DCU 205 User’s Manual
DIESEL ENGINE
CONTROL UNIT
DCU 205
- USER’S MANUAL -
N-2000 Lillestrøm, Norway
Tel: (+47) 64 84 52 00
Fax: (+47) 64 84 52 12
office@auto-maskin.no
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DCU 205 User’s Manual
TABLE OF CONTENTS
1. INTRODUCTION TO THE DCU 205 .....................................................................4
1.1. TYPE APPROVAL CERTIFICATES ...................................................................4
2. TECHNICAL SPECIFICATION..............................................................................5
2.1. IN GENERAL ................................................................................................5
2.2. FUSES........................................................................................................5
2.3. FRONT PANEL LAYOUT ................................................................................6
3. BEFORE OPERATION..........................................................................................7
3.1. CONTROL INDICATOR ..................................................................................7
4. OPERATING THE CONTROL UNIT .....................................................................8
4.1. START BUTTON ...........................................................................................8
4.2. STOP BUTTON.............................................................................................8
4.3. STANDBY BUTTON .......................................................................................8
4.4. MANUAL BUTTON ........................................................................................9
4.5. RESET BUTTON ...........................................................................................9
4.6. SIREN-OFF BUTTON.....................................................................................9
4.7. LAMP TEST BUTTON ....................................................................................9
4.8. HOUR COUNTER..........................................................................................9
5. ALARM CENTRE.................................................................................................10
5.1. IN GENERAL ..............................................................................................10
5.2. NOT USED ALARMS ...................................................................................11
6. SHUTDOWN CENTRE........................................................................................12
6.1. IN GENERAL ..............................................................................................12
6.2. EMERGENCY AND HARBOUR GENERATOR SETS...........................................13
6.3. OVERSPEED ADJUSTMENT.........................................................................13
7. ADJUSTMENTS AND TIMER SETTINGS ..........................................................14
7.1. FRONTPANEL TEXT LABELS ........................................................................14
8. REMOTE CONTROL...........................................................................................15
8.1. MANUAL START AND STOP .........................................................................15
8.2. AUTOMATIC START, DELAYED STOP ...........................................................15
9. TROUBLE SHOOTING........................................................................................16
10. WIRE CONNECTIONS TABLE .........................................................................17
11. SCHEMATIC DIAGRAM ....................................................................................19
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DCU 205 User’s Manual
Document revisions
Date
Revision
January 1998
March 1997
August 1996
May 1996
March 1996
Release automatic resettable fuses
Release v.1.1
Release v1.0
Prototype
Created
Approved by:
• Det norske Veritas (DnV), certificate no. A-6246.
• Lloyd's Register of Shipping, certificate no. 96/00095.
DnV logo
Lloyd's logo
Copyright  Auto-Maskin A/S, 1994 - 2001
Information given in this specification may change without prior notice.
This document should not be copied without permission from AutoMaskin A/S.
Description:
Revision: august, 2001
User’s Manual order no.: 05012
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DCU 205 User’s Manual
INTRODUCTION TO THE DCU 205
The Diesel Control Unit type DCU 205, is a unit for control and monitoring of marine diesel
engines used as generator sets, main propulsion engines or pumping stations.
The unit covers functions such as manual start and stop, automatic start and stop,
shutdowns and alarms for the diesel engine. Furthermore, it has built-in functions that make
it easy to interface the unit to other control units onboard the ship.
DCU 205 is made up of two separate parts, mainly an alarm unit and a control unit. The
alarm unit must be powered from the ships alarm centre, and the control unit from the start
battery. The alarm unit will operate independently of the control unit.
The front panel contains separate
indication for alarms and shutdown
functions, as well as buttons for start,
stop, manual, standby, reset, siren off
and lamp test. All inputs are electrically
isolated with optocouplers, and the relay
outputs can withstand 2 ampère load.
The unit is built for console mounting
and requires little cabinet depth. It is
delivered with a separate wire terminal
unit which should be mounted in the
cabinet. The cable between these units
has snap-on connectors, which ensure
quick and easy mounting and servicing.
The unit can be placed wherever suitable, or where it feels most natural to control and
monitor the diesel engine. It can be fitted in the ship's control console or delivered in a steel
enclosure for bulkhead mounting. The unit is robust and has a high degree of dust and
water protection, and thus can be placed in the engine room.
Type approval certificates
The DCU 205 diesel control unit is CE-marked and type approved by the following
classification bodies:
• Det norske Veritas (DnV), certificate no. A-6246.
• Lloyd's Register of Shipping, certificate no. 96/00095.
To obtain a copy of the certificates for your documentation, please contact your distributor,
or Auto-Maskin directly.
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DCU 205 User’s Manual
TECHNICAL SPECIFICATION
In general
Supply
To control unit, from startbattery
To alarm unit, from alarmcentre battery
Voltage
20-30VDC
20-30VDC
Output relay contact load
Operating ambient temperature
Max. 125V, 2A
0 - 70°C
Current consumption
Ca. 100mA
Ca. 50 mA
DCU 205 unit
Cut-out dimensions
Overall dimensions
Centre distance, mounting holes
Total depth
Holding screws
Total weight
Front cabinet protection
188 x 167mm (HxW)
204 x 182mm (HxW)
193 x 172mm (HxW)
67mm
M3 - countersunk
900 g
IP55
Wire terminal card
Overall dimensions
Cable length (standard)
40 x 211 x 83 mm (HxWxD)
1.5 meters
Steel enclosure version
Overall dimensions
Total weight (DCU 205 and enclosure)
Degree of protection
300 x 300 x 140mm (HxWxD)
4300 g
IP44
Fuses
A total of 3 automatic resettable fuses are built into the unit. If the fuse breaks, it will reset
itself in about 20 seconds.
Fuse
F1, Circuit fuse
F2, Alarm fuse
F4, Output fuse
Purpose
Protects the functions in the shutdown unit.
Protects the functions in the alarm unit.
Protects the start- and stop signal outputs to the diesel engine.
Table 0-Feil! Bryterargument er ikke angitt., The built-in automatic fuses
The fuses are of type Raychem Polyswitch ®, RXE040.
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DCU 205 User’s Manual
Front panel layout
The Alarm
section with
replaceable
textlabels and
one spare field
The Shutdown
section indicates
conditions that will
stop the engine
Select mode of
operation in the
Function section
Get Status from the
Status section
The Hour meter
indicates engine
running hours
Figure 0-A, DCU 205 front panel layout
The frontpanel is divided into the four sections Alarm, Shutdown, Function and Status.
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DCU 205 User’s Manual
BEFORE OPERATION
Before switching on the Control Unit's 24VDC voltage supply, the following should be
verified:
1.
The switch for selecting the speed sensor
type must be set to the right position
according to the table below. The switch is
located on the back panel.
Speed sensor type
Tachogenerator
Pick-up at the timing gear
Pick-up at the flywheel
Frequency range
0-80 Hz
0-2 kHz
0-8 kHz
Switch position
1
2
3
Table 0-Feil! Bokmerke er ikke definert., Selection of speed sensor type
2.
Alarms not in use must be set in the OVERRIDE
position. This is accomplished using DIP switch nos. 16, located on the back panel of the Control Unit. For
further instructions, please see chapter 0.
3.
Shutdown functions not in use should not be connected.
4.
Verify all connections.
5.
Check that the voltage supply is correct, positive 24VDC on terminal 1 and 39, negative
on terminal 2 and 40. See chapter 0 and 0.
6.
Make the necessary adjustments as noted under chapter 0.
Control Indicator
Verify with the Control Indicator on the back panel,
that a red and green lamp is flashing.
This indicates that the Alarm and Shutdown parts of
the unit are activated and operating.
A constant light indicates malfunction.
Flashing lights indicates
the unit is operating:
One flashing and one black light normally
indicates that power is applied to only one
unit.
Red: Alarm unit
Green: Shutdown unit
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DCU 205 User’s Manual
OPERATING THE CONTROL UNIT
The DCU 205 Control Unit is controlled using the seven pressure-sensitive push buttons on
the front panel. For remote operation see chapter 0. The functions of these push buttons
are discussed underneath.
Start button
For manual starting of the engine. The start solenoid is
activated as long as the button is pressed, but is disabled
when the RUNNING signal comes on. The RUNNING
signal indicates that the engine has reached ignition
speed.
The lamp in the start button area lights up when the button
is pressed, when a remote start signal is given, or when
the Control Unit receives an AUTOMATIC START signal in
the STANDBY mode.
Stop button
The engine will stop immediately when voltage is applied
to the stop solenoid connected to terminal no. 9. A brief
press on the button is enough to activate the stop
solenoid, which is then activated for approx. 50 seconds.
The voltage on terminal no. 10, used for run solenoids or
as feed voltage for electronic regulators, disappears at the
same time.
The lamp in the STOP button will light during the stop
holding time (the time terminal 9 has voltage), or if the
engine has a DELAYED STOP command in STANDBY mode.
Standby button
Standby START
STANDBY is a situation where the Control Unit will try to start the engine three times if an
external start signal, AUTOMATIC START, e.g. in the form of a blackout signal, is applied to
terminals no. 21-22. The signal must be applied during the entire start sequence, approx. 45
sec., and may then be removed.
The lamp in the START button will remain on as long as the AUTOMATIC START signal is
present. If the signal is removed, the start sequence will be aborted.
Each start attempt lasts 7 seconds followed by a 7-second pause (50% duty cycle). In
addition, there is a 2-second delay before the first start. These delays are not adjustable.
If three start attempts have elapsed without a successful start of the diesel engine, the
AUTOMATIC START FAILED alarm will be activated and the RESET button lamp will come
on to indicate that no further starts can be made until the operator has pressed the RESET
button.
Standby STOP
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DCU 205 User’s Manual
The engine may be given a delayed stop by applying the DELAYED STOP signal to
terminals no. 21-23. The engine will then run the pre-set DELAYED STOP time, before the
generator circuit breaker disconnect signal is given to terminals 35-36. The engine will then
run at idle for a pre-set cooling time before finally stopping.
The STOP lamp will remain on as long as the DELAYED STOP signal is present, to indicate
that the engine is in the stop cycle and about to stop.
If AUTOMATIC START and DELAYED STOP are applied simultaneously, priority is given to
AUTOMATIC START.
A relay contact will be closed on Control Unit wire terminals no. 33-34 when the Unit is on
STANDBY and START DISABLED lamp does NOT light up. These terminals can be used
as an indication that the engine is ready for operation.
Manual button
This button is used to get the system out of STANDBY and into MANUAL. Once this is
done, the lamp in the MANUAL area will light up and the automatic start and delayed stop
inputs will be blocked.
Reset button
The RESET button is used to reset all alarms and shutdown functions. In addition, the
STOP solenoid holding time will be reset. Alarms with flashing lamps will stop blinking but
remain lit to indicate that the alarm has been reset but is still present. If the alarm switch is
in normal position before RESET is pressed, the alarm light will turn off. The common alarm
relay will return to normal position.
Siren-off button
The internal siren is activated by any alarm or shutdown. The siren is pulsing if caused by a
shutdown situation and continuously if caused by an alarm.
The siren is turned off using the SIREN OFF button. This however, does not have any
influence on the alarm conditions or relay outputs.
Lamp test button
Pressing this button will light all the lamps and activate the siren in the DCU 205.
Hour counter
The LCD counter shows the engine's total running hours, and runs when the RUNNING lamp
is on.
This is indicated by the blinking hour glass symbol.
When the engine is stopped the hour glass lamp
remains visible but does not blink.
The meter has 1/10 of an hour resolution. It counts up
to 99,999.9 hours and can only be reset by the supplier.
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DCU 205 User’s Manual
ALARM CENTRE
In general
The Control Unit has a total of 9 alarms. Three of these alarms are internally generated by
the Control Unit, and the remaining 6 alarms are based on normally closed contacts from the
controlled system, i.e., an open contact will set off an alarm. The three internal alarms are:
• Supply voltage low
• Automatic start failed, and
• Speed sensor failure
An activated alarm is indicated by its flashing
lamp on the front panel. At the same time, the
alarm will start the siren and activate the
common alarm output relay.
The siren can be silenced by pressing the Siren
Off button (marked with a symbol) located on the
front panel.
The alarms are reset by pressing the RESET
button. The common alarm relay will return to
normal and the flashing lamp will stop flashing
but remain lit. This indicates that the alarm has
been acknowledged but is still present. The light
turns off when the alarm actually disappears.
Supply voltage low
Alarm is given if the supply voltage drops below 23.5V. Interlocked in
60 sec. and while starting.
Failed automatic start
After 3 failed start attempts AUTOMATIC START FAILED and
COMMON ALARM will appear.
Speed sensor failure
If the alarm is activated while the engine is running, it is either a broken wire connection or
the signal might be too weak. Signal strength can be measured between wire terminals 3
and 4, and should be at least 2.0VAC.
If the actual alarm has disappeared before it has been acknowledged (reset), the flashing
lamp and the common alarm will remain on until the RESET button has been pressed. All
alarm inputs are delayed by 1.5 seconds.
The LUB. OIL PRESS. LOW and the extra SPARE alarm inputs are interlocked for 15
seconds after the engine has started, thus these alarms will not be triggered while the
engine is stopped.
If the alarm is activated when the engine is at standstill, there is a problem with the oil
pressure switch (shutdown switch) connected to terminal 5, since it is this signal that
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DCU 205 User’s Manual
interlocks the alarm. At the same time, this situation will activate the RUNNING signal and
SPEED SENSOR FAIL.
Not used alarms
Alarms that are not in use must be overridden by switching the
DIP switches located on the Control Unit’s back panel to the
Override position.
Otherwise, these inputs will give an alarm.
DIP switch
no.
1
2
3
4
5
6
Wire
terminal
12
13
14
15
16
17
Alarm
Up = Override
Down = Normal
LUB. OIL PRESS. LOW
LUB. OIL TEMP. HIGH
COOLING WATER TEMP. HIGH
COOLING WATER LEVEL LOW
FUEL OIL LEAKAGE
SPARE
Table 0-Feil! Bokmerke er ikke definert., Overriding alarms that are not in use
Please take a moment to mark here which
alarms (if any) should be overridden in this
particular system.
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DCU 205 User’s Manual
SHUTDOWN CENTRE
In general
The Control Unit recognises up to 4 conditions that will activate engine shutdown. They are:
• Overspeed
• Lub. oil press. low
NO
• Cooling water temp. high NO
• Spare
NO
The Overspeed alarm is based upon the speed
sensor frequency. The other three are normally open
(NO) contact inputs.
The LUB. OIL PRESS LOW and SPARE alarms are
excluded for 15 seconds after the engine has
started, and are excluded if the engine is stopped.
An activated shutdown will flash its corresponding
alarm lamp and start the siren. The siren can be silenced by pressing the Siren Off button
located on the front panel, without resetting the alarm.
The shutdown sequence is as follows:
• The SHUTDOWN alarm output is activated.
• The Emergency Stop system output (wire terminal 11) is activated (OVERSPEED only).
• The stop solenoid is activated by applying voltage to terminal 9, and the engine stops.
(The solenoid is activated for approximately 50 seconds).
• The run solenoid or electronic regulator on terminal 10 is deactivated.
• The STOP lamp located in the units FUNCTION area remain on as long as the stop
solenoid is activated, or run solenoid is deactivated.
• The START DISABLED lamp activates.
Any Shutdown is reset by pressing the RESET button.
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DCU 205 User’s Manual
Emergency and harbour generator sets
When the generator set is used as a combined emergency and harbour generator set, it can
be necessary to disable all shutdown functions, except overspeed, when used for emergency
power.
This function is enabled or disabled using DIP switch no.
7, located on the unit's back panel.
When the Control Unit is set in the STANDBY position and
DIP switch no. 7 is in the OVERRIDE (ON) position, all the
shutdown functions are disabled except for overspeed. If
the Control Unit is set in MANUAL, all the shutdown functions are enabled, regardless of the
position of DIP switch no. 7.
The following table illustrates the situation.
Selected Function
STANDBY
STANDBY
MANUAL
DIP switch no. 7
OFF
ON
Don’t care
Shutdown Functions
Enabled
Disabled
Enabled
Table 0-Feil! Bokmerke er ikke definert., Disabling the Shutdown Functions in Standby mode
When shutdown function DISABLED is selected, the three lamps LUB. OIL LOW, COOLING
WATER TEMP. HIGH and SPARE will flash simultaneously every 3 seconds, to indicate and
remind of this particular selection.
Overspeed adjustment
The Control Unit activates alarm and shutdown when it detects engine overspeed. Here is
how to adjust the overspeed setting to 15% above nominal speed.
1. Set DIP switch no. 8 to the OVERRIDE position.
2. Turn the OVERSPEED SETPOINT potentiometer a few revolutions clockwise.
3. For generator sets, run the engine at nominal speed. For main propulsion engines, run
the engine at maximum speed
4. Now, slowly adjust the potentiometer anticlockwise, until the engine stops and the
OVERSPEED lamp begins to blink.
5. Important!!! Turn DIP switch no. 8 back to the NORMAL position.
The overspeed set point has now been raised 15% above nominal or maximum speed.
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DCU 205 User’s Manual
ADJUSTMENTS AND TIMER SETTINGS
The table below shows the predefined time delays
and the adjustable functions.
All adjustments are done on the back panel, see
figure.
Use a fine screwdriver and a delicate hand when
adjusting.
Function
Delayed automatic start
Start and pause intervals
during automatic start
RUN signal
Min.
-
Max.
-
Default value
2 sec.
7 sec.
Comment
Not adjustable
Not adjustable
200
600
400 rev/min.
Overspeed (rev./min.)
1000
3000
15% above
nominal speed
Adjustable from back
panel
Adjustable from back
panel. See chapter 0,
Overspeed
adjustment.
Stop solenoid, holding time
Delay before disconnecting
generator breaker
Cooling time
5
180
50 sec.
30 sec.
5
180
30 sec.
0 - 20 mA output for external
rev. counter
Monitoring delay
Alarms delay
Shutdown delay
2200
3000
-
-
20mA @ 2500
rev./min.
15 sec.
1.5 sec.
1.5 sec.
Not adjustable
Adjustable from back
panel
Adjustable from back
panel
Adjustable from back
panel
Not adjustable
Not adjustable
Not adjustable
Table 0-Feil! Bokmerke er ikke definert., Table of predefined time delays and adjustable functions.
Frontpanel text labels
The DCU 205 Control Unit is delivered with the most commonly used wording for alarms and
shutdowns. However, there will be situations where other texts may be necessary.
New labels can be inserted by sliding the labels into place from the backside of the
frontpanel.
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DCU 205 User’s Manual
REMOTE CONTROL
The Control Unit has wire terminals for two remote start and stop alternatives.
• Manual start and stop
• Automatic start and delayed stop
Manual start and stop
The Unit has terminals for remote start and stop. They work in the same way as the local
push buttons.
Remote Start is connected to terminals no. 18-19. Remote Stop is connected to terminals
no. 18-20.
Remember, a brief press on the stop button is enough to stop the engine.
Automatic start, delayed stop
When the Control Unit is set in the STANDBY mode, an internal start/stop program can be
activated by means of external signals. Closed contact between terminals no. 21-22
activates start, and closed contact between terminals no. 21 and 23 activates stop.
For a more in-depth description of the above, see section 0, Standby, on page 8.
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DCU 205 User’s Manual
TROUBLE SHOOTING
Symptom
1. The engine does not
start manually.
Possible cause
Action
1. Charge the battery, replace if
defective.
2. Wait approx. 20 seconds.
3. RESET alarms.
1. Low battery capacity.
2. Blown fuse.
3. START DISABLED
indication.
4. RUNNING indication.
2. The engine does not
start automatically.
3. The RUNNING lamp
is lit when the engine
is stopped and the
SPEED SENSOR
FAILURE alarm is
activated.
4. The SPEED SENSOR
FAILURE alarm
comes on while the
engine is running.
1. Low battery capacity.
2. Control Unit not in
STANDBY mode.
3. Missing AUTOMATIC
START signal.
1. Lost connection between oil
pressure shutdown switch
connected to terminal 5.
1. Lost connection to terminal 3
and/or 4.
2. Signal too weak.
5. The common alarm
relay is activated
without any indication
on the control panel.
1. Blown fuse.
2. Control Unit fault.
6.
1. The CIRCUIT fuse is blown.
2. DCU 205 malfunction.
Simultaneous alarm
for SUPPLY
VOLTAGE LOW,
SPEED SENSOR
FAILURE and
AUTOMATIC START
FAILED.
4. Check oil pressure switch and
its connections, terminal no. 5.
1. Charge the battery, replace if
defective.
2. Set the Unit in STANDBY
mode.
3. Check connections to terminals
21-22, or the signal source.
1. Check the oil pressure switch
and its connections. There
should be connection between
terminals 2 (negative) and 5 on a
stopped engine.
1. Check relevant cables.
2. The signal must be at least
2.0VAC. Adjust or change
tachogenerator.
1. Wait approx. 20 seconds.
2. Check that the lamp marked
CONTROL on the back panel of
the unit is flashing. Turn power
off and on again. If the lamp
does not flash, contact
distributor.
1. Wait approx. 20 seconds.
2. Contact distributor.
Table 0-Feil! Bokmerke er ikke definert., Trouble shooting table
Further, please verify the following:• Verify that the Control Unit has the correct voltage and polarity.
• Make sure the battery is connected in such a way that the Control Unit is sourced from
the battery, not the battery charger only.
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DCU 205 User’s Manual
WIRE CONNECTIONS TABLE
This is a description of all wire connections to the DCU 205 unit. Maximum output relay
contact load is 125V, 2A.
Terminal no.
1, 2
In/Out
In
3, 4
In
5, 6, 7
In
8
Out
9
Out
10
Out
11
Out
12, 13, 14, 15,
16, 17
18, 19
18, 20
21, 22
In
21, 23
In
24, 25, 26
Out
27, 28, 29
Out
30, 31, 32
Out
33, 34
Out
35, 36
Out
37, 38
Out
39, 40
In
In
In
In
Comments
24VDC mains, supplied from engine start battery. Also supplies
the shutdown unit in the DCU 205. Positive on terminal 1,
negative (0V) on terminal 2.
From engine speed sensor. Use shielded cable and shield to
battery negative (0V, terminal 2), not to ground. Signal strength
must be 2-12VAC (pk-pk).
Shutdown inputs. 0V in gives shutdown after 1.5 seconds. Input
5 and 7 are interlocked 15 seconds after detected RUN signal.
24VDC output for operating auxiliary start-motor relay. Protected
with a 2 amp. fuse.
24VDC output for operating auxiliary stop-solenoid relay.
Protected with a 2 amp. fuse.
24VDC output for operating auxiliary run-solenoid or electronic
regulator relay. Voltage remains until a STOP command is given.
Protected with a 2 amp. fuse.
24VDC output for operating auxiliary emergency stop relay. Not
activated during normal STOP. Protected with a 2 amp. fuse.
Alarm inputs. If 0V is removed, alarm is given. Input 12 and 17
are interlocked 15 seconds after detected RUN signal.
Remote START button.
Remote STOP button.
Input for automatic start when in STANDBY mode, e.g. blackout
signal from main switchboard.
Input for delayed stop, e.g. signal from load-dependent start/stop
equipment.
Voltage free change over contact for Common alarm. 24-25 is
NC, 25-26 is NO. Relay deactivates in case of Common alarm.
Voltage free change over contact indicating engine running. 2728 is NC, 28-29 is NO. Relay activates when engine running.
Voltage free change over contact indicating engine disabled. 3031 is NC, 31-32 is NO. Relay activates if Shutdown is detected.
Voltage free contact (NO). If START DISABLED is not given, this
indicates DCU 205 unit in STANDBY.
Voltage free contact (NO) for generator circuit disconnect.
Closes at STOP or when stop delay time has elapsed during a
delayed stop.
0-20mA output as a function of engine speed. Positive on 37,
negative on 38. Use potmeter at the backpanel to calibrate. Use
any correctly scaled 0-20mA meter.
24VDC supply for the DCU 205 alarm section. Supply taken from
the alarm centre battery. Positive on terminal 39, negative on
terminal 40.
Table 0-Feil! Bokmerke er ikke definert., DCU 205 wiring connections
The terminal blocks are 2.5mm2. All connections can be made using 0.5mm2 cable, except
to terminal 1-2 and 39-40 (power supply) where 1.5mm2 should be used.
The diesel engine's terminal box must include auxiliary relays for start and stop, see drawing
no. 1205-1, page 19.
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DCU 205 User’s Manual
The DCU 205
unit
Wire terminal
connector
- 18 -
DCU 205 User’s Manual
SCHEMATIC DIAGRAM
Figure 0-Feil! Bokmerke er ikke definert., DCU 205 wire connection diagram
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