dkg-207 automatic mains failure and remote start unit
Contents
1. Term Function Technical data Description 17 RELAY 2 STOP RELAY Output 10A 28VDC This relay has programmable function selectable from a list 18 LOW OIL PRESSURE Digital inputs These inputs have programmable 19 HIGH TEMP characteristics selected via the program 20 RECTIFIER FAIL menu Each input may be driven by a 21 EMERGENCY STOP normally closed or normally open contact 22 SPARE REMOTE START switching either battery or battery The 23 PROGRAM LOCK effect of the switch is also selectable from a list See PROGRAMMING section for more details 24 CURR U Current transformer Connect the generator current transformer inputs 5A AC terminals to these inputs Do not connect the same current transformer to other instruments otherwise a unit fault will occur Connect each terminal of the transformer to the unit s related 25 CURR U terminal Do not use common terminals Do not use grounding Correct polarity of connection is vital If the measured power is negative then change the polarity of each 3 current transformers The secondary winding rating shall be 5 Amperes For ex 200 5 Amps DKG 207 User Manual V 01 03 14 02 2006 3 DISPLAY 3 1 Led Displays The unit has 18 LEDs divided in 4 groups Group 1 Operating mode This group indicates the genset function Group 2 Mimic diagram This group indicates the current status of the mains and genset voltages and contactors G2. DKG 207 User Manual V 01 03 14 02 2006 3 2 Digital Display The unit has a seven segment display It shows Measured parameters Parameter names Service counters Program parameters The navigation between different screens in a group is made with the MENU button When the MENU key is pressed the parameter name will be displayed By pressing the MENU key below values may be displayed R S T mains phase to neutral voltages generator phase U to neutral voltage generator phase U current generator frequency Hz generator 5 generator active power KW oil pressure bar coolant temperature battery voltage V DC Holding the MENU button pressed for 1 second makes the display to switch to the service counters group total engine hours engine hours to service time to service DKG 207 User Manual V 01 03 14 02 2006 4 ALARMS AND WARNINGS Alarms indicate an abnormal situation in the generating set are divided into 2 priority levels 1 ALARMS These are the most important fault conditions and cause Therelated alarm led to turn on steadily The genset contactor to be released immediately The engine to be stopped immediately The Horn Alarm and Alarm Warning relay outputs to operate if selected via programming menu 2 WARNINGS These conditions cause related alarm led to flash Horn Alarm Warning relay outputs to operate if selected
3. 71 ohms 104 9C 40 ohms 121 9C 30 ohms Pgm Description Unit Value 101 Point 1 resistor ohm 30 102 Point 1 temperature e 121 103 Point 2 resistor ohm 40 104 Point 2 temperature e 104 105 Point_3 resistor ohm 71 106 Point_3 temperature e 82 107 Point 4 resistor ohm 342 108 Point 4 temperature 38 109 Point 5 resistor ohm 0 110 Point 5 temperature e 0 111 Point 6 resistor ohm 0 112 Point 6 temperature 9 0 The parameters from P_113 to P_116 define the exerciser operation Pgm Definition Unit Std Val Description 113 Exercise start day and 168 This parameter defines the start day and hour 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 1 exercise starts at Monday 01 00 8 exercise starts at Monday 08 00 24 exercise starts at Tuesday 00 00 167 exercise starts at Sunday 23 00 168 exerciser off If a daily exercise is selected with parameter P 11620 then the day information is don t care and the exercise will be performed every day regardless of the day selection If the monthly exercise is selected with parameter P 116z2 then the exercise will be performed during the first 7 days of each month at the programmed day and hour 114
4. 4sec EMERGENCY STOP INPUT Pgm Description Std 71 Operation 0 0 Alarm the engine stops and horn relay operates 2 Warning the horn relay operates 3 No operation 72 Fault monitoring 0 0 Always 1 After holdoff timer 2 When mains present 73 Latching 0 0 Non latching 1 Latching 74 Contact type 0 0 Normally open 1 Normally closed 75 Switching 0 0 Battery negative 1 Battery positive 76 Response delay 0 0 No delay 1 Delayed 4sec DKG 207 User Manual SPARE FAULT INPUT V 01 03 14 02 2006 Pgm Description Std 77 Operation 0 0 Alarm the engine stops and horn relay operates 2 Warning the horn relay operates 3 No operation 78 Fault monitoring 0 0 Always 1 After holdoff timer 2 When mains present 79 Latching 0 0 Non latching 1 Latching 80 Contact type 0 0 Normally open 1 Normally closed 81 Switching 0 0 Battery negative 1 Battery positive 82 Response delay 0 0 No delay 1 Delayed 4sec PROGRAM LOCK INPUT Pgm Description Std 83 Operation 3 0 Alarm the engine stops and horn relay operates 2 Warning the horn relay operates 3 No operation 84 Fault monitoring 0 0 Always 1 After holdoff timer 2 When mains present 85 Latching 0 0 Non latching 1 Latching 86 Contact type 0 0 Normally open 1 Normally closed 87 Switching 0 0 Battery negative 1 Battery positive 88
5. Alarm the engine stops and horn relay operates 2 Warning the horn relay operates 3 No operation 54 Fault monitoring 1 0 Always 1 After holdoff timer 2 When mains present 55 Latching 1 0 Non latching 1 Latching 56 Contact type 0 0 Normally open 1 Normally closed 57 Switching 0 0 Battery negative 1 Battery positive 58 Response delay 0 0 No delay 1 Delayed 4sec 20 DKG 207 User Manual HIGH TEMPERATURE SWITCH INPUT V 01 03 14 02 2006 Pgm Description Std 59 Operation 0 0 Alarm the engine stops and horn relay operates 2 Warning the horn relay operates 3 No operation 60 Fault monitoring 0 0 Always 1 After holdoff timer 2 When mains present 61 Latching 1 0 Non latching 1 Latching 62 Contact type 0 0 Normally open 1 Normally closed 63 Switching 0 0 Battery negative 1 Battery positive 64 Response delay 0 0 No delay 1 Delayed 4sec RECTIFIER FAIL INPUT Pgm Description Std 65 Operation 2 0 Alarm the engine stops and horn relay operates 2 Warning the horn relay operates 3 No operation 66 Fault monitoring 2 0 Always 1 After holdoff timer 2 When mains present 67 Latching 1 0 Non latching 1 Latching 68 Contact type 0 0 Normally open 1 Normally closed 69 Switching 0 0 Battery negative 1 Battery positive 70 Response delay 1 0 No delay 1 Delayed
6. temperature range DKG 207 User Manual V 01 03 14 02 2006 2 INPUTS AND OUTPUTS SERIAL DATA This connector provides logic level serial data input and output for various purposes like remote monitoring and remote programming In order to connect to a PC an RS 232 adapter module is needed Term Function Technical data Description 1 GENERATOR CONTACTOR Relay output 16A AC This output provides energy to the generator contactor If the generator phases do not have acceptable voltage or frequency values the generator contactor will be de energized In order to provide extra security the normally closed contact of the mains contactor should be serially connected to this output Generator phase input 0 300V AC Connect the generator phases to these inputs The generator phase voltages upper and lower limits are programmable GENERATOR NEUTRAL Input 0 300V AC Neutral terminal for the generator phases MAINS NEUTRAL Input 0 300V AC Neutral terminal for the mains phases T S R Mains phase inputs 0 300V AC Connect the mains phases to these inputs The mains voltages upper and lower limits are programmable amp MAINS CONTACTOR Relay output 16A AC This output provides energy to the mains contactor If the mains phases do not have acceptable voltages the mains contactor will be de energized In order to provide extra securi
7. the display will show 5 time to service When the MENU key is released it will show the last digits of the remaining days to service 6 5 Engine Hour Meter The unit features a non erasable incremental engine hour meter The hour meter information is kept in a non volatile memory and is not modified by power supply failures The engine hours may be displayed via the statistics menu selected by pressing the MENU key for 1 second When the MENU key is pressed the display will show EnH engine hours When the MENU key is released it will show the first 3 digits of the engine hours When the MENU key is pressed again the display will show EnH engine hours When the MENU key is released it will show the last 3 digits of the engine hours s12 DKG 207 User Manual V 01 03 14 02 2006 6 6 Modem Connection The unit offers the remote monitoring and programming features over the telephone network via a modem connection The program used for remote monitoring and programming is the same as the program used for RS 232 connection If the modem is connected the program parameter P 043 should be set to 1 otherwise faulty operation may occur 6 7 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 may be downloaded from www datakom com tr internet site The software allows the visua
8. 0 V for 100ms Typical current consumption 100 ma DC Maximum current consumption 350 mA DC Relay outputs open Generator mains contactor outputs 16 A 250 V DC relay outputs 10A 28 V Max current for each terminal 10A RMS Charge alternator excitation current 54 mA DC 12 V DC Communication port Logic levels 2400 bauds no parity 1 stop bit Operating temperature range 20 to 70 4 F to 158 F Storage temperature range 40 C to 80 C 40 F to 176 F Maximum humidity 95 non condensing IP protection IP65 from front panel IP30 from the rear Dimensions 120 x 90 x 39mm WxHxD Mounting opening dimensions 116 x 86mm minimum Mounting Front panel mounted retaining steel spring at the rear Weight 250 g approx Case material High temperature self extinguishing ABS UL94 VO 110 C 397 V 01 03 14 02 2006 DKG 207 User Manual 13 CONNECTION DIAGRAM 207 Jepuas eJnsseJd dois S 4 ubiH 6b 8 CL 9 Aejoy 203221009 SUE Bjoy 701283007 JojeJouac N 21 11 avol p punou6 aq jsnui Asoyjeg 1 eneg 10 01N joues huei d pue Qoway 5 2 __ v bb L 202 9 vc SZ YOLVNYALIV 28
9. 114 Exercise duration P 116 Daily Weekly Monthly Exercise Please refer to the programming section for a more detailed description of the above parameters When the start day and hour of exercise has come the unit will automatically switch to TEST mode and the engine will run If a mains failure occurs during the exercise the load will not be transferred to the genset unless the Emergency Backup Operation is allowed by setting the parameter P 041 to 1 Thus it is highly recommended that the Emergency Backup mode enabled with 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 ended 14 DKG 207 User Manual V 01 03 14 02 2006 7 STATISTICAL COUNTERS The unit provides a set of non resettable incremental counters for statistical purposes The counters consist on total engine cranks total genset runs total genset on load These counters are kept in a non volatile memory and are not affected from power failures The statistical counters are only displayed on the PC screen using the remote monitoring and programming software They can not be displayed on the unit 8 MAINTENANCE DO NOT OPEN THE UNIT There are NO serviceable parts inside the unit Wipe the unit if necessary with a soft damp cloth Do not use chemical agents 15 DKG 207 User Manual V 01 03 14
10. Warning 31 0 If the battery voltage goes over this limit this will generate a BATTERY warning 14 High Battery Voltage Alarm 33 0 If the battery voltage goes over this limit this will generate a BATTERY alarm and the engine will stop 15 Low Oil Pressure Warning Bar 1 5 If the oil pressure measured from the analog input falls below this limit this will generate an OIL PRESSURE warning This input will be monitored after delay defined in P 023 when the engine runs 16 Low Pressure Alarm Bar 1 0 If the oil pressure measured from the analog input falls below this limit this will generate an OIL PRESSURE alarm This input will be monitored after delay defined in P 023 when the engine runs 17 High Temperature Warning 90 If the coolant temperature measured from the analog input goes over this limit this will generate a HIGH TEMP warning 18 High Temperature Alarm 98 If the coolant temperature measured from the analog input goes over this limit this will generate a HIGH TEMP alarm and the engine will stop 19 Oil pressure sender type This parameter selects the oil pressure sender type 0 Non standard sender The sender characteristics are defined in table using parameters P 131 to P 142 VDO 0 7 bars 10 180 ohms VDO 0 10 bars 280 20 ohms DATCON 0 7 bars 240 33 ohms DATCON 0 10 bars 240 33 ohms DATCON 0
11. flashes 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 25 DKG 207 User Manual V 01 03 14 02 2006 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 voltage is not connected to the unit Measure the AC voltage between terminals U 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 20 volts The unit removes starting with the generator frequency and needs at least 20 volts to measure the frequency If this situation is to be avoided the only solution is to add an auxiliary relay The coil of the relay will be between BATTERY and charging alternator D terminal The normally closed contact of the relay will be connected serially to the unit s START output So the starting will also be removed when the D pulls to battery positive The unit is inoperative Measure the DC supply voltage between terminals 11 and 12 at the rear
12. via programming menu If the ALARM MUTE button is pressed the Horn relay output will be deactivated however the existing alarms will persist and disable the operation of the genset Alarms operate in a first occurring basis If an alarm is present following alarms and warnings will not be accepted If a warning is present following warnings will not be accepted Alarms may be of LATCHING type following programming For latching alarms even if the alarm condition is removed the alarms will stay on and disable the operation of the genset The existing alarms may be canceled by pressing one of the operating mode buttons LOAD TEST TEST OFF AUTO Most of the alarms have programmable trip levels See the programming chapter for user adjustable alarm limits LOW OIL PRESSURE Set if a signal is detected at the Low Oil Pressure Switch input or the oil pressure value measured from the sender is below the programmed limit Warning P 016 and alarm P 015 limits are separately programmable for the oil pressure sender input This fault will be monitored with holdoff timer P 023 delay after the engine is running Also if the oil pressure switch is open at the beginning of a start attempt then the engine will not be started and the oil pressure led will flash When the oil pressure switch closes normal operation will be resumed HIGH TEMPERATURE Set if a signal is detected at the High Temperature Switch input or the coolant temperature value
13. 02 2006 9 PROGRAMMING The program mode is used to program the timers operational limits and the configuration of the unit To enter the program mode press the MENU button for 5 seconds The program mode is only allowed if the PROGRAM LOCK input terminal_23 is left open If this input is tied to GROUND the program value modification will be disabled to prevent unauthorized intervention It is advised to keep the PROGRAM LOCK input tied to GROUND The program mode will not affect the operation of the unit Thus programs may be modified anytime even while the genset is running In program mode when the MENU key is pressed the display will show the program parameter number when the MENU key is released the display will show the program parameter value The first program number is 000 Each depression of the MENU key will cause the display to switch to the next program parameter If the MENU key is hold pressed the program numbers will increase by steps of 10 After the last parameter the display switches back to the first parameter The displayed parameter value may be increased or decreased using A and W keys If these keys are hold pressed the program value will be increased decreased by steps of 10 Program parameters are kept in a non volatile memory and are not affected from power failures To exit the program mode press one of the mode selection keys If no button is pressed during 1 minute the program mode will be c
14. 05 Standard values are 170 270 volts The hysteresis voltage may be given to excessive Check the parameter P 021 the standard value is 8 volts AC voltages or frequency displayed on the unit are not correct Check engine body grounding it is necessary The error margin of the unit is 3 volts If there are faulty measurements only when the engine is running there may be a faulty charging alternator or voltage regulator on the engine Disconnect the charging alternator connection of the engine and check if the error is removed If there are faulty measurements only when mains are present then the battery charger may be failed Turn off the rectifier fuse and check KW and cosQ readings are negative although the Amp readings are correct The current transformer is connected with reverse polarity Change the CT polarity AN Short circuit the outputs of unused Current Transformers When the AC mains fails the unit energizes the fuel solenoid but does not start and OIL PRESSURE led flashes The unit is not supplied with battery voltage at the oil pressure input Oil pressure switch not connected Oil pressure switch connection wire cut Oil pressure switch faulty Oil pressure switch closes too lately If oil pressure switch closes the unit will start Optionally oil pressure switch may be replaced The engine does not run after the first start attempt then the unit does not start again and OIL PRESSURE led
15. 7 bars 0 90 ohms DATCON 0 10 bars 0 90 ohms DATCON 0 7 bars 75 10 ohms NOoOohOND 17 DKG 207 User Manual V 01 03 14 02 2006 Pgm Definition Std Val Description 20 Temperature sender type Unit 1 This parameter selects the temperature sender type 0 The sender characteristics are defined in table using parameters P 143to P 154 1 VDO 2 DATCON DAH type 3 DATCON DAL type 21 Hysteresis Voltage This parameter provides the mains and genset voltage limits with a hysteresis feature in order to prevent faulty decisions For example when the mains are present the mains voltage low limit will be used as the programmed low limit P 004 When the mains fail the low limit will be used as P 004 021 It is advised to set this value to 8 volts 22 Engine Heating Temperature 50 If itis requested that the engine runs without load until reaching a certain temperature this parameter defines the temperature 23 Holdoff timer sec This parameter defines delay after the engine runs and before the fault monitoring is enabled 24 Overcurrent Excess Power Frequency Timer sec This is the period between the current or active power goes over the limits P 002 P 003 and OVERLOAD alarms occurs This is also the period between the frequency goes out of the limits P 008 P 011 and SPEED FAULT alarm occurs 25 Wait before Fuel mi
16. DKG 207 User Manual V 01 03 14 02 2006 D DATAKOM Tel 90 216 466 84 60 Fax 490 216 364 65 65 datakom datakom com tr http www datakom com tr D DATAKOM DKG 207 AUTOMATIC MAINS FAILURE AND REMOTE START UNIT on pr eattery Q hich temp chance start ran rect ran sreco EeE stop voitace spare overtoan service DKG 207 ALARMS FEATURES Automatic mains failure Engine control Generator protection Built in alarms and warnings 3 phase mains voltage inputs 1 phase genset voltage input 1 phase genset CT input Engine oil pressure measurement Engine coolant temperature measurement Genset active power measurement Genset power factor measurement Periodic maintenance request indicator Daily weekly monthly exerciser Engine hours counter Statistical counters Field adjustable parameters Logic level serial port Optional RS 232 adapter Free MS Windows Remote monitoring SW local LAN IP and modem connection monitoring download of parameters LED displays Configurable analogue inputs 2 Configurable digital inputs 5 Configurable relay outputs 2 Total relay outputs 6 Remote Siart operation available Survives cranking dropouts Sealed front panel Plug in connection system for easy replacement Small dimensions 120x90x39mm Low cost DKG 207 User Manual V 01 03 14 02 2006 TABLE OF CONTENTS Section 1 INSTALLA
17. Exercise duration min 10 This parameter defines the exercise duration and programmed in 10 minute steps up to 24 hours 116 Daily Weekly Monthly Exercise 0 exercise every day the exercise will be performed every day regardless of the day selection with parameter P 113 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 28 DKG 207 User Manual V 01 03 14 02 2006 The parameters from P 117 to P 122 adjust the date and time Pgm Definition Unit Std Val Description 117 Year 00 99 Last two digits of the current year 118 Month 01 12 Current month 119 Date 01 31 Current day of the month 120 Day 0 6 Current day of the week 0 Monday 1 Tuesday 2 Wednesday 3 Thursday 4 Friday 5 Saturday 6 Sunday 121 Hour 00 23 Current hour of the day 122 Minute 00 59 Current minute of the hour DA DKG 207 User Manual V 01 03 14 02 2006 10 TROUBLESHOOTING The genset operates while AC mains are OK or continues to operate after AC mains are OK Check engine body grounding AC mains voltages may be outside programmed limits measure the phase voltages Check the AC voltage readings by pressing the MENU button Upper and lower limits of the mains voltages may be too tight Check the parameters P_004 and _0
18. IFIER FAIL Set if a signal is detected at the rectifier fail input This input is only monitored when mains voltages are present EMERGENCY STOP Set if a signal is detected at the emergency stop input SPARE Set if a signal is detected in one of the spare fault input DKG 207 User Manual V 01 03 14 02 2006 5 MODES OF OPERATION The modes of operation are selected by pushing the front panel keys Changing the operation mode while the genset is running will result to a behavior suitable for the new operating mode For example if the AUTO mode is selected when genset is running at TEST mode then the genset will stop assuming that the mains voltages are present OFF In this mode the mains contactor will be energized if mains phase voltages are within the programmed limits The engine will be stopped AUTO It is used for genset and mains automatic transfer If at least one of the mains phase voltages is outside limits P_004 P_005 the mains contactor will be deactivated The diesel will be started for programmed times P_035 after the wait period P_0026 When the engine runs the crank relay will be immediately deactivated The engine will run without load during engine heating period P_029 After this if alternator phase voltages and frequency are within limits then the unit will wait for the generator contactor period P_032 and the generator contactor will be energized When all the mains phase voltages are within the lim
19. MOTE START signal is present then the mains will be supposed to fail inversely if the REMOTE START signal is absent then mains voltages will be supposed to be present The front panels mimic diagram s mains LEDs will reflect the status of the REMOTE START input 10 DKG 207 User Manual V 01 03 14 02 2006 6 2 Sender type Selection The unit has the ability to adapt to any type of oil pressure and temperature senders The commonly used standard sender characteristics are recorded in memory and selectable from a list However non standard senders may also be used by entering their characteristics to the table Oil Pressure Sender Type Selection The oil pressure sender is selected using parameter P 019 The selectable sender types are 0 The sender characteristics are defined in table using parameters P 131 to P 142 1 VDO 0 7 bars 10 180 ohms VDO 0 10 bars 280 20 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 NOoR WD Temperature Sender Selection The temperature sender is selected using parameter P_020 The selectable sender types are 0 The sender characteristics are defined in table using parameters P_143 to P_154 1 VDO 2 DATCON DAH type 3 DATCON DAL type 6 3 Engine Heating Operation Especially on engine without a body heater or with a failing one it may be desired that the genset
20. Response delay 0 0 No delay 1 Delayed 4sec Parameters from P 089 to P 100 define the ohm bar characteristics of the oil pressure sender The sender characteristics will be defined using maximum 6 points The values should be entered in the increasing order of ohm values For unused points ohm values should be entered as 0 An example table is given below The sensor characteristics used in this table are 0 0 bar 240 ohms 1 0 bar 218 ohms 5 0 bar 153 ohms 10 0 bar 103 ohms Pgm Description Unit Value 89 Point 1 resistor ohm 103 90 Point 1 pressure bar 10 0 91 Point 2 resistor ohm 153 92 Point 2 pressure Bar 5 0 93 Point 3 resistor Ohm 218 94 Point 3 pressure Bar 1 0 95 Point 4 resistor Ohm 240 96 Point 4 pressure Bar 0 0 97 Point 5 resistor Ohm 0 98 Point 5 pressure Bar 0 0 99 Point 6 resistor Ohm 0 100 Point 6 pressure bar 0 0 22 DKG 207 User Manual V 01 03 14 02 2006 Parameters from P 101 to P 116 define the ohm degrees characteristics of the temperature sender The sender characteristics will be defined using maximum 6 points The values should be entered in the increasing order of ohm values For unused points ohm values should be entered as 0 An example table is given below The sensor characteristics used in this table are 38 342 ohms 82 C
21. TION 1 1 Introduction to the Control Panel 1 2 Mounting the Unit 1 3 Wiring the Unit 2 INPUTS AND OUTPUTS 3 DISPLAYS 3 1 Led Displays 3 2 Digital Display 4 ALARMS AND WARNINGS 5 MODES OF OPERATION 6 OTHER FEATURES 6 1 Remote start operation 6 2 Sender type selection 6 3 Engine heating operation 6 4 Service Request Display 6 5 Engine Hour Meter 6 6 Modem connection 6 7 Remote Monitoring and Programming 6 8 Intermittent operation in AUTO mode 6 9 Exerciser 7 STATISTICAL COUNTERS 8 MAINTENANCE 9 PROGRAMMING 10 TROUBLESHOOTING 11 DECLARATION OF CONFORMITY 12 TECHNICAL SPECIFICATIONS 13 CONNECTION DIAGRAM DKG 207 User Manual V 01 03 14 02 2006 1 INSTALLATION 1 1 Introduction to the Control Panel The unit is a control and protection panel used in gensets It shows the measured values on its displays The unit is designed to provide user friendliness for both the installer and the user Programming is usually unnecessary as the factory settings have been carefully selected to fit most applications However programmable parameters allow the complete control over the generating set Programmed parameters are stored in a Non Volatile Memory and thus all information is retained even in the event of complete loss of power The measured parameters are Mains voltage phase R to neutral Mains voltage phase S to neutral Mains voltage phase T to neutral Mains voltage phase R S Mains voltage phase S T Mains vol
22. ancelled automatically Pgm Definition Unit Std Val Description This is the rated value of the current transformer The secondary of the transformer will be 5 Amps For values over 990A use 10 0 Current Transformer A 500 of the value These values will be displayed as Primary K Amperes for ex 1 85KA Values under 100A may be used by multiplying with 10 in order to enable the current display with 0 1A precision for ex 35 7A This parameter determines the display range of current and active power Current Transformer 1 0 0 000 999 Decimal Point 1 0 00 9 99 2 00 0 99 9 If the current goes above this limit during the period defined in P 024 an OVERLOAD alarm will be generated Enter this information with the same format as parameter P 000 2 Overcurrent Limit A 500 If the active power measured on phase U goes above this limit during the period defined in 3 Excess Power Limit KW 350 P 024 an OVERLOAD alarm will be generated Enter this information with the same format as parameter P 000 If one of the mains phases goes under this limit it means that the mains are off and it starts the transfer to the genset in AUTO and TEST modes 4 Mains Voltage Low Limit V 170 If one of the mains phases goes over this limit it means that the mains are off and it starts the transfer to the genset in AUTO and TEST modes 5 Mains Voltage High Limit V 270 If the generator phase volta
23. ge goes under this 6 Gen Voltage Low Limit V 180 limit when feeding the load this will generate a VOLTAGE alarm and the engine will stop If the generator phase voltage goes over this limit f Gen Voltage High Limit V 270 when feeding the load this will generate a VOLTAGE alarm and the engine will stop DKG 207 User Manual V 01 03 14 02 2006 Pgm Definition Unit Std Val Description Low Freq Alarm Hz 30 If the genset frequency goes under this limit a SPEED alarm will be generated and the engine will stop This alarm will be monitored after delay defined in P 023 when the engine runs Low Freq Warning Hz 40 If the genset frequency goes under this limit a SPEED warning will be generated This warning will be monitored after delay defined in P 023 when the engine runs 10 High Freq Warning Hz 54 If the genset frequency goes over this limit a SPEED warning will be generated This warning will be monitored after delay defined in P 023 when the engine runs 11 High Freq Alarm Hz 57 If the genset frequency goes over this limit a SPEED alarm will be generated and the engine will stop This alarm will be monitored after delay defined in P 023 when the engine runs 12 Low Battery Voltage Warning 9 0 If the battery voltage falls below this limit this will generate a BATTERY warning 13 High Battery Voltage
24. ins voltages the engine runs when a signal from the REMOTE START 22 comes 43 Modem Connection 0 No modem connection the serial port is connected to PC 1 Modem connected 44 Maintenance Period Engine Hours hours 200 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 45 Maintenance Period Months 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 vwill be indicated depending on time 46 Not used Max Engine Run Period hours This is the maximum engine operation period If the period is set to zero then the engine will run indefinitely It may not be necessary to run the genset indefinitely in battery backed up systems Thanks to this parameter the engine may stop after a sufficient operation period for battery charging 48 Not used Not used 50 Not used Contactor and Generator Contactor The parameters from P 051 to P 052 define the functions of relay outputs The unit has 6 relay outputs and 2 of them have programmable functions The fixed function relays are Fuel Start Mains 19 DKG 207 User Manual V 01 03 14 02 2006 The function of a programmable relay output may be selec
25. ith 1 month steps P 045 If any of the programmed values is zero this means that the parameter will not be used For example a maintenance period of 0 months indicates that the unit will request maintenance only based on engine hours there will be no time limit If the engine hours is also selected as O hours this will mean that the SERVICE REQUEST display will be inoperative When the engine hours OR the time limit is over the SERVICE REQUEST led red will start to flash To turn off the led and reset the service period press together the ALARM MUTE and LAMP TEST keys for 5 seconds The upper display will show SER The remaining engine hours and the remaining time limit are kept stored in a non volatile memory and are not modified by power supply failures The remaining time and engine hours to service may be checked via the statistics menu selected by pressing the MENU key for 1 second When the MENU key is pressed the display will show hours to service When the MENU key is released it will show the first 3 digits of the engine hours to service When the MENU key is pressed again the display will show HtS hours to service When the MENU key is released it will show the last 3 digits of the engine hours to service When the MENU key is pressed the display will show ttS time to service When the MENU key is released it will show the first 3 digits of the remaining days to service When the MENU key is pressed again
26. its the engine will continue to run for the mains waiting period P_030 At the end of this period the generator contactor is deactivated and the mains contactor will be energized If a cooling period is given P_031 the generator will continue to run during cooling period At the end of the period the fuel solenoid will be de energized and the diesel will stop The unit will be ready for the next mains failure TEST It is used to test the generator when the mains are on or keep the generator running in the emergency backup mode P_041 The operation of the generator is similar to the AUTO mode but the mains contactor will not be deactivated if the mains are not off If the mains are off mains contactor will be deactivated and the generator contactor will be activated When the mains are on again a changeover to the mains will be made but the engine will be kept running unless another mode is selected To stop the engine select AUTO or OFF mode 6 OTHER FEATURES 6 1 Remote Start Operation The unit offers the possibility of REMOTE START mode of operation If the program parameter P_042 is set to 1 then the unit will enter to the Remote Start operation The Remote Start signal should be connected to the SPARE_2 22 input The REMOTE START signal may be a NO or NC contact switching to either battery positive or battery negative These selections are made using programming menu In this mode the mains phases are not monitored If the RE
27. lization 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 6 8 Intermittent operation in AUTO mode If the load is a battery operated system like a GSM base station it may not be necessary to run the genset immediately after a mains failure The program parameter P 025 defines the genset operation delay after a mains failure in minutes The delay range is from 0 to 4 hours Equally it may not be necessary to run the genset indefinitely because the load charges its batteries when the engine runs Thus the engine may stop after a sufficient operation period for battery charging The program parameter P 047 defines the maximum engine operation delay The range is from 6 minutes to 14 hours If the delay is set to zero then the engine will run indefinitely The parameters P 025 and P 047 used together provide the intermittent operation needed in GSM base stations 2482 DKG 207 User Manual V 01 03 14 02 2006 6 9 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 program parameters related to the exerciser are P 113 Exercise start day and hour P
28. measured from the sender is above the programmed limit Warning P 017 and alarm P 018 limits are separately programmable for the temperature sender input SPEED Set if the generator frequency is outside programmed limits overspeed Underspeed This fault will be monitored with holdoff timer P 023 delay after the engine is running Different low and high limits for warning and alarm are separately programmable P 008 P 009 P 010 P 011 START FAIL Set if the engine is not running after programmed number of start attempts P 035 OVERLOAD Set if the genset phase current goes over the Overcurrent Limit P 002 or if the genset power KW measured on phase U goes over the Excess Power P 003 limit for Overcurrent Excess Power Timer P 511 If the currents and power goes below the limits before expiration of the timer then no alarm will be set VOLTAGE Set if any of the generator phase voltages goes outside programmed limits P 006 P 007 This fault will be monitored with holdoff timer P 023 delay after the engine is running BATTERY Set if the battery voltage goes outside programmed limits During engine cranking this fault is not monitored Warning level for low battery voltage P 012 and both warning P 013 and alarm P 014 levels for high battery voltage are programmable CHARGE Set if a charge alternator failure or broken belt occurs This fault condition may result to a warning or alarm following programming P 038 RECT
29. n 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 26 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 defined by programming 27 Start Timer sec This is the maximum start period Starting will be automatically cancelled if the genset fires before the timer 28 Wait between Starts sec This is the waiting period between two start attempts 29 Engine Heating Timer sec This is the period used for engine heating following the program parameter P 037 30 Mains Waiting Timer min 0 5 This is the time between the mains voltages entered within the limits and the generator contactor is deactivated 31 Cooling Timer min 1 0 This is the period that the generator runs for cooling purpose after the load is transferred to mains 32 Generator Contactor Timer sec This is the period after the mains contactor has been deactivated and before the generator contactor has been activated 33 Mains Contactor Timer sec This is the period after the generator contactor has been deactivated and before the mains contactor has been activated 34 Stop Timer sec This is the maximum time duration for the engine to sto
30. of the unit If OK turn all the fuses off then turn all the fuses on starting from the DC supply fuse Then test the unit again Programming mode can not be entered The program lock input disables programming mode entry Disconnect the program lock input from battery negative before modification Do not forget to make this connection again to prevent unauthorized program modifications 11 DECLARATION OF CONFORMITY The unit conforms to the EU directives 73 23 EEC and 93 68 EEC low voltage 89 336 EEC 92 31 EEC and 93 68 EEC electro magnetic compatibility Norms of reference EN 61010 safety requirements EN 50081 2 EMC requirements EN 50082 2 EMC requirements The CE mark indicates that this product complies with the European requirements for safety health environmental and customer protection 26 DKG 207 User Manual V 01 03 14 02 2006 12 TECHNICAL SPECIFICATIONS Alternator voltage 0 10300 V AC Ph N Alternator frequency 0 100 Hz Mains voltage 0 to 300 V AC Ph N Current input from current transformer 5A Max load 0 7VA per phase Digital inputs input voltage 0 30 V DC Internally connected to battery positive via 4700 ohm resistor Analog inputs Resistor input 0 to 5000 ohms connected to the battery negative Sources 10 mA when closed to battery negative Measurement category CAT II Air category Pollution degree Il DC Supply range 9 0 V DC to 30 0 V DC Cranking dropouts survives
31. p During this period the STOP relay output is energized if defined by programming 35 Start Attempts This is the maximum number of start attempts 18 DKG 207 User Manual V 01 03 14 02 2006 Pgm Definition Unit Std Val Description 36 Horn Timer sec 10 This is the period during which the HORN relay is active If the period is set to 0 this will mean that the period is unlimited 37 Engine Heating Type This parameter defines the engine heating method The genset will not take the load before engine heating is completed 0 engine is heated during the period defined by the Engine Heating Timer P 029 1 engine is heated until the coolant temperature reaches the temperature defined by Engine Heating Temperature P 022 and at least during the period defined by the Engine Heating Timer P 029 38 Charge input alarm 0 The charge input generates CHARGE warning and does not stop the engine 1 The charge input generates CHARGE alarm and stops the engine 39 Not used Not used 41 Emergency Backup Operation 0 In TEST mode the load will not be transferred to the genset even if the mains fail 1 In TEST mode the load will be transferred to the genset if the mains fail 42 Remote Start Operation 0 Not REMOTE START mode the engine runs when the mains fail 1 REMOTE START mode the unit does not monitor ma
32. roup 3 Warnings and alarms This group indicates the existence of abnormal conditions encountered during operation Group 4 Unit This group indicates the unit of the value displayed in the bottom display Function Color Description GENERATOR Yellow The LED will flash when the generator phase voltage is within the programmed limits It turns on when the generator contactor is activated MAINS Green The LED will flash when all 3 mains phase voltages are within the limits It turns on when the mains contactor is activated TEST Yellow It turns on when the related operation mode is AUTO Green selected These LEDs indicate which operation mode is selected Both leds are off in the OFF mode SERVICE REQUEST Red Engine periodic maintenance request indicator It turns on when the preset engine hours or time duration after previous service has elapsed ALARM GROUP Red If a fault condition resulting to the engine shutdown has occurred the related alarm led turns on steadily If a warning condition has occurred the related led flashes The alarms work on a first occurring basis The occurrence of a fault will disable other faults of lower or equal priority UNIT GROUP Red This group indicates the unit of the value displayed in the digital display When the engine is running the unit displays the genset frequency otherwise it displays the mains phase R voltage Different values may be scrolled by pressing the MENU key
33. 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 parameter P_037 is set to 0 In this mode the engine will run during parameter P_029 and then the genset will take the load 2 Timer and temperature controlled heating This operation mode is selected when the parameter P_037 is set to 1 In this mode at first the engine will run during parameter P_029 then it will continue to run until the measured coolant temperature reaches the limit defined in parameter P_022 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 zd DKG 207 User Manual V 01 03 14 02 2006 6 4 Service Request Display This led is designed to help the periodic maintenance of the genset to be made consistently The periodic maintenance is basically carried out after a given engine hours for example 200 hours but even if this amount of engine hours is not fulfilled it is performed after a given time limit for example 12 months The SERVICE REQUEST led has no effect on the genset operation The unit has both programmable engine hours and maintenance time limit The engine hours is programmable with 50 hour steps P 044 the time limit is programmable between w
34. tage phase T R Gen voltage phase U to neutral Gen current phase U Gen KW phase U Gen cos phase U Battery voltage Coolant temperature Oil pressure Gen frequency 1 2 Mounting the Unit The unit is designed for panel mounting The user should not be able to access parts of the unit other than the front panel Mount the unit on a flat vertical surface The unit fits into an opening of 116x86 millimeters Before mounting remove the retaining steel spring and connectors from the unit then pass the unit through the mounting opening The unit will be maintained in its position by the steel spring Engine body must be grounded for correct operation of the unit otherwise incorrect voltage and frequency measurements may occur The output of the current transformers shall be 5 Amperes The input current rating of the current transformers may be selected as needed between 10 5 and 9000 5 amps Current transformer outputs shall be connected by separate cable pairs from each transformer to related inputs Never use common terminals or grounding The power rating of the transformer should be at least 5 VA It is recommended to use 1 precision transformers If analogue senders e g temperature or oil pressure are connected to the unit it is not possible to use auxiliary displays otherwise the unit may be destroyed If temperature or oil pressure displays are already present on the generator control panel do not connect the senders
35. ted from the below list RELAY FUNCTION LIST Pgm Description Std 00 Fuel 24 Oil sender alarm 51 RELAY 1 function 01 01 Horn 25 Temp sender alarm 52 RELAY 2 function 03 02 Start 26 Speed alarm 03 Stop 27 Start fail alarm 04 Gen Contactor 28 Charge alarm 05 mains Contactor 29 Overload alarm 06 Choke 30 Voltage alarm 07 Preheat 31 Battery High alarm 08 Alarm 32 Oil switch warning 09 Warning 33 Temp switch warn 10 Alarm Warning 34 Level switch warn 11 Automatic ready 35 Rectifier warning 12 36 Emerg Stop warn 13 37 14 38 Spare warning 15 39 16 Oil switch alarm 40 Oil sender warning 17 Temp switch alarm 41 Temp sender warn 18 42 Speed warning 19 Rectifier alarm 43 20 Emerg Stop alarm 44 Charge warning 21 45 Battery low warning 22 Spare Alarm 46 23 47 Battery high warn Parameters from P 053 to P 088 program the functions of the digital inputs The programmable properties of digital inputs are action to be taken upon arrival of the fault signal alarm warning etc when the fault monitoring will be enabled latching of the fault signal contact type NO NC switching bat bat response delay LOW OIL PRESSURE SWITCH INPUT Pgm Description Std 53 Operation 0 0
36. to the unit The unit is factory programmed for VDO type senders However different types of senders are selectable via programming menu Please check the programming section The programmable digital inputs are compatible with both normally open and normally closed contacts switching either to BAT or BAT The charge alternator connection terminal provides also the excitation current thus it is not necessary to use an external charge lamp DKG 207 User Manual V 01 03 14 02 2006 1 3 Wiring the Unit WARNING THE UNIT IS NOT FUSED Use external fuses for Mains phases R S T Generator phase U Battery positive BAT Install the fuses as nearly as possible to the unit in a place easily accessible for the user The fuse rating should be 6 Amps WARNING ELECTRICITY CAN KILL ALWAYS disconnect the power BEFORE connecting the unit ALWAYS remove the plug connectors when inserting wires with a screwdriver ALWAYS refer to the National Wiring Regulations when conducting installation An appropriate and readily accessible set of disconnection devices e g automatic fuses MUST be provided as part of the installation The disconnection device must NOT be fitted in a flexible cord The building mains supply MUST incorporate appropriate short circuit backup protection e g a fuse or circuit breaker of High Breaking Capacity HBC at least 1500A Use cables of adequate current carrying capacity at least 0 75mm and
37. ty the normally closed contact of the generator contactor should be serially connected to this output OIL PRESSURE SENDER Input 0 5000 ohms Analogue oil pressure sender connection Do not connect the sender to other devices The input has programmable characteristics and connects to any kind of sender 10 COOLANT TEMP SENDER Input 0 5000 ohms Analogue high temperature sender connection Do not connect the sender to other devices The input has programmable characteristics and connects to any kind of sender 11 BATTERY POSITIVE 12 or 24VDC The positive terminal of the DC Supply shall be connected to this terminal The unit operates on both 12V and 24V battery systems 12 GROUND O VDC Power supply negative connection 13 RELAY 1 HORN RELAY Output 10A 28VDC This relay has programmable function selectable from a list 14 START RELAY Output 10A 28VDC This relay controls the engine cranking 15 FUEL RELAY Output 10A 28VDC This relay is used for fuel solenoid control It is internally connected to terminal 16 for supplying the charge alternators excitation current 16 CHARGE Input and output Connect the charge alternator s terminal to this terminal This terminal will supply the excitation current and measure the voltage of the charge alternator DKG 207 User Manual V 01 03 14 02 2006
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