Datakom DKG-319 Manuale utente

DKG-319 User Manual V-27

(14.04.2011)

Tel:

+90

216

466 84 60

Fax: +90-216 364 65 65

[email protected]

http://www.datakom.com.tr

DKG

MANUAL AND REMOTE START

UNIT

FEATURES

True RMS measurements

Engine control

Generator protection

Built in alarms and warnings

Dual genset mutual standby operation

Load shedding, dummy load

Gas engine support

Engine idle speed control

3 phase genset voltage inputs

3 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

Periodic maintenance request indicator

Daily / weekly / monthly exerciser

Engine hours counter

Event logging with date-time stamp and complete

measurement values

Stores last 100 events

Statistical counters

Battery backed-up real time clock

Weekly operation schedule programs

3 level password protection

Programmable parameters

All parameters field adjustable

Return to factory settings enabled

RS-232 serial port

Firmware downloadable from serial port

Free MS-Windows Remote monitoring SW:

-local and modem connection

-monitoring, download of parameters

-networking via modems

GSM and PSTN modem support

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

Magnetic pickup input

Configurable analogue inputs: 3

Configurable digital inputs: 7

Configurable digital outputs: 2

Total digital outputs: 4

Output expansion capability

Remote Start operation available

Engine Idle speed control

Survives cranking dropouts

Sealed front panel

Plug-in connection system for easy replacement

Dimensions (165x125x48mm)

DKG-319 User Manual V-27

(14.04.2011)

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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 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. Date-Time Display

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. Automatic Exerciser

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. Engine Control Mode

6.25. Dual Voltage and Frequency

6.26. Single Phase Operation

7. -

8. MODBUS COMMUNICATION

9. WEEKLY OPERATION SCHEDULE

10. EVENT LOGGING

11. STATISTICAL COUNTERS

12. MAINTENANCE

13. PROGRAMMING

14. TROUBLESHOOTING

15. DECLARATION OF CONFORMITY

16. TECHNICAL SPECIFICATIONS

17. CONNECTION DIAGRAM

DKG-319 User Manual V-27

(14.04.2011)

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1. INSTALLATION

1.1 Introduction to the Control Panel

The unit is a control and protection panel used in gensets. It shows the measured values on its

displays. The unit is designed to provide user friendliness for both the installer and the user.

Programming is usually unnecessary, as the factory settings have been carefully selected to fit most

applications. However programmable parameters allow the complete control over the generating set.

Programmed parameters are stored in a Non Volatile Memory and thus all information is retained even

in the event of complete loss of power.

The measured parameters are:

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

Engine speed (rpm)

Gen KW phase L1

Gen KW phase L2

Gen KW phase L3

Gen total KW

Gen pf phase L1

Gen pf phase L2

Gen pf phase L3

Gen total pf

Battery voltage,

Coolant temperature

Oil pressure

Fuel level

Gen frequency

DKG-319 User Manual V-27

(14.04.2011)

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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. 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.

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 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.

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) 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 0.75mm

) and

temperature range.

DKG-319 User Manual V-27

(14.04.2011)

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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 -

2 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.

3 GEN-L2

4 GEN-L3

5 GENERATOR NEUTRAL Input, 0-300V-AC

Neutral terminal for the generator phases.

6 -

7 -

8 -

9 -

10 -

11 GROUND O VDC Power supply negative connection.

12 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.

13 FUEL LEVEL SENDER Input, 0-5000 ohms Analogue fuel level sender connection. Do not

connect the sender to other devices. The input

has programmable ohm value.

14 OIL PRESSURE SENDER Input, 0-5000 ohms Analogue oil pressure sender connection. Do

not connect the sender to other devices. The

input has programmable characteristics and

connects to any kind of sender.

15 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.

16 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.

17 RELAY-2 (HORN RELAY) Output 1A/28VDC This relay has programmable function,

selectable from a list.

18 RELAY-1 (STOP RELAY) Output 1A/28VDC This relay has programmable function,

selectable from a list.

19 START RELAY Output 1A/28VDC This relay controls the engine cranking.

20 FUEL RELAY Output 1A/28VDC This relay is used for fuel solenoid control. It is

internally connected to terminal 16 for

supplying the charge alternator’s excitation

current.

DKG-319 User Manual V-27

(14.04.2011)

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Term Function Technical data Description

21 EMERGENCY STOP 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.

22 SPARE-2

23 PROGRAM LOCK

24 SPARE-1

25 COOLANT LEVEL

26 HIGH TEMP

27 LOW OIL PRESSURE

28 RECTIFIER FAIL

29 CURR_1+ 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 common terminals. Do

not use grounding. Correct polarity of

connection is vital. If the measured power is

negative, then change the polarity of each 3

current transformers. The 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).

30 CURR_1-

31 CURR_2+

32 CURR_2-

33 CURR_3+

34 CURR_3-

35 -

36 MAGNETIC PICKUP Inputs, 1-30V

0-8KHz

Connect the magnetic pickup signal to these

inputs.

37 MAGNETIC PICKUP

DKG-319 User Manual V-27

(14.04.2011)

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3. DISPLAYS

3.1 Led Displays

The unit has 8 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 Green 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 Green

It turns on when the mains contactor is activated.

LOAD GENERATOR Yellow

It turns on when the generator contactor is activated.

GENERATOR Yellow The LED will 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.

If the operation of the genset is disabled by the

weekly operation schedule, then the AUTO led will

flash.

OFF Yellow

AUTO Green

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.

DKG-319 User Manual V-27

(14.04.2011)

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3.2 Language Selection

The unit is able to display information in 3 languages. Language selection is made through

program parameter CONTROLLER CONFIGURATION > LANGUAGE SELECTION. Below selections

are available:

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.

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 and date-time information,

-Statistical counters,

-Event records,

-Program parameters.

Navigation between different screens s 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 4 hours to allow power economy.

DKG-319 User Manual V-27

(14.04.2011)

- 9 -

Scre

Description

Contents

Genset parameters

(phase to neutral)

Genset status

Genset Current L1, Genset Frequency

Genset Current L2, Genset Active Power (KW)

Genset Current L3, Genset Volts L1

Genset parameters

(phase to phase)

Genset status

Genset Current L1, Genset Frequency

Genset Current L2, Genset Active Power (KW)

Genset Current L3, Genset Volts L1-L2

Engine parameters

Genset status

Oil Pressure, Engine rpm

Coolant Temperature, Battery Voltage

Fuel Level,

Complete Genset

parameters

(phase to neutral)

Genset status

Genset Volts L1, Genset Volts L2, Genset Volts L3

Genset Curr

ent L1, Genset Current L2, Genset Current L3,

Genset Frequency, Oil Pressure

Genset Active Power (KW), Coolant Temperature

Genset power factor, Fuel Level

Engine rpm, Battery Voltage

Complete Genset

parameters

(phase to phase)

Genset status

Genset Volts L1-L2, Genset Volts L2-L3, Genset Volts L3-L1

Genset Current L1, Genset Current L2, Genset Current L3

Genset Frequency, Oil Pressure

Genset Active Power (KW), Coolant Temperature

Genset power factor, Fuel Level

Engine rpm, Battery Voltage

Graphical Genset

parameters

(phase to neutral)

Genset status

Genset Current L1

Genset Volts L1

Genset Active Power (%), Genset Frequency

Oil Pressure

Coolant Temperature

Fuel Level

Graphical Genset

parameters

(phase to phase)

Genset status

Genset Current L1

Genset Volts L1-L2

Genset Active Power (%), Genset Frequency

Oil Pressure

Coolant Temperature

Fuel Level

Genset Phase Power

parameters

Genset status

Genset Phase L1 : Active Power(KW) / Power Factor

Genset Phase L2 : Active Power(KW) / Power Factor

Genset Phase L3 : Active Power(KW) / Power Factor

DKG-319 User Manual V-27

(14.04.2011)

- 10 -

Screen

Description

Contents

Company Logo

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

▼

button.

Date-Time,

Software Version

Date and time.

Operating software version.

Statistical Counters 1 / 3

Engine Hours Run

Total Genset Active Power (KW-h)

Statistical Counters 2/ 3

Engine Hours to Service

Time to Service

Statistical Counters 3 / 3

Total Engine Cranks

Total Engine Runs

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.

Indice

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