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dkg-109 automatic mains failure unit features

1. DKG 109 User Manual V 03 23 09 2009 Program Group Input Configuration Low Oil Pressure Switch password level 2 Parameter Definition Unit 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 1 1 After holdoff timer 2 When mains present 0 Non latching Latching 1 Latching 0 Normally open Contact type Y 1 Normally closed Tia 0 Battery negative Switching 0 1 Battery positive 0 No dela Response delay 0 1 Delaye dt 4566 Program Group Input Configuration High Temperature Switch password level 2 Factory Parameter Definition Unit 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 Response delay 0 Delayed 4sec aA OA O H Ol ON A 0 MN 0 35 DKG 109 User Manual V 03 23 09 2009 Program Group Input Configuration Emergency Stop password level 2 Parameter Definition Unit Fac Set Description Action Shutd
2. 6 8 Delayed Mains Simulation Battery Charging The Delayed Mains Simulation feature is used in battery backed up telecom systems where batteries are able to supply the load during a certain period The genset is requested to run only when battery voltage drops below the critical level Once the engine runs the rectifier system starts charging the batteries and the battery voltage goes up immediately Thus the engine should continue to run a programmed period for effective charging The critical battery voltage level will be detected by an external unit which provides the digital Simulate Mains signal for the genset control unit The unit offers an optional SIMULATE MAINS 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 in order to prevent any alarms generated from this input The SIMULATE MAINS signal may be a NO or NC contact switching to either battery positive or battery negative These selections are made using the programming menu If the Delayed Simulate Mains program parameter 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
3. 0 crank stop with oil pressure ae Stop VIENT 0 1 cranking is stopped when oil presure switch is open or the oil pressure measured is above shutdown limit 0 no crank stop with charge input 2 Crank Stop with Charge 0 1 cranking is stopped when the charge alternator voltage is established If the engine speed goes under this limit a GENSET 2 Lover pi ohuldown rpm Q LOW SPEED alarm is generated and the engine stops 2 Low rpm Warning rpm 0 If the engine speed goes under this limit a GENSET LOW SPEED warning is generated If the engine speed goes over this limit a GENSET 2 Pign rani Warming pN 0 HIGH SPEED warning is generated If the engine speed goes over this limit a GENSET 2 High rpm Shutdown rom 0 HIGH SPEED alarm is generated and the engine stops DKG 109 User Manual V 03 23 09 2009 Program Group Sender Characteristics password level 2 Parameter Definition Unit Factory Description Set Oil Pressure Sender Ohms 1 ohm 10 Oil Pressure Sender point 1 ohm value Oil Pressure Value 1 bar 0 0 Oil Pressure Sender point 1 bar value Oil Pressure Sender Ohms 2 ohm 52 Oil Pressure Sender point 2 ohm value Oil Pressure Value 2 bar 2 0 Oil Pressure Sender point 2 bar value Oil Pressure Sender Ohms 3 ohm 90 Oil Pressure Sender point 3 ohm value Oil Pressure Value 3 bar 4 0 Oil Pressure Sender point 3 bar value Oil Pre
4. Factory Set Description 2 SMS Enable 0 SMS not enabled 1 SMS enabled 2 MODBUS Address 0 RAINBOW communication protocol 1 144 MODBUS communication This parameter is also the MODBUS controller address of the unit 1 Oil Pressure in psi 0 oil pressure display in bars 1 oil pressure display in psi 1 Temperature in F 0 temperature display in degrees C 1 temperature display in degrees F 2 Flashing Relay Timer hours Delayed Simulate Mains Operation max genset running time after Simulate Mains signal disappears Dual Genset Systems flashing relay toggle timer Please contact DATAKOM for dual genset mutual stanby operation 2 Hysteresis Voltage This parameter provides the mains and genset voltage limits with a hysteresis feature in order to prevent faulty decisions For example when the mains are present the mains voltage low limit will be used as the programmed low limit When the mains fail the low limit will be incremented by this value It is advised to set this value to 8 volts 2 RPM from genset frequency 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 2 Crank Teeth Count 30 This is the number of pulses generated by the magnetic pickup sensing unit in one turn of the flywheel This parameter is also used in the co
5. Low and high limits for warning and alarm are separately programmable Another high frequency shutdown limit which is 12 above the high limit is always monitored and stops the engine immediately START FAIL alarm Set if the engine is not running after programmed number of start attempts STOP FAIL warning Set if the engine has not stopped before the expiration of the Stop Timer OVERLOAD load dump Set if the genset phase current goes over the Overcurrent Limit for Overload Timer If the current goes below the limit before expiration of the timer then no alarm will be set EXCESS POWER load dump Set if the genset phase power KW supplied to the load goes over the Excess Power limit for Overload Timer If the power goes below the limit before expiration of the timer then no alarm will be set GENSET LOW VOLTAGE Set if any of the generator phase voltages goes outside programmed limits for Overload Timer This fault will be monitored with holdoff timer delay after the engine is running GENSET HIGH VOLTAGE Set if any of the generator phase voltages goes outside programmed limits for Overload Timer This fault will be monitored with holdoff timer delay after the engine is running LOW BATTERY VOLTAGE warning Set if the battery voltage goes below the programmed limit During engine cranking this fault is not monitored HIGH BATTERY VOLTAGE Set if the battery voltage goes above programmed limits Both warning and alarm levels for high batte
6. 0 to 520 V AC Phase to Phase Alternator frequency 0 100 Hz Mains voltage 0 to 300 V AC Phase to Neutral 0 to 520 V AC Phase to Phase Mains frequency 0 100 Hz DC Supply range 9 0 VDC to 30 0 VDC Cranking dropouts survives 0 V for 100ms Typical stand by current consumption 100 mADc Maximum current consumption 200 mADC Generator mains contactor outputs 16 250 DC outputs 1A 28 Protected semiconductor outputs Charge alternator excitation current min 150 mADC 10 to 30 VDG Current inputs from current transformers 5A Max load 0 7VA per phase Digital inputs input voltage 0 30 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 III Air category Pollution degree II Communication port logic levels 9600 bauds no parity 1 stop bit Operating temperature range 20 C 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 Dimensions 96x96x53mm WxHxD Panel Cut out dimensions 92x92mm minimum Weight 200 g approx Case material High temperature self extinguishing ABS PC UL94 VO IP protection IP65 from front panel IP30 from the rear 43 V 03 23 09 2009 DKG 109 User Manual 15 CONNECTION DIAGRAM 1 c1 V1
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8. alarm 40 Oil sender 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 11 Automatic ready 45 High voltagealarm 93 Low temp warning 12 46 Fail to start alarm 94 Fail to stop warning 13 47 Low fuel sender alarm 95 Low fuel sender 14 Load dump alarm 48 warning 15 49 96 Service request 16 Mains Fail 50 warning 17 Block Heater 51 High battery voltage 97 Mains Phase Order 18 Service Request alarm Fail 19 52 Charge fail alarm 98 Low battery warning 20 Load Shedding Relay 53 99 High battery warning 21 Flashing Relay 54 100 Charge fail warning 22 Gas Solenoid 55 101 23 Fuel Pump 56 Oil switch load dump 102 24 Mains Phase Order 57 Temp switch 103 Fail load_dump 25 58 26 Idle Speed 59 27 60 Emerg Stop load dump 28 61 Spare 1 load dump 29 62 Spare 2 load_dump 30 63 31 64 65 66 67 68 69 70 71 72 Overcurrent load dump 73 Excess power load dump 74 75 76 77 78 79 38 DKG 109 User Manual V 03 23 09 2009 The parameters below define the functions of digital inputs selected from a list Functions from 12 to 23 activate also the related operat
9. extra security the normally closed contact of the generator contactor should serially connected to this output 2 MAINS L1 Mains phase inputs Connect the mains phases to these inputs 3 MAINS L2 0 300V AC The mains voltages upper and lower limits are 4 MAINS L3 programmable 5 MAINS NEUTRAL Input 0 300V AC Neutral terminal for the mains phases 6 LOW OIL PRESSURE Digital inputs These inputs have programmable characteristics selected via the program 7 HIGH TEMP menu Each input may be driven by a 8 EMERGENCY STOP normally closed or normally open contact 9 SPARE 2 switching either battery or battery The effect 10 SPARE 1 of the switch is also selectable from a list See PROGRAMMING section for more details 11 GENERATOR NEUTRAL Input 0 300V AC Neutral terminal for the generator phase 12 GEN L1 Generator phase Connect the generator phase to this input The inputs 0 300V AC generator phase voltage upper and lower limits are programmable 13 GENERATOR CONTACTOR Relay output 16A AC This output provides energy to the generator contactor If the generator phase do not have acceptable voltage or frequency 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 DKG 109 User Manual V 03 23 09 2009 Term Function Techn
10. position by the mounting brackets 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 oil pressure or fuel level are connected to the unit it is not possible to use auxiliary displays otherwise the unit may be damaged If temperature or oil pressure or fuel level displays are already present on the generator control panel do not connect the senders to the unit The unit is factory programmed for VDO type senders However different types of senders are selectable via programming menu Please check the programming section The programmable digital inputs are compatible with both normally open and normally closed contacts switching either to BAT or BAT The charge alternator connection terminal provides also the excitation current thus it is not necessary to use an external charge lamp 1 3 Wiring the Unit WARNING THE UNIT IS NOT FUSED Use external fuses for Mains phase
11. 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 new GSM SMS message The new message will indicate all existing alarms even masked ones A logic level to RS 232 converter is necessary in order to connect the unit to modem The necessary GSM modem cable will be supplied by DATAKOM This is the same cable as PSTN land modems 19 DKG 109 User Manual V 03 23 09 2009 6 14 Remote Monitoring and Programming Thanks to its logic level serial port the unit offers the remote monitoring and programming feature A logic level to RS 232 converter is necessary in order to connect the unit to the PC 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 t
12. CK input tied to GROUND When the program mode is entered below password entry screen will be displayed fore ENTER PASSWORD 10 8 8 8 A 4 digit password must be entered using V MENUP and MENU buttons The unit stores 3 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 3 is reserved to Datakom and allows access to calibration parameters AN The password level 1 is factory set to 1234 The password level 2 is factory set to 9876 Passwords can only be modified through Rainbow program The program mode will not affect the operation of the unit Thus programs may be modified anytime even while the genset is running The program mode is driven with a two level menu system The top menu consists on program groups and each group consists of various program parameters When program mode is entered a list of available groups will be displayed Navigation between different groups are made with Wand Abuttons Selected group is shown in reverse video blue on white In order to enter inside a group please press MENUP button In order to exit from the group to the main list please press lt 4 MENU button Navigation inside a group is made also with Wand A buttons A list of available parameters will be displayed Selected pa
13. CON 0 7 bars 0 90 ohms 6 DATCON 0 10 bars 0 90 ohms 7 DATCON 0 7 bars 75 10 ohms This parameter selects the temperature sender type 0 The sender characteristics are defined in Sender 2 Coolant Temp Sender 1 Characteristics table Type 1 VDO 2 DATCON DAH type 3 DATCON DAL type If it is requested that the engine runs without load until reaching certain temperature this parameter defines eee E C 0 the temperature If the coolant temperature falls below this parameter an Engine Low Temperature warning will occur This is the time between the mains fails and the fuel solenoid turns on before starting the genset It 2 Engine Start Delay Spe 2 prevents unwanted genset operation in battery backed up loads This is the time after the fuel solenoid is energized 2 Preheat Timer sac 1 and before the genset is started During this period the PREHEAT relay output is energized if assigned by Relay Definitions Jada DKG 109 User Manual V 03 23 09 2009 Program Group Engine Parameters continued Parameter Definition Password Level Unit Factory Set Description 2 Crank Timer sec 10 This is the maximum start period Starting will be automatically cancelled if the genset fires before the timer 2 Wait Between Starts sec 10 This is the waiting period between two start attempts 1 Engine Heating Timer sec This is the period used for engin
14. DKG 109 User Manual V 03 23 09 2009 D Tel 90 216 466 84 60 Fax 90 216 364 65 65 datakom datakom com tr http www datakom com tr DKG 109 AUTOMATIC MAINS FAILURE UNIT GS B aes FEATURES Automatic mains failure Engine control Generator protection Built in alarms and warning Dual genset mutual standby operation Load shedding dummy load Gas engine support Engine idle speed control 3 phase mains voltage inputs 1 phase genset voltage inputs 1 phase genset CT inputs Engine oil pressure measurement Engine coolant temperature measurement Fuel level measurement Genset active power measurement Genset power factor measurement Engine rpm display Remote Start operation available Mains simulation input Engine Idle speed control Periodic maintenance request Engine hours counter Event logging with complete measurement values Stores last 100 events Statistical counters 3 level password protection Programmable parameters All parameters field adjustable Return to factory settings enabled Logic level serial port Firmware downloadable from serial port Free MS Windows Remote monitoring SW monitoring and control download of parameters GSM SMS sending in case of alarm Modem call in case of alarm MODBUS communication 128x64 graphic LCD display Triple language support Customer logo display capability Configurable analogue inputs 3 Configurable digital in
15. EED alarm is generated and the engine stops If the genset frequency goes under this limit a GENSET 1 Low Frequency aring 99 LOW SPEED warning is generated If the genset frequency goes over this limit GENSET 1 High Frequency Warning Hz 54 HIGH SPEED warning is generated 2 High Frequency Hz 55 If the genset frequency goes over this limit a GENSET Shutdown HIGH SPEED alarm is generated and the engine stops If the oil pressure measured from the analog input LE bar 14 falls below this limit this will generate a LOW OIL PRESSURE SENDER warning If the oil pressure measured from the analog input 2 Low Oil Pressure bar 10 falls below this limit this will generate a LOW OIL Shutdown PRESSURE SENDER alarm is generated and the engine stops 1 High Temperature if the coolant temperature measured from the analog Warning C 95 input goes over this limit this will generate a HIGH TEMPERATURE SENDER warning f the coolant temperature measured from the analog 2 High Temperature C 98 input goes over this limit this will generate a HIGH Shutdown TEMPERATURE SENDER alarm and the engine will stop This parameter selects the oil pressure sender type 0 Non standard sender The sender characteristics are defined in Sender Characteristics table 1 VDO 0 7 bars 10 180 ohms 2 VDO 0 10 bars 10 180 ohms 2 Ol Pressure Sender type 1 13 DATCON 0 7 bars 240 33 ohms 4 DATCON 0 10 bars 240 33 ohms 5 DAT
16. FF LAMP TEST and ALARM MUTE buttons for 5 seconds RETURN TO FACTORY SET will be displayed immediately press and hold pressed the ALARM MUTE button for 5 seconds factory set values will be reprogrammed to the parameter memory PAN It is not possible to restore user parameters 6 17 Gas Engine Fuel Solenoid Control The unit provides a special function for the fuel solenoid control of a gas engine The fuel solenoid of a gas engine is different from a diesel engine It should be opened after the cranking has been started and should be closed between crank cycles The delay between the crank start and solenoid opening is adjusted using the Gas Solenoid Delay program parameter The gas engine fuel solenoid relay function may be assigned to spare relays using Relay Definition program parameters Also relays on an extension module may be assigned to this function B TE DKG 109 User Manual V 03 23 09 2009 6 18 Load Shedding Dummy Load The load shedding feature consists on the disconnection of the least crucial loads when the genset power approaches to its limits These loads will be supplied again when the genset power falls below the programmed limit The internal Load Shedding function is always active Any of the auxiliary relays may be used as the load shedding output The dummy load function consists on the connection of a dummy load if the total genset load is below a limit and to disconnection of the dummy load when t
17. ainbow or a special DOS program A logic level to RS 232 converter is necessary in order to connect the unit to the PC 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 V1 00 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 22 DKG 109 User Manual 7 MODBUS COMMUNICATION V 03 23 09 2009 The unit offers the possibility of MODBUS communication via its logic level serial port A logic level to RS 232 converter is necessary in order to connect the unit to the PC The connection to the MODBUS master may be done in 3 ways 1 RS232 connection using directly the RS232 port provided 2 RS422 485 connection using external RS422 485 converter 3 Modem connection using external modem The MODBUS mode is activated by assigning a controller address to the unit using MODBUS Address program parameter The possible address range is 1 to 144 Setting the address to 0 will disable the MODBUS mode and allow communication under RAINBOW protocol The MODBUS properties of the unit are Data transfer mode RTU Serial data 9600 bps 8 bit data no parity 1 bit stop Supported functions Function 3 Read multiple registers Function 6 Wr
18. 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 DELAYED SIMULATE MAINS operation When both parameters Remote Start Operation and Delayed Simulate Mains are set then REMOTE START operation mode is performed 16 DKG 109 User Manual V 03 23 09 2009 6 9 Dual Genset Mutual Standby Operation Dual genset intermittent operation consists of regular switching of the load between 2 gensets The use of 2 gensets instead of one is due either to safety purposes in case of a genset failure or to a continuous operation requesting service stops The running period for each genset is adjustable using Flashing Relay Timer program parameter If the time is adjusted as 0 hours it will be actually set to 2 minutes for faster testing purposes A flashing relay output function is provided based on the parameter Flashing Relay Timer Each time the period programmed using Flashing Relay Timer elapses the relay output will change position The fla
19. ange periodic etc Genset operating mode STOP AUTO RUN Genset operation status mains ok running cooldown etc Genset phase voltage L1 Genset phase current L1 Genset frequency Genset active power KW Genset power factor Engine rpm Oil pressure Coolant temperature Fuel level Battery voltage Mains phase voltages L1 L2 L3 Mains frequency Digital input statuses Charge input status 24 DKG 109 User Manual V 03 23 09 2009 9 STATISTICAL COUNTERS The unit provides a set of non resettable incremental counters for statistical purposes The counters consist on total engine hours total genset KWh engine hours to service time to service total engine cranks total genset runs These counters are kept in a non volatile memory and are not affected from power failures 10 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 25 DKG 109 User Manual V 03 23 09 2009 11 PROGRAMMING The program mode is used to program timers operational limits and the configuration of the unit To enter the program mode press together MENU and MENUP buttons for 1 second The program mode is only allowed if the PROGRAM LOCK input 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 LO
20. at the Low Oil Pressure Switch input or the oil pressure value measured from the sender is below the programmed limit Warning and alarm limits are separately programmable for the oil pressure sender input This fault will be monitored with Holdoff Timer delay after the engine is running Also if the oil pressure switch is open at the beginning of a start attempt then the engine will not be started and 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 temperature value measured from the sender is above the programmed limit Warning and alarm limits are separately programmable for the temperature sender input LOW TEMPERATURE warning Set if the coolant temperature value measured from the sender is blow the Engine Heating Temperature limit LOW FUEL Set if the the fuel level measured from the sender is below the programmed limit Warning and alarm limits are separately programmable for the fuel level sender input EMERGENCY STOP Set if a signal is detected at the emergency stop input SPARE 1 SPARE 2 Set if a signal is detected from the related spare fault input 10 DKG 109 User Manual V 03 23 09 2009 LOW SPEED HIGH SPEED Set if the generator frequency is outside programmed limits These faults will be monitored with Holdoff Timer delay after the engine is running
21. d Site Id String Program Group Modem 1 SMS 1 Telephone Number password level 2 Parameter Definition Factory Set Description This telephone number buffer accepts up to 16 digits including the wait charater in order to enable dialing through a pabx If Modem Enabled This is the first telephone number used for modem calls If Modem Disabled This is the first SMS telephone number Modem 1 SMS 1 telephone number Program Group Modem 2 SMS 2 Telephone Number password level 2 Parameter Definition Factory Set Description This telephone number buffer accepts up to 16 digits including the wait charater in order to enable dialing through a pabx If Modem Enabled This is the second telephone number used for modem calls If Modem Disabled This is the second SMS telephone number Modem 2 SMS 2 telephone number Program Group SMS 3 Telephone Number password level 2 Parameter Definition Factory Set Description SMS 3 telephone number This SMS telephone number accepts up to 16 digits Program Group SMS 4 Telephone Number password level 2 Parameter Definition Factory Set Description This SMS telephone number accepts up to 16 digits SMS 3 telephone number Program Group SMS 5 Telephone Number password level 2 Parameter Definition Factory Set Description Thi
22. display to the previous screen During operation the unit will switch automatically between different screens displaying always the most important parameters for the current operating status If an alarm loaddump or warning occurs during operation in other then programming mode the display will automatically switch to ALARM LIST position If there is more than one alarm the next alarm is displayed by pressing the MENU or buttons Thus all existing alarms can be scanned END OF ALARM LIST will be displayed when there is no more alarm to display As long as alarms are not muted only the ALARM LIST is displayed In order to mute alarms and enable display navigation long press lt MENU ALARM MUTE button first DKG 109 User Manual V 03 23 09 2009 Screen Description Contents 1 Mains parameters phase to neutral Genset status Mains Volts L1 Mains Volts 12 Mains Volts L3 Mains Frequency Battery Voltage Coolant Temperature 2 Mains parameters Genset status phase to phase Mains Volts L1 L2 Mains Frequency Mains Volts L2 L3 Battery Voltage Mains Volts L3 L1 Coolant Temperature 3 Genset parameters Genset status Engine rpm Genset Frequency Genset Current L1 Genset Volts L1 Genset power factor Genset Active Power KW 4 Engine parameters Genset status Oil Pressure Engine rpm Coolant Temperature Battery Voltage Fuel Level 5 Complete Gense
23. duction to the Control Panel The unit is a control and protection panel used in gensets It shows the measured values on its displays The unit is designed to provide user friendliness for both the installer and the user Programming is usually unnecessary as the factory settings have been carefully selected to fit most applications However programmable parameters allow the complete control over the generating set Programmed parameters are stored in a Non Volatile Memory and thus all information is retained even in the event of complete loss of power The measured parameters are Mains voltage phase L1 to neutral Mains voltage phase L2 to neutral Mains voltage phase L3 to neutral Mains voltage phase L1 L2 Mains voltage phase L2 L3 Mains voltage phase L3 L1 Gen voltage phase L1 to neutral Gen current phase L1 Gen frequency Engine speed rpm Gen phase L1 KW Gen phase L1 cos Battery voltage Coolant temperature Oil pressure Fuel level Gen frequency Mains frequency DKG 109 User Manual V 03 23 09 2009 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 a standard panel meter opening of 92x92 millimeters Before mounting remove the mounting brackets and connectors from the unit then pass the unit through the mounting opening The unit will be maintained in its
24. e heating following the program parameter 1 Cooldown Timer min This is the period that the generator runs for cooling purpose after the load is transferred to mains 1 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 not stopped after this period a FAIL TO STOP warning occurs 2 Number of Starts This is the maximum number of start attempts 2 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 2 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 1 Service Engine Hours hour 50 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 1 Service Period month The SERVICE REQUEST led indicator will turn on after this amount of time from the last service If the pe
25. e protections are disabled during idle speed operation 6 5 Engine Block Heater The unit is able to provide a relay output in order to drive the block heater resistor The temperature reference is the coolant temperature measured from the the analog sender input The block heater relay function may be assigned to spare relays using Relay Definition program parameters Also relays on an extension module may be assigned to this function The engine body temperature limit is adjusted using the parameter Engine Heating Temperature The same parameter is used for engine heating operation The relay will become active if the 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 6 6 Fuel Pump Control The unit is able to provide a relay output in order to drive the fuel pump motor The fuel pump is used in order to transfer fuel from the large capacity main tank if exists to the genset daily tank which is generally integrated in the chassis and has a limited capacity The fuel level reference is measured through the analog fuel level sender When the measured fuel level falls below Fuel Pump Low Limit parameter the fuel pump relay output will operate When the fuel level reaches Fuel Pump High Limit parameter the relay will turn off Thus the chassis fuel tank level will be always kept between Fuel Pump Low Limit and Fuel Pump High Limi
26. e 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 13 DKG 109 User Manual V 03 23 09 2009 6 4 Engine Idle Speed Operation It may be required that the engine runs at the idle speed for a programmed duration for engine heating and cooldown The idle operation duration is adjusted with the parameter Idle Speed Timer The idle speed will be set by the governor control unit of the engine Any of the spare relay outputs may be assigned as IDLE output using Relay Definition program parameters Also relays on an extension module may be assigned to this function The Idle speed operation is performed both in engine start up and cool down sequences Speed and voltag
27. ec This is the period between the current or active power go over the limits and OVERCURRENT or EXCESS POWER Load Dump alarms occur This is also the period between the frequency goes out of the limits and OVERSPEED or UNDERSPEED alarms occur This is also the period between the genset voltage goes out of the limits and HIGH VOLTAGE or LOW VOLTAGE alarms occur 1 Mains Voltage Low Limit 170 If one of the mains phases goes under this limit it means that the mains are off and it starts the transfer to the genset in AUTO mode 1 Mains Voltage High Limit 270 If one of the mains phases goes over this limit it means that the mains are off and it starts the transfer to the genset in AUTO mode 2 Genset Voltage Low Limit 170 If one of the generator phase voltages goes under this limit when feeding the load this will generate a GENSET LOW VOLTAGE alarm and the engine will stop 2 Genset Voltage High Limit 270 If one of the generator phase voltages goes over this limit when feeding the load this will generate a GENSET HIGH VOLTAGE alarm and the engine will stop 29 DKG 109 User Manual V 03 23 09 2009 Program Group Electrical Parameters Parameter Definition Unit Factory Description Password Level Set 2 Low Battery Voltage V 9 0 If the battery voltage falls below this limit this will Warning generate a LOW BATTERY war
28. ect the sender to other devices The input has programmable characteristics and connects to any kind of sender 23 CHARGE 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 24 FUEL RELAY Output 1A 28VDC This relay is used for fuel solenoid control 25 START RELAY Output 1A 28VDC This relay controls the engine cranking 26 RELAY 1 STOP RELAY Output 1A 28VDC This relay has programmable function selectable from a list 27 RELAY 2 HORN RELAY Output 1A 28VDC This relay has programmable function selectable from a list DKG 109 User Manual V 03 23 09 2009 3 DISPLAYS 3 1 Led Displays The unit has 5 LEDs divided in 2 groups Group 1 Operating mode This group indicates the genset function Group_2 Warnings and alarms This group indicates the existence of abnormal conditions encountered during operation Function Color Description RUN Yellow It turns on when the related operation mode is selected One of these LEDs is always on and OFF Yellow indicates which operation mode is selected If the operation of the genset is disabled by the AUTO Yellow weekly operation schedule then the AUTO led will flash ALARM Red If a fault condition resulting to the engine shutdown has occurred the alarm led turns on steadily If a warning condition occ
29. he 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 The parameters used in Load Shedding feature are in the Electrical Parameters Group Load Shedding Low Limit If the genset active power output goes below this limit then the Load Shedding relay will be deactivated Load Shedding High Limit If the genset active power output goes above this limit then the Load Shedding relay will be activated 6 19 Fuel Theft Fuelling Messages The unit is able to send SMS messages in fuel theft or fuelling conditions These SMS messages are sent without creating visible fault condition These features are enabled by setting the program parameter Engine Parameters gt Fuel Consumption Hour to a value other than 0 The Fuel Consumption Hour parameter should be set to a value clearly greater than the maximum fuel consumption of the engine If the fuel level measured from the sender input is decreased more than this parameter in 1 hour period then a FUEL THEFT sms message is sent to programmed telephone numbers If the fuel level measured from the sender input is increased more than this parameter in 1 hour period then a FUELLING sms message is sent to programmed telephone numbers 6 20 Firmware Update The unit offers possibility of updating the firmware in the field The firmware is updated through the logic level serial port using R
30. hen be analyzed graphically and printed The software also allows the programming of the unit and the storage of the program parameters to PC or the downloading of stored parameters from PC to the unit For PCs without a serial port below USB to serial adapters are tested and approved DIGITUS USB 2 0 TO RS 232 ADAPTER PRODUCT CODE DA70146 REV 1 1 DIGITUS USB 1 1 TO RS 232 ADAPTER PRODUCT CODE DA70145 REV 1 1 FLEXY USB 1 1 TO SERIAL ADAPTER PRODUCT CODE BF 810 CASECOM USB TO SERIAL CONVERTER MODEL RS 01 The necessary PC connection cable will be supplied by DATAKOM 6 15 External Control of the Unit The unit offers total external control through programmable digital inputs Each digital input may be programmed for below functions Force OFF mode Force AUTO mode Force TEST mode Force LOAD 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 keys 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 20 DKG 109 User Manual V 03 23 09 2009 6 16 Resuming to factory set parameters In order to resume to the factory set parameter values hold pressed the O
31. hen mains present Latching Non latching Latching Contact type Normally open Normally closed Switching Battery negative Battery positive Response delay No delay Delayed 4sec Og o o ON OLN O The parameters below define the functions of relay outputs The unit has 6 relay outputs The fixed function relays are Fuel Start Mains Contactor and Generator Contactor RELAY 1 and RELAY 2 have programmable functions selected from a list Program Group Relay Definitions password level 2 Parameter Definition Unit Fac Set Description Relay 01 Definition 3 RELAY 1 function selected from list Relay 02 Definition 1 RELAY 2 function selected from list 37 DKG 109 User Manual V 03 23 09 2009 The function of a programmable relay output may be selected from the below list 00 Fuel 32 Oil switch alarm 80 Oil switch warning 01 Alarm 33 Temp switch alarm 81 Temp switch warn 02 Start 34 82 03 Stop 35 83 04 Gen Contactor 36 Emerg Stop alarm 84 Emerg Stop warn 05 Mains Contactor 37 Spare 1 Alarm 85 Spare 1 warning 06 Choke 38 Spare 2 Alarm 86 Spare 2 warning 07 Preheat 39 87 08 Shutdown
32. his parameter selects the screen which is displayed during genset on load operation 0 screen 3 electrical large characters 1 screen 4 engine parameters large characters 2 screen 5 maximum information small characters 3 screen 6 analog power meter Details of each screen are explained in chapter 3 2 2 Fault Holdoff Timer sec 12 This parameter defines the delay after the engine runs and before the fault monitoring is enabled 1 Alarm Relay Timer sec 60 This is the period during which the ALARM relay is active If the period is set to 0 this will mean that the _period is unlimited 1 Intermittent Alarm Relay 0 continuous 1 intermittent turns on and off every second 2 Charge Alternator Shutdown 0 The charge input generates CHARGE FAIL warning and does not stop the engine 1 The charge input generates CHARGE FAIL alarm and stops the engine 1 Emergency Backup Operation 0 In RUN mode the load will not be transferred to the genset even if the mains fail 1 In RUN mode the load will be transferred to the genset if the mains fail 2 Delayed Simulate Mains 0 The SPARE 2 input has normal function 1 The SPARE 2 input has delayed simulate mains function See chapter 6 8 for more info 97 DKG 109 User Manual V 03 23 09 2009 Program Group Controller Configuration continued Parameter Definition Password Level Unit
33. hours is not fulfilled it is performed after a given time limit for example 12 months AN The SERVICE REQUEST function has no effect on the genset operation The unit has both programmable engine hours and maintenance time limit The engine hours is programmable with 50 hour steps the time limit is programmable with 1 month steps If any of the programmed values is zero this means that the parameter will not be used For example a maintenance period of 0 months indicates that the unit will request maintenance only based on engine hours there will be no time limit If the engine hours is also selected as 0 hours this will mean that the SERVICE REQUEST function will be inoperative When the engine hours OR the time limit is over the SERVICE REQUEST warning will occur and the display will switch to the ALARM LIST The service request relay function may be assigned to spare relays using Relay Definition program parameters Also relays on an extension module may be assigned to this function AN To reset the service period press together the ALARM MUTE and LAMP TEST keys for 5 seconds The remaining engine hours and the remaining time limit are kept stored in a non volatile memory and are not affected from power supply failures The time and engine hours to service are displayed in the STATISTICAL COUNTERS menu 6 11 Engine Hour Meter The unit features a non erasable incremental engine hour meter The hour meter information is ke
34. ical data Description 14 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 15 MAGNETIC PICKUP Inputs 1 30V Connect the magnetic pickup signal to these 16 MAGNETIC PICKUP 0 10KHz inputs 17 GROUND O VDC Power supply negative connection 18 CURR 1 Current transformer Connect the generator current transformer inputs 5A AC terminals to these inputs Do not connect the 19 CURR 1 same current transformer to other instruments otherwise a unit fault will occur Connect each terminal of the transformer to the unit s related 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 the current transformer The secondary winding rating shall be 5 Amperes For ex 200 5 Amps 20 FUEL LEVEL SENDER Input 0 5000 ohms Analogue fuel level sender connection Do not connect the sender to other devices The input has programmable resistor value and connects to various senders 21 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 22 OIL PRESSURE SENDER Input 0 5000 ohms Analogue oil pressure sender connection Do not conn
35. ing 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 Program Group Input Function Select password level 2 Parameter Definition Description Input 01 Function Select 0 _ Oil Pressure Switch Input 02 Function Select 1 High Temp Switch Input 03 Function Select 4 Emergency Stop Input 04 Function Select 11 Spare 1 Input Input 05 Function Select 10 Spare 2 Input 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 Spare 3 Input 10 Spare 2 Input 11 Spare 1 Input 12 Force AUTO Mode 13 Force OFF Mode 14 Force TEST Mode 15 Force LOAD TEST Mode 16 Spare 4 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 39 DKG 109 User Manual V 03 23 09 2009 Program Group Site Id password level 2 Parameter Definition Factory Set Description This is the site Id string sent at the beginning of an DATAKOM SITE SMS message for the identification of the genset ID sending the SMS message Any 20 character long string may be entere
36. ite single register Detailed description about the MODBUS protocol is found in the document Modicon Modbus Protocol Reference Guide The web address is www modbus org docs PI MBUS 300 pdf Below is a limited shortlist of readable registers For the detailed Modbus Application Manual and a complete list of registers please contact DATAKOM ADDRESS hex R W DATA SIZE COEFFICIENT DESCRIPTION 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 0006 R 16bit x1 Genset Phase L1 current 000C R 16bit x1 Mains Phase L12 voltage 000D R 16bit x1 Mains Phase L23 voltage 000E R 16bit x1 Mains 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 H 16bit x10 Oil pressure in bars 002C H 16bit x1 Coolant temperature in degrees C 002D H 16bit x1 Fuel level as 002F R 16bit x10 Battery voltage 003D R 8bit Operating mode bit_4 auto m
37. larm 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 flash genset contactor to be released immediately The engine to be stopped after Cooldown period Horn Alarm Load dump and Alarm Load dump Warning digital outputs to operate if selected via programming menu 3 WARNINGS These conditions cause The WARNING led to be on steadily Horn and Alarm Load_dump Warning digital outputs to operate if selected via programming menu If the ALARM MUTE button is long pressed the Horn output will be deactivated however the existing alarms will persist and disable the operation of the genset Alarms operate in a first occurring basis If an alarm is present following alarms load_dumps and warnings will not be accepted If a load_dump is present following load_dumps and warnings will not be accepted If a warning is present following warnings will not be accepted Alarms may be of LATCHING type following programming For latching alarms even if the alarm condition is removed the alarms will stay on and disable the operation of the genset The existing alarms may be canceled by pressing one of the operating mode buttons TEST OFF AUTO Most of the alarms have programmable trip levels See the programming chapter for adjustable alarm limits LOW OIL PRESSURE Set if a signal is detected
38. ll the mains phase voltages are within the limits the engine will continue to run for the mains waiting period At the end of this period the generator contactor is deactivated and the mains contactor will be energized If a cooldown period is given the generator will continue to run during cooldown period At the end of the period the fuel solenoid will be de energized and the diesel will stop The unit will be ready for the next mains failure RUN It is used to test the generator when the mains are on or keep the generator running in the emergency backup mode The operation of the generator is similar to the AUTO mode but the mains contactor will not be deactivated if the mains are not off If the mains are off mains contactor will be deactivated and the generator contactor will be activated When the mains are on again a changeover to the mains will be made but the engine will be kept running unless another mode is selected To stop the engine select AUTO or STOP mode 6 OTHER FEATURES 6 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 positive 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 pre
39. lthough the Amp readings are correct The current transformer is connected with reverse polarity Reverse the CT terminals 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 supplied with battery voltage at the oil pressure input Oil pressure switch not connected Oil pressure switch connection wire cut Oil pressure switch faulty Oil pressure switch closes too lately If oil pressure switch closes the unit will start Optionally oil pressure switch may be replaced The engine does not run after the first start attempt then the unit does not start again and OIL PRESSURE EXISTS message is displayed The oil pressure switch closes very lately As the unit senses an oil pressure it does not start When oil pressure switch closes the unit will start Optionally the oil pressure switch may be replaced 41 DKG 109 User Manual V 03 23 09 2009 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 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 fu
40. ning 2 High Battery Voltage V 31 0 If the battery voltage goes over this limit this will Warning generate HIGH BATTERY warning If the battery voltage goes over this limit this will Ao Battery voltage V 33 0 generate a HIGH BATTERY shutdown alarm and the Shutdown engine will stop This is the time between the mains voltages entered 1 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 2 Genset Contactor Timer sec 1 deactivated and before the generator contactor has been activated This is the period after the generator contactor has been 2 Mains Contactor Timer sec 1 deactivated and before the mains contactor has been activated 0 mains phase order checking disabled SAP Me 0 1 if mains phase order is faulty then a warning is given and mains contactor deenergized 2 Load Shedding Low KW 0 If the genset power goes below this limit then the load Limit shedding relay will be deactivated 2 Load Shedding High KW 0 If the genset power goes above this limit then the load Limit shedding relay will be activated 280 DKG 109 User Manual V 03 23 09 2009 Program Group Engine Parameters Parameter Definition Factor er Password Level unn Set Doecupton 2 Low Frequency Hz 30 If the genset frequency goes under this limit a GENSET Shutdown LOW SP
41. nversion of the genset frequency to engine rpm The frequency in Hz is multiplied with this parameter during conversion to rpm 2 SMS on Mains Change This parameter controls SMS sending when mains voltages status is changed No warning is generated 0 no SMS when mains failed or restored 1 SMS sent when mains failed or restored 2 Fuel Pump Low Limit 20 If the fuel level measured from the sender input falls below this level then the FUEL PUMP function will become active 2 Fuel Pump High Limit 80 If the fuel level measured from the sender input goes above this level then the FUEL PUMP function will become passive 28 DKG 109 User Manual V 03 23 09 2009 Program Group Electrical Parameters Parameter Definition Password Level Unit Factory Set Description 2 Current Transformer Ratio A 500 This is the rated value of the current transformer The secondary of the transformer will be 5 Amps 2 Overcurrent Limit If the current goes above this limit during Overload Timeout then a Overcurrent Load Dump alarm will be generated If this parameter is 0 then Overcurrent check is disabled 2 Excess Power Limit KW If the active power goes above this limit during Overload Timeout then an Excess Power Load Dump alarm will be generated If this parameter is 0 then Excess Power check is disabled 2 Overload Timeout s
42. ode bit_5 stop mode bit_6 run mode 209 DKG 109 User Manual V 03 23 09 2009 8 EVENT LOGGING The unit keeps record of the last 100 events in order to supply information for the service personal The genset status information and a comprehensive set of measured values are stored within the event memory 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 Events are kept in a non volatile memory and are not affected from power failures In the event display mode each depression of the MENU button switches the display to the next page of the current event After the last page of the current event the first page of the previous event is displayed Each depression of the MENUP button switches the display to the previous page of the current event After the first page of the current event the last page of the next event is displayed Zl To exit event record pages please hold pressed MENU or MENUP buttons Each event is displayed in 3 pages Event and page numbers are shown at the top right corner of the display Events are numbered starting from 1 number 1 being the latest one Pages are listed from A to D Event sources are Shutdown alarms Load dump alarms Warnings Operating mode change STOP AUTO RUN Periodic records Event record contents are Event type alarms mode ch
43. own 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 Og og 0 2 ona ouno No delay Delayed 4sec Program Group Input Configuration Spare 1 Input password level 2 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 No delay Delayed 4sec 36 DKG 109 User Manual V 03 23 09 2009 Program Group Input Configuration Spare 2 Input password level 2 Parameter Definition Unit Fac Set Description Action Shutdown the engine stops immediately Warning the horn relay operates No operation Load Dump the engine stops after cooldown Sampling Always After holdoff timer W
44. pt in a non volatile memory and is not affected from power supply failures 6 12 Software Version Display Some additional features are installed within consecutive software releases In order to be sure of the validity of the status of the unit the software version needs to be known The software version number represents the operating software version of the unit 18 DKG 109 User Manual V 03 23 09 2009 6 13 SMS Message Sending The GSM SMS sending is activated by setting the SMS Enable program parameter to 1 If SMS Enable or MODBUS Address parameters are different from zero the local PC connection will not work When a fault condition occurs the unit will compose an SMS message and will send it to up to 6 phone numbers The unit is also able 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 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 sample GSM SMS message is given below DKGxxx lt SITE ID gt STOP LOW OIL PRESSURE SW END OF ALARM LIST The first line of the message carries information about
45. puts 5 Configurable digital outputs 2 Total digital outputs 6 Survives cranking dropouts Sealed front panel Plug in connection system for easy replacement Dimensions 96x96x53mm DKG 109 User Manual V 03 23 09 2009 TABLE OF CONTENTS Section 1 INSTALLATION 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 Language Selection 3 3 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 Engine Idle Speed Operation 6 5 Engine Block Heater 6 6 Fuel Pump Control 6 7 Mains Simulation Disable Start 6 8 Delayed Mains Simulation Battery Charging 6 9 Dual Genset Mutual Standby Operation 6 10 Periodic Service Request Monitoring 6 11 Engine Hours Meter 6 12 Display of Software Version 6 13 SMS message sending 6 14 Remote Monitoring and Programming 6 15 External Control of the Unit 6 16 Resuming to factory set parameters 6 17 Gas engine fuel solenoid control 6 18 Load Shedding Dummy Load 6 19 Fuel Theft Fuelling Messages 6 20 Firmware Update 7 MODBUS COMMUNICATION 8 EVENT LOGGING 9 STATISTICAL COUNTERS 10 MAINTENANCE 11 PROGRAMMING 12 TROUBLESHOOTING 13 DECLARATION OF CONFORMITY 14 TECHNICAL SPECIFICATIONS 15 CONNECTION DIAGRAM DKG 109 User Manual V 03 23 09 2009 1 INSTALLATION 1 1 Intro
46. rameter is shown in reverse video blue on white In order display change the value of this parameter please press MENU button Parameter value may be increased and decreased with Wand A buttons If these keys 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 MENUP button is pressed next parameter will be displayed If MENU button is pressed then the list of parameters in this group will be displayed Program parameters are kept in a non volatile memory and are not affected from power failures To exit the program mode press one of the mode selection keys If no button is pressed during 1 minute the program mode will be cancelled automatically 26 DKG 109 User Manual V 03 23 09 2009 Program Group Controller Configuration Parameter Definition Password Level Unit Factory Set Description 1 LCD Contrast 22 This parameter is used to set LCD contrast Adjust for the best viewing angle 2 Language 0 English language selected 1 Turkish language selected This language may depend on the country where the unit is intended to be used 2 Chinese language selected 3 The unit will ask for manual language selection at power on 2 Line to Line Voltages 0 Display Line to Neutral voltages as default 1 Display Line to Line voltages as default 1 Genset Default Display T
47. riod is set to 0 no SERVICE REQUEST will be indicated depending on time 2 Idle Speed Timer sec When the engine runs the Idle output relay function will be active during this timer 2 Gas Solenoid Delay sec The gas solenoid of the gas engine will be opened after this delay during cranking 1 Low Fuel Warning 20 If the fuel level measured from the analog input falls below this limit a LOW FUEL LEVEL SENDER warning is generated 2 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 2 Fuel Consumption per Hour This parameter is 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 If SMS is required set this parameter to a value above the hourly fuel consumption of the genset 2 Fuel Level sender Ohms ohms 180 Fuel level sender max resistance 180 ohms and 300 ohms senders are common 525 DKG 109 User Manual V 03 23 09 2009 Program Group Engine Parameters continued Parameter Definition Unit Factory Description Password Level Set When the genset frequency reaches this limit the 3 Crank Cut Frequency Hz 10 0 engine is supposed running and the crank output will release
48. ry 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 MAINS PHASE ORDER FAIL warning Set if the mains phase order checking is enabled mains phases are present and mains phase order is reversed This fault prevents the Mains Contactor to close 11 DKG 109 User Manual V 03 23 09 2009 5 MODES OF OPERATION The modes of operation are selected by pushing the front panel keys Changing the operation mode while the genset is running will result into a behavior suitable for the new operating mode For example if the AUTO mode is selected when genset is running at RUN mode if mains phase voltages are present then the genset will stop STOP In this mode the mains contactor will be energized if mains phase voltages are within the programmed limits The engine will be stopped AUTO It is used for genset and mains automatic transfer If at least one of the mains phase voltages is outside limits the mains contactor will be deactivated The diesel will be started for programmed times after the preheat timer When the engine runs the crank relay will be immediately deactivated The engine will run without load during engine heating period After this if alternator phase voltages and frequency are within limits then the unit will wait for the generator contactor period and the generator contactor will be energized When a
49. s L1 L2 L3 Generator phase L1 Battery positive BAT Install the fuses as nearly as possible to the unit 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 1 ALWAYS remove the plug connectors when inserting wires with a screwdriver 2 Anappropriate and readily accessible set of disconnection devices e g automatic fuses MUST be provided as part of the installation 3 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 4 Use cables of adequate current carrying capacity at least 0 75mm and temperature range DKG 109 User Manual V 03 23 09 2009 2 INPUTS AND OUTPUTS RS 232 SERIAL PORT This connector provides serial data input and output for various purposes like remote monitoring and remote programming EXTENSION CONNECTOR This connector is intended for the connection to output extension modules The optional relay extension module provides 8 programmable 16A relay outputs The unit allows the use of up to 2 I O extension modules Term Function Technical data Description 1 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
50. s SMS telephone number accepts up to 16 digits SMS 3 telephone number Program Group SMS 6 Telephone Number password level 2 Parameter Definition Factory Set Description SMS 3 telephone number This SMS telephone number accepts up to 16 digits 40 DKG 109 User Manual V 03 23 09 2009 12 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 Mains Voltage Low Limit and Mains Voltage High Limit Standard values are 170 270 volts The hysteresis voltage may be given to excessive The standard value is 8 volts AC voltages or frequency displayed on the unit are not correct Check engine body grounding it is necessary The error margin of the unit is 3 volts If there are faulty measurements only when the engine is running there may be a faulty charging alternator or voltage regulator on the engine Disconnect the charging alternator connection of the engine and check if the error is removed If there are faulty measurements only when mains are present then the battery charger may be failed Turn off the rectifier fuse and check again KW and cos readings are faulty a
51. se 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 19 and 22 at the rear of the unit If OK turn all the fuses off then turn all the fuses on starting from the DC supply fuse Then test the unit again Some program parameters are skipped These parameters are reserved for factory setting and cannot be modified 42 DKG 109 User Manual V 03 23 09 2009 13 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 14 TECHNICAL SPECIFICATIONS Alternator voltage 0 to 300 V AC Phase to Neutral
52. shing relay function may be assigned to spare relays using Relay Definition program parameters Also relays on an extension module may be assigned to this function The dual genset intermittent operation uses also the Mains Simulation feature Please review chapter 6 7 for a detailed explanation of this feature 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 AN Please contact DATAKOM for a complete application manual 17 DKG 109 User Manual V 03 23 09 2009 6 10 Periodic Service Request Monitoring The periodic maintenance is basically carried out after a given engine hours for example 200 hours but even if this amount of engine
53. ssure Sender Ohms 4 ohm 140 Oil Pressure Sender point 4 ohm value Oil Pressure Value 4 bar 7 0 Oil Pressure Sender point 4 bar value Oil Pressure Sender Ohms 5 ohm 156 Oil Pressure Sender point 5 ohm value Oil Pressure Value 5 bar 8 0 Oil Pressure Sender point 5 bar value Oil Pressure Sender Ohms 6 ohm 184 Oil Pressure Sender point 6 ohm value Oil Pressure Value 6 bar 10 0 Oil Pressure Sender point 6 bar value Program Group Sender Characteristics password level 2 Parameter Definition Unit Factory Description Set Temperature Sender Ohms 1 ohm 38 Temperature Sender point 1 ohm value Temperature Value 1 C 100 Temperature Sender point 1 C value Temperature Sender Ohms 2 ohm 51 Temperature Sender point 2 ohm value Temperature Value 2 C 90 Temperature Sender point 2 C value Temperature Sender Ohms 3 ohm 134 Temperature Sender point 3 ohm value Temperature Value 3 C 60 Temperature Sender point 3 C value Temperature Sender Ohms 4 ohm 322 Temperature Sender point 4 ohm value Temperature Value 4 C 39 Temperature Sender point 4 C value Temperature Sender Ohms 5 ohm 650 Temperature Sender point 5 ohm value Temperature Value 5 C 20 Temperature Sender point 5 C value Temperature Sender Ohms 6 ohm 1630 Temperature Sender point 6 ohm value Temperature Value 6 C 02 Temperature Sender point 6 C value 34
54. t Genset status parameters Engine rpm Genset Frequency Genset Volts L1 Oil Pressure Genset Current L1 Coolant Temperature Genset Active Power KW Fuel Level Genset power factor Battery Voltage 6 Graphical Genset Genset status parameters Genset Volts L1 Genset Current L1 Genset Active Power Genset Frequency Oil Pressure Coolant Temperature Fuel Level 7 Company Logo D KO D DATAKOM 8 Alarm List If no alarm exists END OF ALARM LIST will be displayed Existing alarms load dumps warnings will be displayed as one screen for each entry Switching to the next entry will be made with the W button 9 Software Version Operating software version 10 Statistical Counters 1 3 Engine Hours Run Total Genset Active Power KW h 11 Statistical Counters 2 3 Engine Hours to Service Time to Service 12 Statistical Counters 3 3 Total Engine Cranks Total Engine Runs 13 Event Records The unit provides information about last 100 events starting from the most recent one Please review chapter 10 for detailed information about event logging DKG 109 User Manual V 03 23 09 2009 4 ALARMS AND WARNINGS Alarms indicate an abnormal situation in the generating set are divided into 3 priority levels 1 ALARMS These are the most important fault conditions and cause The ALARM led to be on steadily The genset contactor to be released immediately The engine to be stopped immediately Horn Alarm A
55. t parameters The fuel pump relay function may be assigned to spare relays using Relay Definition program parameters Also relays on an extension module may be assigned to this function 14 DKG 109 User Manual V 03 23 09 2009 6 7 Mains Simulation Disable Start The unit offers an optional SIMULATE MAINS 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 in order to prevent any alarms generated from this input The SIMULATE MAINS signal may be a NO or NC contact switching to either battery positive or battery negative These selections are made using the programming menu If the Simulate Mains input is defined and the input signal is active the mains phases are not monitored and supposed to be inside limits This will prevent the genset from starting even in case of a mains failure If the genset is running when the signal is applied then usual Mains Waiting and Cooldown cycles will be performed before engine stop When the SIMULATE MAINS signal is present the front panels mimic diagram s mains LEDs will reflect the mains voltages as present When the signal is passive the unit will revert to normal operation and monitor the mains voltage status The REMOTE START operation overrides SIMULATE MAINS and FORCE TO START operations 15 DKG 109 User Manual V 03 23 09 2009
56. urs this led will flash Alarms work on a first occurring basis The occurrence of a fault will disable other faults of lower or equal priority SERVICE REQUEST Red Engine periodic maintenance request indicator It turns on when the preset engine hours or time duration after previous service has elapsed 3 2 Language Selection The unit is able to display information in 3 languages Language selection is made through program parameter CONTROLLER CONFIGURATION gt LANGUAGE SELECTION Below selections are available 0 English language 1 Turkish language spanish language on some models 2 Chinese language 3 ask selection at power up If language is set to 3 below screen will come at power on Enslish 4 Turkce Left Up Down arrow pushbuttons will select the screen language The language will be asked everytime power is turned on With language selections of 0 1 2 this screen will not appear and the selected language is enabled DKG 109 User Manual V 03 23 09 2009 3 3 Digital Display The unit has a graphical 128x64 pixel LCD display It shows Measured parameters The company logo The alarm list Software version Statistical counters Event records Program parameters Navigation between different screens is made with the MENU and MENUP buttons Each depression of the MENUP button switches the display to the next screen Each depression of the MENU button switches the
57. vent any alarm from this input In this mode the mains phases are not monitored If the REMOTE START signal is present then the mains will be supposed to fail inversely if the REMOTE START signal is absent then mains voltages will be supposed to be present 12 DKG 109 User Manual V 03 23 09 2009 6 2 Sender type Selection The unit has the ability to adapt to any type of oil pressure and temperature senders The commonly used standard sender characteristics are recorded in memory and selectable from a list However non standard senders may also be used by entering their characteristics to the table Oil Pressure Sender Type Selection Selectable sender types are 0 Sender characteristics are defined in Sender Characteristics table 1 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 Temperature Sender Selection Selectable sender types are 0 Sender characteristics are defined in Sender Characteristics table 1 VDO 2 DATCON DAH type 3 DATCON DAL type Fuel Level Sender Selection The Fuel Level Sender Ohms is also programmable 6 3 Engine Heating Operation Especially on engines without a body heater or with a failing one it may be desired that the genset should not take the load before reaching a suitable temperature Th

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