Mebay DC5 D MK3 Series, User Manual

Page 1: ...DC5xD MK3 GENSET CONTROLLER USER MANUAL DC50D MK3 DC52D MK3 ...

Page 2: ... 2020 08 01 Original release 2 V1 1 2021 02 04 Unify the description of input and output ports Chongqing Mebay Technology Co Ltd Add No6 2 Building 4 Gangan Rd Jiangbei District Chongqing Tel 86 23 6869 3061 Fax 86 23 6765 8207 Web http www mebay cn http www cqmb cn E_mail sales mebay cn ...

Page 3: ...wise it may cause the equipment not to work correctly Be care It is indicated that potential hazards can damage equipment without proper precautions Warning It is indicated if appropriate preventive measures are not taken potentially dangerous situations may result in death serious personal injury or significant property losses ...

Page 4: ...amage to related equipment 5 The engine must have an overspeed protection device independent of the controller system to avoid casualties or other damage caused by engine out of control 6 After the installation of the controller is completed please verify that all protection functions are valid Be Care 1 Please keep the good connection of the power supply of the controller Do not share the connect...

Page 5: ...l and operation instruction 19 10 Warnings and Shutdown Alarms 21 11 Parameters setting 28 12 Fault finding 41 Notes 1 All rights reserved No part of this duplication may be reproduced in any material form including photocopying or storing in any medium by electronic means or others without the written permission of the copyright holder 2 MEBAY Technology reserves the rights to change the contents...

Page 6: ...C50DR MK3 Based on DC50D MK3 it adds RS485 port DC52DR MK3 Based on DC52D MK3 it adds RS485 port Dual core 32bit high performance single chip microcomputer 3 5 inch 240 128 high resolution LCD screen Available in 6 languages user s language set if necessary Indicator and number display through UI surface Acrylic material is adapted to protect the screen Silicone panels USB Port parameters can be s...

Page 7: ... more easily 3 Parameters Display Engine RPM Engine oil pressure Engine temperature Engine fuel level Engine battery voltage Charging voltage Mains Frequency only for DC52D MK3 Mains phase voltage L N only for DC52D MK3 Mains phase voltage L L only for DC52D MK3 Generator 3 Phase voltage L N Generator 3 Phase voltage L L Generator 3 phase current A Generator Frequency Hz Generator Power Factor COS...

Page 8: ...ge The charger fails to charge Charger charging failure Stop Failure 5 Parameters Options Parameters Working voltage DC8V 36V Continuous Power consumption Standby 24V MAX 1W Working 24V MAX5W AC Voltage Input 1P2W 30VAC 276VAC ph N 2P3W 30VAC 276VAC ph N 3P4W 30VAC 276VAC ph N Rotate speed sensor Frequency 50 10000Hz MAX Accumulating Time 99999 9Hours Min Store time 6min Fuel Relay Output Max 16Am...

Page 9: ...ith Battery Working condition 25 65 Storage condition 40 85 Protection Level IP54 when waterproof rubber gasket is added between controller and its panel Insulation strength Apply AC1 5kV voltage between high voltage terminal and low voltage terminal The leakage current is not more than 3mA within 1min Overall dimension 210mm 160mm 50mm Panel cutout 186mm 142mm Weight 0 85Kg 6 Overall Dimension an...

Page 10: ... connection No Function Description Cable cross sectional area 1 Battery Negative Input B Controller power supply input B 2 5mm2 2 Battery Negative Input B Controller power supply input B 2 5mm2 3 Emergency Stop Input B voltage input is active and connected to 2 5mm2 ...

Page 11: ...the function selection switch input 1 0mm2 21 Aux Input 2 1 0mm2 22 Aux Input 3 1 0mm2 23 Load CT Secondary L1 Current Transformer Secondary Rated 5A 1 5mm2 24 Load CT Secondary L2 1 5mm2 25 Load CT Secondary L3 1 5mm2 26 Load CT Secondary ICOM Connect to the common 1 5mm2 27 Generator Voltage U Connected to the power generation output R phase 1 0mm2 28 Generator Voltage V Connected to the power g...

Page 12: ...C0 300V AC0 6A DC5A GEN CURRENT GEN VOLTS AUX OUTPUT 1 AUX OUTPUT 2 BATTERY FUSE 10 AMPS FUSE 20 AMPS EMERGENCY STOP SWITCH ALT CRANK REMOTE START LOW OIL PRESSURE ALARM HIGH COOLANT TEMP ALARM LOW COOLANT LEVEL ALARM LOW FUEL LEVEL WARNING 1 No 40 E2 common sensor lines must be securely attached to the vicinity of the sensor body 2 To ensure reliable operation of the module and the measuring accu...

Page 13: ... EMERGENCY STOP SWITCH ALT CRANK REMOTE START LOW OIL PRESSURE ALARM HIGH COOLANT TEMP ALARM LOW COOLANT LEVEL ALARM LOW FUEL LEVEL WARNING 1 No 40 E2 common sensor lines must be securely attached to the vicinity of the sensor body 2 To ensure reliable operation of the module and the measuring accuracy power lines as much as possible and do not share power cable crude and other devices REMARK FUEL...

Page 14: ...AC0 6A GEN CURRENT GEN VOLTS AC5A AC5A AC0 300V MAIN VOLTS 1 PHASE 2 WIRE MODEL DC50D MK3 AUX OUTPUT 3 AUX OUTPUT 4 DC50D MK3 2 phase 3 wire Typical Wiring Diagram G P1 P2 S1S2 P1 P2 S1S2 U V N2 CTs MUST BE 5 AMP SECONDARY FROM GENERATOR TO LOAD SWITCHING DEVICE 29 W 28 27 V U 25 CT2 30 N2 24 23 11 CT1 CT3 CTN 33 T 32 31 S R 34 N1 12 26 10 13 AC0 300V AC0 6A GEN CURRENT GEN VOLTS AC5A AC5A AC0 300...

Page 15: ...R 34 N1 12 26 10 13 AC0 300V AC0 6A GEN CURRENT GEN VOLTS AC5A AC5A AC0 300V MAIN VOLTS AUX OUTPUT 3 AUX OUTPUT 4 DC50D MK3 2 phase 3 wire Typical Wiring Diagram P1 P2 S1S2 G M P1 P2 S1S2 U V N2 R S N1 L1 L2 N FUSE 2A FUSE 2A CTs MUST BE 5 AMP SECONDARY FROM GENERATOR FROM MAINS MECHANICAL INTERLOCK TO LOAD SWITCHING DEVICE ELECTRICAL INTERLOCK 2 PHASE 3 WIRE 29 W 28 27 V U 25 CT2 30 N2 MODEL DC52...

Page 16: ...charger output to battery positive and negative directly then connect battery positive and negative poles to controller positive and negative power supply Output and relay expansion Note All outputs of the controller are relay contacts The maximum current capacity is described in the Parameters in this manual Please use it in the relay current capacity If an extended relay is needed add a continuo...

Page 17: ...ections in order to prevent high voltage from damaging it 8 Panel and display DC50D MK3 DC52D MK3 Running Warning Alarm Alarm record Load transfer on MAN mode On load Gens status LCD Left Up Right OK HOME Down LED Test MUTE Stop Manual Start Manual Auto Running Warning Alarm Close On Gens on load Gens status Mains Status Mains on load Close On Test LED Test MUTE Right Down Stop Manual Start Manual...

Page 18: ...de pressing MANUAL can start the genset and transfer to normal loading after running which is to test if the auto start is in normal status LED Test Warning clear Test if all LED lights are ok pressing this key to test if all lighted all off when loosen it Under warning pressing this key can clear warning and controller will re check warning Under alarm pressing this key can clear the buzzer call ...

Page 19: ...s and for more than 0 5 seconds the controller will automatically calculate and save the number of flywheel teeth according to the generation frequency and generator poles 3 After calculating and saving the number of flywheel teeth successfully the controller shows Flywheel xxx teeth saved successfully Alarm records checking DC5XD MK3 controller can save 14 groups of alarm records which contains t...

Page 20: ... ETS solen oid hold 10S Wait Stop 30S warming up time Crank test time Manual Start Mode press and make sure it is in the stop position before starting Press and the test file indicator is on At this time it is detected whether the connection of each sensor is normal If the sensor is open the sensor opens an alarm If it is normal the unit start process is executed in the following sequence after pr...

Page 21: ...status in real time DC52D MK3 is available When the remote start signal fails and the mains provide the power returns to normal the shutdown process after the loop time delay is performed DC52D MK3 is available Auto start and stop process Auto Start delay 0RPM Idle Rated speed Pre heat delay 5S 5S Long est pre oil supply delay 0S Start Crank delay 2S Crank test time 8S Crank rest time 10S 8S Safe ...

Page 22: ...eration will be entered again Note 10 If the stop key is pressed again during idle time the idle time will be canceled and the stop operation will be executed directly 10 Warnings and Shutdown Alarms Warnings Notes Warning is a non serious failure state which will not harm the gensets system for the time being It only reminds operators to pay attention to the situation that does not meet the requi...

Page 23: ... up Generators will not stop displays High WT sensor on the current fault screen Low fuel level sensor warning When the controller detects that the fuel level value is lower than the Low fuel level warning Then start warning delay and the duration Normal alarm delay have not returned to normal the warning of Low fuel level warning is reported WARNING lights will light up Generators will not stop d...

Page 24: ...rs will not stop displays Over voltage on the current fault screen External instant unloading switch warning When the controller detects that the AUX INPUT External instant unloading shutdown disabled switch is active it starts warning delay and lasts for Normal alarm delay When the External instant unloading shutdown disabled switch is enabled the warning is reported WARNING lights will light up ...

Page 25: ... between D and B is over than this value and there is charging failure but still high normal warning delay then charge failure warns WARNING lights will light up Generators will not stop displays Charger fault on the current fault screen Once the gap is lower than the value warns clear Starting fault Fail to Start If the number of cranks exceeds the predetermined number of cranks the failure of st...

Page 26: ...s higher than the High temperature alarm Then start alarm delay and the duration Normal alarm delay have not returned to normal the alarm of High temperature alarm is reported ALARM lights will light up Generator stops running and displays High Temp sensor on the current fault screen High Temperature Switch Alarm When the controller detects that the High temperature alarm switch input is valid to ...

Page 27: ...urrent fault screen Temperature sensor disconnected alarm When the controller parameter Action if temperature sensor disconnected is set to alarm When the temperature sensor is detected to be disconnected Then start alarm delay and the duration Normal alarm delay have not returned to normal the alarm of temperature sensor disconnected alarm is reported ALARM lights will light up Generator stops ru...

Page 28: ...larm When the controller detects that the generator power is higher than Over total power alarm Then start alarm delay and the duration Normal alarm delay have not returned to normal the alarm of over power is reported ALARM lights will light up Generator stops running displays Over power on the current fault screen Non balance current ratio alarm When the controller is 2 phase 3 wire or 3 phase 4...

Page 29: ...op fail Hz on the current fault screen Stop failure with pressure alarm When the controller detects that the Oil Pressure is not 0 after the execution of the shutdown the alarm of stop failure is reported ALARM lights will light up and displays Stop fail OP A on the current fault screen Stop failure with oil pressure switch When the controller detects that the oil pressure switch has not returned ...

Page 30: ...0 the RPM will be resulted by frequency Pole 2 50Hz 3000RPM Pole 4 50Hz 1500RPM Pole 6 50Hz 1000RPM Pole 8 50Hz 750RPM 2 Gens AC system Disable 1 phase 2 wire 2 phase 3 wire 3 phase 3 wire 3 phase 4 wire Gens phases No gens parameters can be displayed if setting as disable which is applied to water pump genset 3 CT rate 5 6000A 5A 500A 5A Used for setting genset CT primary current secondary rated ...

Page 31: ... be User defined 12 Temperature sensor 0 Disable 1 User defined 2 VDO 40 120 3 MEBAY 001B 4 SGH 5 SGD 6 SGX 7 CURTIS 8 DATCON 9 VOLVO EC 10 3015238 11 PT100 12 MEBAY Mier 13 WEICHAI 40 120 14 GENCON 40 120 Choose the usual temperature sensor if the sensor users choose is not the 11 types it can be User defined 13 Fuel level sensor 0 Disable 1 User defined 2 0 100Ω 3 100 0Ω 4 0 107Ω 5 107 0Ω 6 0 18...

Page 32: ...e AUX INPUT should be set as high temperature stop disabled and input is valid When the temperature value is higher than the preset value or high temperature alarm input signal is valid then controller only display warning but not stop If setting as alarm and stop after unloading the AUX INPUT should be set as high temperature stop and input is valid When the temperature value is higher than the p...

Page 33: ...200 28 Rated frequency multiplying by this value is regarded as crank success condition When the gens frequency is over the condition value then system regards it as crank success 7 Oil pressure disconnect 0 400kpa 200kpa When the engine oil pressure is over the condition value then system regards it as crank success motor escaped 8 RPM disconnect 0 200 24 Rated RPM multiplying by this value is re...

Page 34: ...mote signal is valid 2 Preheat time 0 6500 0s 0 0s The time needed to be preheat before the starter on power 3 Longest pre oil supply 0 180 0s 0 0s Under pre oil supply if the oil pressure is higher than setting value then pre oil supply stopped 4 Cranking time 3 0 60 0s 8 0s The time when the starter is on power 5 Crank rest time 3 0 60 0s 10 0s If crank failure the waiting time before the second...

Page 35: ...y stop and over frequency 21 Normal warning delay 1 0 20 0s 2 0s The warning delay 22 AC Voltage abnormal delay 2 0 20 0s 10 0s Over under voltage delay 23 Over current inverse time 0 1 36 0 36 0 This option will not take effect until the 27 Over phase current delay is set to 0 The overcurrent delay is inverse time and the formula is T t IA IT 1 2 24 Over power inverse time 0 1 36 0 36 0 This opti...

Page 36: ... then low fuel level warns If it is higher than the value then warning clears If the value is set as 0 then the low fuel level warning is disabled 6 Low fuel level alarm 0 100 0 When the fuel level is lower than the alarm value and comes into low fuel level delay but still lower normal faults delay then low fuel level alarms if the value is set as 0 then the under speed alarm is disabled 7 Over ba...

Page 37: ...y but still lower normal faults delay then under voltage alarms If the value is set as 0 then the alarm is disabled 5 Phase current over load alarm 0 200 100 Rated current multiplying by this value is regarded as over current alarm value When the current is higher than the value and comes into over current delay but still higher over current faults delay then over current alarms If the value is se...

Page 38: ...eted and the output is closed after high speed heat dissipation 13 Excitation output there is output during cranking procession and there is 2s output if there is no frequency under high speed status 14 Gens load continuous or pulse type according to time setting 15 Gens unload continuous or pulse type according to time setting 16 Speed down control the output time is shutdown idle delay during sh...

Page 39: ...if there is signal input 10 External instant warning input 11 External instant alarm input 12 Gens un loading input connect to the gens loading switchs auxiliary point 13 Mains un loading input connect to auxiliary point of mains loading switch Only for DC52D MK3 14 Shades status input 15 Auto start disabled gens will not start if there is signal input whatever mains normal or not 16 Auto stop dis...

Page 40: ... valid 0 Normal close 1 Normal open 7 Working plan and maintenance setting NO Parameter Range defaults Notes 1 Working plan format Disable Every month Every week This mode must be under auto mode Working plan is disabled once setting as disable The working plan will be executed according the chosen date when setting as every month The working plan will be executed according the chosen date when se...

Page 41: ... display 0 20 0s 5 0s Start screen display time 0 No display 2 Saving mode 5 0 6000 0s 600 0s LCD light will be closed automatically without any button pressed after delay If setting as 200 0s back light always lighted 3 Homing display 5 0 600 0s 600 0s The time when the page reverts back to the home page If setting as 600 0s disabled 4 LOGO delay display under standby 5 0 6000 0 6000 0s Start scr...

Page 42: ...gh or not Check the genset AC voltage Check DC fuse Genset Emergency Stop Check the emergency stop button Check that the voltage of the controller s 3 feet to the ground should be the battery voltage Check the controller connection Low oil pressure alarm Check oil pressure sensor and its wiring Check the oil pressure sensor type and controller settings must be consistent Check whether the low oil ...

Page 43: ...the USB port of the computer is normal Check whether the USB driver is installed RS485 cannot communicate normally Check the connection Check if the communication ID number setting is correct Check if the A and B lines of RS485 are reversed Check if the RS485 communication line driver is installed or not Check if the communication port of the PC is damaged Add a 120 Ω resistor between the AB of th...