0% 5.3 GEN. V3 offset ±10.0% 5.4 Current I1 offset ±10.0% 5.5 Current I2 offset ±10.0% 5.6 Current I3 offset ±10.0%
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DCP-10 Page 1/27 1. Description The DCP-10 is an Automatic Controller for generator. When running in “AUTO” mode, it starts the Genset after receiving remote start signal and on failure automatically stops the Genset. The generator’s controlling procedure and protection parameters can be modified, which fully
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