User Manual KG 934
Contents
1. lt lt 3 ccs Relay MCB Relay 5 Typical Contactor Control Enriching Lives KIRLOSKAR OIL ENGINES LIMITED Laxmanrao Kirloskar Road Khadki Pune 411 003 India Tel 91 20 2581 0341 Fax 91 20 2581 3208 2581 0209 www kirloskar com Part No 2H 831 04 0 00 Page 30 of 302. The generator output frequency and standard RPM must be Known Calculate Speed Calibration value as follows Cal Value Freq x 600 RPM Eg 50Hz x 600 1500 20 Enter the number 20 9 Battery Charging Alternator Excitation The battery charging alternator excitation system is implemented using a burst mode pulse system This ensures reliable self excitation while managing current consumption during standby heat dissipation during fault conditions and pulsing the battery charging alternator prior to cranking for improved speed signal output During standby and Ready the alternator excitation is pulsed once per minute to maintain some level of residual magnetism in the alternator but still maintaining minimum power consumption On receiving a start signal the unit pulses the alternator excitation input with a burst of 200mA pulses The pulse width is dependent on the battery voltage This pulse burst establishes a definite magnetic field in the battery charging alternator prior to cranking This ensures a significant soeed sensing signal is generated for crank disconnect sensing The alternator excitation is turned off and the engine is cranked without the usual alternator burden loading the cranking process This aids easier starting When the engine has fired and is running more 200mA pulse bursts are applied Given the alternator is rotating at more than the 3000RPM the alternator will achieve self excitation If self excitatio
3. Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS KG934V1 Genset Controller User Manual Enriching Lives KIRLOSKAR OIL ENGINES LIMITED Laxmanrao Kirloskar Road Khadki Pune 411 003 India Tel 91 20 2581 0341 Fax 91 20 2581 3208 2581 0209 www kirloskar com The information contained in this document is copyright and shall not be reproduced without the written authority of KOEL 2010 Page 1 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS KG934V1 Genset Controller 1 Introduction The KG934V1 is an integrated Engine and AC controller for small gensets It is a custom unit specifically designed and manufactured for Kirloskar Oil Engines Ltd The unit incorporates both manual and autostart initiated start and stop sequencing monitors engine and alternator operating parameters and provides both engine and alternator protection in a single integrated package The genset operating parameters are shown by scrolling screens on a backlit 128 x 64 dot Graphics LCD Alarms and warning are also shown on the LCD and supplemented by an alarm LED and Hooter output The unit provides comprehensive monitoring of the engine and generator operating parameters and provides automatic shutdown of the genset in the event of damaging conditions In addition to the usual engine safety protections the unit monitors coolant level fuel level canopy temperature and generator loading to provide ev
4. 155 x 117mm IP56 front IP20 rear Supply Voltage 8 V to 36V DC Nominal Automotive Running 7OmMA Short Circuit protected Digital Input Rating Whetting current 10mA at 12 V DC ee DC input protection for 30V DC Transient Protected Current limited outputs approx 15mA or less as required by sensors Short circuit and reverse voltage protected 0 99999 9 Hours Kilo Watt Hours 0 999999 9 KWH Oil Pressure Sensor Type Switch Close on fault Resistive 10 to 180 Ohms User Curve Oil Pressure Ranges 5 0 7 5 10 Bar Engine Temperature Sensor Type Switch Close on fault Resistive NTC Engine Temperature Ranges VDO 150 C User Curve Canopy Temperature Sensor Type Switch Close on fault Fuel Level Sensor Type Switch Close on fault Resistive 10 to 180 Ohms User Curve Battery Volts Measurement 8 to 36 Volts Set up and Adjustment All features may be adjusted using set up buttons and LCD menu or via a PC Windows based utility Amp DUAC Molex Mini Fit JNR Testing Environmental Tests IEC68 Part2 EMC Compliance EN50081 1 EN50081 2 IEC6100 4 3 Electrical Safety AS 3100 and AS 3260 Page 24 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS 13 Inputs Electrical Specification Input Type Comment Battery Volts Power Nominal 12VDC or 24VDC or Station Battery Supply Range 6 36VDC OVDC Common Fuel Level Sensor Analog Digital Suitable for either resistive or switch C O F send
5. 19 08 09 11 13 Nc 21 23 18 onodonodAad oad onnooao Oo ood The unit is fitted with 2 3 6 and 14 way Molex Minifit or equivalent socket connectors for which mating plugs can be selected from the Molex Tyco Amp PE or TPK 5566 range The unit is also fitted with 4 way Mate N Lok or equivalent socket connectors for which mating plugs supplied by Tyco Electronics or equivalent can be used The majority of unit wiring is low current for which 0 75mm wire is sufficient This excludes the CT wires CTR CTY CTB CTCom for which 1 5mm wire should be used Connector Details Connector Assignment Pin Wire Name Function J1 1 01 DC Battery Supply OV Common This connection must be made directly to the engine crankcase for lowest electrical G noise This connection must not have 2 currents other than the controller currents J1 DC Power Supply J1 DC flowing and must be used exclusively for the controller Battery Supply This connection must be made directly to the positive terminal of the battery for best performance Do not make this connection to the positive terminal on the Starting Motor Page 26 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS Wire Name Function point Switches to common Switches to common Switches to common Activate by switching to common i A Connector Assignment Pin J2 Engine J2 Engine AL 3105 LZ L2 lada AL ele el Oil Swi
6. 8 J2 9 J 11 2 12 2 13 3 2 3 3 3 4 3 5 3 6 5 3 19 15 10 12 14 13 16 C 0 1 2 3 17 18 J Page 27 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS Connector Assignment Pin ai Name Function J4 Speed J4 1 Speed A Frequency sensing Input for speed sensors Connects to MPU MPU J4 Speed Battery Charging Alternator W or ANIB Magneto i i Note Not suitable for connecting to the Generator Output Instead Use the Generator Voltage Input GR ail 2 B Return connection for the MPU Connect awe ie MPU Shield Sanaa connection for the MPU shield J5 Current Transformers J5 1 7 CTR Connects to the external Red Phase CT terminal S2 The load wire must pass we CIs through the CT in the direction of the CT arrow 2 4 ial inal Com Connects to the external CT s commoned S1 terminals Connects to the external Yellow Phase CT terminal S2 The load wire must pass through the CT in the direction of the CT arrow Connects to the external Blue Phase CT terminal S2 The load wire must pass through the CT in the direction of the CT arrow J6 Generator oR ja J6 Connects to the Generator Yellow Phase 1A aR ar er Screncarear oor ore aaa output Connects to the Generator Neutral output where available J7 Test Port T Test Port Programming Validation Test Port ae NB Connect ONLY KG expansion modules to this port NB The unit is a complex electronic
7. engine stop with optional configuration parameters and clear LCD status messages Engine Monitoring Description Over Under Speed Monitors engine speed with optional configuration parameters and clear LCD status messages this ensures the engine speed remains within configured limits Exceeding these limits will result in automatic engine shutdown to prevent damage Lubrication Oil Pressure Monitors engine oil pressure with optional configuration parameters and clear LCD status messages this ensures the oil pressure remains within configured limits Exceeding these limits will result in automatic engine shutdown to prevent damage Engine Temperature Monitors engine temperature with optional configuration parameters and clear LCD status messages this ensures the engine temperature remains within configured limits Exceeding these limits will result in automatic engine shutdown to prevent damage Monitors engine battery voltage with optional configuration parameters and clear LCD status messages this ensures the battery voltage remains within configured limits this ensures the battery is charged when the engine Is running Radiator Water Level Monitors engine radiator water minimum level with clear LCD status messages this ensures the radiator water level remains sufficient Low water will result in automatic engine shutdown to prevent damage Monitors engine fuel level with clear LCD status messages Low fuel level will result in automati
8. filter system is not blocked Check the engine is not running with a failed speed sensing system The emergency stop input has been activated Deactivate the emergency stop input then press the stop button to clear this alarm 7 Load Transfer and Contactor Operation The unit provides for both Mains and Generator contactor control even though in many applications this function will not be used instead an MCB is used to switch the generator to and from the load Contactor outputs if selected are controlled in both Manual and Auto operating modes The Mains contactor output can be setup to deactivate the Mains contactor in several ways e Immediately when the start button is pressed or the autostart input is activated e A short delay after the start request e When the genset is running and able to take load The Generator contactor output will activate only after the Mains contactor has opened and only when the genset able to take load The timing is controlled by the XFR DELAY configuration setting If the genset was started by activating the Autostart input then deactivating the input will move the sequence to the Run On sequence then to the Cool Down sequence During cool down the Generator contactor output is deactivated and after a delay the Mains Contactor output is controlled to re activate the Mains contactor Page 14 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS 8 Speed Sensing The
9. fuel tank volume Used to calculate the litres of fuel i remaining in fuel tank for current fuel level 10 Fuel level sensor type User Curve uploaded by KOEL Setup utility a Fuel level alarm setpoint Alarm output activates and engine is shutdown When low fuel alarm is active engine start is inhibited 50 55 Fuel level warning setpoint 5 55 Note This must be set above the Alarm setpoint Fuel Alarm 10 180 10 Selects type of oil sensor being used User 180 Dual station sensors can be used on same analog input User Curve uploaded by KOEL Setup utilit Used to select the oil sensor full scale in Bar Low oil pressure alarm shutdown set point Alarm output activates and engine is shutdown 1 5 Low oil pressure warning set point and engine continues to run NOTE This value must be set above the alarm setpoint Switch Oil protection sensor mode Switch Protection from switch input only Sender Protection from analog input only Both Combined protection No Yes Checks for oil pressure prior to cranking and raises the Yes warning Oil Present if oil pressure is present No Yes Yes Uses the digital Oil Pressure input to disconnect the Yes crank This may be used as an auxiliary mechanism to disconnect the crank quickly when the speed source is slow to establish No Switch is only used for alarm if enabled Oil Prot Off Off Oil Pressure Disconnect delay Used to delay the effect of the On
10. start Fuel Pullin Controls the high current coil on the Starter motor Crit Alarm Turn on output when the is shut down for alarm Idle Control Start and stop engine with Idle Output Start Fail Turns on when the Engine failed to start Stop Fail Turns on when the engine failed to stop Low Oil Stop Turns on when the engine stopped for low oil HilempStop Turns on when the engine stopped for Hi ETemp Low Fuel Stop Turns on when the engine stopped for low Fuel P1 Off Selectable Digital Input Function from one of the following I P2 Off Trip Stop the engine when sensor is activated Fire Alarm Stop the engine if fire alarm input is activated Bypass prevent engine form starting while activated Door Raise a warning while input is activated Calibration Setup Column Item Range Default Description Clear Cal this to Yes to reset unit to KG default calibration Yes Mains VR Adj 10Vrms OVrms Allows KEIL factory to adjust the Main Red phase offset Mains VY Adj 10Vrms OVrms Allows KEIL factory to adjust the Main Yellow phase offset Mains VB Adj 10Vrms OVrms Allows KEIL factory to adjust the Main Blue phase offset 0 Note The engine needs to be running to adjust this Note The engine needs to be running to adjust this A j Amps IY Adj 10Vrms llows KEIL factory to adjust the Amps Yellow phase offset Amps IB Adj 10Vrms OVrms Allows KEIL factory to adjust the Amps Blue phase offset Notes
11. 1 These items are intended to allow KEIL factory to make adjustments for variations in CTs and external voltage measuring points 2 The engine needs to be running to adjust Genset related values Comms Setup Column Item Range Default Description CommsID 1 240 134 Comms Address Required for remote communications Baud Rate 1200 9600 Comms Port Baud Rate 57600 1200 2400 4800 9600 19200 38400 57600 Data Bits Number of Data Bits Parity Even None Parity Select Odd None Stop Bits tor2_ 1 Number of Stop Bits UART Mode None None RS232 Handshaking Mode Modem None No RTS CTS control 3 wire connection LAN Modem Uses RTS CTS flow control 5 wire connection LAN Allows connection to an RS485 adapter EG KG18 Page 22 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS Notes 1 Unit has basic communications to allow factory testing and validation 2 Allows the unit to be connected to external KG modules for enhanced communication functions Test I P Column Item Range Description Stop Alarm Log Viewer Column This log contains the last 10 reasons that the Engine was stopped Stop Alarm log history items cannot be deleted or changed except by using the KOEL Windows setup utility program Page 23 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS 12 Unit General Specifications Feature Specification Overall Dimensions 180 x 126 x 51mm Mounting Hole
12. Code ID Sequence Status Engine Speed in RPMs Oil Pressure Engine Temperature Genset Battery Voltage Status Page 11 of 30 a KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS Fuel Status If Enabled The Hours remaining can optionally hidden Oil Temperature If enabled Engine Running Hours Total Engine Starts Genset Voltages Line to Neutral Line to Line Genset Amps and Hz Genset KW and KVA Genset KVAR and Power Factor Genset Power Totals Genset Average Genset KWHours Contactor Status This screen only appears if contactor out control has been configured Any active warnings are shown here This is an example warning screen The sequence returns to the Sequence Status screen Page 12 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS 6 Alarms and Warnings In the event of abnormal operating conditions the unit will issue a warning of an impending alarm then an alarm if a failure is detected The genset is then shut down The LCD shows an appropriate message indicating the nature of the condition To draw operator attention to the condition the flashing general alarm LED is used In most cases Warnings do not stop the genset and are self resetting Alarms will normally stop the genset and require the operator to clear the alarm by pressing the Stop or Hooter button The gen
13. Voltage Internal measurement of battery charging alternator excitation voltage Low Water Level Vbelt Oscillating AC coupled Zero net current flow Selectable between Low Water detection and V Belt broken Outputs Function Description Battery charging alternator excitation control WL Current controlled pulse Open drain 300mA overload protected Crank relay coil control Open drain 300 mA overload protected Output 1 ConA Default Contactor A ConB Output 2 PreHeat Default Contactor B Start Warn Output 3 Fuel Pullin Default Preheat Crit Alarm Output 4 Idle Control Default Off Start Fail Stop Fail Low Oil Stop HiTempStop Low Fuel Stop Open drain 300mA overload protected Page 6 of 30 KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS 4 Operation Front Layout BK IRLOSKAR GREEN POWER IDEAS O ACK RESET LOW OIL HIGH ENGINE BATTERY UNDER OVER LOW FUEL GENSET PRESSURE TEMPERATURE CHARGING SPEED LEVEL RUNNING STOP START Buttons Function Description Manual Stop button Menu Control Used to initiate generator manual stop sequence LED blinks during the stopping sequence Used to select Off mode when the engine is in standby Used to clear alarms when the Genset was stopped for an alarm Used as system menu LEFT button Manual mode button Used to select manual mode Allows genset to be started only with start button press LED indicates manual mode is active Auto mode butto
14. c engine shutdown to prevent damage Canopy Temperature Monitors an engine canopy temperature switch with clear LCD status messages This function will result in automatic engine shutdown to prevent damage Records engine run hours with clear LCD status messages Page 4 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS Generator Monitoring Function Description Monitors Genset 1 2 or 3 phases of AC voltage with optional configuration parameters and clear LCD status messages Monitors Genset 1 2 or 3 phases of AC current with optional configuration parameters and clear LCD status messages Uses externally fitted 5A CTs parameters and clear LCD status messages Monitors Genset AC for Phase reversal with optional configuration parameters and clear LCD status messages Monitors AC load as a percentage of full load capacity with optional configuration parameters Overload units can be selected between KW and Amps Monitors AC power output KW KVA KVAR PF KWH with optional configuration parameters and clear LCD status messages System LED Indications Function Description Red LED indication of system alarm System LCD Displays Function Description Setup menu System configuration menus Start Up Clear step by step start up sequencing messages Shutdown Clear step by step shutdown sequencing messages Transfer Clear step by step load transfer messages Engine LCD Displays Function Descri
15. device and caution should be taken to ensure correct wiring before power is applied Page 28 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS 16 Trouble shooting The unit displays the following messages when an alarm occurs Alarms shut down the engine set the alarm output and flash the alarm indicator The alarm indications can be cleared after the genset has stopped by pressing the stop button The hooter can be silenced with the Hooter Button Alarm Messages Message Low Oil Pressure Oil pressure has not reached the Oil Alarm set point Oil Alarm at the end of the run up time or has dropped below this value when the engine is running Low Fuel Level Fuel level is less than the minimum value set point High Engine Temp Engine temperature has exceeded the high temperature set point The temperature icon turns on Either message may also be shown depending on temperature system setup Stop Failure The engine has failed to stop E S Lock out The emergency stop input has stopped the engine Oil Pressure Flt The unit has detected that the Oil Pressure sender has become open circuit Normally this indicates a faulty sender or broken wiring This will only shut down when the Oil System is set to Sender Engine Temp Fit The unit has detected engine temperature has not risen above 50 degrees after 5 minutes of running or the temperature This indicates a faulty temperature sender or damaged Oil Temp Fit The senso
16. en more comprehensive protection In the factory environment the unit is configured by cloning through a PC system Field specific parameters can be adjusted by using the front panel buttons and an inbuilt menu system 2 Benefits e Reduces system cost e Integrates engine gauges and AC metering into one unit e Minimises control panel wiring offering reduced material and labour costs e Reduces warranty costs by providing comprehensive engine and generator protection and a maintenance due timer e Flexible the unit can be customised by PC cloning with application codes for individual genset model characteristics and fitments Page 2 of 30 KG934V1 User Manual T O KIRLOSKAR GREEN 3 Physical Form Front View R E KIRLOSKAR GREEN POWER IDEAS oe G ACK RESET Ko fe E HIGH ENGINE PRESSURE TEMPERATURE BATTERY CHARGING Back View 27 28 29 30 J6 Generator 54 4 DC 01 J1 2 DC 02 J2 3 Crank Relay 03 J2 1 Charger WL 05 J2 11 Auto Start Switch 14 J2 5 HCT Switch 15 J2 13 Analog Input 1 16 J3 5 Digital Input 1 17 Danger J2 2 Stop Fuel Relay 06 J3 6 Digital Input 2 18 High J2 6 Oil Switch 08 J2 4 Fault Relay 19 J2 8 Engine Temp Sensor 09 J3 1 Output 1 20 J2 7 LOP Sensor 10 J3 2 Output 2 21 J2 10 Wat Lev Sw V Belt 11 J3 3 Output 3 22 E J2 9 Fuel Lev Sensor 12 J3 4 Output 4 23 J2 12 Emergency Stop Sw 13 J4 1 Speed A 24 Voltage J2 En
17. ers Coolant Temperature Analog Digital Suitable for either resistive or switch C O F senders Sensor protection or display only Suitable for probe or switch input Open Circuit No water present High Impedance High Impedance Red Phase CT Amps S2 5A RMS Max 6A for 1 second Yellow Phase CT Amps S2 5A RMS Max 6A for 1 second Blue Phase CT Amps S2 5A RMS Max 6A for 1 second CTCom Amps Common connection for CT S1 terminals Do not connect to earth SPA Voltage Speed A magnetic pickup input 3V 70V peak at gt 500 to 10KHz Speed A Battery Alternator input 2V 70V peak at 20Hz to 1KHz SPB Voltage Speed B magnetic pickup input 3V 70V peak at gt 500 to OKHz Speed B Battery Alternator input Connect to common Speed Common 0VDC 14 Outputs Electrical Specification Output Type Comment the battery charging alternator with excitation current Stop Fuel Relay Open Drain 300mA Open Drain protected coil drive Max 36VDC This output is used to control the fuel solenoid interposing relay and can be set for either Energise to Run or Energise to Stop functionality It is recommended that the fuel relay is located near to the fuel control solenoid This position removes the need for high current wiring to the control box and thus leads to lower cost Crank Relay Open Drain 300mA Open Drain protected coil drive Max 36VDC This output is used to control the interposing crank relay coil The crank relay should be s
18. gine J7 Test Port J1 DC UNDER OVER SPEED EMGIHE SPEEDO Bren LOW FUEL LEVEL STOP KG934V1 Generator Controller J4 2 Speed B 25 J4 3 Shield 26 J6 1 GR 27 J6 2 GY 28 J6 3 GB 29 J6 4 GN 30 J5 1 CTR 31 J5 3 CTY 32 J5 4 CTB 33 J5 2 CT Com 34 J2 14 No Connection NC J3 I O 05 03 15 10 12 14 16 102 06 19 08 09 11 13 Nc 24 23 16 Page 3 of 30 POWER IDEAS O GENSET RUNNING START J4 Speed Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS Functions System Function Description Protection Shutdown Automatic preventative engine and genset shutdown in the event of a abnormal operating conditions with optional configuration parameters and clear LCD status messages Manual Start In response to the front panel pushbutton performs a fully sequenced eke engine start with optional configuration parameters and clear LCD status messages Manual Stop In response to the front panel pushbutton performs a fully sequenced oe engine stop with optional configuration parameters and clear LCD status messages Auto Start Stop In response to a digital input activation the unit performs a fully sequenced engine start Deactivating the input performs a fully sequenced engine cool down then stop Contactors if used are also fully sequenced for changing the load between Mains and DG Emergency Stop In response to a digital input performs a fully sequenced
19. ized for the crank contactor current It is recommended that the crank relay is located near to the starter motor This position removes the need for high current wiring to the control box and thus leads to lower cost Output 1 to Output 4 Open Drain 300mA Open Drain protected coil drive Max 36VDC These outputs can be configured for various functions The are intended to drive interposing relays and not the particular loads directly Page 25 of 30 R o1 KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS 15 Installation and Wiring NB The unit is a complex electronic device and caution should be taken to ensure correct wiring before power is applied 27 28 29 30 KG934V1 Generator Controller J6 Generator 34 4 pc 01 J2 11 Auto Start Switch 14 J4 2 Speed B 25 J1 2 DC 02 J2 5 HCT Switch 15 J4 3 Shield 26 J2 3 Crank Relay 03 J2 13 Analog Input 1 16 J6 1 GR 27 J2 1 Charger WL 05 J3 5 Digital Input 1 17 J6 2 GY 28 Danger J2 2 Stop Fuel Relay 06 J3 6 Digital Input 2 18 High J2 6 Oil Switch 08 J2 4 Fault Relay 19 Voltage J2 8 Engine Temp Sensor 09 J3 1 Output 1 20 J2 7 LOP Sensor 10 J3 2 Output 2 21 J2 10 Wat Lev Sw V Belt 11 J3 3 Output 3 22 E J2 9 Fuel Lev Sensor 12 J3 4 Output 4 23 J5 2 CT Com 34 J2 12 Emergency Stop Sw 13 J4 1 Speed A 24 J2 14 No Connection NC J7 Test Port J1 DC J2 Engine J3 I O J4 Speed 05 03 15 10 12 14 16 02 06
20. l information The unit constantly measures the battery terminal voltage and can detect proper charging and discharging performance Voltage readings are taken and compared against an inbuilt voltage profile If the battery terminal voltage falls outside the critical voltages for each action then a battery warning is indicated During standby and particularly where an on line charger is not available monitoring the health of the battery is vital The unit regularly wakes and measures the battery voltage if it falls below the set point a warning is issued to ensure the operator is aware of the need for battery recharging 11 Set up In the factory environment the unit can be setup by the KOEL Cloning Utility or by the KOEL Windows setup utility In the field adjustments to the unit can be made using the buttons on the front panel The KOEL Windows setup utility and the KOEL Cloning options are detailed elsewhere and only the field adjustment method is discussed here To enter set up when the unit is showing READY press and hold the Y button for 20 seconds When the unit enters set up mode the LCD will show Setup and request a PIN number PIN Entry Column Selection Item Selection Entry to Setup mode can also be done while the unit is RUNNING to allow the Genset Amps and Voltages to be adjusted against the calibration standard This should ONLY be done in the factory Navigating in the setup menu The setup menu comp
21. ll soeed before going on load Oil pressure and Over speed are monitored e RUNNING o The display shows RUNNING Operating parameters are scrolled onto the display o Engine temperature alarms have a hold off period and will not prematurely cause engine shutdown if the engine has been previously run and has a high temperature o Contactors if configured are controlled Page 9 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS To stop the genset Push the stop button briefly The unit will perform a stopping sequence as follows e COOLDOWN o The display will show COOLDOWN with a count down time o The B contactor if configured is opened immediately and after a short delay contactor A if selected is closed o On expiry of the cool down timer the sequence continues to stop the engine o The cool down timer can be set to zero in the menu system to skip this sequence step o To truncate the cool down timer press the stop button again o The set can be returned to the running sequence by pressing the start button The contactors return to place the genset on load again e STOPPING o The display will show STOPPING with a countdown time o If ETR fuel control has been selected the Fuel output will be deactivated o If ETS fuel control has been selected then the Fuel output will be activated for the Max Fuel Time or until the engine stops The stopping process will retry if the engine fails to stop the firs
22. metimes be caused by ripple generated by mains powered battery chargers the engine needs to be started in Auto mode The Oil Pressure has dropped below the Oil Pressure Warning set point while the engine is running The Oil Pressure Icon is lit Page 29 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS Engine Coolant temperature has exceeded the high temperature warning High Water Temp set point after the Temperature monitoring delay has expired High Canopy Temp Canopy Temperature was activated after the Temperature monitoring delay has expired Low Fuel Level Fuel level is less than the warning set point Fuel Level Fit The unit has detected that the fuel sender is open circuit This is only a warning and will not shut down the engine No Speed Signal A speed signal could not be detected after the engine had started Maintenance The time since the last maintenance has exceeded the maintenance time The alarm output is not activated for this warning The warning is cleared by pressing and holding the 4 button for 30 seconds If the engine maintenance is carried out prior to the timer expiring pressing the 4 button for 60 seconds will reset the timer Load Li L2 13 N E Main Switchboard fje o ol ol ol Mechanical Interlock Co no NC ot C NO
23. mode Run Imed Unloads contactor A at the beginning of the Start Delay Delay Unloads contactor A after a delay see next item or when the genset is ready for load whichever is the sooner Run Unloads contactor A when the genset is ready for load Unload me oe _ Den Only displayed if Unload is set to Delay Delay for Delayed Unload mode see above w Delay Sa Delay time between break and make operations for A to B and B sec to A contactor transfer control Start Stop Column Range Default Description 2 Autostart Delay Time The time between the detection of an Autostart activation and the initiation of starting Start time units are set in the next item Min Sec Seconds Min Minutes pews p S E before the start delay timer is reset and starting aborted n a Prestart warning time If an output has been assigned to a Start Warning function then it will turn on for this time period before a start occurs Run On 0 3600 Run On Time During run on reactivation of Autostart input will sec return the engine to running state The generator remains on load 0 3600 E Down Time Used to cool the turbo and alternator as sec required The generator is off load Page 20 of 30 Start Warn Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS Item Range Default Description eee Idle Down O Engine Is run and low speed prior to stopping The Idel output is on during this time AC Set
24. n Used to select auto mode Allows genset to be started only with Auto start input activation LED indicates auto mode is active Test mode button Menu Control Used to select Test mode Allows the genset to be started manually without changing the contactors LED indicates test mode is active Used as system menu DOWN button Manual Start button Menu Control Used to initiate generator manual start or test sequence Used as system menu RIGHT button Screen Scroll button Menu Control Used to scroll LCD display to next screen Used to enter the menu system and accept changes Alarm Acknowledge Menu Control Used to silence the sounder when the system is in alarm or has an active warning Self resetting if enabled LED indicates warnings and alarms Used as menu system UP button Page 7 of 30 Re KIRLOSKAR GREEN KG934V1 User Manual LEDs LED LOW OIL PRESSURE HIGH ENGINE TEMPERATU RE UNDER OVER SPEED LOW FUEL LEVEL G ENSET POWER IDEAS Function Description Alarm LED Indicates warnings and alarm Warnings are indicated by 1 blink per second Alarms are indicated by 4 blinks per second Low oil pressure LED LOP Indicates low oil pressure warnings and alarms Warnings are indicated by 1 blink per second Alarm is on solid High Engine Temperature LED Indicates warnings and alarm Warnings are indicated by 1 blink per second Alarm is on solid Battery Charging LED Bli
25. n is not achieved this process will repeat for a few seconds before the excitation failed warning is given Alternator excitation may also be used as a secondary crank disconnect signal for the case where the speed signal has failed immediately the engine starts to run This feature can be disabled if not required by setting Excite Dis to NO Page 15 of 30 KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS For systems where a battery charging alternator is not fitted turning off the excitation warning will disable the excitation system 10 Battery Voltage Monitoring and Charging Detection A battery is considered charged if assuming a 12V system x2 for 24V its terminal voltage is above 13 1Volts Typically a fully charged battery has a terminal voltage of 13 6V above this and the battery is being overcharged During cranking the large discharge current will reduce the battery terminal voltage below 12 5V and the battery cannot increase the terminal voltage again without the assistance of a charger This sequence provides a useful mechanism to determine if a battery is being actively charged Many applications have a current meter to show charging current Such meters provide very limited value as a good battery will recover its terminal voltage very quickly and then be maintained with a very low level of trickle current This trickle current is usually too small a percentage of the current meters range to provide any usefu
26. nking indicates under voltage over voltage and charge failure On solid indicates no excitation while the engine is running Off indicates battery charging condition is OK Under over speed LED Indicates warnings and alarm Warnings are indicated by 1 blink per second Alarm is on solid Low Fuel Level LED Indicates warnings and alarm Warning is indicated by 1 blink per second Alarm is on solid Genset Running LED Indicates the genset is running Blinks to indicate the genset is starting or stopping RUNNING Initial Power Up On power up the unit displays the Kirloskar logo and turns on LEDs for a lamp test The unit then displays the Serial number Application Code and Firmware version After the initialisation process is complete the unit enters the mode selected in the setup menu and changes to READY Ready When the unit is in READY all measuring systems and display systems are turned on The unit remains on for 1 minute and if the genset is not started in that time the unit goes into sleep mode to conserve battery power In this mode the unit wakes periodically to check for any unusual conditions and if it finds none it goes back to sleep otherwise it alarms accordingly Any activity on the buttons immediately wakes the unit and the appropriate action is taken In this state the engine and generator parameters are as expected for a stationary genset If the conditions are not as expected an appropriate warning or alarm is displa
27. not permitted and the engine can run to destruction This option is only settable using the KOEL Windows setup utility Timers Column Item Range Default Description PreHeat Time J oy l bts to turn on the PreHeating output prior to cranking 0 Skip Preheat delay Crank Time i 6 Maximum cranking time Crank Rest Delay between cranking retries sec Page 19 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS Range Default Description aa DA Manual and Test start sequencing will not retry a ay Oil pressure Temperature Underspeed and Overspeed checking is disabled to allow these to stabilize during the starting process Hirev is active to protect against a jammed governor aa e Under speed is not monitored ia a a sec Under speed is not monitored nme Time 3 ns Time to allow large engines to completely stop rotating and oil pressure decline when stopping During this time if Energize to Stop option is chosen the fuel solenoid will activate up to the Fuel Max Time pers REAR ee sec before the unit considers the engine to be stop ped ere om e e min 0 Run until the user stops the engine Time 0 600 oP Sounder remains on indefinitely until acknowledged sec EE Sounder maximum time is the value in seconds anahi Hours between Maintenance Requests 50 1000 hours Contactor A Column Item Range Default Description Unload Imed Delay Imed Contactor A unload
28. oil disconnect switch by 1 second for cold climatic conditions Only configurable via the PC configuration Software Enables the Radiator Water Level Alarm Must be disabled if On the Water level is not monitored When the ETemp Type Engine this becomes the VBelt input 30 Monitoring Delay time from engine starting before monitoring for high engine temperature This is to allow the starting of a hot engine sec ETemp system Water Water Engine Cooling Temperature Source Engine Water Water monitoring Engine Engine Air temperature monitoring D 3 U D lt l OO 5 Q O Q Q QO Q O Q u u o oj O y z k a a on a z O v D 9 a 4 Q D 5 O lt D U 2 3 3 D D 2 al D 3 m gt Page 18 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS Item Range Default Description ETemp Type COF TS150 Selects Engine temperature sensor type TS150 COF Switch Close on Fault User TS150 VDO Sensor with FSD of 150 C User Curve uploaded by KOEL Setup utility Alarm output activates Engine is shutdown 70 EN mja High Engine temperature warning set point P Engine continues to run NOTE This value must be set below the alarm setpoint OTemp Type COF TS150 Selects Oil temperature sensor type via Analog input 1 TS150 COF Switch Close on Fault User TS150 VDO Sensor with FSD of 150 C User Curve uploaded by KOEL Setup y Alarm outpu
29. pixels on and showing the background with pixels on 0 30000 Site Identifier May also be used for asset numbering RemoteSetup EERE the unit to request remote units to enter setup mode Yes Defaults No N Setting to Yes will load all configuration items to their factory Yes default values Note Engine RPM Cal Value calibration will be lost Engine Column 4 3 30 O O Range Default Description 100 1000 300 Crank Disconnect Frequency Hz Cal Value 1 2500 20 RPM Calibration Value Refer to Speed Sensing section U Spd Wrn OFF OFF Warning threshold for slow engine speed 400 3600 RPM OFF OFF Alarm threshold for slow engine speed 400 3600 RPM 400 4000 RPM 400 4000 RPM Fuel Select ETR ETR Fuel Solenoid Type eSa ee ETS Energize To Stop ETS Tries 1 2 2 Note This item is only displayed when Fuel Select ETS See Above Maximum Stop Retries for ETS Fuel Control Page 17 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS Item Range Default Description ETS Rest 5 60 5 Note This item is only displayed when Fuel Select ETS sec See Above Stop Retry Pause time for ETS Fuel Control During this time the Fuel output is Off sec alarm is raised FuelLitreHr 1 600 4 Genset fuel consumption Used to calculate the number of na Off runtime hours remaining for current fuel level Litre When set to Off the Hrs is removed from the Fuel Screen FuelTotal Total
30. ption Low oil pressure Engine oil pressure low High engine temperature Engine temperature high Low coolant level Radiator water level low Low fuel level Engine fuel level low Battery Voltage Engine Battery Voltage and Droop voltage at last cranking cycle Genset LCD Displays Function Description Phase Voltages Phase 1 2 and 3 Voltages Line to Neutral and Line to Line Phase Currents Phase 1 2 and 3 Currents Phase Frequencies Phase 1 AC Power Metering Monitors AC power output KW KVA KVAR PF KWH with optional configuration parameters and clear LCD status messages AC Inputs Function Description 2 3 Phase Genset AC Voltage Genset AC voltages 0 300V AC RMS 3 Phase Genset Current Genset AC currents via external 5A CTs 0 5 Amp input Analog Inputs Function Description Lubrication Oil Pressure Engine oil pressure sensor LOP Current limited excitation for resistance sensing Engine coolant temperature sensor Air or Water Current limited excitation for resistance sensing Engine fuel level sensor Current limited excitation for resistance sensing Page 5 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS Analog 1 Yet to be defined Current limited excitation for resistance sensing Digital Inputs Function Description Oil pressure switch LLOP Close to Common to activate Special Inputs Function Description Battery Voltage Internal measurement of incoming DC supply Excitation
31. r connected to Analog 1 input is faulty or open circuit The following warning messages indicate potential problems When a warning occurs the message associated with the warning is displayed Warnings clear automatically when the warning condition is cleared Warning Messages Message Cause charging fault or the alternator belt has broken running Indicates that the alternator is not charging the battery Under Voltage Battery Voltage is below the low battery setpoint Over Voltage Battery Voltage is above the high battery volts setpoint This may be due to a faulty regulator or battery charger Oil Lock Out The unit has detected that the oil pressure is above the oil pressure alarm setpoint with the engine not running This warning prevents the engine from attempting to crank with the engine potentially running This may be due to a faulty oil sender or a very tight engine This warning is disabled if Oil Pressure Check before Cranking is set to Off Tacho Lock Out The unit has detected that a speed signal is present with the engine not running This warning prevents the engine from attempting to crank with the engine potentially running This warning can sometimes be caused by ripple generated by mains powered battery chargers Excite Lock Out The unit has detected that Excitation is present with the engine not running This warning prevents the engine from attempting to crank with the engine potentially running This warning can so
32. radiator water level is below the required level The water level needs topping up The engine has failed to start Check Fuel supply check battery condition check air filters The engine has failed to stop Check stop solenoid check rack operation If the belt break detector has been activated Check the belts The Oil Pressure sensor system is not functioning as expected Check oil pressure sensor and associated wiring The Engine Temperature Sensor is not functioning as expected Check engine temperature sensor and associated wiring The Fuel Level Sensor is not functioning as expected Check the Fuel Level Sensor and associated wiring Speed Fault The Speed Sensing system is not working as expected Check the associated speed sensor wiring and external influences such as poorly operating battery chargers and poorly filtered UPS systems connect to the load Page 13 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS Message Function description Speed Detected Speed signal is unexpectedly present Check the associated speed sensor wiring and external influences such as poorly operating battery chargers and poorly filtered UPS systems connected to the load Check electrical safety earthing systems Check associated communications networks are isolated and not part of an unexpected earth loop Oil Detected Oil Pressure is unexpectedly present Check the Oil Pressure Sensors and associated wiring a Check the Oil
33. rises a range of columns where each column comprises of a list of items and each item has a range of settable values Column Headings are as follows Engine Timers cona starvSt Seup Sup vl oomms top Am Test The a button UP is used to select the previous Column Item or to Increment a value The button DOWN is used to select the next Column Item or to Decrement a value Page 16 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS The button RIGHT changes from Column to Item to Value editor The 0 button LEFT changes from Item to Column and Exit setup mode The button ENTER is used to accept Value changes and Start Setup mode Setup mode automatically terminates if no button in pressed for 60 seconds or when you press the button with the column headers list visible System Column Item Range Default Description CD Contrast 2 60 Display Cycle Time sets frequency of display updates se For manual scrolling press the Y button for the next 1 M C measurement screen C alarm button is pressed to halt the scrolling pve e a e a e ee Last either Manual or the last used mode ae S T mete ae theo Ea min alarms etc When set to 0 the unit will never enter sleep mode LCDReverse No Cycle Controls the LCD Pixel Reverse Yes No LCD Always shows information with pixels on Cycle Yes LCD Always shows background with pixels on Cycle LCD alternates showing information with
34. set can not be started if an alarm exists Warnings are indicated by slow flashing of the alarm LED and displaying the appropriate message on the LCD as follows Alarms are indicated by fast flashing of the ALARM LED and displaying the appropriate message on the LCD Message Function description eee The oil pressure went below the alarm setpoint while running Check oil level and replenish Check for blocked oil filter The Engine Coolant temperature went above the alarm setpoint while the Coolant Temp High genset was running Check for over loading Check cooling air flows Check coolant level The Canopy Temperature switch input was activated Check cooling air flows Check for overloading Fuel Level Low The Fuel Level is below the alarm setpoint The engine is stopped to prevent air and dirt infiltration to the engine Replenish the fuel Battery Voltage High The battery voltage went above the setpoint High battery voltage usually indicates that the battery charging alternator has failed and it is producing a voltage which might damage the battery control relays or the controller Engine shutdown is recommended to minimise the risk of damage and fire The engine was running below the under speed setpoint Check for overloading Check fuel system The engine was running above the setpoint Check governor system Check power takeoff couplings The speed signal indicates the engine is grossly over speed Check Governor system The
35. t activates Engine is shutdown jian Warn bra T High Oil temperature warning set point C Engine continues to run NOTE This value must be set below the alarm setpoint OTemp Delay 1 300 Monitoring Delay time from engine starting before monitoring m T for high Oil temperature This is to allow the starting of a hot Lo Bat VIt OFF Low Battery voltage level warning e peeo Volts Hi Bat Vit 12 32 High Battery voltage level warning Se Volts MaxBat VIt 12 0 38 0 1 tt Battery Voltage If the Battery voltage exceeds this OFF level then the engine is shut down This is used to protect the Volts ett from a failed alternator Charge Min V OFF The minimum battery voltage below which a Low Charge 10 28 Volts warning is activated when the engine is running This Volts generally indicates an excitation failure or broken alternator belt a Warn Yes charging alternator excitation failure warning enabled No charging alternator excitation failure warning disabled n Dis No Yes es uses successful charging alternator excitation as a Yes secondary crank disconnect signal to prevent over cranking No Excitation Disconnect function disabled Stop on Alarm Off On On Engine protection functions are enabled Normal setting On Off All protection shutdown mechanisms for the engine are disabled Warnings and Alarms continue to be indicated Off should only be chosen for mission critical applications when shutdown is
36. t time Between stopping retries the Fuel output is deactivated for a short time to help overcome any jamming o The fuel output is controlled until the engine stops rotating and oil pressure decays If the Oil Pressure has not decayed by the end of the Max Fuel Time the fuel output is deactivated and the controller raises the alarm FAILED TO STOP The speed must remain at zero and the oil pressure must be below the alarm set point for the Stop Time before the engine is considered stopped e READY o The engine has stopped and is ready to start again as required Page 10 of 30 KG934V1 User Manual ee KIRLOSKAR GREEN Display Operation When the genset is ready POWER IDEAS When the genset is in standby and waiting for a start signal the following display is shown When the genset is running When the genset is starting and stopping the display shows the state of the sequence together with the time remaining before the next state will commence Once the genset is fully running or if the genset is stopped and in READY the running parameters are displayed This includes generator and engine parameters simultaneously on separate displays The unit sequentially scrolls through screens as shown below Splash Screen 1 Only shown at Power up Splash Screen 2 Only shown at Power up Product Identification Only shown at Power up Software Version KOEL Serial Number KOEL Application
37. tch Low Oil Pressure Switch Input Activate by switching to common Measures Resistance Sensor Measures Resistance Fuel Lev Sensor Fuel Level sensor Input Measures Resistance Wat Lev Sw Water Level or V Belt sensing Input V Belt Oscillating Output Input system a NO 2 10 11 Connects to water level probe water level switch or V Belt broken switch a eee Switch common Starts the DG r T A eee Sw switching to common Stops the DG e ee E E A soca Used for the Oil Temperature Sensor No Connection Analog Input 2 Measures Resistance No pe pemean hardware fitted and No Functions assigned to this input at this time Output 1 Coil Drive for an external control Relay Switches to common Configurable for various functions q NO J J J 2 14 J J3 Input Output Q Output 2 Coil Drive for an external control Relay Switches to common Configurable for various functions Output 3 Coil Drive for an external control Relay na Switches to common Configurable for various functions Output 4 Coil Drive for an external control Relay Switches to common Configurable for various functions Digital Input 1 Activate by switching to common Configurable for various functions See Menu Options above Digital Input 2 Digital Input 2 Activate by switching to common Configurable for various functions See Menu Options above N 2 2 2 2 J J J J J2 2 J2 3 J2 4 J2 5 J2 6 J2 7 J2
38. trol is configured the unit will control the fuel output and display FUEL ON and the proceeds to the CRANK state If the Fuel Pull in is configured it will be on for the first second of this sequence o ForETS Energise To Stop the sequence does not activate the output and proceeds to the Crank sequence after a short delay e CRANK o The Crank output is activated and the display shows Cranking with a count down time o The Crank output is deactivated when the unit has detected a speed signal above the crank disconnect speed specified in the settings If selected the crank will also terminate on achieving oil pressure or Battery charging alternator excitation has been achieved This provides a secondary crank disconnect function to avoid over cranking o If the genset does not start the LCD will show STOPPING control the Fuel and Crank outputs accordingly and return to READY There are no retries with a Manual Start o Ifthe unit looses power due to battery voltage droop during cranking and the engine fires then on regaining adequate battery voltage the unit will continue to allow the engine to run e RUN UP o When the engine starts the display shows RUN UP with a count down in seconds This allows the engine measurement system to stabilise Over speed and loss of speed signal are the only parameters checked during RUN UP e WARM UP o The display shows WARM UP with a countdown time This allows the engine to stabilise at fu
39. unit can obtain speed information from one of four sources e Magnetic pickup unit MPU e Battery charging flywheel magneto e Generator output 50 60HZz if used for genset control internally connected from GR e Battery charging alternator MPU The magnetic pickup unit counts teeth on the flywheel and is mounted in the bell housing It is important to ensure the gap between the MPU face and the teeth is 1mm to 2mm as this distance greatly affects the output of the MPU The unit requires a minimum of 3VRMS at low speed to ensure proper crank disconnect Setup requires calculating the number pulses per 10 revolutions and the calculated number is then entered into the menu system Cal Value Calculate Number of Teeth x 10 Speed Pulses Per 10 Revolutions Eg 125 teeth x 10 1250 Enter the number 1250 Generator If the unit is used in a genset application the speed source can be the generator 50 60 Hz output and is connected internally within the unit from the AC input connectors AC should NOT be connected directly to the soeed MPU Magneto input For correct crank disconnect the generator must be providing a detectable output at low speed and therefore the voltage at 300 RPM must be greater than 40VRMS This can be affected by the AVR and must be confirmed to provide suitable signals and timing for proper crank disconnect For setup the number of pulses per 10 revolutions must be calculated and entered into the menu system Cal Value
40. up Column Default Description 1 1 Phase Alternator system 2 2 Phase Alternator system 3 3 Phase Alternator system 3 Selects the number of CTs used When the load is balanced between phases and cost minimisation is important a single CT for phase 1 may be used CT Ratio 1 2000 12 Selects the CT ratio PhaseRev Off On Enables genset phase reversal to generate an alarm and shut On down the engine AGF Setup Column Item Range Default Description me 25 aan rae a mr EE before the alarm will react to a voltage ma pea 30 0 This is only checked while the engine is Running on load pew ae 2 Reman antesteerisee E e e Z a 30 gt before the alarm will react to ee a frequency 5 6553 KW pasar e eea Sec O Load Amp Off Maximum KW above which the Genset will shut down 5 6553 Amps oe 60 i before the alarm will react to Amps ne ee oe 5 6553 down the engine Amps Sec Manual Column Item RECULIS Default Description inn a ha Enables Transfer of the load to the Genset in manual mode Yes Page 21 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS I O Config Column Default Description O P 1 ConA Selectable Digital Output Function from one of the following ConA Contactor A Control ConB Contactor B Control PreHeat Control Preheater prior to cranking O P4 Off Start Warn Turn on output to warn of an impending
41. yed on the LCD Mode Selection The unit may be operated in Auto Manual Test or Stop modes The mode is selected by pressing the appropriate mode button The mode is indicated on the LCD and the LED associated with the mode buttons The engine can be stopped with the Stop button in MANUAL AUTO or TEST modes In MANUAL mode the unit responds only to the manual push button and may control A and B contactors if these options have been enabled In the AUTO mode the unit responds to the autostart input or Remote Starts and controls A and B contactors Page 8 of 30 Re KG934V1 User Manual KIRLOSKAR GREEN POWER IDEAS In TEST mode the engine responds only to the manual start button and runs for a preset test time if configured Contactors are not controlled In STOP mode the unit will enter low power mode which turns off all LED s and sensor checking and will not start the genset To enter STOP mode press the Manual Stop button when the unit is showing READY in the manual mode To exit STOP mode press any button Manual Mode Operation To start the genset When the display is showing READY press the start button momentarily to start the genset Any warning or alarm conditions must be cleared before the genset can be started The unit will perform the starting sequence as follows e PREHEAT o The PREHEAT Output if configured will activate for the time specified e FUEL ON o If ETR Energise To Run fuel con
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