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DKG-507 AUTOMATIC MAINS FAILURE UNIT

1. genset voltage and frequency protections are disabled However engine rpm protections will be active It is strongly recommended to enter correct low and high rpm limit values in order to enable engine speed protection 23 DKG 507 User Manual V 37 01 03 2012 6 25 Dual Voltage and Frequency The unit offers 2 sets of voltage and frequency protection limit values The user is allowed to switch between these 2 sets anytime This feature is especially usefull in dual voltage or frequency gensets for easy switching between 2 operating conditions The switching to the second set of limit values is performed by applying signal to the SPARE 1 digital input In order to assign this functionality to the SPARE 1 input the program parameter P 092 Secondary Volt Freq should be set to 1 Below parameters are available for second voltage frequency selection Mains Low Voltage Limit Genset Low Voltage Shutdown Limit Mains High Voltage Limit Genset Low Voltage Warning Limit Mains Low Frequency Limit Genset High Voltage Warning Limit Mains High Frequency Limit Genset High Voltage Shutdown Limit Genset Low Frequency Shutdown Limit Genset Low Frequency Warning Limit Genset High Frequency Warning Limit Genset High Frequency Shutdown Limit Genset Low RPM Shutdown Limit Genset Low RPM Warning Limit Genset High RPM Warning Limit Genset High RPM Shutdown Limit 6 26 Single Phase Operation If the unit is used in a single phase el
2. MAINS L2 00 MAINS L1 MAINS CONTACTOR Relay output 16A AC This output provides energy to the mains contactor If the mains phases do not have acceptable voltages the mains contactor will be de energized In order to provide extra security the normally closed contact of the generator contactor should be serially connected to this output 11 GROUND O VDC Power supply negative connection 12 BATTERY POSITIVE 12 or 24VDC The positive terminal of the DC Supply shall be connected to this terminal The unit operates on both 12V and 24V battery systems 13 FUEL LEVEL SENDER Input 0 5000 ohms Analogue fuel level sender connection Do not connect the sender to other devices The input has programmable ohms for VDO senders 14 OIL PRESSURE SENDER Input 0 5000 ohms Analogue oil pressure sender connection Do not connect the sender to other devices The input has programmable characteristics and connecis to any kind of sender 15 COOLANT TEMP SENDER Input 0 5000 ohms Analogue high temperature sender connection Do not connect the sender to other devices The input has programmable characteristics and connects to any kind of sender DKG 507 User Manual V 37 01 03 2012 Term Function Technical data Description 16 CHARGE I
3. 90 When secondary volt freg limits are active If one of the generator phase voltages goes under this limit when feeding the load this will generate a GENSET LOW VOLTAGE shutdown alarm and the engine will stop P 104 2 Genset Low Voltage Warning Limit 94 When secondary volt freg limits are active If one of the generator phase voltages goes under this limit when feeding the load this will generate a GENSET LOW VOLTAGE warning P 105 2 Genset High Voltage Warning Limit 130 When secondary volt freg limits are active If one of the generator phase voltages goes above this limit when feeding the load this will generate a GENSET HIGH VOLTAGE warning P 106 2 Genset High Voltage Shutdown Limit 136 When secondary volt freq limits are active If one of the generator phase voltages goes over this limit when feeding the load this will generate a GENSET HIGH VOLTAGE alarm and the engine will stop P 107 2 Low Frequency Shutdown Hz 40 When secondary volt freg limits are active If the genset frequency goes under this limit a GENSET LOW SPEED alarm is generated and the engine stops P 108 2 Low Frequency Warning Hz 45 When secondary volt freg limits are active If the genset frequency goes under this limit a GENSET LOW SPEED warning is generated P 109 2 High Frequency Warning Hz 65 When secondary volt freg limits are active If the gens
4. hex W SIZE 0000 R 16bit x1 Mains Phase L1 voltage 0001 R 16bit x1 Mains Phase L2 voltage 0002 R 16bit x1 Mains Phase L3 voltage 0003 R 16bit x1 Genset Phase L1 voltage 0004 R 16bit x1 Genset Phase L2 voltage 0005 R 16bit x1 Genset Phase L3 voltage 0006 H 16bit x1 Genset Phase L1 current 0007 R 16bit x1 Genset Phase L2 current 0008 H 16bit x1 Genset Phase L3 current 000C H 16bit x1 Mains Phase L12 voltage 000D R 16bit x1 Mains Phase L23 voltage 000E R 16bit x1 Mains Phase L31 voltage 000F R 16bit x1 Genset Phase L12 voltage 0010 R 16bit x1 Genset Phase L23 voltage 0011 R 16bit x1 Genset Phase L31 voltage 0012 H 16bit x10 Mains frequency 0013 H 16bit x10 Genset frequency 0016 0017 R 32bit x256 Genset active power this 24 bit signed register holds the genset active power multiplied by 256 Least significant 16 bits are in the register 0016h Most significant 8 bits are in the LSB of the register 0017h 0018 R 8bit x100 Power factor multiplied by 100 signed byte Negative values indicate a capacitive power factor 002A H 16bit x1 Engine speed rpm 002B H 16bit x10 Oil pressure in bars 002C H 16bit x1 Coolant temperature in degrees C 002D R 16bit x1 Fuel level as 002F R 16bit x10 Battery voltage 003D R 8bit Operating mode bit 3 manual mode bit 4 auto mode bit 5 off mode bit 6 test mode bit 7 load test mode 28 DKG 507 User Manual V 37 01 03 2012 9 WEEKLY OPERATION SCHED
5. 26 not used reserved 27 not used reserved 28 not used reserved 29 not used reserved 30 not used reserved 31 Condition exist V 37 01 03 2012 27 DKG 507 User Manual V 37 01 03 2012 8 MODBUS COMMUNICATION The unit offers the possibility of MODBUS communication via its RS232 serial port The connection to the MODBUS master may be done in 3 ways 1 RS232 connection using directly the RS232 port provided 2 RS422 485 connection using external RS422 485 converter 3 Modem connection using external modem The MODBUS mode is activated by assigning a controller address to the unit using MODBUS Address program parameter The possible address range is 1 to 144 Setting the address to 0 will disable the MODBUS mode and allow communication under RAINBOW protocol The MODBUS properties of the unit are Data transfer mode RTU Serial data 9600 bps 8 bit data no parity 1 bit stop Supported functions Function 3 Read multiple registers Function 6 Write single register Detailed description about the MODBUS protocol is found in the document Modicon Modbus Protocol Reference Guide The web address is www modbus org docs PI MBUS 300 pdf Below is a limited shortlist of readable registers For the detailed Modbus Application Manual and a complete list of registers please contact DATAKOM ADDRESS R DATA COEFFICIENT DESCRIPTION
6. Relay Definitions password level 2 PGM Parameter Definition Unit Fac Set Description P 226 Relay 01 Definition 3 RELAY 1 function selected from list 227 Relay 02 Definition 1 RELAY 2 function selected from list P 228 Relay 03 Definition 0 Arne function expansion module selected from P 229 Relay 04 Definition 2 emi function expansion module 1 selected rom list P 230 Relay 05 Definition 4 RELAY 5 function expansion module 1 selected from list P 231 Relay 06 Definition 5 RELAY 6 function expansion module 1 selected from list P 232 Relay 07 Definition 0 RELAY 7 function expansion module 1 selected from list P 233 Relay 08 Definition 2 RELAY 8 function expansion module 1 selected from list P 234 Relay 09 Definition 4 RELAY 9 function expansion module 1 selected from list P 235 Relay 10 Definition 5 RELAY 10 function expansion module 1 selected from list P 236 Relay 11 Definition 0 RELAY 11 function expansion module 2 selected from list P 237 Relay 12 Definition 2 RELAY 12 function expansion module 2 selected from list P 238 Relay 13 Definition 4 RELAY 13 function expansion module 2 selected from list P 239 Relay 14 Definition 5 RELAY 14 function expansion module 2 selected from list P 240 Relay 15 Definition 0 RELAY 15 function expansion module 2 selected from list P 241 Relay 16 Definition 2 RELAY 16 function expansion modul
7. 200 hours but even if this amount of engine hours is not fulfilled it is performed after a given time limit for example 12 months The SERVICE REQUEST led has no effect on the genset operation The unit has both programmable engine hours and maintenance time limit The engine hours is programmable with 50 hour steps the time limit is programmable with 1 month steps If any of the programmed values is zero this means that the parameter will not be used For example a maintenance period of 0 months indicates that the unit will request maintenance only based on engine hours there will be no time limit If the engine hours is also selected as 0 hours this will mean that the SERVICE REQUEST display will be inoperative When the engine hours OR the time limit is over the SERVICE REQUEST led red will start to flash and the service request relay function will be active The service request relay function may be assigned to spare relays using Relay Definition program parameters Also relays on an extension module may be assigned to this function To turn off the SERVICE REQUEST led and reset the service period press together the ALARM MUTE and LAMP TEST keys for 5 seconds The remaining engine hours and the remaining time limit are kept stored in a non volatile memory and are not affected from power supply failures The time and engine hours to service are displayed in the STATISTICAL COUNTERS menu 17 DKG 507 User Manua
8. High rpm Shutdown rpm 0 HIGH SPEED alarm is generated and the engine stops This is the period during which the ALARM relay P 055 Alarm Relay Timer Sec 60 is active If the period is set to 0 this will mean that the period is unlimited P 056 Intermittent Alarm 0 0 continuous Relay 1 intermittent turns on and off every second The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last P 057 Service Engine Hours hour 50 service If the period is set to 0 no SERVICE REQUEST will be generated depending on engine hours The SERVICE REQUEST led indicator will turn on P 058 Service Period month 6 after this amount of time from the last service If the period is set to 0 no SERVICE REQUEST will be indicated depending on time 36 DKG 507 User Manual V 37 01 03 2012 Following parameters are in high priority group PGM Parameter Definition Unit Fact Set Description Reverse power If the genset power is negative and goes above P 059 ee ci KW 0 this limit then a REVERSE POWER warning will warning limit b e generated Reverse power If the genset power is negative and goes above _060 loaddumpa limit KW 0 this limit then a REVERSE POWER loaddump will Pg be generated P 061 Load Shedding Low KW 0 If the genset power goes below this limit then the Limit load shedding relay will be deactivate
9. Set if the engine has not stopped before the expiration of the Stop Timer ECU FAIL warning Set when an engine fault code is received from the ECU of the electronic engine This fault will not cause an engine stop If necessary the engine will be stopped by the ECU ECU FAIL alarm Set if no information has been received during 3 seconds from the ECU of the electronic engine This fault condition is only controlled if fuel is on OVERLOAD load dump Set if at least one of the genset phase currents goes over the Overcurrent Limit for Overload Timer If currents go below the limit before expiration of the timer then no alarm will be set EXCESS POWER load dump Set if the genset power KW supplied to the load goes over the Excess Power limit for Overload Timer If the power goes below the limit before expiration of the timer then no alarm will be set GENSET LOW VOLTAGE Set if any of the generator phase voltages goes outside programmed limits for Overload Timer This fault will be monitored with holdoff timer delay after the engine is running GENSET HIGH VOLTAGE Set if any of the generator phase voltages goes outside programmed limits for Overload Timer This fault will be monitored with holdoff timer delay after the engine is running LOW COOLANT LEVEL Set if a signal is detected at the low coolant level input HIGH BATTERY VOLTAGE Set if the battery voltage goes above programmed limits Both warning and alarm levels for high battery
10. circuit breaker of High Breaking Capacity HBC at least 1500A DKG 507 User Manual V 37 01 03 2012 2 INPUTS AND OUTPUTS RS 232 SERIAL PORT This connector provides serial data input and output for various purposes like remote monitoring and remote programming EXTENSION CONNECTOR This connector is intended for the connection to output extension modules The optional relay extension module provides 8 programmable 16 relay outputs The unit allows the use of up to 2 I O extension modules Term Function Technical data Description 1 GENERATOR CONTACTOR Relay output 16A AC This output provides energy to the generator contactor If the generator phases do not have acceptable voltage or frequency values the generator contactor will be de energized In order to provide extra security the normally closed contact of the mains contactor should be serially connected to this output GEN L1 GEN L2 GEN L3 Generator phase inputs 0 300V AC Connect the generator phases to these inputs The generator phase voltages upper and lower limits are programmable GENERATOR NEUTRAL Input 0 300V AC Neutral terminal for the generator phases MAINS NEUTRAL Input 0 300V AC Neutral terminal for the mains phases NIOO QD IO MAINS L3 Mains phase inputs 0 300V AC Connect the mains phases to these inputs The mains voltages upper and lower limits are programmable
11. current transformers The rating of the transformers should be the same for each of 34 CURR 3 the 3 phases The secondary winding rating shall be 5 Amperes For ex 200 5 Amps 35 OIL TEMP SENDER Input 0 5000 ohms Analogue oil temperature sender connection Do not connect the sender to other devices The input has programmable characteristics and connects to any kind of sender CANBUS VERSIONS 36 CANBUS L Digital communication Connect the J1939 port of an electronic 37 CANBUS H port engine to these terminals The 120 ohm terminating resistors are inside the unit Please do not connect external resistors Use a twisted cable pair or coaxial cable for best results MPU INPUT VERSIONS 36 MPU Analog input 0 5 to Connect the MPU unit to these inputs 37 MPU 30V AC Use a twisted cable pair or coaxial cable for best results DKG 507 User Manual 3 DISPLAYS 3 1 Led Displays The unit has 12 LEDs divided in 3 groups V 37 01 03 2012 Group 1 Operating mode This group indicates the genset function Group 2 Mimic diagram This group indicates the current status of the mains and genset voltages and contactors Group 3 Warnings and alarms This group indicates the existence of abnormal conditions encountered during operation Function Color Description MAINS ON Green The LED will turn on when all 3 mains phase voltages are within the limits MAINS OFF R
12. either battery positive or battery negative These selections are made using the programming menu If the Simulate Mains input is defined and the input signal is active the mains phases are not monitored and supposed to be inside limits This will prevent the genset from starting even in case of a mains failure If the genset is running when the signal is applied then usual Mains Waiting and Cooldown cycles will be performed before engine stop When the SIMULATE MAINS signal is present the front panels mimic diagram s mains LEDs will reflect the mains voltages as present When the signal is passive the unit will revert to normal operation and monitor the mains voltage status The REMOTE START operation overrides SIMULATE MAINS and FORCE TO START operations 14 DKG 507 User Manual V 37 01 03 2012 6 8 Delayed Mains Simulation Battery Charging The Delayed Mains Simulation feature is used in battery backed up telecom systems where batteries are able to supply the load during a certain period The genset is requested to run only when battery voltage drops below the critical level Once the engine runs the rectifier system starts charging the batteries and the battery voltage goes up immediately Thus the engine should continue to run a programmed period for effective charging The critical battery voltage level will be detected by an external unit which provides the digital Simulate Mains signal for the genset control unit T
13. ohm value P_159 Temperature Value 6 C 02 Temperature Sender point 6 C value Fuel Level Sender Characteristics PGM Parameter Definition Unit Factory Set Description P 160 Fuel Level Sender Ohms 1 ohm 4 Fuel Level Sender point 1 ohm value P 161 Fuel Level Value 1 96 0 Fuel Level Sender point 1 value P 162 Fuel Level Sender Ohms 2 ohm 31 Fuel Level Sender point 2 ohm value P 163 Fuel Level Value 2 96 25 Fuel Level Sender point 2 value P 164 Fuel Level Sender Ohms 3 ohm 67 Fuel Level Sender point 3 ohm value P 165 Fuel Level Value 3 96 50 Fuel Level Sender point 3 value P 166 Fuel Level Sender Ohms 4 ohm 110 Fuel Level Sender point 4 ohm value P 167 FuelLevel Value 4 96 75 Fuel Level Sender point 4 value P 168 Fuel Level Sender Ohms 5 ohm 180 Fuel Level Sender point 5 ohm value P 169 Fuel Level Value 5 96 100 Fuel Level Sender point 5 value P 170 Fuel Level Sender Ohms 6 ohm 1000 Fuel Level Sender point 6 ohm value P 171 Fuel Level Value 6 96 100 Fuel Level Sender point 6 value 43 DKG 507 User Manual V 37 01 03 2012 Program Group Sender Characteristics password level 2 PGM Parameter Definition Unit Fact Set Description P 172 Oil Temperature Sender Ohms 1 ohm 38 Temperature Sender point 1 ohm value P 173 Oil Temperature Value 1 C 100 Temperature Sender po
14. pressure sender type 0 Non standard sender The sender characteristics are defined in Sender Characteristics table VDO 0 7 bars 10 180 ohms VDO 0 10 bars 10 180 ohms DATCON 0 7 bars 240 33 ohms DATCON 0 10 bars 240 33 ohms DATCON 0 7 bars 0 90 ohms DATCON 0 10 bars 0 90 ohms DATCON 0 7 bars 75 10 ohms gt _027 Coolant Temp Sender Type This parameter selects the temperature sender type 0 The sender characteristics are defined in Sender Characteristics table 1 VDO 2 DATCON DAH type 3 DATCON DAL type P 028 Oil Temp Sender Type This parameter selects the temperature sender type 0 The sender characteristics are defined in Sender Characteristics table 1 VDO 2 DATCON DAH type 3 DATCON DAL type 24 DKG 507 User Manual V 37 01 03 2012 PGM Parameter Definition Unit Fact Set Description P 029 Hysteresis Voltage This parameter provides the mains and genset voltage limits with a hysteresis feature in order to prevent faulty decisions For example when the mains are present the mains voltage low limit will be used as the programmed low limit When the mains fail the low limit will be incremented by this value It is advised to set this value to 8 volts P 030 Engine Heating Temperature C If it is requested that the engine runs without load until reaching a certain
15. sender alarm 95 Low fuel sender 15 Fuel Main winding 48 High oil temp alarm warning 16 Mains Fail 49 96 Service request 17 Block Heater 50 warning 18 Service Request 51 High battery voltage 97 Mains Phase Order 19 alarm Fail 20 Load Shedding Relay 52 Charge fail alarm 98 Low battery warning 21 Flashing Relay 53 99 High battery warning 22 Gas Solenoid 54 100 Charge fail warning 23 Fuel Pump 55 101 24 Mains Phase Order 56 Oil switch load dump 102 Fail 57 Temp switch 103 25 Genset Phase Order load dump 104 Gen Low voltge warn Fail 58 Coolant Level switch 105 Gen High voltge warn 26 Idle Speed load dump 106 Reverse Power warn 27 Cooler Fan 59 Rectifier load dump 107 High oil temp warn 28 2 volt frequency 60 Emerg Stop load dump 108 29 Crank 1 2 Selector 61 Spare 1 load dump 109 30 62 Spare 2 load dump 110 31 63 111 64 112 65 113 66 114 67 115 68 116 69 117 70 118 71 119 72 Overcurrent load dump 73 Excess power Idd 74 Reverse power Idd 75 76 77 78 79 Genset Phase Order Fail Loaddump 48 DKG 507 User Manual V 37 01 03 2012 14 TROUBLESHOOTING The genset operates while AC mains are OK or continues to operate after AC mains are OK Check engine body grounding AC mains voltages may be outside programmed limits measure th
16. temperature this parameter defines the temperature If the coolant temperature falls below this parameter an Engine Low Temperature warning will occur P 031 Fault Holdoff Timer sec This parameter defines the delay after the engine runs and before the fault monitoring is enabled P 032 Overload Timeout sec This is the period between the current or active power go over the limits and OVERCURRENT or EXCESS POWER Load Dump alarms occur This is also the period between the frequency goes out of the limits and OVERSPEED or UNDERSPEED alarms occur This is also the period between the genset voltage goes out of the limits and HIGH VOLTAGE or LOW VOLTAGE alarms occur P 033 Engine Start Delay sec This is the time between the mains fails and the fuel solenoid turns on before starting the genset It prevents unwanted genset operation in battery backed up loads P 034 Preheat Timer sec This is the time after the fuel solenoid is energized and before the genset is started During this period the PREHEAT relay output is energized if assigned by Relay Definitions P 035 Choke Timer sec This is the control delay of CHOKE output The choke output is activated together with the crank output It is released after this delay or when engine runs whichever occurs first P 036 Gas Solenoid Delay sec The gas solenoid of the gas engine will be opened after this delay during cran
17. the program parameter number to increase faster Parameter value may be increased and decreased with Vand A buttons If these keys are held pressed the program value will be increased decreased faster When a program parameter is modified it is automatically saved in memory If MENUP button is pressed next parameter will be displayed Program parameters are kept in a non volatile memory and are not affected from power failures To exit the program mode press one of the mode selection keys If no button is pressed during 1 minute the program mode will be cancelled automatically Program parameters are organized in 2 groups as low and high levels Entering the program mode by pressing the MENUD button will allow access to only low level parameters In order to access all parameters please hold OFF and MENUD buttons pressed 32 DKG 507 User Manual V 37 01 03 2012 PGM Parameter Definition Unit Fact Set Description C renttranstormer This is the rated value of current transformers P_000 Ratio A 500 All transformers must have the same rating The secondary of the transformer will be 5 Amps If the current goes above this limit during the period defined in Overload Timeout then a P 001 Overcurrent Limit A 0 Overcurrent Load Dump alarm will be generated If this parameter is 0 then Overcurrent check is disabled If the active power goes above this limit durin
18. to the exerciser are Exercise start day and hour Exercise duration Exercise off load on load Exerciser Period Daily Weekly Monthly Please refer to the programming section for a more detailed description of the above parameters When the start day and hour of exercise has come the unit will automatically switch to either OFF LOAD TEST or LOAD TEST mode The engine will run and if the on load exercise is selected then the load will be transferred to the genset If a mains failure occurs during the off load exercise the load will not be transferred to the genset unless the Emergency Backup Operation is allowed by setting the related program parameter to 1 Thus it is highly recommended that the Emergency Backup mode enabled with off load exerciser At the end of the exercise duration the unit will switch back to the initial mode of operation If any of the mode selection keys are pressed during exercise then the exercise will be terminated Using the daily exercise mode the unit may feed the load from the genset during predefined hours of the day This operation may be used in high tariff periods of the day 6 18 Resuming to factory set parameters In order to resume to the factory set parameter values hold pressed the OFF LAMP TEST and ALARM MUTE buttons for 5 seconds FACT RSET will be displayed immediately press and hold pressed the ALARM MUTE button for 5 seconds factory set values will be reprogrammed
19. 0 180 ohms DATCON 0 7 bars 240 33 ohms DATCON 0 10 bars 240 33 ohms DATCON 0 7 bars 0 90 ohms DATCON 0 10 bars 0 90 ohms DATCON 0 7 bars 75 10 ohms Bm m e PTO Temperature Sender Selection Selectable sender types are 0 Sender characteristics are defined in Sender Characteristics table 1 VDO 2 DATCON DAH type 3 DATCON DAL type Fuel Level Sender Selection The Fuel Level Sender characteristic is programmable through table Oil Temperature Sender Selection Selectable sender types are 0 Sender characteristics are defined in Sender Characteristics table 1 VDO 2 DATCON DAH type 3 DATCON DAL type 12 DKG 507 User Manual V 37 01 03 2012 6 3 Engine Heating Operation Especially on engines without a body heater or with a failing one it may be desired that the genset should not take the load before reaching a suitable temperature The unit offers 2 different ways of engine heating 1 Timer controlled heating This operation mode is selected when the Engine Heating Method parameter is set to 0 In this mode the engine will run during parameter Engine Heating Timer and then the genset will take the load 2 Timer and temperature controlled heating This operation mode is selected when the Engine Heating Method parameter is set to 1 In this mode at first the engine will run during parameter Engine Heating Timer then it will continue to run until the measured coolant temperature reache
20. DKG 507 User Manual V 37 01 03 2012 Q DATAKOM PK6 507 AUTOMATIC MAINS FAILURE UNIT CANBUS AND MPU VERSIONS DKG 507 DATAKOM ALARMS COOLANT 1 OIL PRESS LEVEL HIGH TEMP SPEED FAULT HIGH OIL TEMP BATTERY CHARGE FAIL RECTIFIER EMERG STOP ECU FAIL START FAIL STOP FAIL LOW FUEL OVERLOAD SPARE SERVICE REQUEST 390 9000 TEST AUTO STOP PMH YEA SE VOLTAGE DESCRIPTION FEATURES The controller is a comprehensive AMF unit for True RMS measurements single genset standby or dual genset mutual standby ECU connection through J1939 CAN option operations MPU input option The unit is available with MPU or CANBUS versions Dual genset mutual standby operation The CANBUS version connects to ECU controlled Event logging with time stamp and electronic engines providing engine control measurements protection and instrumentation without extra senders Battery backed up real time clock The unit is able to initiate modem calls and send Built in daily weekly monthly exerciser SMS messages in fault conditions through external Weekly operation schedule programs modems Field adjustable parameters The unit provides a comprehensive set of digitally RS 232 serial port adjustable timers threshold levels input and output Free MS Windows Remote monitoring SW configurations operating sequences and engine GSM and PSTN modem support types All programs may be modified via front panel GSM SMS messa
21. G 507 User Manual V 37 01 03 2012 LOW OIL PRESSURE Set if a signal is detected at the Low Oil Pressure Switch input or the oil pressure value measured from the sender is below the programmed limit Warning and alarm limits are separately programmable for the oil pressure sender input This fault will be monitored with Holdoff Timer delay after the engine is running Also if the oil pressure switch is open at the beginning of a start attempt then the engine will not be started and the oil pressure alarm led will flash When the oil pressure switch closes normal operation will be resumed HIGH TEMPERATURE Set if a signal is detected at the High Temperature Switch input or the coolant temperature value measured from the sender is above the programmed limit Warning and alarm limits are separately programmable for the temperature sender input LOW TEMPERATURE warning Set if the coolant temperature value measured from the sender is blow the Engine Heating Temperature limit LOW SPEED HIGH SPEED Set if the generator frequency or rpm is outside programmed limits These faults will be monitored with Holdoff Timer delay after the engine is running Low and high limits for warning and alarm are separately programmable Another high shutdown limit which is 12 above the high limit is always monitored and stops the engine immediately START FAIL alarm Set if the engine is not running after programmed number of start attempts STOP FAIL warning
22. Ltd GAD Tel 90 216 466 84 60 Fax 90 216 364 65 65 e mail datakom 2datakom com tr http www datakom com tr 54
23. RESSURE SENDER warning P 019 Low Oil Pressure Shutdown bar 1 0 If the oil pressure measured from the analog input falls below this limit this will generate a LOW OIL PRESSURE SENDER alarm is generated and the engine stops P 020 High Temperature Warning C 95 If the coolant temperature measured from the analog input goes over this limit this will generate a HIGH TEMPERATURE SENDER warning P 021 High Temperature Shutdown C 98 f the coolant temperature measured from the analog input goes over this limit this will generate a HIGH TEMPERATURE SENDER alarm and the engine will stop P 022 Low Fuel Warning 20 If the fuel level measured from the analog input falls below this limit a LOW FUEL LEVEL SENDER warning is generated P 023 Low Fuel Shutdown the fuel level measured from the analog input falls below this limit a LOW FUEL LEVEL SENDER shutdown alarm is generated and the engine stops P 024 High Oil Temperature Warning C 100 If the oil temperature measured from the analog input goes over this limit this will generate a HIGH OILTEMPERATURE SENDER warning P 025 High Oil Temperature Shutdown C 120 f the oil temperature measured from the analog input goes over this limit this will generate a HIGH OIL TEMPERATURE SENDER alarm and the engine will stop P 026 Oil Pressure Sender type This parameter selects the oil
24. Seconds Current second of the minute Weekly Schedule Programs PGM Parameter Definition Unit Factory Description Set P 122 Monday Turn on hh mm 24 00 P 123 Monday Turn off hh mm 24 00 P 124 Tuesday Turn on hh mm 24 00 P 125 Tuesday Turn off hh mm 24 00 P 126 Wednesday Turn on hh mm 24 00 Wednesday Fur off Mhm 2400 Please review chapter 9 for a detailed EE SA JUIN 06 description of weekly programming schedule P 129 Thursday Turn off hh mm 24 00 operation P 130 Friday Turn on hh mm 24 00 P 131 Friday Turn off hh mm 24 00 P 132 Saturday Turn on hh mm 24 00 P 133 Saturday Turn off hh mm 24 00 P 134 Sunday Turn on hh mm 24 00 P 135 Sunday Turn off hh mm 24 00 42 DKG 507 User Manual V 37 01 03 2012 Oil Pressure Sender Characteristics PGM Parameter Definition Unit Factory Set Description P 136 Oil Pressure Sender Ohms 1 ohm 10 Oil Pressure Sender point 1 ohm value P 137 Oil Pressure Value 1 bar 0 0 Oil Pressure Sender point 1 bar value P 138 Oil Pressure Sender Ohms 2 ohm 52 Oil Pressure Sender point 2 ohm value P 139 Oil Pressure Value 2 bar 2 0 Oil Pressure Sender point 2 bar value P 140 Oil Pressure Sender Ohms 3 ohm 90 Oil Pressure Sender point 3 ohm value P 141 Oil Pressure Value 3 bar 4 0 Oil Pressure Sender point 3 bar value P 142 Oil Pressure Sender Ohms 4 ohm 140 Oil Pressure Sender point 4 ohm
25. ULE In most applications the genset is requested to operate only in working hours Thanks to the weekly program feature unwanted operation of the genset may be prohibited The unit has one programmable turn on turn off time pairs for each day of week These programmable parameters allow the genset to operate automatically only in allowed time limits The weekly operation schedule is only active in AUTO mode In other modes it will not affect the genset operation In AUTO mode if the operation of the genset is disabled by the weekly schedule then the AUTO led will flash instead of a steady on state Each turn on turn off time is defined in 10 minute steps Unused programs should be set to 24 00 An example setup may be as follows m Monday Turn on 07 00 Monday Turn off 18 00 Tuesday Turn on 07 00 Tuesday Turn off 18 00 Wednesday Turn on 07 00 Wednesday Turn off 18 00 Thursday Turn on 07 00 Thursday Turn off 18 00 Friday Turn on 07 00 Friday Turn off 18 00 Saturday Turn on 07 00 Saturday Turn off 13 00 Sunday Turn on 24 00 Sunday no turn on time last operation mode continues Sunday Turn off 24 00 Sunday no turn off time last operation mode continues If the same time is used for turn on and turn off then it will be considered as a turn on time The unit has a battery backed up precision real time clock circuit The real time clock circuit will continue its operation even in power failures The real tim
26. al Mains voltage phase L1 L2 Mains voltage phase L2 L3 Mains voltage phase L3 L 1 Gen voltage phase L1 to neutral Gen voltage phase L2 to neutral Gen voltage phase L3 to neutral Gen voltage phase L1 L2 Gen voltage phase L2 L3 Gen voltage phase L3 L1 Gen current phase L1 Gen current phase L2 Gen current phase L3 Gen frequency Engine speed rpm Gen total kW Gen total pf Battery voltage Coolant temperature Oil pressure Oil temperature Fuel level DKG 507 User Manual V 37 01 03 2012 1 2 Mounting the Unit The unit is designed for panel mounting The user should not be able to access parts of the unit other than the front panel Mount the unit on a flat vertical surface Before mounting remove the mounting brackets and connectors from the unit then pass the unit through the mounting opening The unit will be maintained in its position by the mounting brackets spring Engine body must be grounded for correct operation the unit otherwise incorrect voltage and frequency measurements may occur The output of the current transformers shall be 5 Amperes The input current rating of the current transformers may be selected as needed between 10 5 and 9000 5 amps Current transformer outputs shall be connected by separate cable pairs from each transformer to related inputs Never use common terminals or grounding The power rating of the transformer should be at least 5 VA It is recommended to use 196 precision tr
27. ansformers If analogue senders e g temperature oil pressure or fuel level are connected to the unit it is not possible to use auxiliary displays otherwise the unit may be damaged If temperature or oil pressure or fuel level displays are already present on the generator control panel do not connect the senders to the unit The unit is factory programmed for VDO type senders However different types of senders are selectable via programming menu Please check the programming section The programmable digital inputs are compatible with both normally open and normally closed contacts switching either to BAT or BAT The charge alternator connection terminal provides also the excitation current thus it is not necessary to use an external charge lamp 1 3 Wiring the Unit WARNING THE UNIT IS NOT FUSED Use external fuses for Mains phases L1 L2 L3 Generator phase L1 L2 L3 Battery positive BAT Install the fuses as nearly as possible to the unit in a place easilv accessible for the user WARNING ELECTRICITY CAN KILL ALWAYS disconnect the power BEFORE connecting the unit The fuse rating should be 6 Amps 1 ALWAYS remove the plug connectors when inserting wires with a screwdriver 2 An appropriate and readily accessible set of disconnection device e g automatic fuses MUST be provided as part of the installation 3 The building mains supply MUST incorporate appropriate short cii backup protection e g a fuse or
28. body temperature falls to 4 degrees below the limit set by Engine Heating Temperature It turns off when the body temperature exceeds Engine Heating Temperature 13 DKG 507 User Manual V 37 01 03 2012 6 6 Fuel Pump Control The unit is able to provide a relay output in order to drive the fuel pump motor The fuel pump is used in order to transfer fuel from the large capacity main tank if exists to the genset daily tank which is generally integrated in the chassis and has a limited capacity The fuel level reference is measured through the analog fuel level sender When the measured fuel level falls below Fuel Pump Low Limit parameter the fuel pump relay output will operate When the fuel level reaches Fuel Pump High Limit parameter the relay will turn off Thus the chassis fuel tank level will be always kept between Fuel Pump Low Limit and Fuel Pump High Limit parameters The fuel pump relay function may be assigned to spare relays using Relay Definition program parameters Also relays on an extension module may be assigned to this function 6 7 Mains Simulation Disable Start The unit offers an optional SIMULATE MAINS signal input The SPARE 2 digital input may be assigned as Simulate Mains using program parameter P 084 It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarms generated from this input The SIMULATE MAINS signal may be a NO or NC contact switching to
29. cable 11 STATISTICAL COUNTERS The unit provides a set of non resettable incremental counters for statistical purposes The counters consist on total engine hours total genset KWh engine hours to service time to service total engine cranks total genset runs These counters are kept in a non volatile memory and are not affected from power failures 30 DKG 507 User Manual V 37 01 03 2012 12 MAINTENANCE DO NOT OPEN THE UNIT There are NO serviceable parts inside the unit Wipe the unit if necessary with a soft damp cloth Do not use chemical agents 31 DKG 507 User Manual V 37 01 03 2012 13 PROGRAMMING The program mode is used to program timers operational limits and the configuration of the unit To enter the program mode hold pressed the MENUP button for 5 seconds When the program mode is entered the upper display will show and the mid display will indicate the program parameter number The lower display will show the parameter value If the PROGRAM LOCK input is tied to GROUND the program value modification will be disabled to prevent unauthorized intervention It is advised to keep the PROGRAM LOCK input tied to GROUND The program mode will not affect the operation of the unit Thus programs may be modified anytime even while the genset is running Navigation between program parameters is performed via the MENU button Holding the button pressed will cause
30. d Delayed Simulate Mains are set then REMOTE START operation mode performed 15 DKG 507 User Manual V 37 01 03 2012 6 9 Dual Genset Mutual Standby Operation Dual genset intermittent operation consists of regular switching of the load between 2 gensets The use of 2 gensets instead of one is due either to safety purposes in case of a genset failure or to a continuous operation requesting service stops The running period for each genset is adjustable using Flashing Relay Timer program parameter If the time is adjusted as 0 hours it will be actually set to 2 minutes for faster testing purposes A flashing relay output function is provided based on the parameter Flashing Relay Timer Each time the period programmed using Flashing Relay Timer elapses the relay output will change position The flashing relay function may be assigned to spare relays using Relay Definition program parameters Also relays on an extension module may be assigned to this function The dual genset intermittent operation uses also the Mains Simulation feature Please review chapter 6 7 for a detailed explanation of this feature Please contact DATAKOM for a complete application manual 16 DKG 507 User Manual V 37 01 03 2012 6 10 Service Request Display This led is designed to help the periodic maintenance of the genset to be made consistently The periodic maintenance is basically carried out after a given engine hours for example
31. d P 062 Load Shedding High KW 0 If the genset power goes above this limit then the Limit load shedding relay will be activated If the fuel level measured from the sender input P 063 Fuel Pump Low Limit 96 20 falls below this level then the FUEL PUMP function will become active If the fuel level measured from the sender input P 064 Fuel Pump High Limit 96 80 goes above this level then the FUEL PUMP function will become passive If the coolant temp is above this limit then the fan P poa Fe ON temp E a relay function will become active If the coolant temp is below this limit then the fan 066 Pan tele e 99 relay function will become inactive This parameter defines the engine heating method The genset will not take the load before Engine Heating engine heating is completed _067 Method 0 0 engine is heated during Engine Heating Timer 1 engine is heated until the coolant temperature reaches the Engine Heating Temperature and at least during the Engine Heating Timer When the genset frequency reaches this limit the P 068 Crank Cut Frequency Hz 10 0 engine is supposed running and the crank output will release 0 no crank stop with oil pressure P 069 Crank Stop with Oil 0 1 cranking is stopped when oil presure switch is Pressure open or the oil pressure measured is above shutdown limit 0 no crank stop with charge input P_070 NE with 0 1 cranking is stopped when the charge alternator 9 voltage is establis
32. d programming feature The remote monitoring and programming PC software is called RAINBOW and may be downloaded from www datakom com tr internet site with password login The modem SMS and Modbus modes are not compatible with the local PC connection Modem Enable SMS Enable and MODBUS Address program parameters should be set to 0 before connection The RAINBOW software allows the visualization and recording of all measured parameters The recorded parameters may then be analyzed graphically and printed The software also allows the programming of the unit and the storage of the program parameters to PC or the downloading of stored parameters from PC to the unit For PCs without a serial port below USB to serial adapters are tested and approved DIGITUS USB 2 0 TO RS 232 ADAPTER PRODUCT CODE DA70146 REV 1 1 DIGITUS USB 1 1 TO RS 232 ADAPTER PRODUCT CODE DA70145 REV 1 1 FLEXY USB 1 1 TO SERIAL ADAPTER PRODUCT CODE BF 810 CASECOM USB TO SERIAL CONVERTER MODEL RS 01 The necessary PC connection cable will be supplied by DATAKOM The cable length should not be over 3 meters 20 DKG 507 User Manual V 37 01 03 2012 6 17 Exerciser The unit offers automatic exerciser operation The exercise operation may be done on a daily weekly or monthly basis The start day and time of the exercise is programmable as well as its duration The exercise may be done with or without load following programming Program parameters related
33. d or restored This parameter is the threshold for sending FUEL THEFT and FUELLING sms messages P 081 Fuel Consumption per 0 If this parameter is set 0 then Fuel Theft and i Fuelling sms messages will be sent If SMS is required set this parameter to a value above the hourly fuel consumption of the genset This parameter trims precisely the real time clock circuit P 082 Real Time Clock 117 Values from 0 63 speed up the clock with Adjust 0 25sec day steps Values from 127 to 64 slow down the clock with 0 25sec day steps 0 no Remote Start signal Pees AE i 0 1 SPARE 2 input is Remote Start signal P 084 Simulate Mains _ 0 0 no Simulate Mains signal Enable 1 SPARE 2 input is Simulate Mains signal Delayed Simulate 0 The SPARE 2 input has normal function P_085 Mains 0 1 The SPARE 2 input has delayed simulate mains function See chapter 6 8 for more info Delayed Simulate Mains Operation max genset running time after Simulate Mains signal P 086 Flashing Relay Timer hours 0 7 disappears Dual Genset Systems flashing relay toggle timer Please contact DATAKOM for dual genset mutual stanby operation 38 DKG 507 User Manual V 37 01 03 2012 PGM Parameter Definition Unit Fact Set Description P 087 Exercise Day and Time 168 This parameter defines the start day and hour of the exerciser Values higher or equal to 168 mean that the
34. d select operation 1 Initiate the secondary speed select operation 40 DKG 507 User Manual V 37 01 03 2012 PGM Parameter Definition Unit Fact Set Description P 098 2 Overcurrent Limit When secondary volt freg limits are active If the current goes above this limit during the period defined in Overload Timeout then a Overcurrent Load Dump alarm will be generated If this parameter is 0 then Overcurrent check is disabled P_099 2 Mains Voltage Low Limit 84 When secondary volt freq limits are active If one of the mains phases goes under this limit it means that the mains are off and it starts the transfer to the genset in AUTO mode P 100 2 Mains Voltage High Limit 136 When secondary volt freq limits are active If one of the mains phases goes over this limit it means that the mains are off and it starts the transfer to the genset in AUTO mode P 101 2 Mains Frequency Low Limit Hz 55 When secondary volt freg limits are active If the mains frequency goes under this limit it means that the mains are off and it starts the transfer to the genset in AUTO mode P 102 2 Mains Frequency High Limit Hz 65 When secondary volt freg limits are active If the mains frequency goes above this limit it means that the mains are off and it starts the transfer to the genset in AUTO mode P 103 2 Genset Low Voltage Shutdown Limit
35. diately The Horn Alarm Alarm Load dump and Alarm Load dump Warning digital outputs to operate if selected via programming menu 2 LOAD DUMPS These fault conditions cause Therelated ALARM led to be on steadily The genset contactor to be released immediately The engine to be stopped after Cooldown period The Horn Alarm Load dump and Alarm Load_dump Warning digital outputs to operate if selected via programming menu 3 WARNINGS These conditions cause Therelated ALARM led to flash Horn and Alarm Load dump Warning digital outputs to operate if selected via programming menu If the ALARM MUTE button is pressed the Horn output will be deactivated however the existing alarms will persist and disable the operation of the genset Alarms operate in a first occurring basis If an alarm is present following alarms load dumps and warnings will not be accepted If aload dump is present following load dumps and warnings will not be accepted If a warning is present following warnings will not be accepted Alarms may be of LATCHING type following programming For latching alarms even if the alarm condition is removed the alarms will stay on and disable the operation of the genset The existing alarms may be canceled by pressing one of the operating mode buttons LOAD TEST TEST OFF AUTO Most of the alarms have programmable trip levels See the programming chapter for adjustable alarm limits DK
36. different from zero the local PC connection will not work Advised modems are DATAKOM types which are powered up from the same DC battery voltage than the unit Most of other desktop modems with standard AT commands are also usable but itis the user s responsibility to provide an uninterrupted AC supply source to the modem The necessary modem cable will be supplied by DATAKOM Modem calls are always terminated by the central RAINBOW software However the unit does not allow connection durations exceeding 2 minutes and hangs up the modem when this period expires The PC program used for remote monitoring and programming is the same RAINBOW software used for RS 232 connection Please note that the modem operation is also compatible with the MODBUS communication Thus the unit can iniate and receive calls to from a MODBUS master station Please review chapter 8 for more details on MODBUS communication 18 DKG 507 User Manual V 37 01 03 2012 6 15 SMS Message Sending The GSM SMS sending is activated by setting the SMS Enable program parameter to 1 If Modem Enable or SMS Enable or MODBUS Address parameters are different from zero the local PC connection will not work When a fault condition occurs the unit will compose an SMS message and will send it to up to 6 phone numbers If modem is enabled only 4 telephone numbers are available for SMS sending The unit is also able to send SMS messages in below conditions wi
37. e 2 selected from list P 242 Relay 17 Definition 4 RELAY 17 function expansion module 2 selected from list P 243 Relay 18 Definition 5 RELAY 18 function expansion module 2 selected from list 47 DKG 507 User Manual V 37 01 03 2012 The function of a programmable relay output may be selected from below list 00 Fuel 32 Oil switch alarm 80 Oil switch warning 01 Alarm 33 Temp switch alarm 81 Temp switch warn 02 Start 34 Coolant Level switch 82 Coolant Level switch 03 Stop alarm warning 04 Gen Contactor 35 Rectifier alarm 83 Rectifier warning 05 Mains Contactor 36 Emerg Stop alarm 84 Emerg Stop warn 06 Choke 37 Spare 1 Alarm 85 Spare 1 warning 07 Preheat 38 Spare 2 Alarm 86 Spare 2 warning 08 Shutdown alarm 39 87 09 Shutdown or 40 Oil sender alarm 88 Oil sender warning load dump alarm 41 Temp sender alarm 89 Temp sender warn 10 Shutdown or 42 Low speed alarm 90 Low speed warning load dump or warning 43 High speed alarm 91 High speed warning 11 Automatic ready 44 Low voltage alarm 92 12 Week on time 45 High voltagealarm 93 Low temp warning 13 Exerciser on 46 Fail to start alarm 94 Fail to stop warning 14 Load dump alarm 47 Low fuel
38. e clock is precisely trimmed using the Real Time Clock Adjust program parameter For more details check the programming section 29 DKG 507 User Manual V 37 01 03 2012 10 EVENT LOGGING The unit keeps record of the last 100 events in order to supply information for the service personal The genset status information and a comprehensive set of measured values are stored within the event memory The events are recorded with a time stamp which comes from the internal real time clock circuit of the unit The events are stored in a circular memory This means that a new coming event will erase the oldest recorded event Events are kept in a non volatile memory and are not affected from power failures Events are not visible on the device display They can be downloaded to the computer and saved in an Excel file Event sources are Shutdown alarms Load dump alarms Warnings Engine crank starts Periodic records Event record contents are Event type alarms mode change periodic etc Date and time Genset operating mode AUTO MANUAL OFF TEST LOAD TEST Genset operation status mains ok running cooldown etc Genset phase voltages L1 L2 L3 Genset phase currents L1 L2 L3 Genset frequency Genset active power KW Genset power factor Engine rpm Oil pressure Coolant temperature Fuel level Battery voltage Mains phase voltages L1 L2 L3 Mains frequency Digital input statuses Charge input status J1939 VAlues if appli
39. e heating period After this if alternator phase voltages and frequency are within limits then the unit will wait for the generator contactor period and the generator contactor will be energized When all the mains phase voltages are within the limits the engine will continue to run for the mains waiting period At the end of this period the generator contactor is deactivated and the mains contactor will be energized If a cooldown period is given the generator will continue to run during cooldown period At the end of the period the fuel solenoid will be de energized and the diesel will stop The unit will be ready for the next mains failure If the operation of the genset is disabled by the weekly schedule then the AUTO led will flash and the operation of the genset will be as in the OFF mode RUN It is used to test the generator when the mains are on or keep the generator running in the emergency backup mode The operation of the generator is similar to the AUTO mode but the mains contactor will not be deactivated if the mains are not off If the mains are off mains contactor will be deactivated and the generator contactor will be activated When the mains are on again a changeover to the mains will be made but the engine will be kept running unless another mode is selected To stop the engine select AUTO or OFF mode TEST It is used to test the genset under load Once this mode is selected the engine will run and the load will be t
40. e normal working range 1 Value too low Valid data but below the normal working range 2 Faulty data Intermittent or faulty data or Short circuit to battery voltage injector high voltage side 3 Electrical fault Abnormally high voltage or short circuit to battery voltage injector low voltage side 4 Electrical fault Abnormally low voltage or short circuit to battery negative injector low voltage or high voltage side 5 Electrical fault Abnormally low current or open circuit 6 Electrical fault Abnormally high current or short circuit to battery negative 7 Mechanical fault Faulty response from mechanical system 8 Mechanical or electrical fault Abnormal frequency 9 Communication fault Abnormal updating rate or Open circuit in injector circuit 10 Mechanical or electrical fault Abnormally large variations 11 Unknown fault Unidentified fault 12 Component fault Faulty unit or component 13 Faulty calibration Calibration values outside the limits 14 Unknown fault Special instructions 15 Data valid but above normal operating range least severe level 16 Data valid but above normal operating range moderately severe level 17 Data valid but below normal operating range least severe level 18 Data valid but below normal operating range moderately severe level 19 Received network data in error 20 not used reserved 21 not used reserved 22 not used reserved 23 not used reserved 24 not used reserved 25 not used reserved
41. e phase voltages Check the AC voltage readings by pressing the MENU button Upper and lower limits of the mains voltages may be too tight Check the parameters Mains Voltage Low Limit and Mains Voltage High Limit Standard values are 170 270 volts The hysteresis voltage may be given to excessive The standard value is 8 volts AC voltages or frequency displayed on the unit are not correct Check engine body grounding it is necessary The error margin of the unit is 3 volts If there are faulty measurements only when the engine is running there may be a faulty charging alternator or voltage regulator on the engine Disconnect the charging alternator connection of the engine and check if the error is removed If there are faulty measurements only when mains are present then the battery charger may be failed Turn off the rectifier fuse and check again Phase to Phase AC voltages are not correct although Phase to Neutral voltages are correct Incorrect phase order Please connect phase voltages in the correct order KW and cos readings are faulty although the Amp readings are correct Current transformers are not connected to the correct inputs or some of the CTs are connected with reverse polarity Determine the correct connections of each individual CT in order to obtain correct KW and cos for the related phase and then connect all CTs Short circuit the outputs of unused Current Transformers When the AC main
42. easurements have no effect on engine operation In total the unit is capable of receiving 21 parameters from the J1939 The J1939 measurements are also available for Modbus operation Please check chapter 8 for more details When the fuel output is active if no information is received from the ECU during last 3 seconds then the unit will give a ECU FAIL alarm and stop the engine This feature prevents uncontrolled engine operation The fault conditions of an electronic engine are considered by the unit as warnings and do not cause engine stop The engine is supposed protected by the ECU which will stop it when necessary The electronic engine fault codes are displayed within the alarm list table in text together with their SPN FMI codes A maximum of 8 fault codes can be displayed The complete list of fault codes is given in the engine manufacturer s user manual 25 DKG 507 User Manual Below is a basic list of fault conditions x denotes any FMI V 37 01 03 2012 SPN FMI DESCRIPTION 94 X Fuel filter restriction Fuel pressure sensor fail 98 X Low oil level High oil level Oil level sensor fail 100 X Low oil pressure Oil pressure sensor fail 102 X High boost pressure Turbo outlet pressure sensor fail 105 X Intake manifold temp high Intake manifold temp sensor fail 107 X Air filter restriction Air filter senso
43. ectrical network it is advised t set the Single Phase Enable program parameter in CONTROLLER CONFIGURATION group to 1 When Single Phase Enable is set to 1 then the unit will measure electrical parameters only on phases L1 of genset and mains Voltage and overcurrent checks will be performed on phases L1 only Phases L2 and L3 parameters as well as phase to phase voltages are removed from display Screens 24 DKG 507 User Manual V 37 01 03 2012 7 J1939 ENGINE MONITORING AND CONTROL PORT ONLY CANBUS VERSIONS The unit offers a special J1939 port in order to communicate with electronic engines controlled by an ECU electronic control unit The J1939 port consists of 2 terminals which are J1939 and J1939 The connection between the unit and the engine should be made with either a twisted cable pair or a coaxial cable If a coaxial cable is used the external conductor should be grounded at one end only The 120 ohms termination resistor is included inside the unit Please do not connect external resistor The J1939 port is activated by setting the program parameter J1939 Enable to 1 The J1939 Engine Type parameter should be set accordingly The list of available engines is given at the programming section Please contact DATAKOM for the most current list of engines If the J1939 port is enabled then the oil pressure coolant temperature and the engine rpm information are picked up from the ECU unit Other available m
44. ed The LED will turn on when at least one of the mains phase voltages is outside limits LOAD MAINS Green It turns on when the mains contactor is activated LOAD GENERATOR Yellow It turns on when the generator contactor is activated GENERATOR Yellow The LED will flash when the engine is running It will turn on steadily when all 3 generator phase voltages are within the programmed limits TEST Yellow It turns on when the related operation mode is selected One of these LEDs is always on and RUN Yellow ah indicates which operation mode is selected STOP Yellow If the operation of the genset is disabled by the AUTO Green merid operation schedule then the AUTO led will WARNINGS amp ALARMS Red If a fault condition resulting to the engine shutdown or loaddump condition has occurred the related alarm led turns on steadily If a warning condition occurs this led will flash Alarms work on a first occurring basis The occurrence of a fault will disable other faults of lower or equal priority SERVICE REQUEST Red Engine periodic maintenance request indicator It turns on when the preset engine hours or time duration after previous service has elapsed DKG 507 User Manual V 37 01 03 2012 3 2 Digital Displays The unit has 3 seven segment displays They show Measured parameters Service counters Statistical counters Program parameters The navigation between different screens in a group is made with the MENUP bu
45. emnant voltage is below 20 volts The unit removes starting with the generator frequency and needs at least 20 volts to measure the frequency If this situation is to be avoided the only solution is to add an auxiliary relay The coil of the relay will be between BATTERY and charging alternator D terminal The normally closed contact of the relay will be connected serially to the unit s START output So the starting will also be removed when the D pulls to battery positive The unit is inoperative Measure the DC supply voltage between terminals 19 and 22 at the rear of the unit If OK turn all the fuses off then turn all the fuses on starting from the DC supply fuse Then test the unit again Programming mode can not be entered The program lock input disables programming mode entry Disconnect the program lock input from battery negative before modification Do not forget to make this connection again to prevent unauthorized program modifications Some program parameters are skipped These parameters are reserved for factory setting and cannot be modified AUTO led flashes and the genset does not run when mains fail The unit is in Weekly Schedule OFF time Please check date and time setting of the unit Please check also Weekly Schedule program parameters 50 DKG 507 User Manual V 37 01 03 2012 15 DECLARATION OF CONFORMITY The unit conforms to the EU directives 2006 95 EC low voltage 2004 08 EC elec
46. es The parameters used in Load Shedding feature are in the Electrical Parameters Group Load Shedding Low Limit If the genset active power output goes below this limit then the Load Shedding relay will be deactivated Load Shedding High Limit If the genset active power output goes above this limit then the Load Shedding relay will be activated 6 21 Fuel Theft Fuelling Messages The unit is able to send SMS messages in fuel theft or fuelling conditions These SMS messages are sent without creating visible fault condition These features are enabled by setting the program parameter Engine Parameters gt Fuel Consumption Hour to a value other than 096 The Fuel Consumption Hour parameter should be set to a value clearly greater than the maximum fuel consumption of the engine If the fuel level measured from the sender input is decreased more than this parameter in 1 hour period then a FUEL THEFT sms message is sent to programmed telephone numbers If the fuel level measured from the sender input is increased more than this parameter in 1 hour period then a FUELLING sms message is sent to programmed telephone numbers 22 DKG 507 User Manual V 37 01 03 2012 6 22 Firmware Update The unit offers possibility of updating the firmware in the field The firmware is updated through the RS 232 serial port using Rainbow or a special DOS program The unit will go to firmware download mode with a special command from the PC p
47. et frequency goes over this limit a GENSET HIGH SPEED warning is generated P 110 2 High Frequency Shutdown Hz 69 When secondary volt freg limits are active If the genset frequency goes over this limit a GENSET HIGH SPEED alarm is generated and the engine stops 41 DKG 507 User Manual V 37 01 03 2012 PGM Parameter Definition Unit Fact Set Description When secondary volt freg limits are active P 111 2 Low rpm rpm 0 If the engine speed goes under this limit GENSET Shutdown LOW SPEED alarm is generated and the engine stops When secondary volt freg limits are active P 112 2 Low rpm Warning rpm 0 If the engine speed goes under this limit GENSET LOW SPEED warning is generated nd Lj If the engine speed goes over this limit a GENSET vette een pri Warning apri 0 SPEED warning is generated When secondary volt freq limits are active P 114 2 High rpm rpm 0 If the engine speed goes over this limit a GENSET m Shutdown HIGH SPEED alarm is generated and the engine stops P 115 reserved 0 Reserved parameter do not use Date Time P 116 Date Current day of the month P 117 Month Current month P 118 Year Last two digits of the current year P 119 Hours Current hour of the day P 120 Minutes Current minute of the hour P 121
48. exerciser is off The exercise may be selected to start at the beginning of the any hour of the week The parameter value is the hour count of the start time Examples 0 exercise starts at Monday 00 00 8 exercise starts at Monday 08 00 24 exercise starts at Tuesday 00 00 167 exercise starts at Sunday 23 00 168 exerciser off If a daily exercise is selected then the day information is don t care and the exercise will be performed every day regardless of the day selection If the monthly exerciser is selected then the exercise will be performed during the first 7 days of each month at the programmed day and hour P 088 Exercise Duration min This parameter defines the exercise duration and programmed in 10 minute steps up to 24 hours P 089 Exercise Off On Load 0 Exercise at TEST mode 1 Exercise at LOAD TEST mode P 090 Exercise Period 0 exercise every day the exercise will be performed every day regardless of the day selection of Exercise Dat and Time parameter 1 exercise once per week 2 exercise once per month the exercise will be performed during the first 7 days of each month at the programmed day and hour P 091 Language Selection This is the language used in SMS messages 0 english turkish french P 092 Secondary Volt Freq 1 2 3 russian 0 Use primary voltage frequency limits 1 When signal is applied to the SPARE 1 input use secondary voltage f
49. g the period defined in Overload Timeout then an Excess Power Load Dump alarm will be P 002 Excess Power Limit KW 0 generated If this parameter is 0 then Excess Power check is disabled Mains Voltage Low If one of the mains phases goes under this limit it P 003 Limit V 170 means that the mains are off and it starts the transfer to the genset in AUTO mode Mains Voltage High If one of the mains phases goes over this limit it P 004 Limit V 270 means that the mains are off and it starts the transfer to the genset in AUTO mode Mains Frequency Low If the mains frequency goes under this limit it P 005 Limit Hz 45 means that the mains are off and it starts the transfer to the genset in AUTO mode Mains Frequency If the mains frequency goes above this limit it P 006 High Limit Hz 55 means that the mains are off and it starts the transfer to the genset in AUTO mode If one of the generator phase voltages goes under P 007 Genset Low Voltage V 190 this limit when feeding the load this will generate a Shutdown Limit GENSET LOW VOLTAGE shutdown alarm and the engine will stop Genset Low Voltage If one of the generator phase voltages goes under P 008 Warning Limit V 200 this limit when feeding the load this will generate a 9 GENSET LOW VOLTAGE warning If one of the generator phase voltages goes above P_009 us D EE V 250 this limit when feeding the load this will generate a 9 GENSET HIGH VOLTAGE warning If one of the generator phase vo
50. ge sending on fault pushbuttons and do not require an external unit MODBUS communications Last 100 faults are stored in the event log file The Customer logo display capability event log includes not only the date time information 10ADC relay outputs but also a comprehensive list of measured genset Configurable analogue inputs 4 parameters at the time that the fault has occurred Configurable digital inputs 7 The WINDOWS based RAINBOW program allows Configurable relay outputs 2 remote monitoring and control Total relay outputs 6 The unit supports MODBUS protocol enabling I O expansion capability communication with PLCs and building management Plug in connection system systems The MODBUS protocol is also supported through GSM and PSTN modems SE Pa Ws DKG 507 User Manual V 37 01 03 2012 Section 1 INSTALLATION 1 1 1 2 1 3 TABLE OF CONTENTS Introduction to the Control Panel Mounting the Unit Wiring the Unit 2 INPUTS AND OUTPUTS 3 DISPLAYS 3 1 3 2 Led Displays Digital Displays 4 ALARMS AND WARNINGS 5 MODES OF OPERATION 6 OTHER FEATURES 6 26 Remote start operation Sender type selection Engine heating operation Engine Idle Speed Operation Engine Block Heater Fuel Pump Control Mains Simulation Disable Start Delayed Mains Simulation Battery Charging Dual Genset Mutual Standby Operation Service Request Display Engine Hours Meter Date Time Di
51. he engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operation P 203 Sampling Always After holdoff timer When mains present P 204 Latching Non latching Latching P 205 Contact type Normally open Normally closed P 206 Switching Battery negative Battery positive P 207 Response delay Oje O OJIN No delay Delayed 4sec Emergency Stop Input Configuration PGM Parameter Definition Unit Fac Set Description P_208 Action Shutdown the engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operation P_209 Sampling Always After holdoff timer When mains present P 210 Latching Non latching Latching P 211 P 212 Contact type Switching Normally open Normally closed Battery negative Battery positive P 213 Response delay Oo 0 40 4O0ON 00N 40 No delay Delayed 4sec 45 DKG 507 User Manual Spare 1 Input Input Configuration V 37 01 03 2012 PGM Parameter Definition Unit Fac Set Description P 214 Action 2 Shutdown the engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operatio
52. he unit offers an optional SIMULATE MAINS signal input The SPARE 2 digital input may be assigned as Simulate Mains using program parameter P 084 It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarms generated from this input The SIMULATE MAINS signal may be a NO or NC contact switching to either battery positive or battery negative These selections are made using the programming menu If the Delayed Simulate Mains program parameter P 085 is set to 1 and the input signal is active when the genset is not feeding the load the mains phases are not monitored and supposed to be inside limits This will prevent the genset from starting when the simulate mains signal is present batteries charged The genset will start when mains voltages are out of limits and the simulate mains signal not present If the genset is running when the signal is applied then MAINS SIMULATION will be prevented during P 086 Flashing Relay Timer program parameter After this usual Mains Waiting and Cooldown cycles will be performed before engine stop When the SIMULATE MAINS signal is present the front panels mimic diagram s mains LEDs will reflect the mains voltages as present When the signal is passive the unit will revert to normal operation and monitor the mains voltage status The REMOTE START operation overrides DELAYED SIMULATE MAINS operation When both parameters Remote Start Operation an
53. hed 0 The charge input generates CHARGE FAIL P 071 Charge Alternator 0 warning and does stop the engine m Shutdown 1 The charge input generates CHARGE FAIL alarm and stops the engine 0 Display Line to Neutral voltages as default P072 Line to Line Voltages i d 1 Display Line to Line voltages as default 0 oil pressure display in bars POTS GUPressue in p i i 1 oil pressure display in psi P 074 Temperature in F _ 0 temperature display in degrees C temperature display in degrees F 487 x DKG 507 User Manual V 37 01 03 2012 PGM Parameter Definition Unit Fact Set Description 0 3 phase system P 075 Single phase Enable 0 1 Single phase system 0 In TEST mode the load will not be transferred P 076 Emergency Backup _ 0 to the genset even if the mains fail Operation 1 In TEST mode the load will be transferred to the genset if the mains fail 0 No modem connection the serial port is P 077 Modem Enable 0 connected to PC 1 Modem connected 0 SMS not enabled P 078 SMS Enable 0 1 SMS enabled 0 RAINBOW communication protocol P 079 MODBUS Address 0 1 144 MODBUS communication This parameter is also the MODBUS controller address of the unit This parameter controls SMS sending when mains voltages status is changed No warning is P 080 Maing 0 generated 0 no SMS when mains failed or restored 1 SMS sent when mains faile
54. int 1 C value P 174 Oil Temperature Sender Ohms 2 ohm 51 Temperature Sender point 2 ohm value P 175 Oil Temperature Value 2 C 90 Temperature Sender point 2 C value P_176 Oil Temperature Sender Ohms 3 ohm 134 Temperature Sender point 3 ohm value P 177 Oil Temperature Value 3 C 60 Temperature Sender point 3 C value P_178 Oil Temperature Sender Ohms 4 ohm 322 Temperature Sender point 4 ohm value P_179 Oil Temperature Value 4 C 39 Temperature Sender point 4 C value P_180 Oil Temperature Sender Ohms 5 ohm 650 Temperature Sender point 5 ohm value P_181 Oil Temperature Value 5 C 20 Temperature Sender point 5 C value P 182 Oil Temperature Sender Ohms 6 ohm 1630 Temperature Sender point 6 ohm value P_183 Oil Temperature Value 6 C 02 Temperature Sender point 6 C value Low Oil Pressure Switch Input Configuration PGM Parameter Definition Unit Fac Set Description 0 Shutdown the engine stops immediately 1 Load Dump the engine stops after cooldown dd ed 0 2 Warning the horn relay operates 3 No operation 0 Always P 185 Sampling 1 1 After holdoff timer 2 When mains present 0 Non latching P 186 Latching 1 1 Latching 0 Normally open P 187 Contact type 9 1 Normally closed 0 Battery negative F188 Switching 0 1 Battery positive 0 No delay P 189 Response delay 0 1 Delayed 4sec High Temperature Switch Input Configurat
55. ion PGM Parameter Definition Unit Fac Set Description P 190 Action Shutdown the engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operation P 191 Sampling Always After holdoff timer When mains present P 192 Latching Non latching Latching P 193 Contact type Normally open Normally closed P 194 Switching Battery negative Battery positive P 195 Response delay No delay Delayed 4sec O O W 44 DKG 507 User Manual V 37 01 03 2012 Coolant Level Switch Input Configuration PGM Parameter Definition Unit Fac Set Description P 196 Action Shutdown the engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operation P 197 Sampling Always After holdoff timer When mains present P 198 Latching Non latching Latching P 199 Contact type Normally open Normally closed P 200 Switching Battery negative Battery positive P 201 Response delay 0 2 O OJN O No delay Delayed 4sec Rectifier Fail Input Configuration PGM Parameter Definition Unit Fac Set Description P 202 Action Shutdown t
56. king P 037 Crank Timer sec This is the maximum start period Starting will be automatically cancelled if the genset fires before the timer P 038 Wait Between Starts sec This is the waiting period between two start attempts P 039 Idle Speed Timer sec When the engine runs the Idle output relay function will be active during this timer P 040 Engine Heating Timer sec This is the period used for engine heating following the program parameter P 041 Mains Waiting Timer min 0 5 This is the time between the mains voltages entered within the limits and the generator contactor is deactivated P 042 Cooldown Timer min 1 0 This is the period that the generator runs for cooling purpose after the load is transferred to mains 35 DKG 507 User Manual V 37 01 03 2012 PGM Parameter Definition Unit Fact Set Description This is the period after the mains contactor has P 043 Ti Sec 1 been deactivated and before the generator imer contactor has been activated Mains Contactor This is the period after the generator contactor has P 044 Sec 1 been deactivated and before the mains contactor Timer has been activated This is the maximum time duration for the engine to stop During this period the STOP relay output P 045 Stop Solenoid Timer sec 10 is ene
57. l V 37 01 03 2012 6 11 Engine Hour Meter The unit features a non erasable incremental engine hour meter The hour meter information is kept in a non volatile memory and is not affected from power supply failures The engine hours may be displayed STATISTICAL COUNTERS menu 6 12 Date amp Time Display The date amp time display is provided for verification 6 13 Software Version Display Some additional features are installed within consecutive software releases In order to be sure of the validity of the status of the unit the software version needs to be known The software version of the unit is displayed together with the data time information The software version consists of 2 numbers The first number represent the operating software version of the unit 6 14 Modem Connection The unit is capable of making modem calls in case of alarm as well as answering modem calls made from a remote location GSM modems and classic cable network PSTN modems are acceptable If the modem is connected to the unit the Modem Enable program parameter should be set to 1 otherwise faulty operation may occur A maximum of 2 telephone numbers can be defined for outgoing modem calls In case of alarm the unit will attempt to reach control centers associated with each number In case of modem connection failure the call will be repeated up to 30 times with 2 minute intervals If Modem Enable or SMS Enable or MODBUS Address parameters are
58. ltages goes over P 010 Genset High Voltage V 260 this limit when feeding the load this will generate a Shutdown Limit GENSET HIGH VOLTAGE alarm and the engine will stop Low Frequency If the genset frequency goes under this limit a P 011 Sh Hz 30 GENSET LOW SPEED alarm is generated and the utdown engine stops P 012 Low Frequency Hz 35 If the genset frequency goes under this limit a m Warning GENSET LOW SPEED warning is generated P 013 High Frequency Hz 54 If the genset frequency goes over this limit a Warming GENSET HIGH SPEED warning is generated If the genset frequency goes over this limit p_014 9 Frequency Hz 55 GENSET HIGH SPEED alarm is generated and the Shutdown engine stops P 015 Low Battery Voltage V 90 If the battery voltage falls below this limit this will Warning generate a LOW BATTERY warning P 016 High Battery Voltage V 31 0 If the battery voltage goes over this limit this will Warning generate a HIGH BATTERY warning High Battery Voltage If the battery voltage goes over this limit this will P_017 V 33 0 generate a HIGH BATTERY shutdown alarm and Shutdown the engine will stop 33 DKG 507 User Manual V 37 01 03 2012 PGM Parameter Definition Unit Fact Set Description P 018 Low Oil Pressure Warning bar 1 4 If the oil pressure measured from the analog input falls below this limit this will generate a LOW OIL P
59. n P 215 Sampling 0 Always After holdoff timer When mains present P 216 Latching 0 Non latching Latching P 217 Contact type 0 Normally open Normally closed P 218 Switching 0 Battery negative Battery positive O ON P 219 Response delay 0 No delay Delayed 4sec Spare 2 Input Input Configuration PGM Parameter Definition Unit Fac Set Description P 220 Action 2 Shutdown the engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operation P 221 Sampling 0 Always After holdoff timer When mains present P 222 Latching 0 Non latching Latching P 223 Contact type 0 Normally open Normally closed P 224 Switching 0 Battery negative Battery positive P 225 Response delay 0 Oje O OJIN O WND O No delay Delayed 4sec 46 DKG 507 User Manual V 37 01 03 2012 The parameters below define the functions of relay outputs The unit has 6 relay outputs The fixed function relays are Fuel Start Mains Contactor and Generator Contactor RELAY 1 and RELAY 2 have programmable functions selected from a list The relays may be extended up to 22 using Relay Extension Modules Other relays are in the optional Extension Modules Program Group
60. nput and output Connect the charge alternator s D terminal to this terminal This terminal will supply the excitation current and measure the voltage of the charge alternator 17 RELAY 2 HORN RELAY Output 10A 28VDC This relay has programmable function selectable from a list 18 RELAY 1 STOP RELAY Output 10A 28VDC This relay has programmable function selectable from a list 19 START RELAY Output 10A 28VDC This relay controls the engine cranking 20 FUEL RELAY Output 10A 28VDC This relay is used for fuel solenoid control 21 EMERGENCY STOP Digital inputs These inputs have programmable 22 SPARE 2 characteristics selected via the program 23 PROGRAM LOCK menu Each input may be driven by a 24 SPARE 1 normally closed or normally open contact 25 COOLANT LEVEL switching either battery or battery The effect 26 HIGH TEMP of the switch is also selectable from a list See 27 LOW OIL PRESSURE PROGRAMMING section for more details 28 RECTIFIER FAIL 29 CURR 1 Current transformer Connect the generator current transformer inputs 5A AC terminals to these inputs Do not connect the 30 CURR 1 same current transformer to other instruments otherwise a unit fault will occur Connect each 31 CURR 2 terminal of the transformer to the unit s related terminal Do not use common terminals Do not use grounding Correct polarity of 32 CURN 2 connection vital the measured power is negative then change the polarity of each 3 33 CURR 3
61. on port RS 232 9600 bauds no parity 1 stop bit Operating temperature range 40 C to 70 C 40 F to 158 F Storage temperature range 55 C to 80 C 67 F to 176 F Maximum humidity 95 non condensing Dimensions 200x148x46mm WxHxD Panel Cut out dimensions 176 x 121mm minimum Weight 400 g approx Case material High temperature self extinguishing ABS PC UL94 VO IP protection IP65 from front panel IP30 from the rear 52 V 37 01 03 2012 DKG 507 User Manual 17 CONNECTION DIAGRAMS UoISUaXJ yndjno ndu Hod pue Buuo1uop 1910283 ainssaid ainjesosdway yH 9 8 3207 uie1604d 82 16 96 ST ve EG 2 dois oueBueui3 L oL papuno 1b aq jsnui dAnebau A yeg AvZIZI i Asayeg L ppe iana E ZL 8l Jepues dwa IIO NI Japuas aunsseJd IO Jepues duay jue 00 EU Jopues LAJ L09 95UA 202 3 09 Joje1ouec PORA YOLVNYSALTIV avol 53 DKG 507 User Manual V 37 01 03 2012 o Et ga t z5 c o9 8 t1 p 57 BP cg leq 19113292 eJnsseJd aunyesadwiay uBiH 19497 2 3207 weiboldg 22 23 24 25 26 27 28 21 035 16 15 35 14 13 DKG 517 Battery 12 24V uu Battery negative must be grounded ALTERNATOR DATAKOM Electronics
62. r fail 108 X Athmospheric pressure sensor fail 110 X High coolant temperature Coolant temperature sensor fail 111 X Low coolant level Coolant level sensor fail 164 X High injector activation pressure Injector activation pressure sensor fail 168 X Battery voltage failure 172 X High inlet air temperature High inlet manifold air temperature Inlet manifold air temperature sensor fail 174 X High fuel temperature Fuel temperature sensor fail 175 X High oil temperature Oil temperature sensor fail 190 X Overspeed Speed sensor loss of signal Speed sensor mechanical failure 228 X Timing calibration required 234 X Incorrect ecm software 620 X ECU internal 5V fail 629 X ECU hardware fail 651 X Injector cylinder 1 fault 652 X Injector cylinder 2 fault 653 X Injector cylinder 3 fault 654 X Injector cylinder 4 fault 655 X Injector cylinder 5 fault 656 X Injector cylinder 6 fault 657 X Injector cylinder 7 fault 657 X Injector cylinder 8 fault 678 X ECU internal power supply fail 723 X Secondary engine speed sensor fail 1108 X Critical override enabled 1111 X Check configuration parameters 2000 X ECU failure 26 DKG 507 User Manual model Below is a basic list of FMI codes Please be aware that these codes may differ slightly depending on the engine brand and FMI DESCRIPTION 0 Value too high Valid data but above th
63. ransferred to the genset The genset will feed the load indefinitely unless another mode is selected 11 DKG 507 User Manual V 37 01 03 2012 6 OTHER FEATURES 6 1 Remote Start Operation The unit offers the possibility of REMOTE START mode of operation The SPARE 2 input may be assigned as Remote Start Input using the program parameter P 083 The REMOTE START signal may be a NO or NC contact switching to either battery positive or battery negative These selections are made using programming menu It is also necessary to set the ACTION program parameter of the SPARE 2 input to 3 in order to prevent any alarm from this input In this mode the mains phases are not monitored If the REMOTE START signal is present then the mains will be supposed to fail inversely if the REMOTE START signal is absent then mains voltages will be supposed to be present The front panels mimic diagram s mains LEDs will reflect the status of the REMOTE START input 6 2 Sender type Selection The unit has the ability to adapt to any type of oil pressure and temperature senders The commonly used standard sender characteristics are recorded in memory and selectable from a list However non standard senders may also be used by entering their characteristics to the table Oil Pressure Sender Type Selection Selectable sender types are Sender characteristics are defined in Sender Characteristics table VDO 0 7 bars 10 180 ohms VDO 0 10 bars 1
64. requency limits P 093 Engine Control Only 0 Genset control 1 Engine control no alternator 39 DKG 507 User Manual V 37 01 03 2012 Below parameters are applicable to J1939 enabled versions only PGM Parameter Definition Unit Fact Set Description P 094 J1939 Enable 0 The J1939 port is inoperative 1 The analog measurements oil temp rpm are picked up from the ECU If the ECU communication is lost then the engine will be stopped P 095 J1939 Engine Type 00 GENERIC ENGINE TYPE 16 CUMMINS CM850 32 DETROIT DIESEL 48 DEUTZ Generic 49 DEUTZ EMR2 50 DEUTZ EMR3 64 JOHN DEERE 80 PERKINS 81 PERKINS ADEM 3 82 PERKINS ADEM 1 3 96 VOLVO with CIU unit 97 VOLVO EMS2 98 VOLVO EDC4 112 CATERPILLAR ADEM 11 111 128 SCANIA S6 129 SCANIA Single Speed 130 SCANIA All Speed 144 IVECO 160 MTU MDEC 302 161 MTU MDEC 201 162 MTU MDEC 303 163 MTU MDEC 304 164 MTU MDEC 505 176 BOSCH Generic 177 BOSCH EDC 731 178 BOSCH EDC 9 3 Other values Reserved Do not use P 096 J1939 Speed Adjust 50 This parameter adjusts the speed of an ECU controlled engine by 8 P 097 VOLVO Speed Toggle This program parameter is not stored but only used in order to activate the primary or secondary speed selection operation of a Volvo EMS II engine control unit 0 Initiate the primary spee
65. rgized if assigned by Relay Definitions If the genset has not stopped after this period a FAIL TO STOP warning occurs P_046 Number of Starts 3 This is the maximum number of start attempts Mains Phase Order 0 mains phase order checking disabled P_047 E 0 1 if mains phase order is faulty then a warning is nable given and mains contactor deenergized 0 genset phase order checking disabled P 048 Ger Order 0 1 if genset phase order is faulty then a loaddump is generated and the genset stops after cooldown This parameter is used in the conversion of the genset frequency to engine rpm P 049 d genset 1 0 read rpm from the optional MPU input q 1 convert frequency to rpm using crank teeth count This is the number of pulses generated by the magnetic pickup sensing unit in one turn of the flywheel P 050 Crank Teeth Count 30 This parameter is also used in the conversion of the genset frequency to engine rpm The frequency in Hz is multiplied with this parameter during conversion to rpm If the engine speed goes under this limit GENSET P 051 Low rpm Shutdown rpm 0 LOW SPEED alarm is generated and the engine stops If the engine speed goes under this limit GENSET peeps KOW pa Lab 0 LOW SPEED warning is generated If the engine speed goes over this limit GENSET P5093 rpm 0 HIGH SPEED warning is generated If the engine speed goes over this limit a GENSET P 054
66. rogram In download mode the display of the unit will show DL V1 00 During firmware update process the progress is visible through a percentage counter on the Screen The firmware update operation will take around 3 minutes After completion of the update a special command will set back the unit to normal operation mode 6 23 Changing the Default Engine Speed in Volvo Engines Volvo engines equipped with EMS II engine control unit have the engine speed selectable through the J1939 CANBUS The unit offers the possibility to the user to switch between the primary and secondary speed using the programming menu If the program parameter Volvo Speed Toggle is increased the unit will freeze for a few seconds and switch the engine to 1800 rpm which is generally the secondary speed When the parameter is decreased the speed is set to the primary speed which is generally 1500 rpm The unit must be in OFF mode otherwise the speed switching will not be performed Please note also that a fine adjustment of the engine speed in the 8 range may be done using the program parameter J1939 Speed Adjust 6 24 Engine Control Mode In engine control mode the unit is supposed to control an engine without alternator The engine control mode is activated by a program parameter in the Controller Configuration group When the Engine Control Mode is activated the unit will not display genset AC parameters volts amps kW and pf
67. s fails the unit energizes the fuel solenoid but does not start and OIL PRESSURE EXISTS message is displayed The unit is not supplied with battery voltage at the oil pressure input Oil pressure switch not connected Oil pressure switch connection wire cut Oil pressure switch faulty Oil pressure switch closes too lately If oil pressure switch closes the unit will start Optionally oil pressure switch may be replaced The engine does not run after the first start attempt then the unit does not start again and OIL PRESSURE EXISTS message is displayed The oil pressure switch closes very lately As the unit senses an oil pressure it does not start When oil pressure switch closes the unit will start Optionally the oil pressure switch may be replaced 49 DKG 507 User Manual V 37 01 03 2012 When the AC mains fails the engine starts to run but the unit gives START FAIL alarm and then the engine stops The generator phase voltages are not connected to the unit Measure the AC voltage between terminals GEN L1 L2 L3 and Generator Neutral at the rear of the unit while the engine is running A fuse protecting the generator phases may be failed A misconnection may be occurred If everything is OK turn all the fuses off and then turn all the fuses on starting from the DC supply fuse Then test the unit again The unit is late to remove engine cranking The generator voltage rises lately Also the generator r
68. s the limit defined in parameter Engine Heating Temperature When the requested temperature is reached the load will be transferred to the genset This operation mode may be used as a backup to the engine body heater If the engine body is warm the heating will be skipped 6 4 Engine Idle Speed Operation It may be required that the engine runs at the idle speed for a programmed duration for engine heating The idle operation duration is adjusted with the parameter Idle Speed Timer The idle speed will be set by the governor control unit of the engine Any of the spare relay outputs may be assigned as IDLE output using Relay Definition program parameters Also relays on an extension module may be assigned to this function The Idle speed operation is performed both in engine start up and cool down sequences Speed and voltage protections are disabled during idle speed operation 6 5 Engine Block Heater The unit is able to provide a relay output in order to drive the block heater resistor The temperature reference is the coolant temperature measured from the the analog sender input The block heater relay function may be assigned to spare relays using Relay Definition program parameters Also relays on an extension module may be assigned to this function The engine body temperature limit is adjusted using the parameter Engine Heating Temperature The same parameter is used for engine heating operation The relay will become active if the
69. splay Display of Software Version Modem connection SMS message sending Remote Monitoring and Programming Automatic Exerciser Resuming to factory set parameters Gas engine fuel solenoid control Load Shedding Dummy Load Fuel Theft Fuelling Messages Firmware Update Changing the Default Engine Speed in Volvo Engines Engine Control Mode Dual Voltage and Frequency Single Phase Operation 7 41939 ENGINE MONITORING AND CONTROL PORT 8 MODBUS COMMUNICATION 9 WEEKLY OPERATION SCHEDULE EVENT LOGGING STATISTICAL COUNTERS MAINTENANCE PROGRAMMING TROUBLESHOOTING DECLARATION OF CONFORMITY TECHNICAL SPECIFICATIONS CONNECTION DIAGRAMS DKG 507 User Manual V 37 01 03 2012 1 INSTALLATION 1 1 Introduction to the Control Panel The unit is a control and protection panel used in gensets It shows the measured values on its displays The unit is designed to provide user friendliness for both the installer and the user Programming is usually unnecessary as the factory settings have been carefully selected to fit most applications However programmable parameters allow the complete control over the generating set Programmed parameters are stored in a Non Volatile Memory and thus all information is retained even in the event of complete loss of power The measured parameters are Mains voltage phase L1 to neutral Mains voltage phase L2 to neutral Mains voltage phase L3 to neutr
70. thout creating a visible alarm or warning Mains Fail Mains Restored enabled via SMS on Mains Change program parameter Fuel Theft Fuelling enabled by setting the Fuel Consumption Hour parameter to other than 0 If both modem and SMS are enabled the unit will send SMS messages first and attempt modem connection afterwards The maximum number of alarms transmitted in a SMS message is 4 This limitation is due to the maximum length of an SMS message which is 160 characters A sample GSM SMS message is given below DKGxxx SITE ID STOP LOW OIL PRESSURE SW END OF ALARM LIST The first line of the message carries information about the unit type and the site identity string This line is intended for the identification of the genset sending the SMS message Each following line will give one fault information The message will always be terminated by the END OF ALARM LIST string When the message is sent the existing alarms will be masked causing the audible alarm relay to release and preventing consecutive GSM SMS messages Any new upcoming alarm will result in a new GSM SMS message The new message will indicate all existing alarms even masked ones The necessary GSM modem cable will be supplied by DATAKOM This is the same cable as PSTN land modems 19 DKG 507 User Manual V 37 01 03 2012 6 16 Remote Monitoring and Programming Thanks to its standard serial RS 232 port the unit offers the remote monitoring an
71. to the parameter memory and FACT RSET DONE will be displayed during 5 seconds It is not possible to restore user parameters 24 DKG 507 User Manual V 37 01 03 2012 6 19 Gas Engine Fuel Solenoid Control The unit provides a special function for the fuel solenoid control of a gas engine The fuel solenoid of a gas engine is different from a diesel engine It should be opened after the cranking has been started and should be closed between crank cycles The delay between the crank start and solenoid opening is adjusted using the Gas Solenoid Delay program parameter The gas engine fuel solenoid relay function may be assigned to spare relays using Relay Definition program parameters Also relays on an extension module may be assigned to this function 6 20 Load Shedding Dummy Load The load shedding feature consists on the disconnection of the least crucial loads when the genset power approaches to its limits These loads will be supplied again when the genset power falls below the programmed limit The internal Load Shedding function is always active Any of the auxiliary relays may be used as the load shedding output The dummy load function consists on the connection of a dummy load if the total genset load is below a limit and to disconnection of the dummy load when the total power exceeds another limit The dummy load function is the inverse of the load shedding function thus the same output may be used for both purpos
72. tro magnetic compatibility Norms of reference EN 61010 safety requirements EN 61326 EMC requirements The CE mark indicates that this product complies with the European requirements for safety health environmental and customer protection UL CSA Conformity certificate 201 10527 E314374 UL 508 Edition 17 UL 2200 1st Edition UL 840 Edition 3 CSA C22 2 NO 14 Edition 10 51 DKG 507 User Manual V 37 01 03 2012 16 TECHNICAL SPECIFICATIONS Alternator voltage 0 to 300 V AC Phase to Neutral 0 to 520 V AC Phase to Phase Alternator frequency 0 100 Hz Mains voltage 0 to 300 V AC Phase to Neutral 0 to 520 V AC Phase to Phase Mains frequency 0 100 Hz DC Supply range 9 0 VDC to 33 0 VDC Cranking dropouts survives 0 V for 100ms Typical stand by current consumption 100 mADC Maximum current consumption 250 mADC Generator mains contactor outputs 16 A 250 VAC DC outputs 10A 28 VDC relay outputs Charge alternator excitation min 2W Magnetic pickup input 0 5 30 V AC Magnetic pickup frequency 10 KHz max Current inputs from current transformers 5A Max load 0 7VA per phase Digital inputs input voltage 0 30 VDC Internally connected to battery positive via 47 000 ohm resistor Analog inputs Resistor input 0 to 5000 ohms connected to the battery negative Sources 5 mA when closed to battery negative Measurement category CAT II Air category Pollution degree Il Communicati
73. tton Holding the MENUP button pressed for 1 second makes the display to switch to the next group VOLTAGE DISPLAY This display shows phase R voltage if the load is on mains Phase U voltage if the load is on the genset By pressing the MENU key below values may be displayed L1 L2 L3 mains phase to neutral voltages L1 L2 L3 generator phase to neutral voltages L12 L23 L31 mains phase to phase voltages L12 L23 L31 generator phase to phase voltages If the service counters group is displayed then this display will show the counter name In programming mode it displays CURRENT DISPLAY This display will show the current values measured using the current transformers Using the programming menu current transformers within the range of 10 5A to 9000 5A may be programmed In programming mode it displays the program number MULTIFUNCTION DISPLAYS By pressing the MENU key below values may read generator frequency Hz generator active power KW engine rpm fuel level oil temperature battery voltage V DC In programming mode it displays the program value DKG 507 User Manual V 37 01 03 2012 4 ALARMS AND WARNINGS Alarms indicate an abnormal situation in the generating set are divided into 3 priority levels 1 ALARMS These are the most important fault conditions and cause Therelated ALARM led to be on steadily The genset contactor to be released immediately The engine to be stopped imme
74. value P 143 Oil Pressure Value 4 bar 7 0 Oil Pressure Sender point 4 bar value P 144 Oil Pressure Sender Ohms 5 ohm 156 Oil Pressure Sender point 5 ohm value P 145 Oil Pressure Value 5 bar 8 0 Oil Pressure Sender point 5 bar value P 146 Oil Pressure Sender Ohms 6 ohm 184 Oil Pressure Sender point 6 ohm value P 147 Oil Pressure Value 6 bar 10 0 Oil Pressure Sender point 6 bar value Coolant Temperatire Sender Characteristics PGM Parameter Definition Unit Factory Set Description P 148 Temperature Sender Ohms 1 ohm 38 Temperature Sender point 1 ohm value P 149 Temperature Value 1 C 100 Temperature Sender point 1 C value P_150 Temperature Sender Ohms 2 ohm 51 Temperature Sender point 2 ohm value P_151 Temperature Value 2 C 90 Temperature Sender point 2 C value P_152 Temperature Sender Ohms 3 ohm 134 Temperature Sender point 3 ohm value P_153 Temperature Value 3 C 60 Temperature Sender point 3 C value P_154 Temperature Sender Ohms 4 ohm 322 Temperature Sender point 4 ohm value P_155 Temperature Value 4 C 39 Temperature Sender point 4 C value P_156 Temperature Sender Ohms 5 ohm 650 Temperature Sender point 5 ohm value P_157 Temperature Value 5 C 20 Temperature Sender point 5 C value P_158 Temperature Sender Ohms 6 ohm 1630 Temperature Sender point 6
75. voltage are programmable LOW BATTERY VOLTAGE warning Set if the battery voltage goes below the programmed limit During engine cranking this fault is not monitored CHARGE Set if a charge alternator failure or broken belt occurs This fault condition may result to a warning or alarm following programming RECTIFIER FAIL Set if a signal is detected at the rectifier fail input This input is only monitored when mains voltages are present EMERGENCY STOP Set if a signal is detected at the emergency stop input SPARE Set if a signal is detected from the related spare fault input 10 DKG 507 User Manual V 37 01 03 2012 5 MODES OF OPERATION The modes of operation are selected by pushing the front panel keys Changing the operation mode while the genset is running will result into a behavior suitable for the new operating mode For example if the TEST mode is selected when genset is running at RUN mode then the genset will take the load STOP In this mode the mains contactor will be energized if mains phase voltages are within the programmed limits The engine will be stopped AUTO It is used for genset and mains automatic transfer If at least one of the mains phase voltages is outside limits the mains contactor will be deactivated The diesel will be started for programmed times after the preheat timer When the engine runs the crank relay will be immediately deactivated The engine will run without load during engin

DKG-507 AUTOMATIC MAINS FAILURE UNIT

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