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KG-545

1. K35D01 EN 58 KG 545 User Manual 13 3 ELECTRICAL PARAMETERS GROUP Factory Parameter Definition Unit Set Description This is the rated value of current transformers Current Transformer Ratio A 500 All transformers must have the same rating The secondary of the transformer will be 5 Amps Earth Leakage Current A 500 This is the rated value of earth current transformer Transformer Ratio The secondary of the transformer will be 5 Amps If the current goes above this limit during the period defined in Overcurrent Timeout then a Overcurrent Overcurrent Limit A 700 Load Dump alarm will be generated If this parameter is 0 then Overcurrent check is disabled If the active power goes above this limit during the period defined in Overload Timeout then an Excess Excess Power Limit KW 440 Power Load Dump alarm will be generated If this parameter is 0 then Excess Power check is disabled This is the period between the active power goes over Overload Timeout sec 5 the limits and EXCESS POWER Load Dump alarm occur If one of the mains phases goes under this limit it Mains Voltage Low Limit V 180 means that the mains are off and it starts the transfer to the genset in AUTO mode If one of the mains phases goes over this limit it Mains Voltage High Limit V 260 means that the mains are off and it starts the transfer to the genset in AUTO mode If the mains frequency goes unde
2. Edit parameter value LevelSnd Enable Next Previous H OIL HIGHENGINE BATTERY UNI JER LOW FUEL VER parameter r m r ERATURE V NG V j M l i Mare Se H inside the same group same group Return to the main menu K35D01 EN 53 KG 545 User Manual V 11 12 4 MODIFYING PARAMETER VALUE BAMA e COLIE Tre LUF 103 Decrease parameter Increase cane LOW OIL HIGH ENGINE BATTERY UNDER OVER LOW FUEL parameter PRESSURE TEMPERATURE VOLTAGE SPEED LEVEL value o o O Return to the upper menu 12 5 PROGRAMMING MODE EXIT 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 COMHF IG FCOHTROLLER ELECTRICAL PARAM ACK RESET LOW OIL HIGHENGINE BATTERY UNDER OVER LOW FUEL PRESSURE TEMPERATURE VOLTAGE SPEED LEVEL Oo Press any mode button K35D01 EN 54 KG 545 User Manual V 11 13 PROGRAM PARAMETER LIST 13 1 CONTROLLER CONFIGURATION GROUP Factory Parameter Definition Unit Set Description This parameter is used to set LCD contrast Adjust for Denis I 399 the best viewing angle 0 English language selected 1 Turkish language selected This language may depend on the country where the unit is intended to Language 0 be used 2 Chinese language selected 3 The unit will ask for
3. Noise filtering yes 3 5 ANALOG SENDER INPUTS AND SENDER GROUND Number of inputs 4 inputs all configurable additional sender ground input Function selection from list Structure 667 ohms resistor polarizing to 3 3VDC Measurement Analog resistor measurement Open circuit voltage 3 3VDC Short circuit current 5mA Measurement range 0 to 5000 ohms Open circuit threshold 5000 ohms Resolution 1 ohms 300 ohms or lower Accuracy 2 1 ohm 7 ohms 300 ohms Common mode voltage 3VDC range Noise filtering yes K35D01 EN 17 KG 545 User Manual 3 6 CHARGE INPUT TERMINAL The Charge terminal is both an input and output When the engine is ready to run this terminal supplies the excitation current to the charge alternator The excitation circuit is equivalent to a 2W lamp The threshold voltages for warning and shutdown alarm are adjustable through program parameter Structure battery voltage output through 20 ohm PTC voltage measurement input resolution Output current 160mA 12VDC 80mA 24VDC Voltage measurement 0 1VDC Voltage measurement accuracy 2 0 1V 0 9V 30VDC Alarm Threshold Charge Fail Warning adjustable Threshold Charge Fail Shutdown adjustable Open circuit voltage battery positive Overvoltage protection gt 500VDC continuous with respect to battery ne
4. 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 Canopy Temp Sender Type This parameter selects the temperature sender type 0 The sender characteristics are defined in Sender Characteristics table 1 KOEL 2 VDO 3 KTY13 5 sensor K35D01 EN 63 KG 545 User Manual V 11 13 4 ENGINE PARAMETERS GROUP continued Parameter Definition Unit d dd Description Genset Speed Fail Delay Sec 5 This is the period between the frequency or revolution goes out of the limits and OVERSPEED or UNDERSPEED alarms occur 4 20 mA Oil Pressure 0 0 Disable 4 20 mA Sender Sender Enable 1 Enable 4 20 mA Sender When the 4 20mA sender is enabled the primary oil pressure measurement source is switched to the terminal 16 4 20 mA Sender 4mA bar 0 0 Pressure equivalent of 4mA when 4 20mA oil pressure equivalent pressure sender is enabled 4 20 mA Sender 20mA bar 10 0 Pressure equivalent of 20mA when 4 20mA oil pressure equivalent pressure sender is enabled 13 5 ADJUST DATE AND TIME PROGRHMMING O PROGRHMMING BR eil gel EG ENGINE PARAMETERS Adjust Date ADJUST DATE TIME PADIUST DATE amp TIME Bdiust Month Adrust Month INPUT CONFIGURATION Adtust Year SA Ai 85 12 43 These parameters allow adjusting the batt
5. Use adequate cable section at least 0 75mm AWG18 Follow national rules for electrical installation Current transformers must have 5A output For current transformer inputs use at least 1 5mm section AWG15 cable The current transformer cable length should not exceed 1 5 meters If longer cable is used increase the cable section proportionally Current Transformers must be used for current measurement No direct connection allowed The engine body must be grounded Otherwise faulty voltage and frequency measurements may occur For the correct operation of the exerciser and weekly schedule programs adjust the real time clock of the unit through programming menu K35D01 EN 12 KG 545 User Manual V 11 3 TERMINAL DESCRIPTIONS 3 1 BATTERY VOLTAGE INPUT Supply voltage 8 to 36VDC Cranking dropouts Survives OVDC during 100ms The voltage before surge should be 8VDC minimum Overvoltage protection Withstands 150VDC continuously Reverse voltage 36VDC continuous Maximum operating current 250mA 12 24VDC All options included digital outputs open Typical operating current 100mA 12 24VDC all options passive digital outputs open Measurement range 0 to 36VDC Display resolution 0 1VDC Accuracy 0 5 1 digit 24VDC 3 2 AC VOLTAGE INPUTS Measurement method True RMS Samp
6. The unit is also able to cut cranking from charge alternator voltage and oil pressure input Please read chapter CRANK CUTTING The unit is inoperative Measure the DC supply voltage between terminals BAT and BAT at the rear of the unit If OK turn all fuses off then turn all the fuses on starting from the DC supply fuse Then test the unit again 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 The genset runs but does not take the load Check that the genset Yellow led is on steadily Adjust genset voltage and frequency limits if necessary Check that the digital output 8 is configured as Genset Contactor Check Genset Contactor Timer program parameter Check that a Genset Loading Inhibit input signal is not active Check input functions If an input is configured as Genset Loading Inhibit then check the signal is not present at this input K35D01 EN 86
7. ENGINE SITE ID GENSET AVERAGE BATTERY VOLTAGE ENGINE SERIAL NO GENSET CURRENT R SENDER 4 OIL TEMP FIRMWARE VERSION GENSET CURRENT Y SENDER 5 CANOPY TMP MAINTENANCE COUNTERS GENSET CURRENT B ENGINE HRS amp START CNT lt lt lt ER lt lt Q Q e e Seege GENSET FREQUENCY GENSET TOTAL kw GENSET AVERAGE V GENSET kWh GENSET CURRENT N lt lt lt lt lt lt a lt lt lt lt Q e e e e e e e e K35D01 EN 38 KG 545 User Manual V 11 8 7 LED LAMPS Alarm indicator Load Mains Alarm Reset led button ACK RESET Load Fault Indicator SUG AERIS ager asus E Genset led leds TEST mode AUTO mode MANUAL STOP mode indicator indicator mode indicator indicator Function Color Description MAINS ON Green This led turns on when all mains phase voltages and the mains frequency are within limits If enabled the mains phase rotation order must be also right When a Remote Start signal is present then the mains status will become not available MAINS OFF Red The LED will turn on when at least one of the mains phase voltages or the mains frequency or phase order 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 fl
8. RS 485 Enable I 2 1 RS 485 comm port enabled 0 RAINBOW communication protocol MODBUS Address 0 1 144 MODBUS communication This parameter is also the MODBUS controller address of the unit 0 oil pressure display in bars OLE ue NDS I 1 oil pressure display in psi 0 crank cut is performed through oil pressure switch Low oil pressure switch s 0 and oil pressure sender reading priority 1 crank cut is performed only through oil pressure switch Delayed Simulate Mains Operation max genset running time after Simulate Mains signal disappears Flashing Relay Timer hours 0 Dual Genset Systems flashing relay toggle timer Please contact DATAKOM for dual genset mutual stanby operation This parameter trims precisely the real time clock circuit Values from 0 to 63 speed up the clock with Real Time Clock Adjust 117 0 25sec day steps Values from 127 to 64 slow down the clock with 0 25sec day steps This parameter provides the mains and genset voltage limits with a hysteresis feature in order to prevent faulty decisions Hysteresis Voltage V 8 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 K35D01 EN 56 KG 545 User Manual 13 2 CONTROLLER CONFIGURATION GROUP continued Parameter Definition RPM from genset frequency
9. Unit Factory Set Description This parameter is used in the conversion of the genset frequency to engine rpm 0 read rpm from the optional MPU input 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 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 This parameter controls SMS sending when mains _ voltages status is changed No warnings generated Sls oA Mans Change 0 no SMS when mains failed or restored 1 SMS sent when mains failed or restored If the fuel level measured from the sender input falls Fuel Pump Low Limit 96 20 below this level then the FUEL PUMP function will become active If the fuel level measured from the sender input Fuel Pump High Limit 96 80 goes above this level then the FUEL PUMP function will become passive 0 Oil pressure sender not connected oll Press sender Enable I 1 1 Oil pressure warning and alarm enabled 0 Engine temp sender not connected Engine Temp sender Enable I 1 1 High engine temp warning and alarm enabled 0 Fuel level sender not connected ttt Enab 1 Low fuel level warning and alarm enabled 0 Oil temp sender not connected EE I u 1 High oil temp warning and alarm ena
10. 5 2 AMF functionality CTs at alternator side 5 3 Remote start functionality 5 4 Engine control functionality 5 5 Remote display panel functionality 6 TERMINAL DESCRIPTION 7 TECHNICAL SPECIFICATIONS 8 DESCRIPTION OF CONTROLS 8 1 Front panel functionality 8 2 Pushbutton functions 8 3 Display screen organization 8 4 Alarm display 8 5 Automatic display scroll 8 6 Display navigation map 8 7 Led lamps 8 8 Measured parameters 9 DISPLAYING EVENT LOGS 10 OPERATION OF THE UNIT 10 1 Quick start guide 10 2 Stop mode 10 3 Auto mode 10 4 Manual mode 10 5 Test mode K35D01 EN e KG 545 User Manual V 11 11 PROTECTIONS AND ALARMS 11 1 11 2 Service request warning Alarms and warnings 12 PROGRAMMING 12 1 12 2 12 3 12 4 12 5 Resetting to factory defaults Entering the programming mode Navigating between menus Modifying parameter value Programming mode exit 13 PROGRAM PARAMETER LIST 13 1 13 2 13 3 13 4 13 5 13 6 13 7 13 8 13 9 Programming mode exit Controller configuration group Electrical parameters group Engine parameters group Adjust date and time Digital input configuration Output configuration Input function selection Site id string 13 10 Engine serial number 13 11 Modem1 2 SMS1 2 3 4 5 6 telephone numbers 14 CRANK CUTTING 15 SOFTWARE FEATURES 15 1 15 2 15 3 15 4 15 5 15 6 15 7 15 8 15 9 Remote start operation Disable auto start main
11. Fuel level It Oil temperature C F Canopy temperature C F K35D01 EN sl KG 545 User Manual V 11 9 DISPLAYING EVENT LOGS The unit keeps record of the last 100 events in order to supply information for the service personal The date time 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 Events are kept in a non volatile memory and are not affected from power failures The events are stored in a circular memory This means that a new coming event will erase the oldest recorded event The events are always displayed starting from the most recent one Stored values in an event record are listed below event number event type fault definition see below for various event sources date and time engine hours run operation mode AUTO MANUAL OFF TEST operation status on load on mains cranking etc mains phase voltages R Y B mains frequency genset phase voltages R Y B genset phase currents R Y B genset frequency genset total active power kW genset total power factor oil pressure engine temperature fuel level oil temperature canopy temperature ambient temperature engine rpm battery voltage charge voltage Possible event sources are various Periodic event recorded every 60 minutes when the engi
12. Load Shedding Relay 52 Charge fail alarm 101 21 Flashing Relay 53 102 22 Gas Solenoid 54 Coolant Level AC 103 High Earth Current 23 Fuel Pump switch alarm warning 24 Mains Phase Order 55 104 Gen Low voltge warn Fail 56 IN 1load dump 105 Gen High voltge warn 25 Genset Phase Order 57 N 2load dump 106 Reverse Power warn Fail 58 IN 3load dump 107 High oil temp warn 26 Idle Speed 59 IN 4load dump 108 High canopy temp 27 Cooler Fan 60 IN 5load dump warning 28 61 IN 6load dump 109 29 62 IN 7load dump 110 Low coolant level AC 30 63 IN_8 load_dump switch warning 31 64 Oil sender fail Idd 111 65 Temp sender fail Idd 112 Oil sender fail warn 66 Fuel Lev sender fail Idd 113 Temp sender fail warn 67 Oil Temp snd fail Idd 114 Fuel sender fail warn 68 Canopy Temp snd fail 115 Oil temp snd fail warn Idd 116 Canopy temp snd fail 69 Spare 1 sender fail Idd warning Not functional by the 117 Spare 1 sender fail hardware version 07 warning 70 Spare 2 sender fail Idd Not functional by the 71 hardware version 07 72 Overcurrent load dump 118 Spare 2 sender fail 73 Excess power Idd warning 74 Reverse power Idd 119 75 High Earth current Idd 76 Autostart lock out 77 78 79 Genset Phase Order K35D01 EN Fail Loaddump 69 KG 545 User Manual V 11 13 8 INPUT FUNCTION SELECTION The parameters below define the
13. every parameter may be modified through the front panel regardless of the operating mode When modified program parameters are automatically recorded into a non erasable memory and take effect immediately The program mode will not affect the operation of the unit Thus programs may be modified anytime even while the genset is running K35D01 EN 51 KG 545 User Manual V 11 12 2 ENTERING THE PROGRAMMING MODE To enter the program mode press together Q buttons for 10 seconds When the program mode is entered below password entry screen will be displayed 4 Press 2 buttons for 10 ENTER PRSSWORD 531 x A 4 digit password must be entered using LG ACK RESET and 9 buttons The unit stores 2 different passwords Each password allows access to a different level of program parameters The password level 1 allows access to field adjusted parameters The level 2 allows access to factory setup The password level 1 is factory set to 1234 and the password level 2 is factory set to 9876 Passwords are not front panel adjustable The program mode will not affect the operation of the unit Thus programs may be modified anytime even while the genset is running If a wrong password is entered the unit will still allow access to the program parameters but in read only mode If password 0000 is entered only EVENT LOG file will be available K35D01 EN 52 KG 545 User Manual V 1
14. then a loaddump alarm will be given and the engine will not start OIL PRESSURE SENDER FAULT WARNING LOADDUMP Set if the fault is enabled and the sender is open circuit ENGINE TEMP SENDER FAULT WARNING LOADDUMP Set if the fault is enabled and the sender is open circuit FUEL LEVEL SENDER FAULT WARNING LOADDUMP Set if the fault is enabled and the sender is open circuit OIL TEMPERATURE SENDER FAULT WARNING LOADDUMP Set if the fault is enabled and the sender is open circuit CANOPY TEMPERATURE SENDER FAULT WARNING LOADDUMP Set if the fault is enabled and the sender is open circuit SERVICE REQUEST Set if at least one of the service counters has expired To reset the service period press together ACK RESET and keys during 5 seconds The screen will display Completed A K35D01 EN 50 KG 545 User Manual V 11 12 PROGRAMMING 12 1 RESETTING TO FACTORY DEFAULTS In order to resume to the factory set parameter values hold pressed the OFF ACK RESET and e buttons for 5 seconds RETURN TO FACTORY SET will be displayed immediately press and hold pressed the ACK RESET button for 5 seconds factory set values will be reprogrammed to the parameter memory Y YUETYFY Hold pressed ACK RESET The program mode is used to adjust timers operational limits and the configuration of the unit Although a free PC program is provided for programming
15. ypeg JeulJojJsueJ JUNO yey 11 3334 3536 3738 3940 KG 545 05 co wey dd Vd ON dois se electrical interloc between contactors 06 07 j iz 04 03 Starter Motor Heg esn Battery Negative must be grounded F Av l AYALIVE l eg MAINS L10 L20 L30 No lt DI Z 295 Y Y o 9 ol DEI wn Ka K35D01 EN 25 KG 545 User Manual V 11 5 2 AMF FUNCTIONALITY CTs AT ALTERNATOR SIDE NO 5 1117 O OO lt as 5 o lt OS o lt LH a ou Q HE Fi lt ndw EST i Hi N z ads Ke ads co N 18497 8n4 MOT N 5 N VEJS 9jouiey 2 om BS doe KoueDieu e 58 N eJnsseJd IO MO OO gt d 110 mo im duet u6iH oo aO SS OV 18187 JUEI00 lt N Q zj N s z d LN 99 punoib jepues A A A A 16 SSeJd O VUI0Z r 15 Japuas duet IIO Jepuss dua doueg E el Xd JOpues 197 Jeng 14 3334 3536 3738 3940 KG 545 12 J uuoJsue1u juaunz2 yey J uuoJsue1l juaun yey 11 e ye B ES 88 K Vz vg 2 Za ON E oO oeds 5 pssds elpl AAA 32 Starter Motor 29 30 31 MAINS L10 L20 L30 No lt a Z 2 3 Sub ol o DEI l o x K35D01 EN 26 Battery Negative must be grounded KG 545 User Manual 5 3 REMOTE START FUNCTIONALITY A
16. 05 ALARM Output 1A 28VDC This output controls the audible alarm hooter OUTPUT Term Function Technical data Description 09 RELAY 06 MAINS Output 1A 28VDC This output controls the mains contactor If the CONTACTOR mains phase voltages and frequency are not within limits the mains contactor will be de energized 10 RELAY 07 GENSET Output 1A 28VDC This output controls the mains contactor If the CONTACTOR mains phase voltages and frequency are not within limits the mains contactor will be de energized 11 COOLANT TEMP SENDER Input 0 5000 ohms Analogue temperature sender connection Do not connect the sender to other devices The input has programmable characteristics 12 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 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 ohm value 14 CANOPY TEMPERATURE Input 0 5000 ohms Analogue canopy temperature sender SENDER connection Do not connect the sender to other devices 15 OIL TEMPERATURE Input 0 5000 ohms Analogue oil temperature sender connection SENDER Do not connect the sender to other devices The input has programmable characteristics 16 4 20mA OIL PRESSURE Input 4 20mA This input offers to the user an alternative oil SENDER pressure measurement
17. 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 19 DISPOSAL OF THE UNIT Following DIRECTIVE 2002 96 EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 27 January 2003 on waste electrical and electronic equipment WEEE this unit should be stored and disposed separately from the usual waste 20 ROHS COMPLIANCE The european ROHS directive restricts and prohibits the use of some chemical materials in electronic devices Following the DIRECTIVE 2011 65 EU OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 8 June 2011 on the restriction of the use of certain hazardous substances in electrical and electronic equipment this product is listed in annex I under category Monitoring and control instruments including industrial monitoring and control instruments and exempted from ROHS directive However Datakom is not using any ROHS uncompliant electronic components in the production Only the solder contains lead The switching to unleaded solderin is in progress K35D01 EN 84 KG 545 User Manual V 11 21 TROUBLESHOOTING GUIDE Below is a basic list of most often encountered troubles More detailed investigation may be required in some cases 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 mea
18. are 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 it is 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 MODBUS SUPPORT for more details on MODBUS communication K35D01 EN 80 KG 545 User Manual V 11 15 16 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 or RS 485 Enable 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
19. battery voltage goes over this limit this will A ied Voltage V 300 generate a HIGH BATTERY shutdown alarm and the engine will stop This is the time between the mains voltages entered Mains Waiting Timer min 0 5 within the limits and the generator contactor is deactivated This is the period after the mains contactor has been Genset Contactor Timer sec 1 deactivated and before the generator contactor has been activated This is the period after the generator contactor has Mains Contactor Timer sec 1 been deactivated and before the mains contactor has been activated 0 mains phase order checking disabled Mains Phase Order Enable 0 1 if mains phase order is faulty then a warning is given and mains contactor deenergized If the genset power is negative and goes above this Reverse power warning limit kW 0 limit then a REVERSE POWER warning will be generated Reverse power loaddumpg If the genset power is negative and goes above this limit kW 0 limit then a REVERSE POWER loaddump will be generated If the genset power goes below this limit then the Load Oi Law imi W S load shedding relay will be deactivated I Weg If the genset power goes above this limit then the Load hoqta Limi K 2 load shedding relay will be activated 0 genset phase order checking disabled m SES 0 1 if genset phase order is faulty then a loaddump is generated and the genset stops after cooldown Earth Leakage Current If the earth current goes above this limit
20. below this limit a LOW FUEL LEVEL SENDER warning is generated Low Fuel Shutdown 10 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 Fuel Consumption per Hour 96 This parameter is used to calculate the fuel quantity in the fuel tank in engine hours This is also the threshold for sending FUEL THEFT and FUELLING sms messages If this parameter is set to 0 then no Fuel Theft and Fuelling sms messages will be sent Check chapter 6 19 for details of fuel theft SMS messages Fuel Tank Capacity Its This parameter is used to calculate the fuel quantity in the fuel tank If this parameter is set to zero then the fuel quantity in liters will not be displayed K35D01 EN 62 KG 545 User Manual 13 4 ENGINE PARAMETERS GROUP continued Factory Parameter Definition Unit Set Description Crank Cut Frequency Hz 10 0 When the genset frequency reaches this limit the engine is Supposed running and the crank output will release Crank Stop with Oil 0 0 no crank stop with oil pressure Pressure 1 cranking is stopped when oil presure switch is open or the oil pressure measured is above shutdown limit Crank Stop with Charge 0 0 no crank stop with charge input 1 cranking is stopped when the charge alternator voltage is established Charge input co
21. engine rpm limits are programmed these faults will be equally set using engine rpm limits GENSET LOW HIGH VOLTAGE ALARM Set if any of the generator phase voltages goes outside programmed limits for Genset Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running LOW HIGH BATTERY VOLTAGE WARNING Set if the genset battery voltage is outside programmed limits Low and high limits are separately programmable The low limit is not checked during engine HIGH BATTERY cranking VOLTAGE ALARM CHARGE FAIL Set if a charge alternator failure or broken belt occurs This fault condition may WARNING ALARM result to a warning or alarm following programming LOW OIL PRESSURE Set if a signal is detected at the Low Oil Pressure Switch input or the oil WARNING ALARM 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 Oil Pressure Exists information is displayed 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 WARNING ALARM temperatu
22. for Overload Timer If the power goes below the limit before expiration of the timer then no alarm will be set REVERSE POWER Set if the genset power KW supplied to the load is negative and goes over the WARNING LOADDUMP Reverse Power limit for Overload Timer If the power goes below the limit before expiration of the timer then no alarm will be set HIGH EARTH Set if the earth current goes over the Earth Current Warning or Loaddump CURRENT Limit for Earth Fault Delay Timer If the current goes below the limit before WARNING LOADDUMP expiration of the timer then no alarm will be set Separate loaddump and warning limits are available through program menu GENSET PHASE Set if the genset phase order checking is enabled genset phases are present ORDER FAIL and genset phase order is reversed LOADDUMP MAINS PHASE ORDER Set if the mains phase order checking is enabled mains phases are present and FAIL WARNING mains phase order is reversed This fault prevents the Mains Contactor to close FAIL TO START Set if the engine is not running after programmed number of start attempts In ALARM MANUAL mode only 1 start attempt is performed FAIL TO STOP Set if the engine has not stopped before the expiration of the Stop Timer AUTO START LOCK The warning is set when a remote start signal arrives in MANUAL mode when OUT the engine is in rest position If AUTO mode is selected when this warning is WARNING LOADDUMP present
23. functions of digital inputs selected from a list Functions from 12 to 23 activate also the related operating sequence The related input configuration parameters apply for each input thus any signal can be programmed for NO or NC contact closing to BAT or BAT Fact Parameter Definition Set Description Input 01 Function Select 1 High Temp Switch Input 02 Function Select 0 Oil Pressure Switch Input 03 Function Select 4 Emergency Stop Input 04 Function Select 20 Force to Start Input 05 Function Select 7 Low Fuel Level Switch Input 06 Function Select 11 Spare 1 Input Input 07 Function Select 10 Spare 2 Input Input 08 Function Select 2 Coolant Level Switch INPUT FUNCTION SELECT LIST Number Description 0 Oil Pressure Switch 1 High Temp Switch 2 Low Coolant Level switch 3 Rectifier Fail 4 Emergency Stop 5 Alternator High Temp 6 Door Open 7 Low Fuel Level Switch 8 Earthquake Detector 9 Annunciator Mode Enable 10 Spare 2 Input 11 Spare 1 Input 12 Force AUTO Mode 13 Force OFF Mode 14 Force TEST Mode 15 Overload Input 16 By Pass I P Input 17 Priority Input 18 Remote Start Input 19 Disable Auto Start 20 Force to Start 21 Fault Reset 22 Alarm Mute 23 Panel Lock K35D01 EN 70 KG 545 User Manual V 11 13 9 SITE ID STRING The site identity string is designed to identif
24. mains availability and the load will be transferred to the genset The genset will feed the load indefinitely unless another mode is selected K35D01 EN 46 KG 545 User Manual V 11 11 PROTECTIONS AND ALARMS The unit provides 3 different protection levels being warnings loaddumps and shutdown alarms 1 SHUTDOWN ALARMS These are the most important fault conditions and cause The ALARM led to be on steadily The genset contactor to be released immediately The engine to be stopped immediately 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 The 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 Wanrning digital outputs to operate if selected via programming menu 3 WARNINGS These conditions cause The ALARM led to flash The Horn and Alarm Load_dump Warning digital outputs to operate if selected via programming menu to the ALARM LIST page A If a fault condition occurs the display will automatically switch Alarms operate in a first occurring basis If a shutdown alarm is present following shutdown alarms loaddumps and warnings will not be accepted If a loaddump is present following loaddumps and warnings will not be accepted If a warning is pr
25. required Common mode voltage 0 5 VDC to 7VDC internally clamped by transient suppressors Max distance 1200m 9600 bauds with 120 ohms balanced cable The RS 485 port features MODBUS RTU protocol Multiple modules up to 128 can be paralleled on the same RS 485 bus for data transfer to automation or building management systems The Modbus register list is available at Datakom technical support The RS 485 port provides also a good solution for distant PC connection where Rainbow program will enable programming control and monitoring JAM 4 d d x S A ENSEM Sere t The RS 485 port is not isolated The external MODBUS device communicating with the unit should use the same potential as qround reference K35D01 EN 22 KG 545 User Manual V 11 4 FUNCTIONALITIES The same unit provides different functionalities through parameter setting Thus a single stock item will fulfill various duties minimizing stock cost 4 1 CT LOCATION SELECTION CTs may be placed at alternator or load busbars The CT location selection is configured with Controller Configuration gt CT Location parameter When CTs are located at the alternator side them mains current and power parameters will not be displayed When CTs are located at load side then both mains and genset currents and power parameters will be displayed based on contactor positions Please review AMF functionality connection diagrams for CT
26. supply voltage Voltage at measuring terminals beyond specified range Voltage applied to digital inputs over specified range Current at measuring terminals beyond specified range t Overload or short circuit at relay outputs Connecting or removing data terminals when the unit is powered up High voltage applied to communication ports Ground potential differences at non isolated communication ports Excessive vibration direct installation on vibrating parts Current Transformers must be used for current measurement No direct connection allowed Below conditions may cause abnormal operation Power supply voltage below minimum acceptable level Power supply frequency out of specified limits Phase order of voltage inputs not correct Current transformers not matching related phases 0 Current transformer polarity incorrect Missing grounding K35D01 EN f KG 545 User Manual V 11 2 MOUNTING 2 1 DIMENSIONS Dimensions 202x148x48mm 7 95 x5 8 x1 9 Panel Cutout 183x134mm minimum 7 2 x5 3 Weight 400g 1 Ib ACK RESET 148mm LOW OIL_ HIGH ENGINE BATTERY UNDER OVER LOW FUEL PRESSURE TEMPERATURE VOLTAGE SPEED LEVEL START 202mm x I Earth RS 232 A6 RS485 L 8 to 35Vdc 300mA max SERIAL TOR 47 RS485 GND N ER aan Hz C AV JE wy Cain xj z A q u gt oju
27. 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 R 16bit x10 Mains frequency 0013 R 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 R 16bit x1 Engine speed rpm 002B R 16bit x10 Oil pressure in bars 002C R 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 run mode bit 7 test mode K35D01 EN 83 KG 545 User Manual V 11 17 DECLARATION OF CONFORMITY The unit conforms to the EU directives 2006 95 EC low voltage 2004 108 EC electro 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 certification teting in progress UL 508 Edition 17 UL 2200 1st Edition UL 840 Edition 3 CSA C22 2 NO 14 Edition 10 18 MAINTENANCE
28. 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 K35D01 EN 55 KG 545 User Manual 13 2 CONTROLLER CONFIGURATION GROUP continued Parameter Definition Unit su Description Exercise Duration min 10 This parameter defines the exercise duration and programmed in 10 minute steps up to 24 hours Exercise Off On Load 0 x GER oo 0 exercise every day the exercise will be performed every day regardless of the day selection of Exercise Dat and Time parameter Exercise Period 1 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 0 DISABLE AUTO START input has normal function Delayed Simulate Mains _ 0 1 DISABLE AUTO START input has delayed simulate mains function See chapter 6 7 for more info 0 AMF unit mains values are displayed AMF Remote Start Device 0 1 Remote Start Unit mains values are not displayed 0 The serial port is connected to PC Modem Enable I g 1 Modem connected 0 SMS not enabled SMS Enable I 1 SMS enabled 0 RS 232 comm port enabled
29. 1 12 3 NAVIGATING BETWEEN MENUS The program mode is driven with a two level menu system The top menu consists on program groups and each group consists on various program parameters When program mode is entered a list of available groups will be displayed Navigation between different groups are made with LG and 9 buttons A character will appear at the first column of the selected group In order to enter inside a group please press In order to exit from the group to the main list please press STOP button Enter inside the group Previous group OO PROGRAMCI NG DISFLAY EVEHT LOG PCOMTROLLER CONFIG ELECTRICAL PARAM y Next group HIGH ENGINE BAT RY E TEMPERATUR OLTAGE Exit from PGM menu Navigation inside a group is made also with and M buttons A list of available parameters will be displayed A Je character will appear at the first column of the selected parameter In order to display change the value of this parameter press button Parameter value may be increased and decreased with and buttons If these buttons are hold pressed the program value will be increased decreased by steps of 10 When a program parameter is modified it is automatically saved in memory If button is pressed next parameter will be displayed If button is pressed then the list of parameters in this group will be displayed KLOSKA PETER kLCD Contrast Fuel
30. 6 F Maximum humidity 95 non condensing Dimensions 202x148x48mm WxHxD Panel Cut out dimensions 183 x 134mm 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 Mounting Flush mounted with rear retaining plastic brackets EU Directives Conformity 2006 95 EC low voltage 2004 108 EC electro magnetic compatibility Norms of reference EN 61010 safety requirements EN 61326 EMC requirements UL Compatibility UL 508 Industrial Control Equipment CSA Compatibility CAN CSA C22 2 No 14 2005 Industrial Control Equipment K35D01 EN 32 KG 545 User Manual V 11 8 DESCRIPTION OF CONTROLS 8 1 FRONT PANEL FUNCTIONALITY Graphic LCD screen Next display Mimic Diagram sysem status Next screen in the same group LAMP TEST if held pressed Alarm Mute amp AQ M E Reset button SN La Mains ACK RESET a Contactor control in Fault condition LOWOIL HIGHENGINE BATTERY UNDER OVER LOW FUEL RUN mode PRESSURE TEMPERATURE VOLTAGE SPEED LEVEL indicators POWER 1DE A S Genset Contactor control in RUN mode TEST mode button AUTO mode button MANUAL mode button STOP mode button RUN mode button K35D01 EN 33 KG 545 User Manual V 11 8 2 PUSHBUTTON FUNCTIONS BUTTON FUNCTION Selects TEST mode The g
31. AY If a fault condition occurs the display will automatically switch to the ALARM LIST page If an alarm or warning occurs during operation in other then programming mode the display will automatically switch to ALARM LIST position The or buttons will not function To enable display navigation and mute the internal buzzer press ACK RESET 63 tton first If there is more than one alarm the next alarm is displayed by pressing the e button Thus all existing alarms can be scanned END OF ALARM LIST will be displayed when there is no more alarm to display 8 5 AUTOMATIC DISPLAY SCROLL The unit will automatically scroll all Mains Genset and Engine measurements with 4 seconds interval When a front panel button is pressed the scrolling is suspended during 2 minutes K35D01 EN 37 KG 545 User Manual V 11 8 6 DISPLAY NAVIGATION MAP lt MAIN MENU ITEMS gt GENSET ENGINE MAINS e ALARM o GSM MODEM STATUS amp ELECTRICAL ELECTRICAL PARAMETERS PARAMETERS LIST PARAMETERS COUNTERS ES 10 Eu 10 10 ES 10 E 10 Es io Eg PARAMETERS 4 SUB MENU ITEMS 4 e D COMPANY LOGO GENSET SENDER 1 OIL PRESS MAINS VOLTAGES VOLTAGES GENSET CURRENTS SENDER 2 ENG TEMP MAINS CURRENTS ALARM GENSET kW amp pf SENDER 3 FUEL LEVEL MAINS FRQ amp AVG NEXT ALARM DATE amp TIME AER GENSET kVA amp kVAr
32. K35D01 EN 68 KG 545 User Manual V 11 OUTPUT FUNCTION LIST 00 Fuel 32 IN_1 alarm 80 IN_1 warning 01 Alarm 33 IN 2 alarm 81 IN_2 warning 02 Start 34 IN 3 alarm 82 IN_3 warning 03 Stop 35 IN 4 alarm 83 IN_4 warning 04 Gen Contactor 36 IN 5 alarm 84 IN_5 warning 05 Mains Contactor 37 IN_6 Alarm 85 IN_6 warning 06 Choke 38 IN_7 Alarm 86 IN_7 warning 07 Preheat 39 IN 8 Alarm 87 IN_8 warning 08 Shutdown alarm 40 Oilsender alarm 88 Oil sender warning 09 Shutdown or 41 Temp sender alarm 89 Temp sender warn load_dump alarm 42 Low speed alarm 90 Low speed warning 10 Shutdown or 43 High speed alarm 91 High speed warning load dump or warning 44 Low voltage alarm 92 Autostart lock out 11 Automatic ready 45 High voltagealarm 93 Low Temp snd warn 12 Week on time 46 Fail to start alarm 94 Fail to stop warning 13 Exerciser on 47 Low fuel sender alarm 95 Low fuel sender warn 14 Load dump alarm 48 Oil Temp sender alarm 96 Service request warn 15 49 Canopy Temp sender 97 Mains Phase Order 16 Mains Fail alarm Fail warning 17 Block Heater 50 98 Low battery warning 18 Service Request 51 High battery voltage 99 High battery warning 19 alarm 100 Charge fail warning 20
33. KG 545 User Manual D DATAKOM V 11 KG 545 AUTOMATIC MAINS FAILURE UNIT ACK RESET LOWOIL HIGH ENGINE BATTERY UND PRESSURE TEMPERATURE VOLTAGE DI ER OVER LOW FUEL OVER PEED LEVEL LOAD FEATURES Automatic mains failure Engine control Generator protection Built in alarms and warning Manual control enabled Magnetic pickup input Dual genset mutual standby operation Load shedding dummy load Gas engine support Engine idle speed control True RMS measurements 3 phase mains voltage inputs 3 phase genset voltage inputs 3 phase genset load CT inputs Engine oil pressure measurement Engine coolant temperature measurement Fuel level measurement Oil temperature measurement Canopy temperature measurement Canopy temperature measurement Genset active power measurement Genset power factor measurement Engine rpm display Periodic maintenance request indicator Engine hours counter Event logging with date time stamp and complete measurement values Remote Panel Feature 4 20mA Oil pressure measurement e v ISO 9001 UKAS Registered am 015 NA Stores last 100 events Statistical counters Battery backed up real time clock 3 level password protection Programmable parameters Return to factory settings enabled RS 232 RS 485 selectable serial port Firmware downloadable from serial port Free MS Windows Remote monitoring SW local and modem connection monitoring download of paramet
34. LTERNATOR LOAD oL1 oL2 oL3 oN snj sn3 41 a o Genset Contactor 7 Bat o Qo l EE O D c lt c mM mM ce co LO CH t oD se e J9UJJOJSUEJ ju9JJn7 yeg J9UJJOJSUEJ JUSIUND yeg L10 L20 L30 No K35D01 EN 42 43 44 10 32 29 30 31 RS 232 RS 485 Serial Input Output RS 485 B RS 485 GN 27 Extension 18 19 20 21 22 23 242526 2728 12 13 14 15 16 17 11 05 V 11 7 fidIN NdW eieds z ejeds L eieds 18497 Ian MOT Hes eJoue x dois AoueBJjeui3 eunsseJg IO MOT duet UBIH OV I A811uelooo punoi6 sapuss SS 1d IO VWOZ Jepues duet IIO L gt 2 ka 8B ao eq Battery Negative must be grounded KG 545 User Manual 5 4 ENGINE CONTROL FUNCTIONALITY K35D01 EN 25 0 98 x zd a eo oam 9 naW N adgs z aeds ads 9 91 8n4 MOT pejs gouen doe AoueBueur3 eJnsseJd IO MO duet UBIH OV I8A811ue ooO 18 19 20 21 22 23 24 25 26 10 17 punoi6 18pues SSeld WO VWOC 15 Japuas duet WO XL Japuas dual IM 14 12 11 3334 3536 3738 3940 KG 545 _ S 2 o fo SE S8 Ka eg lt A Z SE 33 9 a ol DEI DEI o e 28 Battery Negative must be grounded V 11 V 11 KG 545 User Manual 5 5 REMOTE DIS
35. Neutral terminal for the mains phases Term Function Technical data Description 33 CURR E S2 Current transformer Connect the earth current transformer inputs 5A AC terminals to these inputs 34 CURR E S1 35 CURR 3 S1 Current transformer Connect the load current transformer inputs 5A AC terminals to these inputs Do not connect the 36 CURR 3 S2 same current transformer to other instruments otherwise a unit fault will occur Connect each 37 CURR 2 S1 terminal of the transformer to the units related terminal Do not use common terminals Do not use grounding Correct polarity of 38 CURR 2 S2 Ge is SCH If the Se power is negative then change the polarity of each 3 39 CURR_1 S1 current transformers The rating of the transformers should be the same for each of 40 CURR_1 S2 the 3 phases The secondary winding rating shall be 5 Amperes For ex 200 5 Amps Term Function Technical data Description 41 GENERATOR NEUTRAL Input 0 300V AC Neutral terminal for the generator phases 42 GEN L3 Generator phase Connect the generator phases to these inputs 43 GEN L2 inputs 0 300V AC The generator phase voltages upper and 44 GEN L1 lower limits are programmable Term Function Technical data Description 45 RS 485 A Input output This is A terminal of the RS 485 port 46 RS 485 B Input output This is B terminal of the RS 485 port 47 RS 485 GND Output This terminal is internally connected to battery negativ
36. Oil Pressure Warning bar 1 5 If the oil pressure measured from the analog input falls below this limit this will generate a LOW OIL PRESSURE SENDER warning 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 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 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 Oil Pressure Sender type This parameter selects the oil 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 O O1 Q N ch 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 Engine Heating Temperature C If it is requested that the engine runs
37. PLAY PANEL FUNCTIONALITY Nd NdW 8c 4c AVCICL es AYSLLIVE ee de de de de z oeds esnJj y ads ds IL oe 9 ae G ae oe ag Aejdsiq ejoues Eg 92 Ge vc EC Ce LC OC GL 8L AL 9L SL VLEL CL LL GO 80 2090 vO 0 zO uolsua xy yndyno 1ndu lenas c c SH SVS OM Ly OLOVGE STE Q9EGE PELE 60 CE LE OE GC vv ev Ch ED LI Di t Oo N AJUO pue uo WO PUNDID x NS cer Su lx 9v g Sgr SM SG uod G8 S4 Sp eued 01 U09 UIEN OL V 881 SH Z Ka o Q LO CO x KG 545 User Manual 6 TERMINAL DESCRIPTION V 11 Term Function Technical data Description 01 BATTERY NEGATIVE OVDC Power supply negative connection 02 BATTERY POSITIVE 12 or 24VDC The positive DC Supply terminal for both 12V and 24V battery systems Term Function Technical data Description 03 RELAY 01 CRANK Output 1A 28VDC This output controls the engine cranking OUTPUT 04 RELAY 02 FUEL OUTPUT Output 1A 28VDC Fuel solenoid output 05 CHARGER WL Input 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 06 RELAY 03 IDLE OUTPUT Output 1A 28VDC This output controls the idle speed operation 07 RELAY 04 STOP OUTPUT Output 1A 28VDC This output controls the engine stop solenoid 08 RELAY
38. Unit Fac Set Description Action Shutdown the engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operation Sampling Always After holdoff timer When mains present Latching Non latching Latching Contact type Normally open Normally closed Switching Battery negative Battery positive Response delay ch Oj O O O N OO N O No delay Delayed 4sec Input Configuration 08 Low Coolant Level Input Parameter Definition Unit Fac Set Description 0 Shutdown the engine stops immediately Action 3 1 Load Dump the engine stops after cooldown 2 Warning the horn relay operates 3 No operation 0 Always Sampling 0 1 After holdoff timer 2 When mains present 0 Non latching Latching 1 Latching 0 Normally open Contact type 1 1 Normally closed UMS 0 Battery negative Switching i 1 Battery positive 0 No delay Response delay 0 1 Delayed 4sec K35D01 EN 67 KG 545 User Manual V 11 13 7 OUTPUT CONFIGURATION The parameters below define the functions of digital outputs The unit has 7 digital outputs All outputs have programmable functions selected from a list The relays may be extended up to 23 using Relay Extension Modules RELAY 1 function is always CRANK not selectable RELAY 2 function is always FUEL
39. adjusted with the parameter Idle Speed Timer The idle speed will be set by the governor control unit of the engine Any digital output may be assigned as IDLE output using Relay Definition program parameters The Idle speed operation is performed both in engine start up and cool down sequences Low speed and low voltage protections are disabled during idle speed operation K35D01 EN 77 KG 545 User Manual V 11 15 10 Engine Block Heater The unit is able to provide a digital output in order to drive the block heater resistor The temperature reference is the coolant temperature measured from the analog sender input The block heater output function may be assigned to any digital output using Relay Definition program parameters 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 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 15 11 Fuel Pump Control The unit is able to provide a digital output function 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
40. ash when the engine is running It will turn on steadily when all 3 generator phase voltages and the genset frequency are within limits If enabled the genset phase rotation order must be also right TEST Yellow It turns on when the related operation mode is selected One of these LEDs is always on and S A j indicates which operation mode is selected AUTO Green If the operation of the genset is disabled by the MANUAL Yellow weekly operation schedule then the AUTO led will flash K35D01 EN 39 KG 545 User Manual V 11 Function Color Description ALARM Red If a fault condition resulting to the engine shutdown has occurred the 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 LOW OIL PRESSURE Red Turns on when a low oil pressure condition is detected either from the sender or switch input HIGH ENGINE TEMP Red Turns on when a high coolant temperature condition is detected either from the sender or switch input BATTERY VOLTAGE Red Turns on when a low or high battery voltage condition is detected UNDER OVER SPEED Red Turns on when a low or high speed condition is detected LOW FUEL LEVEL Red Turns on when a low fuel level condition is detected either from the sender or switch input OVERCURRENT Red Turns on when overcurrent c
41. 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 immediately 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 K35D01 EN di KG 545 User Manual V 11 15 7 Weekly Operation Scheduler 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 scheduler is active only in AUTO mode When the scheduler prevents genset operation in AUTO mode the AUTO led will flash When the scheduler prevents genset operation in AUTO mode the AUTO led will flash The scheduler consists of 144 programmable parameters one for each hour in a week Thus every hour of the week may be independently selected as ON or OFF times These programmable parameters allow the genset to operate automatically only in allowed time limits The unit has a battery backed
42. bled Canopy Temp Sender _ 0 0 Canopy temp sender not connected Enable 1 High canopy temp warning and alarm enabled 0 no effect eue sender fault 0 1 waming 2 loaddump 0 no effect er temp sender fault _ 0 1 warning 2 loaddump 0 no effect Fuel level sender fault effect 0 1 warning 2 loaddump 0 no effect Oil temp sender fault effect 0 1 warning 2 loaddump 0 no effect a temp sender fault _ 0 1 waming 2 loaddump Spare 2 sender fault effect 0 no effect not active if the terminal is 0 1 warning configured as sender ground 2 loaddump K35D01 EN 57 KG 545 User Manual V 11 13 2 CONTROLLER CONFIGURATION GROUP continued Factory Set This parameter enables the Coolant Level AC Input RE SEET 0 0 Coolant Level AC input not monitored H 1 Coolant Level AC input monitored Parameter Definition Unit Description This parameter enables the Weekly Scedule Timer Disable Weekly timer 0 0 Weekly Schedule Timer is enabled 1 Weekly Schedule Timer is disabled 0 Current transformers at alternator side CT Location i 0 1 Current transformers at load side This parameter defines the period of LCD backlight is lighted up and at the end of this period the LCD backlight will light out automatically LCD backlight LCD Backlight Timer hour 1 timer is restarted by pressing any of navigation pushbuttons or engine running state When this parameter set to 0 the LCD backlight is lighted up permanently
43. capability and must be programmed before using Refer to Chapter 8 for more detail 17 SENDER GROUND Input 3VDC or Used as sender ground SPARE ANALOG INPUT 2 Input 0 5000 ohms K35D01 EN 90 KG 545 User Manual V 11 Term Function Technical data Description 18 COOLANT LEVEL Digital input This terminal drives the coolant level sensor with AC signal and senses the coolant liquid level 19 IN 1 HIGH TEMP Digital inputs These inputs have programmable 20 IN 2 LOW OIL PRESSURE characteristics selected via the program 21 IN 3 EMERGENCY STOP menu Each input may be driven by a 22 IN 4 AUTO START normally closed or normally open contact 23 IN 5 LOW FUEL LEVEL switching either to battery or battery The 24 IN 6 SPARE 1 effect of the switch is also selectable from a 25 IN 7 SPARE 2 list See PROGRAMMING section for more 26 IN 8 Low Coolant Level Sw details Term Function Technical data Description 27 MAGNETIC PICKUP Inputs 1 30V Connect the magnetic pickup signal to these 28 MAGNETIC PICKUP 0 8KHz inputs Term Function Technical data Description 29 MAINS L1 Mains phase inputs Connect the mains phases to these inputs 30 MAINS L2 0 300V AC The mains voltages upper and lower limits are 31 MAINS L3 programmable 32 MAINS NEUTRAL Input 0 300V AC
44. connection details 4 2 AMF FUNCTIONALITY When AMF functionality is selected the unit will monitor mains voltages provide mains and genset contactor control run the engine and provide engine and alternator instrumentation and fault monitoring 4 3 REMOTE START FUNCTIONALITY When the Remote Start functionality is selected the unit will wait for a Remote Start signal from external controller Upon reception of this signal it will run the engine and provide engine and alternator instrumentation and fault monitoring The genset contactor control functionality will be available The unit features both MPU and J1939 CANBUS inputs Thus both mechanical and electronic engines are supported K35D01 EN 23 KG 545 User Manual V 11 4 4 REMOTE DISPLAY UNIT FUNCTIONALITY The standard KG 545 unit may be configured as a remote display and control panel of another KG 545 unit The remote panel will have identical display and led status with the main unit and will allow the user to control the main unit with pushbuttons on the remote panel The remote display control panel needs to have the same RS 485 parameter settings with the main unit On the remote display control panel one of the digital inputs must be configured as Annunciator Mode Enable The remote panel will be connected to main unit through RS 485 lines and a modbus communication is established when Annunciator Mode Enable signal is applied to the display panel Th
45. 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 Pl MBUS 200 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 W DATA COEFFICIENT DESCRIPTION hex 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 R 16bit x1 Genset Phase L1 current 0007 R 16bit x1 Genset Phase L2 current 0008 R 16bit x1 Genset Phase L3 current 000C R 16bit x1 Mains Phase L12 voltage 000D R 16bit x1 Mains Phase L23 voltage 000E R 16bit x1 Mains Phase L31
46. e Connect the shield of the RS 485 cable to this terminal from one end only K35D01 EN 31 KG 545 User Manual V 11 7 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 8 0 Vpc to 36 0 VDC Cranking dropouts survives 0 V for 100ms Typical stand by current consumption 130 mADc Maximum current consumption 250 mADc Charge alternator excitation current min 150 mApc 10 to 30 Voc Current inputs from current transformers 5A Max load 0 7VA per phase Accuracy Voltage 0 5 1 digit Current 0 5 1 digit Frequency 0 5 1 digit Power kW kVAr 1 0 2digit Power factor 0 5 1digit Magnetic pickup input 0 5 30 Vac Magnetic pickup frequency 8KHz max Digital inputs input voltage 0 36 VDc Internally connected to battery positive via 4700 ohm resistor Analog inputs Resistor input 0 to 5000 ohms connected to the battery negative Sources 5 mA when closed to battery negative Digital outputs 1A 28 Vpc Protected semiconductor outputs Measurement category CAT II Air category Pollution degree Il Communication port RS 232 RS 485 9600 bauds no parity 1 stop bit Operating temperature range 20 C to 70 C 4 F to 158 F Storage temperature range 40 C to 80 C 40 F to 17
47. e data rate between the remote panel and the main unit is 9600 bps and this allows up to 1200m distance between 2 units For the best results a balanced low capacitance 120 ohms coaxial cable should be used for the RS 485 connection Necessary program parameter setting is listed below PARAMETER MAIN UNIT REMOTE DISPLAY UNIT RS 485 Enable 1 1 Modbus Address 1 1 same as main unit Digital Input 8 Function any Annunciator Mode Enable Digital Input 8 Signal x 0 Run Normally 1 Run In Remote Panel The remote display panel should be powered up with an isolated voltage source like a wall adapter Otherwise damages due to ground potential differences may occur K35D01 EN 24 KG 545 User Manual V 11 5 CONNECTION DIAGRAMS 5 1 AMF FUNCTIONALITY CTs AT LOAD SIDE gt TNO 2 x Diz o O 0000 D gt e lt 2 5 D Z S2 D D 22 HI C SP o E EHT H H a N eT ae E 3 o e N aedg Sen io S 2 N z adgs X eN ads e N 8487 N4 MOT N b e 5 SS pejs ejouey EXE ER e doe uefiaou pg c o 58 a eJnsseJd IO MO OO o d IIO mo duet uBiH co Ovieeiiuepoo 9 1 punoJB 18pues Batz O 17 LOAD No KREE A A A A 16 Ss 1d IIO VWOZ y CI 1 1 1 1 1 ch AE dD 15 J pu duel IIO J pu duie doueg mow J8pUSS AS On NJ 14 12 J pu s sseJg IO J pu duel Jop NJ J8UO SUEIL juan
48. e same event When the last page is reached it will return to the first page To exit event record pages press STOP button K35D01 EN 43 KG 545 User Manual V 11 10 OPERATION OF THE UNIT 10 1 QUICK START GUIDE STOPPING THE ENGINE Press STOP Ox vcr the engine will enter cooldown mode Press again STOP button for immediate stop STARTING THE ENGINE Press MANUAL 20 then press RUN Q MANUAL LOAD TRANSFER Use MAINS and sense buttons LOAD TEST Press TEST Devon The genset will run and take the load AUTOMATIC OPERATION Press AUTO button Mode can be changed anytime without negative effect Changing the operation mode while the genset is running will result into a behavior suitable for the new operating mode 10 2 STOP MODE The STOP mode is entered by pressing the button In this mode the genset will be in a rest state When STOP mode is selected if the genset is running under load then it will be immediately unloaded The engine will continue to run during Cooldown Timer and will stop afterwards If the STOP button is pressed again then the engine will immediately stop If the engine fails to stop after the expiration of Stop Timer then a Fail to Stop warning will occur In this mode the mains contactor will be energized only if mains phase voltages and frequency are within the programmed limits If enabled the mains phase order is also checked If a Remote Start or Force to Star
49. e unit has an additional 4 20 mA oil pressure input that can be used instead of the resistive sender input 4 20 mA sender parameters are placed in ENGINE PARAMETERS group It is possible to configure the pressure values for 4 and 20mA enabling the use of various products The 4 20mA sensor has priority thus when the 4 20 mA oil pressure sensor is enabled the measurement coming from the 4 20mA sensor will replace the oil pressure measurement coming from the resistive sender input The OIL PRESSURE SENDER FAULT parameter will define the alarm level caused by the misconnection of the 4 20 mA sensor K35D01 EN 9 E KG 545 User Manual V 11 15 15 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 When the modem call is in progress a telephone icon BB will appear at the upper right corner of the screen If Modem Enable or SMS Enable or MODBUS Address or RS 485 Enable parameters
50. ects of 2 5 mm diameter and greater 4 Protected against solid foreign objects of 1 0 mm diameter and greater 5 Protected from the amount of dust that would interfere with normal operation 6 Dust tight 2nd Digit 0 Not protected 1 Protected against vertically falling water drops 2 Protected against vertically falling water drops when enclosure is tilted up to 15 3 Protected against water sprayed at an angle up to 60 on either side of the vertical 4 Protected against water splashed against the component from any direction 6 Protected against water projected in powerful jets from any direction 7 Protected against temporary immersion in water 8 Protected against continuous immersion in water or as specified by the user K35D01 EN 11 KG 545 User Manual V 11 2 3 ELECTRICAL INSTALLATION Do not install the unit close to high electromagnetic noise emitting devices like contactors high current busbars switchmode power supplies and the like Although the unit is protected against electromagnetic disturbance excessive disturbance can affect the operation measurement precision and data communication quality ALWAYS remove plug connectors when inserting wires with a screwdriver Fuses must be connected to the power supply and phase voltage inputs in close proximity of the unit Fuses must be of fast type FF with a maximum rating of 6A Use cables of appropriate temperature range
51. ely Load Dump the engine stops after cooldown Warning the horn relay operates No operation Action 0 Always After holdoff timer When mains present Sampling 1 Non latching Latching 1 Latching Normally open Contact type 0 Normally closed Battery negative Switching 9 Battery positive No delay Response delay 0 Delayed 4sec Oje O O ON OO ND K35D01 EN 65 KG 545 User Manual Input Configuration 03 Emergency Stop Parameter Definition Unit Fac Set Description Action Shutdown the engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operation Sampling Always After holdoff timer When mains present Latching Non latching Latching Contact type Normally open Normally closed Switching Battery negative Battery positive Response delay Oj O sch Cl sch O N O O N oO No delay Delayed 4sec Input Configuration 04 Force to Start Parameter Definition Unit Fac Set Description Action Shutdown the engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operation Sampling Always After holdoff timer When mains present Latching Non latching Latching Contac
52. enset runs and takes the load Selects AUTO mode The genset runs when necessary and takes the load Selects MANUAL mode The genset operation is controlled manually with front panel pushbuttons Active only when MANUAL mode is selected The genset runs off load Selects STOP mode The genset stops FUNCTION Selects next display group Selects next display screen in the same display group Resets existing ALARMS Performs LAMP TEST when held pressed during 5 sec Manual MAINS CONTACTOR control in MANUAL mode Manual GENSET CONTACTOR control in MANUAL mode When held pressed for 10 seconds enters PROGRAMMING mode m z 5 S 066 roO Q f 34 KG 545 User Manual V 11 8 3 DISPLAY SCREEN ORGANIZATION The unit measures a large number of electrical and engine parameters The display of the parameters is organized as PARAMETER GROUPS and items in a group Navigation between different groups are made with e button Each depression of the e button will cause the display to switch to the next group of parameters After the last group the display will switch to the first group Navigation inside a groups is made with e button Each depression of the button will cause the display to switch to the next parameter in the same group After the last parameter the display will switch to the first parameter Below is a basic list of parameter group
53. ers networking via modems GSM and PSTN modem support GSM SMS sending on fault Modem calls on fault MODBUS communication 128x64 graphic LCD display Multiple language support Customer logo display Analogue inputs 5 Digital inputs 9 Digital outputs 7 Input output expansion capability Remote Start operation available Engine Idle speed control Survives cranking dropouts Sealed front panel Plug in connection system for easy replacement Dimensions 202x148x48mm KG 545 User Manual V 11 COPYRIGHT NOTICE Any unauthorized use or copying of the contents or any part of this document is prohibited This applies in particular to trademarks model denominations part numbers and drawings ABOUT THIS DOCUMENT This document describes minimum requirements and necessary steps for the successful installation of the KG 545 family units Follow carefully advices given in the document These are often good practices for the installation of genset control units which reduce future issues For all technical queries please contact Datakom at below e mail address datakom datakom com tr RELATED DOCUMENTS FILENAME DESCRIPTION MODBUS_FOR_545 pdf KG 545 Modbus Manual DUAL GENSET APPLICATION pdf Dual Genset Mutual Standby Application Guide appnote 545 firmware download pdf Firmware Download Guide REVISION HISTORY REVISION DATE AUTHOR DESCRIPTION 01 23 03 2012 MH First issue firmware vers
54. ery backup real time clock of the module Once set the clock will continue to run even if DC power is removed from the unit Parameter Definition Unit Min Max Description Date 01 31 Current day of the month Month 01 12 Current month Year 00 99 Last two digits of the current year Hours 00 23 Current hour of the day Minutes 00 59 Current minute of the hour Seconds 00 59 Current second of the minute K35D01 EN 64 KG 545 User Manual V 11 13 6 DIGITAL INPUT CONFIGURATION E Te Inrut dHWl Hish Temr Suitch ACT SAMF The unit has 8 digital inputs By using external input extension modules up to 24 inputs in total are available Input Configuration 01 High Temperature Switch Parameter Definition Unit Fac Set Description Shutdown the engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operation Action 0 Always After holdoff timer When mains present Sampling 1 Non latching Latching 1 Latching Normally open Contact type 0 Normally closed Battery negative Switching 9 Battery positive No delay Delayed 4sec Oje Oje O OJN O ON Response delay 0 Input Configuration 02 Low Oil Pressure Switch Parameter Definition Unit Fac Set Description Shutdown the engine stops immediat
55. esent following warnings will not be accepted If the ACK RESET button is pressed the Alarm output will be deactivated however the existing alarms will persist and disable the operation of the genset A second press on ACK RESET button will clear existing alarms 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 Existing alarms may be canceled by pressing one of the operating mode buttons Most of the alarms have programmable trip levels See the programming chapter for adjustable alarm limits K35D01 EN 47 KG 545 User Manual V 11 11 1 SERVICE REQUEST WARNING The SERVICE REQUEST 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 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 warning 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 un
56. eter 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 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 Disable Auto Start operation When both Remote Start Operation and Delayed Simulate Mains are enabled then REMOTE START operation mode is performed K35D01 EN 74 KG 545 User Manual V 11 15 4 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 paramete
57. for earth fault Warning Limit 0 timeout then a warning will be generated The value is defined as a percentage of genset CT rating If the earth current goes above this limit for earth fault Earth Leakage Current 0 timeout then a loaddump alarm will be generated Loaddump Limit The value is defined as a percentage of genset CT rating If the earth current goes above limits during this carii Fanii Dalay Se a period an earth fault alarm will be generated This is the period between the genset current goes Overcurrent Delay sec 5 over the limits and OVERCURRENT Load Dump alarm occur This is the period between the genset voltage goes out Genset Voltage Fail Delay sec 5 of the limits and HIGH VOLTAGE or LOW VOLTAGE alarms occur K35D01 EN 60 KG 545 User Manual 13 4 ENGINE PARAMETERS GROUP Parameter Definition Low Frequency Shutdown Unit Hz Factory Set 47 Description If the genset frequency goes under this limit a GENSET LOW SPEED alarm is generated and the engine stops Low Frequency Warning Hz 48 If the genset frequency goes under this limit a GENSET LOW SPEED warning is generated High Frequency Warning Hz 54 If the genset frequency goes over this limit a GENSET HIGH SPEED warning is generated High Frequency Shutdown Hz 55 If the genset frequency goes over this limit a GENSET HIGH SPEED alarm is generated and the engine stops Low
58. fuel level sender When the measured fuel level falls below Fuel Pump Low Limit parameter the fuel pump output function will become active When the fuel level reaches Fuel Pump High Limit parameter the output function will become passive 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 any digital output using Relay Definition program parameters 15 12 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 any digital output using Relay Definition program parameters K35D01 EN 8 KG 545 User Manual V 11 15 13 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 digital output may be used as the load shedding output The dummy load function consists on the connec
59. gative Reverse voltage protection 30VDC with respect to battery negative 3 7 MAGNETIC PICKUP INPUT Structure Differential frequency measurement input Input impedance 50 k ohms Input voltage 0 5VAC RMS to 30VAC RMS Max common mode voltage 5VDC Frequency range 10Hz to 10 kHz Resolution 1 rpm Accuracy 0 2 1 rpm 3rpm 21500 rpm Flywheel teeth range 1 to 500 Do not share MPU with other devices K35D01 EN 18 KG 545 User Manual 3 8 DIGITAL OUTPUTS The unit offers 6 digital outputs with programmable function selectable from list Structure Negative pulling protected semiconductor output One terminal is connected to battery negative protection Max continuous current 1 0 ADC Max switching voltage 36 VDC Overvoltage protection 40 VDC Short circuit protection gt 1 7 ADC Reverse voltage 500 VDC K35D01 EN 19 KG 545 User Manual V 11 3 9 INPUT OUTPUT EXTENSION The module provides resources for 16 additional digital inputs and 16 additional digital outputs Digital inputs can be extended using DKG 188 Digital Input Extension modules each one providing 8 inputs Digital inputs are programmable through the main controller The switching characteristic is not programmable and must be battery negative Any function can be assigned to digital inputs RS 232 Connec
60. 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 twice 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 15 19 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 program In download mode the display of the unit will show DL 01 During firmware update process the progress is visible through a completion bar 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 K35D01 EN 82 KG 545 User Manual V 11 16 MODBUS SUPPORT 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
61. ied 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 K35D01 EN 85 KG 545 User Manual V 11 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 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 remnant voltage is below 15 volts The unit removes starting with the generator frequency and needs at least 15 volts to measure the frequency
62. ils The engine will run at idle speed during Idle Speed Timer The engine will run unloaded during engine heating timer If alternator phase voltages frequency and phase order are correct the unit will wait for the generator contactor period and the generator contactor will be energized When mains are evaluated as available again then an engine stop sequence begins The engine will continue to run for the mains waiting period to allow mains voltages to stabilize Then the generator contactor is deactivated and the mains contactor will be energized after mains contactor timer If a cooldown period is given the generator will continue to run during the cooldown period Before the end of cooldown the unit will reduce the engine speed to idle speed At the end of cooldown the fuel solenoid will be de energized the stop solenoid will be energized for Stop Solenoid timer 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 K35D01 EN 45 KG 545 User Manual V 11 10 4 MANUAL MODE The MANUAL mode is entered by pressing the e button When the RUN 4p button is pressed the engine will be started regardless of the mains availability The starting sequence is as described below The unit
63. ion 11 TERMINOLOGY A CAUTION Potential risk of injury or death A WARNING Potential risk of malfunction or material damage A ATTENTION Useful hints for the understanding of device operation K35D01 EN res KG 545 User Manual V 11 ORDERING CODES The D 500 family units are available in various options and peripheral features Please use below information for ordering the correct version KG545 Variant 00 standard unit 01 99 customer specific products With Sealing gasket Family Code SPARE PARTS Screw type bracket Self Retaining type bracket Stock Code J10P01 per unit Stock Code K16P01 per unit Sealing Gasket Stock Code J46P02 K35D01 EN 3 KG 545 User Manual V 11 SAFETY NOTICE Failure to follow below instructions will result in death or serious injury Electrical equipment should be installed only by qualified specialist No responsibility is assured by the manufacturer or any of its subsidiaries for any consequences resulting from the non compliance to these instructions Check the unit for cracks and damages due to transportation Do not install damaged equipment Do not open the unit There are no serviceable parts inside Fuses must be connected to the power supply and phase voltage inputs in close proximity of the unit Fuses must be of fast type FF with a maximum ra
64. it 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 warning will occur The service request output function may be assigned to any digital output 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 ACK RESET On for 5 seconds The remaining engine hours and the remaining time limits 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 STATUS amp COUNTERS menu group K35D01 EN 48 KG 545 User Manual 11 2 ALARMS AND WARNINGS Digital input alarms are fully programmable for the alarm name sampling and action Onlv internal alarms are explained in this section GENSET LOW HIGH SPEED ALARM Set if the generator frequency is outside programmed limits for Genset Speed Fail Timer 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 frequency shutdown limit which is 6 above the high limit is always monitored and stops the engine immediately If
65. itive or battery negative These selections are made using programming menu It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarm from this input When a Remote Start input is defined if mains phases are inside limits then the engine will never run If mains phases are out of limits then if the REMOTE START signal is present then the engine will run The front panels mimic diagram s mains LEDs will always reflect the status of the Remote Start input 15 2 Disable Auto Start Simulate Mains The unit offers an optional Disable Auto Start signal input Any digital input may be assigned as Disable Auto Start using Input Function Select program parameters 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 Disable Auto Start 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 Disable Auto Start 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 Disable Auto Start signal is present the front panels mimic diagram
66. ling rate 1000 Hz Input voltage range 14 to 300 VAC Minimum voltage for 15 VAC Ph N frequency detection Measurement range 0 to 330VAC ph N 0 to 570VAC ph ph Common mode offset max 100V between neutral and BAT Input impedance 990 K ohms Display resolution 1VDC Accuracy 0 5 1 digit 230VAC ph N 2VAC ph N 0 5 1 digit 400VAC ph ph 3VAC ph ph Frequency range DC to 100Hz Frequency display 0 1 Hz resolution Frequency accuracy 0 2 1 digit 0 1 Hz 50Hz K35D01 EN WER KG 545 User Manual V 11 3 3 AC CURRENT INPUTS Measurement method True RMS Sampling rate 1000 Hz CT secondary rating 5A Measurement range 5 5 to 5000 5A minimum Input impedance 15 mili ohms Burden 0 375W Maximum continuous 6A current Measurement range 0 1 to 7 5A Common mode offset Max 5VAC between BAT and any CT terminal Display resolution 1A Accuracy 0 5 1 digit 5A 4 5A 5 500A full range SELECTING THE CT RATING AND CABLE SECTION 1mm 1 5mm 2 5mm 50 e a tt TL effect of the current transformer Phase 40 nee AE L ae shift in a CT will cause erroneous power ee rT A VY KI and power factor readings although amp readings are correct LT JALZL EMG sc 30 Datakom advises CT rating to be selected lt 25 LEAL LAE L LI LA following this table for the best meas
67. manual language selection at power on This parameter selects the screen which is displayed first during genset on load operation 0 genset voltage table Genset Default Display 0 1 genset currents table 2 genset kW table 3 genset average values table Details of each screen are explained in chapter 3 2 This parameter defines the delay after the engine Fault Holdoff Timer ida 12 runs and before the fault monitoring is enabled This is the period during which the ALARM relay is Alarm Relay Timer sec 60 active If the period is set to 0 this will mean that the period is unlimited 0 continuous Intermittent Alarm Relay I 0 1 intermittent turns on and off every second 0 The charge input generates CHARGE FAIL warning and does not stop the engine SEENEN I 1 The charge input generates CHARGE FAIL alarm and stops the engine 0 In TEST mode the load will not be transferred to Emergency Backup _ 0 the genset even if the mains fail Operation 1 In TEST mode the load will be transferred to the genset if the mains fail This parameter defines the start day and hour of the exerciser Values higher or equal to 168 mean that the 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 Exercise Day and Time 168 8 exercise starts at Monday 08 00 24 exercise starts at Tuesday 00
68. mplete application manual K35D01 EN 75 KG 545 User Manual V 11 15 5 External Control of the Unit The unit offers total external control through programmable digital inputs Any digital input may be programmed for below functions Force STOP mode Force AUTO mode Force TEST mode Disable Auto Start Force to Start Fault Reset Alarm Mute Panel Lock External mode select signals have priority on mode buttons of the unit If the mode is selected by external signal it is impossible to change this mode with front panel pushbuttons However if the external mode select signal is removed the unit will revert to the last selected mode via pushbuttons It is also possible to lock the front panel completely for remote command 15 6 Automatic 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 to the exerciser are Exercise start day and hour Exercise duration Exercise off_load on_load Exerciser can only be enabled through PC It cannot be programmed from front panel When the start day and hour of exercise has come the unit will automatically switch to either RUN or TEST mode The engine will run If the on_load exercise is selected then the load will
69. ne is running and every 120 minutes anyway Engine crank event recorded when the crank output is engaged Shutdown alarm event recorded when a shutdown alarm occurs Loaddump alarm event recorded when a loaddump alarm occurs Warning event recorded when a warning occurs Program mode entrance event recorded when program mode is entered The password level is also saved K35D01 EN 42 KG 545 User Manual V 11 Event logs are displayed within the program mode menu This is designed in order to reduce the interference of event logs with other measurement screens To enter the event display press together GB buttons for 10 seconds When the program mode is entered below password entry screen will be displayed D ER Press 2 buttons H Ge SS it il ALAIN L ES for 10 Aloe EHTER FASSHORD sJ x x eS SRS SS eO ae Skip the password entry screen by pressing the e button 4 times The screen below left will come Press again the button The last stored event will open as in the below right picture The first page will display the event number event type fault type and date time information r PHUGHHITIIMG D were EE FOISPLAY EVENT LOG PGM Mode CONTROLLER COMFIG f Pass Level ELECTRICAL FARAH ij 1zZ BH1 z B8 23 56 When displaying event logs e button will display the same information of the previous event e button will display the next information in th
70. nnected 0 0 charge input not connected 1 charge input connected If the engine speed goes under this limit a GENSET Low rpm Shutdown rpm 0 LOW SPEED alarm is generated and the engine stops If the engine speed goes under this limit a GENSET Low rpm Warming ipn H LOW SPEED warning is generated If the engine speed goes over this limit a GENSET High rom Warning ET HIGH SPEED warning is generated If the engine speed goes over this limit a GENSET High rpm Shutdown rpm 0 HIGH SPEED alarm is generated and the engine stops If the coolant temp is above this limit then the fan relay Fom l ae function will become active If the coolant temp is below this limit then the fan relay PETER E 80 function will become inactive If the oil temperature measured from the analog input Aud Temperate C 100 goes over this limit this will generate a HIGH 9 OILTEMPERATURE SENDER warning f the oil temperature measured from the analog input High Oil Temperature C 120 goes over this limit this will generate a HIGH OIL Shutdown TEMPERATURE SENDER alarm and the engine will stop l If the canopy temperature measured from the analog ao EENG sg 80 input goes over this limit this will generate a HIGH g CANOPY TEMPERATURE SENDER warning f the oil temperature measured from the analog input High Canopy Temperature C 90 goes over this limit this will generate a HGH CANOPY Shutdown TEMPERATURE SENDER alarm and the engine will stop
71. not selectable Parameter Def Factory Set Description RL 03 26 IDLE RELAY 3 function selected from list RL 04 03 STOP RELAY 4 function selected from list RL 05 01 ALARM RELAY 5 function selected from list RL 06 05 MAINS C RELAY 6 function selected from list RL 07 04 GEN C RELAY 7 function selected from list RL 08 0 RELAY 8 function expansion module 1 selected from list RL 09 2 RELAY 9 function expansion module 1 selected from list RL 10 4 RELAY 10 function expansion module 1 selected from list RL 11 5 RELAY 11 function expansion module 1 selected from list RL 12 0 RELAY 12 function expansion module 1 selected from list RL 13 2 RELAY 13 function expansion module 1 selected from list RL 14 4 RELAY 14 function expansion module 1 selected from list RL 15 5 RELAY 15 function expansion module 1 selected from list RL 16 0 RELAY 16 function expansion module 2 selected from list RL 17 2 RELAY 17 function expansion module 2 selected from list RL 18 4 RELAY 18 function expansion module 2 selected from list RL 19 5 RELAY 19 function expansion module 2 selected from list RL 20 0 RELAY 20 function expansion module 2 selected from list RL 21 2 RELAY 21 function expansion module 2 selected from list RL 22 4 RELAY 22 function expansion module 2 selected from list RL 23 5 RELAY 23 function expansion module 2 selected from list
72. oller is 100 kW Measured values are as follows kW kVAr kVA pf Phase L1 100 0 0 0 100 1 00 Phase L2 100 0 0 0 100 1 00 Phase L3 100 0 0 0 100 1 00 Total 100 0 0 0 300 0 33 EFFECT OF PHASE SWAPPING The generator is still loaded with 100 kW on each phase The load Power Factor PF is 1 MAINS or ALTERNATOR CONTROLLER PF in phases L2 and L3 will show 0 50 due to phase shift between voltages and currents which is caused by CT swapping The result is that total generator power displayed by controller is 0 kW Measured values are as follows kW kVAr kVA pf Phase L1 100 0 0 0 100 1 00 Phase L2 50 0 86 6 100 0 50 Phase L3 50 0 86 6 100 0 50 Total 0 0 0 0 300 0 0 K35D01 EN 16 KG 545 User Manual 3 4 DIGITAL INPUTS Number of inputs 8 inputs all configurable Function selection from list Contact type Normally open or normally closed programmable Switching Battery negative or battery positive programmable Structure 47 k ohms resistor to battery positive 110k ohms to battery negative Measurement Analog voltage measurement Open circuit voltage 70 of battery voltage Low level threshold 35 of battery voltage High level threshold 85 of battery voltage Maximum input voltage 100VDC with respect to battery negative Minimum input voltage 70VDC with respect to battery negative
73. ols els IP OP EXTENSION CONNECTOR 05 CHARGER WL 06 IDLE RELAY 07 STOP RELAY 12 OIL SENDER 13 FUEL SENDER CANOPY TMP 16 ANALOG IP 1 ANALOG IP 2 18 COOL LEV AC EMG STOP 22 AUTO START 23 FUEL LEV K35D01 EN 8 KG 545 User Manual V 11 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 Place and tighten mounting brackets 134mm 183mm Panel Cutout Required Panel Depth K35D01 EN 9 KG 545 User Manual V 11 Two different types of brackets are provided Screw type bracket Self retaining type bracket Installation of screw type bracket Installation of self retaining type bracket Do not tighten too much this may break the unit K35D01 EN 10 KG 545 User Manual V 11 2 2 SEALING GASKET The rubber gasket provides a watertight means of mounting the module to the genset panel Together with the gasket IEC 60529 IP65 protection can be reached from the front panel A short definition of IP protection levels is given below 1st Digit 0 Not protected 1 Protected against solid foreign objects of 50 mm diameter and greater 2 Protected against solid foreign objects of 12 5 mm diameter and greater 3 Protected against solid foreign obj
74. ondition is detected EXCESS POWER Red Turns on when excess load condition is detected If a Remote Start signal is present then the Mains led will become red Simulate Mains and Force to Start signals will also affect this led If the operation of the genset is disabled by the weekly operation schedule then the AUTO led will flash K35D01 EN 40 KG 545 User Manual 8 8 MEASURED PARAMETERS The unit performs a detailed set of measurements The list of measured parameters is below Mains voltage phase L1 to neutral Mains voltage phase L2 to neutral Mains voltage phase L3 to neutral Mains voltage phase L1 L2 Mains voltage phase L2 L3 Mains voltage phase L3 L1 Mains current phase L1 Mains current phase L2 Mains current phase L3 Mains frequency Gen voltage phase L1 to neutral Gen voltage phase L2 to neutral Gen voltage phase L3 to neutral Gen average voltage phase 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 average current Gen frequency Gen kW phase L1 Gen kW phase L2 Gen kW phase L3 Gen total kW Gen kVA phase L1 Gen kVA phase L2 Gen kVA phase L3 Gen kVAr phase L1 Gen kVAr phase L2 Gen kVAr phase L3 Gen pf phase L1 Gen pf phase L2 Gen pf phase L3 Gen total pf Earth leakage current Engine speed rpm Battery voltage Coolant temperature Oil pressure bar kPa
75. r this limit it means Mains Frequency Low Limit Hz 45 that the mains are off and it starts the transfer to the genset in AUTO mode If the mains frequency goes above this limit it means Mains Frequency High Limit Hz 55 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 this Genset Low Voltage V 190 limit when feeding the load this will generate a Shutdown Limit GENSET LOW VOLTAGE shutdown alarm and the engine will stop If one of the generator phase voltages goes under this a to V 200 limit when feeding the load this will generate a 9 GENSET LOW VOLTAGE warning If one of the generator phase voltages goes above this ue cu en V 250 limit when feeding the load this will generate a 9 GENSET HIGH VOLTAGE warning If one of the generator phase voltages goes over this Genset High Voltage V 260 limit when feeding the load this will generate a Shutdown Limit GENSET HIGH VOLTAGE alarm and the engine will stop K35D01 EN 59 KG 545 User Manual 13 3 ELECTRICAL PARAMETERS GROUP continued Parameter Definition Unit pm Description Low Battery Voltage V 19 0 If the battery voltage falls below this limit this will Warning generate a LOW BATTERY warning High Battery Voltage V 29 0 If the battery voltage goes over this limit this will Warning generate a HIGH BATTERY warning If the
76. re value measured from the sender is above the programmed limit Warning and alarm limits are separately programmable for the temperature sender input LOW TEMPERATURE Set if the coolant temperature value measured from the sender is below the WARNING Engine Heating Temperature limit LOW FUEL Set if a signal is detected at the low fuel level input or the the fuel level WARNING ALARM measured from the sender is below the programmed limit Warning and alarm limits are separately programmable for the fuel level sender input HIGH OIL Set if the oil temperature value measured from the sender is above the TEMPERATURE programmed limit Warning and alarm limits are separately programmable for WARNING ALARM the temperature sender input HIGH CANOPY Set if the canopy temperature value measured from the sender is above the TEMPERATURE programmed limit Warning and alarm limits are separately programmable for WARNING ALARM the temperature sender input LOW COOLANT Set if the coolant level AC input is enabled and coolant level AC input is open LEVEL AC ALARM circuit K35D01 EN 49 KG 545 User Manual V 41 OVERCURRENT LOADDUMP Set if one of the genset phase currents goes over the Overcurrent Limit for Overcurrent Timer If currents go below the limit before expiration of the timer then no alarm will be set EXCESS POWER Set if the genset power kW supplied to the load goes over the Excess Power LOADDUMP limit
77. rs Total start count is displayed up to 9999 Group Screen Contents Description MAINS 1 Mains Phase voltages Presented as a table PARAMETERS phase to neutral and phase to phase 2 Mains Phase Currents Presented as a table This screen is displayed only if CTs are selected at load side 3 Mains Frequency and Frequency in Hertz Average Voltage The voltage is the average of both phase voltages Group Screen Description ALARM LIST 1 If no alarm exists then END OF ALARM LIST is displayed Otherwise the first alarm is displayed Each depression of the button will cause the screen to switch to the next alarm K35D01 EN 36 KG 545 User Manual V 11 Group Screen Description COMMUNICATION 1 This screen shows the modem parameters STATUS It is displayed only if the modem is enabled Group Screen Contents Description GENSET 1 Genset Status Ascii explanation of the current status STATUS 2 Logo The company logo Kirloskar Green Power Ideas 3 Date amp time Current date and time displayed in large characters 4 Site Id The generator site id string displayed in large characters 5 Serial Number The generator serial number string displayed in large characters 6 Software Version The unit firmware version number displayed in large characters 7 Maintenance Counters Time to maintenance days and engine hours to maintenance 8 4 ALARM DISPL
78. rs 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 any digital output using Output Configuration program parameters The dual genset intermittent operation uses also the Disable Auto Start feature Please review related chapter for a detailed explanation of this feature Priority In Dual Genset Mutual Standby Operation It may be required that the dual genset system starts the same genset at every mains failure This is achieved using the PRIORITY input Any digital input may be assigned as Priority using Input Function Select program parameters 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 Priority 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 a Priority input is defined then the system will work in priority mode If the priority signal is applied the unit will become master after each mains failure If the priority signal is not applied then the unit will become the slave one and the other genset will start Please contact DATAKOM for a co
79. s Genset Parameters Genset voltages currents frequency kW kVA kVAr pf kWh etc Engine Parameters Analog sender readings rpm battery voltage engine hours etc Mains Parameters Mains voltages currents frequency Mains currents are displayed only when CT Selection is made as LOAD SIDE Otherwise mains currents will not be displayed Alarm Display This group displays all existing alarms one screen per alarm When there is no more alarm to display it will show END OF ALARM LIST Status amp Counters Groups This group includes various parameters like genset status company logo service counters date time site id engine serial number firmware version During operation the unit will automatically switch between different screens displaying always the most important parameters for the current operating status Group Screen Contents Description GENSET 1 Genset Phase voltages Presented as a table PARAMETERS phase to neutral and phase to phase 2 Genset Phase Currents Presented as a table and Genset frequency 3 Genset Phase kW and Presented as a table power factor 4 Genset Phase kVA and Presented as a table kVAr values 5 Genset average current Presented as a table and voltage genset frequency total KW and PF 6 Genset R Current Genset Phase R Current large characters 7 Genset Y Current Genset Phase Y Current large characters 8 Genset B Current Genset Pha
80. 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 DISABLE AUTO START and FORCE TO START operations K35D01 EN di KG 545 User Manual V 11 15 3 Battery Charging Operation Delayed Simulate Mains 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 Disable Auto Start signal for the genset control unit The unit offers an optional Disable Auto Start signal input Any digital input may be assigned as Simulate Mains using Input Function Select program parameters 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 Disable Auto Start 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 param
81. s simulation Battery charging operation delayed simulate mains Dual Genset Mutual Standby Operation External Control of the Unit Automatic Exerciser Weekly operation scheduler Engine heating operation Engine Idle Speed Operation 15 10 Engine Block Heater 15 11 Fuel Pump Control 15 12 Gas engine fuel solenoid control 15 13 Load Shedding Dummy Load 15 14 4 20mA Oil Pressure Measurment 15 15 Modem connection 15 16 SMS message sending 15 17 Remote Monitoring and Programming 15 18 Fuel Theft Fuelling Messages 15 19 Firmware Update 16 MODBUS COMMUNICATION 17 DECLARATION OF CONFORMITY 18 MAINTENANCE 19 DISPOSAL OF THE UNIT 20 ROHS COMPLIANCE 21 TROUBLESHOOTING GUIDE K35D01 EN KG 545 User Manual V 11 1 INSTALLATION INSTRUCTIONS Before installation Read the user manual carefully determine the correct connection diagram Remove all connectors and mounting brackets from the unit then pass the unit through the mounting opening Put mounting brackets and tighten Do not tighten too much this can brake the enclosure Make electrical connections with plugs removed from sockets then place plugs to their sockets Be sure that adequate cooling is provided Be sure that the temperature of the environment will not exceed the maximum operating temperature in any case Below conditions may damage the device Incorrect connections Incorrect power
82. se B Current large characters 9 Genset Frequency with large size characters 10 Genset Active Power with large size characters 11 Genset Average Voltage with large size characters 12 Genset kW hours 8 digit counter 13 Earth Leakage Current in Amps and of CT ratio large characters K35D01 EN 35 KG 545 User Manual Group Screen Contents Description ENGINE 1 Oil Pressure Displayed in bars and kPa large characters PARAMETERS If PS display is enabled by program parameter then displayed in bars and psi 2 Engine Temperature Displayed in degrees C and degrees F large characters 3 Fuel Status Displayed in of full tank capacity If Fuel Consumption per Hour parameter is not zero then also displayed in engine hours If Fuel Tank Capacity parameter is not zero then also displayed in liters 4 Engine Speed Displayed in RPMs 5 Battery Voltage Displayed in Volts DC The Minimum Minimum battery voltage Battery Voltage is reset before each engine crank cycle Thus the displayed value reflects the most recent status 6 Oil Temperature Displayed in degrees C and degrees F This screen is displayed only if the Oil Temp analog input is enabled 7 Canopy Temperature Displayed in degrees C and degrees F This screen is displayed only if the Canopy Temp analog input is enabled 8 Engine Hours The engine hours is displayed up to Total Starts 999 999 9 hou
83. ser Manual V 11 15 17 Remote Monitoring and Programming Thanks to its standard serial RS 232 port the unit offers the remote monitoring and 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 The necessary PC connection cable will be supplied by DATAKOM 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 15 18 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
84. set phase L1 AC voltage reaches 100VAC then cranking is immediately stopped Genset frequency over threshold If the genset phase L1 frequency reaches Engine Parameters gt Crank Cut Frequency then cranking is immediately stopped Genset rpm over threshold If the genset rpm reaches 300rpm then cranking is immediately stopped Charge alternator voltage over threshold Following setting is necessary Engine Parameters gt Charge Input Connected 1 Engine Parameters gt Crank Stop with Charge 1 If the charge alternator voltage is established then cranking is immediately stopped Oil pressure above threshold Following setting is necessary Engine Parameters gt Crank Stop with Oil Pressure 1 The crank cutting with oil pressure has a factory set delay of 2 seconds Both low oil pressure switch and oil pressure sender readings may be used for crank cutting The oil pressure switch is always used The sender may be disabled through Controller Configuration gt Oil Pressure Switch Priority parameter If enabled when oil pressure is detected cranking is stopped after delay K35D01 EN SNE KG 545 User Manual V 11 15 SOFTWARE FEATURES 15 1 Remote Start Operation The unit offers the possibility of Remote Start mode of operation Any digital input may be assigned as Remote Start Input using Input Function Select program parameters The Remote Start signal may be a NO or NC contact switching to either battery pos
85. sure the phase voltages Check the AC voltage readings on the screen 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 2 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 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 Please review chapter AC CURRENT INPUTS A Short circuit outputs of unused Current Transformers When the AC mains fails the unit energizes the fuel solenoid but does not start and OIL PRESSURE EXISTS message is displayed The unit is not suppl
86. t signal arrives in STOP mode the genset will not start until AUTO mode is selected K35D01 EN 44 KG 545 User Manual V 11 10 3 AUTO MODE x The AUTO mode is entered by pressing the button The AUTO mode is used for the automatic transfer between genset and mains The controller will constantly monitor the mains availability It will run the engine and transfer the load when a mains failure occurs If a panel lock input is defined and signal is applied then mode change will not occur However display navigation buttons are still enabled and parameters may be visualized The mains availability evaluation sequence is below If at least one of the mains phase voltages or the mains frequency is outside limits the mains will be supposed failing Otherwise mains is available If a Simulate Mains signal is present then mains are made available Ifa Remote Start signal is present then mains are unavailable When mains are evaluated as unavailable then an engine start sequence begins The unit waits during Engine Start Delay for skipping short mains failures If the mains is restored before the end of this timer the genset will not start The unit turns on the fuel and preheat glow plugs if any and waits for preheat timer The engine will be cranked for programmed times during crank timer When the engine fires the crank relay will be immediately deactivated See section Crank Cutting for more deta
87. t stopped after this period a FAIL TO STOP warning occurs Number of Starts This is the maximum number of start attempts 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 Engine Heating Method This parameter defines the engine heating method The genset will not take the load before engine heating is completed 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 Service Engine Hours hour 250 The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last service If the period is set to 0 no SERVICE REQUEST will be generated depending on engine hours Service Period month The SERVICE REQUEST led indicator will turn on 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 Idle Speed Timer Sec 10 When the engine runs the Idle output relay function will be active during this timer Gas Solenoid Delay sec The gas solenoid of the gas engine will be opened after this delay during cranking Low Fuel Warning 20 If the fuel level measured from the analog input falls
88. t type Normally open Normally closed Switching Battery negative Battery positive Response delay Oj O O O N OO N O No delay Delayed 4sec Input Configuration 05 Low Fuel Switch Input Parameter Definition Unit Fac Set Description 0 Shutdown the engine stops immediately Action 0 1 Load Dump the engine stops after cooldown 2 Warning the horn relay operates 3 No operation 0 Always Sampling 0 1 After holdoff timer 2 When mains present 0 Non latching Latching 1 Latching 0 Normally open Contact type 9 1 Normally closed UMS 0 Battery negative Switching S 1 Battery positive 0 No delay Response delay 1 1 Delayed 4sec K35D01 EN 66 KG 545 User Manual Input Configuration 06 Spare 1 Input Parameter Definition Unit Fac Set Description Action Shutdown the engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operation Sampling Always After holdoff timer When mains present Latching Non latching Latching Contact type Normally open Normally closed Switching Battery negative Battery positive Response delay El sch El sch O sch OIN O O N O No delay Delayed 4sec Input Configuration 07 Spare 2 Input Parameter Definition
89. ting of 6A Disconnect all power before working on equipment When the unit is connected to the network do not touch terminals Short circuit terminals of unused current transformers Any electrical parameter applied to the device must be in the range specified in the user manual Although the unit is designed with a wide safety margin over range parameters may reduce lifetime alter operational precision or even damage the unit Do not try to clean the device with solvent or the like Only clean with a dump cloth Verify correct terminal connections before applying power Only for front panel mounting Current Transformers must be used for current measurement No direct connection allowed K35D01 EN ue KG 545 User Manual V 11 TABLE OF CONTENTS Section 1 INSTALLATION INSTRUCTIONS 2 MOUNTING 2 1 Dimensions 2 2 Sealing gasket 2 3 Electrical installation 3 TERMINAL DESCRIPTIONS 3 1 Battery voltage input 3 2 AC voltage input 3 3 AC current inputs 3 4 Digital inputs 3 5 Analog sender inputs and analog ground 3 6 Charge input terminal 3 7 Magnetic pickup input 3 8 Digital outputs 3 9 Input output extension 3 10 RS 232 port 3 11 RS 485 port 4 FUNCTIONALITIES 4 1 CT location selection 4 2 AMF functionality 4 3 Remote start functionality 4 4 Remote display unit functionality 5 CONNECTION DIAGRAMS 5 1 AMF functionality CTs at load side
90. tion 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 purposes It is also possible to control more complex external systems with multiple steps using LOAD_ADD and LOAD_SUBSTRACT output functions Any digital output may be assigned to these signals When the load is below the Load Shedding Low Limit the controller will activate the Load Add output The external system will increase the load until it goes over the low limit where the Load Add output will become inactive When the load is above the Load Shedding High Limit the controller will activate the Load Substract output The external system will decrease the load until it goes below the high limit where the Load Substract output will become inactive There are protection delays between two pulses The parameters used in Load Shedding feature are in the Electrical Parameters Group Factory Parameter Definition Unit Min Max Set Description If the genset power goes below this Load Shedding Low Limit kW 0 65000 0 limit then the load shedding relay will be deactivated If the genset power goes above this kW 0 65000 0 limit then the load shedding relay will be activated Load Shedding High Limit 15 14 4 20mA Oil Pressure Measurement Th
91. to send SMS messages in below conditions without 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 When SMS sending is in progress an SMS icon will appear at the upper right corner of the screen 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 KOEL lt SITE ID gt 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 K35D01 EN 81 KG 545 U
92. tor Va Digital outputs can be extended using DKG 186 Fet Extension modules each one providing 8 outputs Digital outputs have the same electrical characteristics as on board outputs They have programmable functions through the main controller Any function can be assigned to any output I O Extension Connector Input and output extension modules are connected to the main controller in a cascade structure in any order The connection cable is provided with each extension module TO OTHER INPUT OUTPUT EXTENSION MODULES FEREEEEEEE BHHHHHHHHE DKG 188 INPUT DKG 186 OUTPUT EXTENSION MODULE EXTENSION MODULE K35D01 EN 20 KG 545 User Manual 3 10 RS 232 PORT Description RS 232 non isolated Functionality External modem PC connection PLC connection Connector RJ11 6pin Connection 6 wires Rx Tx DTR CxD GND 10V Full duplex Baud rate 9600 bauds Data type 8 bit data no parity 1 bit stop Max distance 15m Terminal description 1 DTR output 6 1 2 Tx output 3 CxD input 4 GND 5 Rx input Front view of RJ11 6 pin 6 10V connector K35D01 EN RS 232 Connector LA 21 KG 545 User Manual V 11 3 11 RS 485 PORT Structure RS 485 non isolated Connection 3 wires A B GND Half duplex Baud rate 9600 bauds selectable Data type 8 bit data no parity 1 bit stop Termination External 120 ohms
93. turns on the fuel and preheat glow plugs if any and waits for preheat timer The engine will be cranked for programmed times during crank timer When the engine fires the crank relay will be immediately deactivated See section Crank Cutting for more details The engine will run at idle speed during Idle Speed Timer The engine will run unloaded until another mode is selected The MANUAL mode allows also manual contactor control through MC and GC buttons When a contactor button is pressed the related contactor will change position Thus if it was on then it will turn off If it was off then it will turn on If the other contactor was on then it will turn off the controller will wait for the related contactor timer and the contactor will turn on This will prevent manual closure of both contactors If Emergency Backup mode is enabled and if the mains are off then the mains contactor will be deactivated and the generator contactor will be activated When the mains are on again a reverse changeover to the mains will be performed but the engine will be kept running unless another mode is selected In order to stop the engine press button or select another mode of operation 10 5 TEST MODE The TEST mode is entered by pressing the button The TEST mode is used in order to test the genset under load Once this mode is selected the engine will run as described in the AUTO mode regardless of the
94. up precision real time clock circuit The real time clock circuit will continue its operation even in power failures The real time clock is precisely trimmed using the Real Time Clock Adjust program parameter For more details check the programming section 15 8 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 reaches 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 15 9 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
95. urement accuracy s AT CAEL WZ L II mm 5 10 15 20 25 30 35 40 45 50 CABLE LENGHT TO CT m SELECTING THE CT ACCURACY CLASS The CT accuracy class should be selected in accordance with the required measurement precision The accuracy class of the Datakom controller is 0 5 Thus 0 5 class CTs are advised for the best result K35D01 EN KG 545 User Manual V 11 CONNECTING CTs Be sure of connecting each CT to the related phase input with the correct polarity Mixing CTs between phases will cause faulty power and pf readings Many combinations of incorrect CTs connections are possible so check both order of CTs and their polarity Reactive power measurement is affected by incorrect CTs connection in similar way as active power measurement CORRECT CT CONNECTIONS MAINS or ALTERNATOR CONTROLLER Let s suppose that the genset is loaded with 100 kW on each phase The load Power Factor PF is 1 Measured values are as follows kW kVAr kVA pf Phase L1 100 0 0 0 100 1 00 Phase L2 100 0 0 0 100 1 00 Phase L3 100 0 0 0 100 1 00 Total 300 0 0 0 300 1 00 K35D01 EN 15 KG 545 User Manual EFFECT OF POLARITY REVERSAL The generator is still loaded with 100 kW On each phase The load Power Factor PF is 1 MAINS or ALTERNATOR CONTROLLER PF in phase L2 will show 1 00 due to reverse CT polarity The result is that total generator power displayed by the contr
96. without load until reaching a certain temperature this parameter defines the temperature If the coolant temperature falls below this parameter an Engine Low Temperature warning will occur 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 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 K35D01 EN 61 KG 545 User Manual 13 4 ENGINE PARAMETERS GROUP continued Parameter Definition Crank Timer Unit sec Factory Set 10 Description This is the maximum start period Starting will be automatically cancelled if the genset fires before the timer Wait Between Starts sec 10 This is the waiting period between two start attempts Engine Heating Timer sec This is the period used for engine heating following the program parameter Cooldown Timer min 1 0 This is the period that the generator runs for cooling purpose after the load is transferred to mains Stop Solenoid Timer sec 10 This is the maximum time duration for the engine to stop During this period the STOP relay output is energized if assigned by Relay Definitions If the genset has no
97. y the current controller This is the site Id string sent at the beginning of SMS messages e mails and web page headers for the identification of the genset sending the message Any 20 character long string may be entered 13 10 ENGINE SERIAL NUMBER The engine serial number string is designed to identify the current controller Ths string is added to GSM SMS messages e mails web page headers etc Any 20 character long string may be entered 13 11 MODEM1 2 SMS1 2 3 4 5 6 TELEPHONE NUMBERS These telephone number buffers accept up to 16 digits including the wait character in order to enable dialing through a pabx Depending of the setting of Modem Enabled parameter fist 2 numbers may be modem or SMS telephone numbers Last 4 numbers are always SMS numbers If Modem Enabled First 2 telephone numbers are used for modem calls If Modem Disabled All 6 numbers are used for SMS sending Enter numbers starting from first character Do not leave blank characters at the beginning K35D01 EN 71 KG 545 User Manual V 11 14 CRANK CUTTING In order to insure fast and reliable crank cutting the unit uses various resources for engine running condition detection Cranking is stopped when at least one of below conditions is met Crank timer expired The crank timer is adjusted through Engine Parameters gt Crank Timer The maximum allowed timer is 15 seconds Genset AC voltage over threshold If the gen

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