DKG-105 AUTOMATIC MAINS FAILURE UNIT
Contents
1. OFF button P01 MAINS VOLTAGE LOWER LIMIT one of the mains phases goes under this limit it means that the mains are off and it starts the transfer to the generator in AUTO or TEST modes P02 MAINS VOLTAGE UPPER LIMIT If one of the mains phases goes over this limit it means that the mains are off and it starts the transfer to the generator in AUTO or TEST modes GENERATOR VOLTAGE LOWER LIMIT If the generator phase voltage goes under this limit when feeding the load this will mean a generator voltage failure and the engine will stop P04 GENERATOR VOLTAGE UPPER LIMIT If the generator phase voltage goes over this limit when feeding the load this will mean a generator voltage failure and the engine will stop P05 FREQUENCY LOWER LIMIT G phase frequency goes under this value for a period longer than frequency delay timer while the generator is feeding the load it causes the frequency alarm underspeed and the engine will stop immediately This limit is not controlled in the first 4 seconds after the generator contactor has been energized FREQUENCY UPPER LIMIT G phase frequency goes over this value for a period longer than frequency delay timer while the generator is feeding the load it causes the frequency alarm overspeed and the engine will stop immediately This limit is not controlled in the first 4 seconds after the generator contactor has been energized P07 FREQUENCY DELAY TIMER If G phase frequen2. Alarm LEDs will stay on and disable the operation of the generating set even if the alarm source is removed In order to reset the alarm condition first choose OFF mode then resume to the previous mode of operation HIGH TEMPERATURE ALARM It is on when a signal comes from the high temperature input OIL ALARM It is on when a signal comes from the oil pressure oil level input This alarm will be controlled 8 seconds after the engine is running If oil pressure is provided when the unit attempts to start the engine the oil alarm indicator will flash and the unit will wait until oil pressure disappears FREQUENCY VOLTAGE ALARM It is on when the alternator frequency is out of the programmed limits for a longer period than the programmed timer It flashes when the alternator voltage is out of the programmed limits Alternator frequency and voltage will be controlled 4 seconds after the generator contactor is on FAIL TO START It is on if the engine cannot start to run after the programmed number of start attempts This alarm will be erased when the mains are on in order to keep the engine ready for the next mains failure DKG 105 User Manual V 16 2 7 Modes of Operation The modes of operation are selected by pressing the front panel keys 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 generator and mains automatic transfer If
3. button then the MENU button and hold the two buttons pressed for 4 seconds The display shows Pr when program mode is selected PGM FACT MIN MAX NUMBER PROGRAM OPTION UNIT SET VAL VAL P01 Mains Voltage Lower Limit 250 P02 Mains Voltage Upper Limit 400 P03 Generator Voltage Lower Limit 250 P04 Generator Voltage Upper Limit 400 P05 Frequency Lower Limit 60 Frequency Upper Limit 100 P07 Frequency Delay Timer Sec 3 o 15 P08 Number of Start Attempts 8 1 6 P09 Wait before Start Timer Sec 3 o 240 10 Wait between Starts Timer 30 P13 Mains Waiting Timer Mi 05 15 P14 Cooling Timer Mi 10 15 P15 Mains Contactor Timer Sec 1 15 16 Generator Contactor Timer 4 o 240 Relay and Oil Pressure P18 Wait Before Fuel Timer Mn 240 P19 Emergency Stop Remote Start 1 P20 Max Engine Run Time Limit Hour 18 P21 Choke Relay Timer 90 P22 Gas Engine Fuel Solenoid Delay Sec 0 0 0 5 20 DKG 105 User Manual V 16 2 INSTALLATION 2 1 Introduction to the Control Panel The control panel 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 Mem
4. 1v Generator frequency 0 5 Hz Case Material Flame Retardant High Temperature ABS UL94 VO 110 C Stresses exceeding above limits may result to a degradation of the unit s protection level 7 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 11 V 16 DKG 105 User Manual 8 CONNECTION DIAGRAM SNOILO3NNOO WIIdAL SOI 9 pepunoJ8 eq 4snw snhiqe6sey 8 b NbZ ZI uo4ing 3388 8035 5 RousBUsu3 Rejex ejay Bu Peo J0438J9U89 30 891J398 3 764284007 sulen Tel 90 216 466 84 60 Fax 90 216 364 65 65 e mail datakom 2datakom com tr http www datakom com tr C Electronics Ltd 12
5. DKG 105 User Manual V 16 Q DATAKOM PK6 105 AUTOMATIC DATAKOM OFF MAINS FAILURE UNIT DKG 105 FEATURES Automatic engine starting and stopping Gas engine support Automatic mains failure monitoring Automatic load transfer Automatic shutdown on fault condition Test mode available Survives cranking dropouts Provision for energize to stop preheat amp choke outputs Mains phases voltage limits checking Generator phase voltage limits checking Delayed overspeed and underspeed alarm Digitally adjustable low amp high mains voltage limits Digitally adjustable low amp high generator voltage limits Digitally adjustable underspeed amp overspeed limits Digitally adjustable delay for speed alarm Digitally adjustable timers Digital display of mains amp generator voltages Digital display of generator frequency Plug in connection system for easy replacement Low cost Small dimensions Standard panel dimensions 72x72mm DKG 105 User Manual V 16 TABLE OF CONTENTS Section 1 PROGRAMMING SUMMARY 2 INSTALLATION 2 1 Introduction to the Control Panel 2 2 Mounting the Unit 2 3 Wiring the Unit 2 4 Inputs and Outputs 2 5 Displays 2 6 Alarms 2 7 Modes of Operation 3 MAINTENANCE 4 TROUBLESHOOTING 5 PROGRAMMING 6 TECHNICAL SPECIFICATIONS 7 DECLARATION OF CONFORMITY 8 CONNECTION DIAGRAM DKG 105 User Manual V 16 1 PROGRAMMING SUMMARY To enter the program mode first press the OFF
6. Switch 01 Fuel Activate to Stop Activate before Start Oil Pressure Switch 02 Preheat Activate before Start Oil Pressure Switch 03 Choke Activate before Start Oil Pressure Switch 04 Alarm Activate before Start Oil Level Switch 05 Fuel Activate to Stop Activate before Start Oil Level Switch 06 Preheat Activate before Start Oil Level Switch 07 Choke Activate before Start Oil Level Switch 08 Alarm Activate to Stop Oil Pressure Switch 09 Fuel Activate to Stop Activate to Stop Oil Pressure Switch 10 Preheat Activate to Stop Oil Pressure Switch 11 Choke Activate to Stop Oil Pressure Switch 12 Alarm Activate to Stop Oil Level Switch 13 Fuel Activate to Stop Activate to Stop Oil Level Switch 14 Preheat Activate to Stop Oil Level Switch 15 Choke Activate to Stop Oil Level Switch P18 WAIT BEFORE FUEL TIMER The waiting period after the mains failure and before the fuel output active used for UPS backed up gensets P19 EMERGENCY STOP REMOTE START SELECTION Valid only if an extra input provided If this parameter is programmed to 0 then the extra input acts as a REMOTE START input so the input is not latched and no alarm signal generated If this parameter is programmed to 1 then the extra input acts as an EMERGENCY STOP input so the fault signal is latched and alarm signal generated P20 MAX ENGINE RUN TIME LIMIT This is the maximum time limit for the engine to run continuously When used together with t
7. activated when the engine runs 5 GAS ENGINE FUEL SOLENOID The relay will operate after the crank output has been activated The delay is programmed with program parameter P 22 13 14 BAT BAT The positive and negative terminals of the DC Supply shall be connected to these terminals Be careful for the polarization in case of polarity error the unit will not operate The unit operates on both 12V and 24V battery systems DKG 105 User Manual V 16 2 5 Displays DIGITAL DISPLAY This display shows R phase voltage when mains are on Alternator frequency if the generator is on Program values in program mode Below values can be read in sequence by pushing the MENU key in AUTO or TEST modes R phase voltage S phase voltage T phase voltage G phase voltage G phase frequency engine RPM GENERATOR yellow it flashes if the G phase voltage is within programmed limits It turns on when the generator contactor is activated MAINS green it flashes when all R S T phase voltages are within the programmed limits It turns on when the mains contactor is activated TEST AUTO It turns on when the related operation mode is selected 2 6 Alarms Alarms indicate an abnormal situation in the generating set and cause the engine to stop immediately If an alarm occurs the related LED will turn on and the alarm relay will be activated If any key is pressed the alarm relay will be deactivated
8. at least one of the mains phase voltages is outside limits the mains contactor will be deactivated The diesel will be started for programmed times after the wait period When the engine runs the crank relay will be immediately deactivated After the G phase voltage is within the limits the unit will wait for the generator contactor period and the generator contactor will be energized When all the mains phase voltages are within the limits the engine will continue to run for the mains waiting period At the end of this period the generator contactor is deactivated and mains contactor will be energized If a cooling period is given 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 waiting in the emergency backup mode The operation of the generator is similar to the AUTO mode but the mains contactor will not be deactivated if the mains are not off If the mains are off mains contactor will be deactivated and the generator contactor will be activated When the mains are on again a changeover to the mains will be made but the engine is kept running In order to stop the engine push the OFF button DISPLAY TEST It is used to test the functionality of the displays This mode is selected when OFF and TEST buttons are p
9. cy goes out of the programmed values for a period longer than frequency delay timer while the engine is running it causes the frequency alarm and the generator will stop immediately NUMBER OF START CYCLES The generator start attempts cannot exceed this number P09 WAIT BEFORE START TIMER The waiting period before start Also called preheat timer P10 WAIT BETWEEN STARTS TIMER The waiting period between starts P11 START TIMER The engine starting period cannot exceed this number P12 zSTOP TIMER It adjusts the stop solenoid energizing period in order to stop the generator P13 MAINS WAITING TIMER This is the time between the mains voltages are within the limits and the load transferred from the generator to the mains DKG 105 User Manual V 16 P14 COOLING TIMER This is the period that the engine runs with no load after the load changeover to the mains P15 MAINS CONTACTOR TIMER This is the period after the generator contactor has been deactivated and before the mains contactor has been activated P16 GENERATOR CONTACTOR TIMER This is the period after the mains contactor has been deactivated and before the generator contactor has been activated P17 RELAY AND OIL PRESSURE CONFIGURATION FUEL and AUXILIARY relay configuration as well as the oil switch input type VL AUX RELAY FUNCTION FUEL RELAY FUNCTION OIL INPUT TYPE 00 Alarm Activate before Start Oil Pressure
10. g Capacity HBC at least 1500A Use cables of adequate current carrying capacity DKG 105 User Manual V 16 2 4 Inputs and Outputs 1 N Neutral terminal for both the mains and generator phases 2 G Connect one of the generator phases to this input The generator phase voltage upper and lower limits are programmable 3 GENERATOR CONTACTOR This output provides energy to the generator contactor If the generator phase voltage is outside of the programmed limits the generator contactor will be de energized In order to provide extra security normally closed contact of the mains contactor should be serially connected to this output Relay contact rating is 16A 250V AC 4 5 6 T S R Connect the mains phases to these inputs The mains voltages upper and lower limits are programmable 7 MAINS CONTACTOR This output provides energy to the mains contactor If the voltage of at least one of the mains voltages is outside of the programmed limits the mains contactor will be de energized In order to provide extra security normally closed contact of the generator contactor should be serially connected to this output Relay contact rating is 16A 250V AC 8 HIGH TEMPERATURE SWITCH Connect the high temperature switch to this input This switch shall be negative closing switch type 9 LOW OIL PRESSURE LOW OIL LEVEL Connect the low oil pressure or low oil level switch to this input The switch should be negative closing in case of loss of o
11. he WAIT BEFORE FUEL TIMER P18 this will provide the genset with an intermittent operation P21 CHOKE TIMER If the AUXILIARY RELAY is defined as choke output this relay will operate together with the start relay and release at the expiration of this timer By programming this timer to adequate values the choke may be released before or after the engine run P22 GAS ENGINE FUEL SOLENOID If this parameter is set to 0 0 factory default then the AUXILIARY RELAY will operate as implied by P21 Otherwise the relay will operate after the crank output delayed by this timer It will release when the engine is to be stopped zs DKG 105 User Manual V 16 6 TECHNICAL SPECIFICATIONS Mains voltage 277VAC Ph N Mains frequency 50 60Hz Power System Type TN or TT Alternator voltage 277VAC Ph N Alternator frequency 0 100Hz Measurement Category CAT II DC Supply Range 9 to 33 VDC 4 0 33 VDC while cranking Current consumption 60 mADC typical AUTO mode mains Ok 200 mADC max Relay outputs open Total DC Current Output Rating 10ADC Total AC Current Output Rating 10AAC Current Rating for each Output Terminal 10ARMS Operating temperature range 20 C 4 F to 70 C 158 F Storage temperature range 30 C 22 F to 80 C 176 Maximum humidity 95 non condensing Dimensions 72 x 72 x 76mm WxHxD Mounting opening dimensions 68 x 68mm minimum Weight 240 g approx Accuracy Phase voltages 296
12. il pressure or low oil level This input must be properly connected for the correct operation of the unit If oil pressure is provided the generator will not start and the oil pressure alarm indicator will flash However if the oil pressure is removed the unit will resume normal operation 10 FUEL OUTPUT This output is used on engines equipped with a fuel solenoid The unit activates this output before starting the engine and deactivates it to stop it By programming this relay can also control Activate to Stop type of engines Relay contact rating is 10A 28V DC 11 CRANK OUTPUT Engine crank output Relay automatically turns off when the alternator voltage reaches 100 volts or the alternator frequency reaches 10Hz Relay contact rating is 10A 28V DC 12 AUXILIARY RELAY OUTPUT This relay fulfills 5 different functions following programming Relay contact rating is 10A 28V DC 1 ALARM RELAY If an alarm occurs the relay will be activated It will be deactivated when any key is pressed 2 STOP RELAY The relay will operate during programmed period in order to stop the engine Activate to Stop 3 PREHEAT RELAY The relay will operate the programmed delay before the cranking of the engine It will be deactivated during cranking and reactivated during the rest period between cranks It will be deactivated when the engine runs 4 CHOKE RELAY The relay will operate the programmed delay before the cranking of the engine It will be de
13. liary relay The coil of the relay will be between BATTERY and charging alternator LAMP 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 CHARGE LAMP turns off DKG 105 User Manual V 16 The unit is inoperative Measure the DC supply voltage between and terminals at the rear of the unit If OK turn all the fuses off then turn all the fuses on starting from the DC supply fuse Then try the unit again 5 PROGRAMMING The programming mode is used to program the timers operational limits and the configuration of the unit To enter the program mode first press the OFF button then the MENU button and hold the two buttons pressed for 4 seconds The display shows Pr when program mode is selected Each time the MENU key is pushed the next program number will display and whenever it is released the program value will be shown For example if you push MENU key and keep pushing you will see P01 on the display When you release MENU key you will see PO1 s value that you can increase or decrease by using TEST and AUTO keys If you push again the MENU key you will see P02 on the display and when you release it you will see P02 value You can continue so until P20 After P20 you will turn back to 1 Programmed values are stored in a Non Volatile Memory which is not affected by energy failures To exit programming press the
14. ory and thus all information is retained even in the event of complete loss of power 2 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 a standard panel meter opening of 68x68 millimeters Before mounting remove the steel spring and the plug connectors from the unit and then pass the unit through the mounting opening The unit will be maintained in its position by the steel spring 2 3 Wiring the Unit WARNING THE UNIT IS NOT FUSED Use external fuses for Mains phases R S T Generator phase Battery positive 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 The fuse rating should be 6 Amps 1 ALWAYS remove the plug connectors when inserting wires with a screwdriver 2 ALWAYS refer to the National Wiring Regulations when conducting installation 3 An appropriate and readily accessible set of disconnection devices e g automatic fuses MUST be provided as part of the installation 4 disconnection device must NOT be fitted in a flexible cord 5 The building mains supply MUST incorporate appropriate short circuit backup protection e g a fuse or circuit breaker of High Breakin
15. ressed together and deselected when no button is pressed PROGRAM It is used to program the timers and operational limits 3 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 DKG 105 User Manual V 16 4 TROUBLESHOOTING The genset starts to operate while AC mains are OK AC mains voltages may be outside programmed limits Read AC voltages by pressing the MENU button Upper and lower limits of the mains voltages may be too tight Get in the PROGRAM mode and check for the AC voltage upper and lower limits If necessary widen the limits The genset continues to operate after AC mains are reestablished Widen the AC voltage limits The hysteresis value for the AC voltages is 10 volts When the AC mains fail the lower limit is raised and the upper limit is reduced by the hysteresis value to prevent a new load transfer after the load is transferred to the mains AC voltages displayed on the unit are not correct The error margin of the unit is 5 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 and check if the error is removed When the AC mains fails the unit energizes the fuel solenoid but does not start also OIL PRESSURE ALARM led flashes The
16. 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 falls 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 the OIL PRESSURE ALARM led flashes The oil pressure switch closes very lately As the unit senses an oil pressure it does not start When oil pressure falls 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 FAIL TO START alarm and then the engine stops The generator phase voltage is not connected to the unit Measure the AC voltage between terminals G and Neutral at the rear of the unit while engine is running The fuse protecting the generator phase 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 alternator voltage rises lately Also the generator remanant voltage is below 30 volts The unit removes starting with the generator frequency and needs at least 30 volts to measure the frequency If this situation is to be avoided the only solution is to add an auxi
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