Datakom DKG-209 Manuale utente

DKG-209 User Manual V-29 (20.08.2013)

DKG-209 AUTOMATIC

MAINS FAILURE UNIT

The controller is a comprehensive low cost AMF

unit for single genset standby or dual genset

mutual standby operations.

The unit is able to initiate modem calls and send

SMS messages in fault conditions through

external modem.

The unit provides a comprehensive set of

digitally adjustable timers, threshold levels, input

and output configurations and operating

sequences. All programs may be modified via

front panel pushbuttons, and do not require an

external unit.

Last 100 faults are stored in the event log file.

The event log includes not only the engine-hours

information, but also a comprehensive list of

measured genset parameters at the time that the

fault has occurred.

The WINDOWS based RAINBOW program

allows remote monitoring and control.

The unit supports MODBUS protocol enabling

communication with PLCs and building

management systems. The MODBUS protocol

is also supported through GSM and PSTN

modems.

The unit offers multiple language support.

Low cost

True RMS measurements

Dual genset mutual standby operation

Event logging with engine run hours

stamp and measurements

Field adjustable parameters

Logic level serial port

Free MS-Windows Remote monitoring

GSM and PSTN modem support

GSM SMS message sending on fault

MODBUS communications

Multiple language support

Customer logo display capability

1A protected semiconductor outputs

Configurable analogue inputs: 3

Configurable digital inputs: 5

Configurable relay outputs: 1

Total relay outputs: 5

Plug-in connection system

FEATURES

DESCRIPTION

DKG-209 User Manual V-29 (20.08.2013)

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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 Displays

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. Service Request Display

6.11. Engine Hours Meter

6.12. -

6.13. Display of Software Version

6.14. Modem connection

6.15. SMS message sending

6.16. Remote Monitoring and Programming

6.17. External Control of the Unit

6.18. -

6.19. Resuming to factory set parameters

6.20. Gas engine fuel solenoid control

6.21. Load Shedding / Dummy Load

6.22. Fuel Theft / Fuelling Messages

6.23. Firmware Update

6.24. -

6.25. -

6.26. Dual Voltage and Frequency

6.27. Single Phase Operation

7. -

8. MODBUS COMMUNICATION

9. -

10. EVENT LOGGING

11. STATISTICAL COUNTERS

12. MAINTENANCE

13. PROGRAMMING

14. TROUBLESHOOTING

15. DECLARATION OF CONFORMITY

16. TECHNICAL SPECIFICATIONS

17. CONNECTION DIAGRAMS

TABLE OF CONTENTS

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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

Mains current phase L1

Mains current phase L2

Mains current phase L3

Mains frequency

Mains kW phase L1

Mains kW phase L2

Mains kW phase L3

Mains pf phase L1

Mains pf phase L2

Mains pf phase L3

Mains kVA phase L1

Mains kVA phase L2

Mains kVA phase L3

Mains kVAr phase L1

Mains kVAr phase L2

Mains kVAr phase L3

Mains average Current

Mains average Voltage

Mains total kW

Mains total pf

Gen voltage phase L1 to neutral

Gen voltage phase L2 to neutral

Gen voltage phase L3 to neutral

Gen voltage phase L1-L2

Gen voltage phase L2-L3

Gen voltage phase L3-L1

Gen current phase L1

Gen current phase L2

Gen current phase L3

Gen frequency

Gen kW phase L1

Gen kW phase L2

Gen kW phase L3

Gen pf phase L1

Gen pf phase L2

Gen pf phase L3

Gen kVA phase L1

Gen kVA phase L2

Gen kVA phase L3

Gen kVAr phase L1

Gen kVAr phase L2

Gen kVAr phase L3

Gen average Current

Gen average Voltage

Gen total kW

Gen total kVA

Gen total pf

Gen kWh

Gen kVAr

Battery voltage

Min. Battery voltage

Coolant temperature

Oil pressure (bar/kPa)

Engine temperature (C/F)

Fuel level

Engine speed (rpm)

1.1 Introduction to the Control Panel

1. INSTALLATION

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The unit is designed for panel mounting. The user should not be able to access parts of the

unit other than the front panel.

Mount the unit on a flat, vertical surface. Before mounting, remove the mounting brackets and

connectors from the unit, then pass the unit through the mounting opening. The unit will be maintained in

its position by the mounting brackets spring.

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.

Engine body must be grounded for correct operation of

the unit, otherwise incorrect voltage and frequency

measurements may occur.

1.2 Mounting the Unit

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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) An appropriate 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

0.75mm2) and temperature range.

WARNING: THE UNIT IS NOT FUSED.

Use external fuses for Mains phases: L1,L2,L3,

Generator phase: L1,L2,L3, Battery positive: BAT(+).

Install the fuses as nearly as possible to the unit in a

place easily accessible for the user.

The fuse rating should be 6 Amps.

1.3 Wiring the Unit

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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

GENERATOR CONTACTOR

Relay output, 16A-AC

This output provides energy to the generator

contactor. If the generator phases do not have

acceptable voltage or frequency values, the

generator contactor will be de-energized. In

order to provide extra security, the normally

closed contact of the mains contactor should

be serially connected to this output.

GEN-L1

Generator phase

inputs, 0-300V-AC

Connect the generator phases to these inputs.

The generator phase voltages upper and

lower limits are programmable.

GEN-L2

GEN-L3

GENERATOR NEUTRAL

Input, 0-300V-AC

Neutral terminal for the generator phases.

MAINS NEUTRAL

Input, 0-300V-AC

Neutral terminal for the mains phases.

MAINS-L3

Mains phase inputs,

0-300V-AC

Connect the mains phases to these inputs.

The mains voltages upper and lower limits are

programmable.

MAINS-L2

MAINS-L1

MAINS CONTACTOR

Relay output, 16A-AC

This output provides energy to the mains

contactor. If the mains phases do not have

acceptable voltages, the mains contactor will

be de-energized. In order to provide extra

security, the normally closed contact of the

generator contactor should be serially

connected to this output.

BATTERY POSITIVE

+12 or 24VDC

The positive terminal of the DC Supply shall

be connected to this terminal. The unit

operates on either 12V or 24V battery

systems.

GROUND

O VDC

Power supply negative connection.

FUEL RELAY

Output 1A/28VDC

This output is used for fuel solenoid control.

CRANK RELAY

Output 1A/28VDC

This output controls the engine cranking.

ALARM RELAY

Output 1A/28VDC

This output has programmable function,

selectable from a list.

CHARGE

Input and output

Connect the charge alternator’s D+/WL

terminal to this terminal. This terminal will

supply the excitation current and measure the

voltage of the charge alternator.

FUEL LEVEL SENDER

Input, 0-5000 ohms

Analogue fuel level sender connection. Do not

connect the sender to other devices. The input

has programmable ohms for VDO senders.

2. INPUTS AND OUTPUTS

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Term

Function

Technical data

Description

OIL PRESSURE SENDER

Input, 0-5000 ohms

Analogue oil pressure sender connection. Do

not connect the sender to other devices. The

input has programmable characteristics and

connects to anykind of sender.

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.

CURR_COMMON

Current transformer

inputs, 5A-AC

Connect the generator current transformer

terminals to these inputs. Do not connect the

same current transformer to other instruments

otherwise a unit fault will occur. Connect each

terminal of the transformer to the unit’s related

terminal. Do not use grounding. Correct

polarity of connection is vital. If the measured

power is negative, then change the polarity of

each 3 current transformers. The rating of the

transformers should be the same for each of

the 3 phases. The secondary winding rating

shall be 5 Amperes. (For ex. 200/5 Amps).

CURR_1

CURR_2

CURR_3

LOW OIL PRESSURE

Digital inputs

These inputs have programmable

characteristics selected via the program

menu. Each input may be driven by a

‘normally closed’ or ‘normally open’ contact,

switching either battery+ or battery-. The effect

of the switch is also selectable from a list. See

PROGRAMMING section for more details.

HIGH TEMP

EMERGENCY STOP

FUEL LEVEL

SPARE-1

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The unit has 12 LEDs, divided in 3 groups:

-Group_1: Operating mode: This group indicates the genset function.

-Group_2: Mimic diagram: This group indicates the current status of the mains and genset

voltages and contactors.

-Group_3: Warnings and alarms: This group indicates the existence of abnormal conditions

encountered during operation.

Function

Color

Description

MAINS ON

Yellow

The LED will turn on when all 3 mains phase voltages

are within the limits.

MAINS OFF

Red

The LED will turn on when at least one of the mains

phase voltages is outside limits.

LOAD MAINS

Yellow

It turns on when the mains contactor is activated.

LOAD GENERATOR

Yellow

It turns on when the generator contactor is activated.

GENERATOR

Yellow

The LED will flash when the engine is running. It will

turn on steadily when all 3 generator phase voltages

are within the programmed limits.

TEST

Yellow

It turns on when the related operation mode is

selected. One of these LEDs is always on and

indicates which operation mode is selected.

RUN

Yellow

STOP

Yellow

AUTO

Yellow

ALARM

Red

If a fault condition resulting to the engine shutdown

has occurred, the alarm led turns on steadily. If a

loaddump condition occurs, this led will flash. Alarms

work on a first occurring basis. The occurrence of a

fault will disable other faults of lower or equal priority.

WARNING

Red

If a warning condition has occurred, this led turns on

steadily. The warnings work on a first occurring basis.

The occurrence of a warning will disable other

warnings, however shutdown and loaddump alarms

are still allowed.

SERVICE REQUEST

Red

Engine periodic maintenance request indicator. It

turns on when the preset engine hours or time

duration after previous service has elapsed.

3.1 Led Displays

3. DISPLAYS

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The unit is able to display information in 3 or 4 languages, following versions. Language selection

is made through program parameter CONTROLLER CONFIGURATION > LANGUAGE SELECTION.

Below selections are available in the standard version:

0: English language

1: Turkish language

2: Chinese language

3: ask selection at power-up

If language is set to 3, below screen will come at power on:

Left / Up / Down arrow pushbuttons will select the screen language. The language will be asked

everytime power is turned on.

With selections of 0,1,2 this screen will not appear and the selected language is enabled.

The unit has a graphical 128x64 pixel LCD display. It shows:

-Measured parameters,

-The company logo,

-The alarm list

-Software version,

-Event records,

-Program parameters.

Navigation between different screens is made with the ◄MENU and MENU►buttons. Each

depression of the MENU►button switches the display to the next screen. Each depression of the

◄MENU button switches the 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 or warning occurs during operation, in other then programming mode, the display

will automatically switch to ALARM LIST position. The ◄MENU or MENU►buttons will not function.

To enable display navigation and mute the internal buzzer, press ALARM MUTE button first. If there is

more than one alarm, the next alarm is displayed by pressing the ▼button. Thus all existing alarms

can be scanned. ‘END OF ALARM LIST’ will be displayed when there is no more alarm to display.

The display has a backlight illumination feature. The backlight turns on with the depression

of any button or when the genset runs. It turns off after 9hours to allow power economy.

3.3 Digital Display

3.2 Language Selection

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Group

Screen

Contents

Description

GENSET

PARAMETERS

Genset Volts L1, Genset Volts L1-L2,

Genset Volts L2 , Genset Volts L2-L3,

Genset Volts L3, Genset Volts L3-L1,

Presented as a table.

Genset Current L1, Genset Frequency

Genset Current L2,

Genset Current L3,

Presented as a table.

Genset kW phase L1, Genset pf phase L1

Genset kW phase L2, Genset pf phase L2

Genset kW phase L3, Genset pf phase L3

Presented as a table.

Genset kVA phase L1, Genset kVAr phase L1

Genset kVA phase L2, Genset kVAr phase L2

Genset kVA phase L3, Genset kVAr phase L3

Presented as a table.

Genset average Current Genset total kW

Genset average Voltage Genset total pf

Genset Frequency Genset total kVA

Presented as a table.

Genset L1 current

Genset Phase L1 Current, large characters

Genset L2 current

Genset Phase L2 Current, large characters

Genset L3 current

Genset Phase L3 Current, large characters

Genset frequency

with large size characters

Genset active power

with large size characters

Genset average voltage

with large size characters

Genset kWh

8 digit counter

Genset kVArh

8 digit counter

Group

Screen

Contents

Description

ENGINE

PARAMETERS

Oil Pressure

Displayed in bars and kPa, large font. If PSI

display is enabled by program parameter,

then displayed in bars and psi.

Engine Temperature

Displayed in degrees C and degrees F,

large characters

Fuel Level

Displayed in % of full tank capacity.

If Fuel Consumption per Hour parameter

is not zero, then also displayed in engine

hours. If Fuel Tank Capacity parameter is

not zero, then also displaed in liters.

Engine Speed

Displayed in RPMs

Battery Voltage,

Minimum battery voltage

Displayed in Volts DC. The Minimum

Battery Voltage is reset before each engine

crank cycle. Thus the displayed value

reflects the most recent status.

Engine Hours,

Total Starts

The engine hours is displayed up to

999’999.9 hours.

Total start count is displayed up to 9999

Group

Screen

Contents

Description

MAINS

PARAMETERS

Mains Volts L1, Mains Volts L1-L2,

Mains Volts L2, Mains Volts L2-L3,

Mains Volts L3, Mains Volts L3-L1,

Presented as a table.

Mains Current L1, Mains Frequency

Mains Current L2,

Mains Current L3,

Presented as a table.

Mains kW phase L1, Mains pf phase L1

Mains kW phase L2, Mains pf phase L2

Mains kW phase L3, Mains pf phase L3

Presented as a table.

Mains kVA phase L1, Mains kVAr phase L1

Mains kVA phase L2, Mains kVAr phase L2

Mains kVA phase L3, Mains kVAr phase L3

Presented as a table.

Mains average Current Mains total kW

Mains average Voltage Mains total pf

Mains Frequency

Presented as a table.

Mains L1 current

Mains Phase L1 Current, large characters

Mains L2 current

Mains Phase L2 Current, large characters

Mains L3 current

Mains Phase L3 Current, large characters

Mains frequency

Mains Phase L1 Current, large characters

Mains active power

with large size characters

Mains average voltage

with large size characters

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