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DKG-119 User Manual V-27

(20.04.2012)

DKG-119 MANUAL AND
REMOTE START UNIT

True RMS measurements
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
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 inputs: 5
Configurable digital outputs: 2
Total digital outputs: 4
Survives cranking dropouts
Sealed front panel
Plug-in connection system for easy
replacement
Dimensions (96x96x53mm)

FEATURES

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Summary of Contents for DKG-119

Page 1: ...nance 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 s...

Page 2: ...tion 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...

Page 3: ...ating 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...

Page 4: ...el 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 excitat...

Page 5: ... 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 7 HIGH TEMP 8 EMERGENCY STOP 9 SPARE 2 10 SPARE 1 11 GENERATOR NEUTRAL Input 0 300V AC Neutral terminal for the generator phase 12 GEN L1 Generator phase inputs 0 300V AC Connect the generator phase to this input The generator phase v...

Page 6: ...1 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 sende...

Page 7: ... 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 The unit is able to display information in 3 languages Language selection is made through program parameter CONTROLL...

Page 8: ...it 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 MENU buttons Thus all existing a...

Page 9: ...Genset Volts L1 Genset Current L1 Genset Active Power Genset Frequency Oil Pressure Coolant Temperature Fuel Level 5 Company Logo 6 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 7 Software Version Operating software version 8 Statistical Co...

Page 10: ...ING led to be on steadily The 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 a...

Page 11: ...r delay after the engine is running 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 t...

Page 12: ...s period the generator contactor function is deactivated 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 REMOTE START cycle RUN It is used to test the generator without REMOTE START signal The engine will run unless another mode is sel...

Page 13: ... Ohms is also programmable 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 The 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 parame...

Page 14: ...mit 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 The unit is able to provide a relay output in order to drive the fuel pump motor The ...

Page 15: ...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 p...

Page 16: ...attery 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 gense...

Page 17: ...ittent 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 parameter...

Page 18: ...tch 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 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 th...

Page 19: ...sage is given below DKGxxx SITE ID STOP LOW OIL PRESSURE SW END OF ALARM LIST The first line of the message carries information about 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 i...

Page 20: ...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 The cable length should not be over 3 meters The unit offers total external control through programmable digital inputs Each digital input may...

Page 21: ...sists 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 l...

Page 22: ...Rainbow or a special DOS program 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 uni...

Page 23: ...h Voltage Limit Mains Low Frequency Limit Mains High Frequency Limit Genset Low Voltage Shutdown Limit Genset Low Voltage Warning Limit Genset High Voltage Warning Limit Genset High Voltage Shutdown Limit Genset Low Frequency Shutdown Limit Genset Low Frequency Warning Limit Genset High Frequency Warning Limit Genset High Frequency Shutdown Limit Genset Low RPM Shutdown Limit Genset Low RPM Warnin...

Page 24: ... 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 0003 R 16bit x1 Genset Phase L1 voltage 0006 R 16bit x1 Genset Phase L1 current 0013 R 16bit x10 Genset frequency 0016 0017 R 32...

Page 25: ...utton 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 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 dum...

Page 26: ...s 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 Wipe the unit if necessary with a soft damp cloth Do not use chemical agents DO NOT OPEN THE UNIT There are NO serviceable parts inside the unit 10 MAINTENANCE 9 STATISTICAL COUNTERS ...

Page 27: ...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 and buttons Selected group is shown in reverse video blue on white In order to enter inside a group please press MENU button In order to exit from the group to the main list please press MENU button Navig...

Page 28: ...gine 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 Engine Control Only 0 0 Genset control 1 Engine control no alternator 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...

Page 29: ... incremented by this value It is advised to set this value to 8 volts 2 RPM from genset frequency 1 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 ...

Page 30: ...top 2 Genset Voltage High Limit V 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 2 Low Battery Voltage Warning V 9 0 If the battery voltage falls below this limit this will generate a LOW BATTERY warning 2 High Battery Voltage Warning V 31 0 If the battery voltage goes over this limit thi...

Page 31: ...t starts the transfer to the genset in AUTO mode 2 2 nd Mains Frequency High Limit Hz 65 When secondary volt freq limits are active If the mains frequency goes above this limit it means that the mains are off and it starts the transfer to the genset in AUTO mode 2 2 nd Genset Low Voltage Shutdown Limit V 90 When secondary volt freq limits are active If one of the generator phase voltages goes unde...

Page 32: ...tdown C 98 f the coolant temperature measured from the analog input goes over this limit this will generate a HIGH TEMPERATURE SENDER alarm and the engine will stop 2 Oil Pressure Sender type 1 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 3 DATC...

Page 33: ...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 mont h 6 The SERVIC...

Page 34: ... the coolant temp is below this limit then the fan relay function will become inactive 2 2 nd Low Frequency Shutdown Hz 40 When secondary volt freq limits are active If the genset frequency goes under this limit a GENSET LOW SPEED alarm is generated and the engine stops 1 2 nd Low Frequency Warning Hz 45 When secondary volt freq limits are active If the genset frequency goes under this limit a GEN...

Page 35: ...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 Set Description 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...

Page 36: ...ally open 1 Normally closed Switching 0 0 Battery negative 1 Battery positive Response delay 0 0 No delay 1 Delayed 4sec Program Group Input Configuration High Temperature Switch password level 2 Parameter Definition Unit Factory Set Description Action 0 0 Shutdown the engine stops immediately 1 Load Dump the engine stops after cooldown 2 Warning the horn relay operates 3 No operation Sampling 1 0...

Page 37: ...ally open 1 Normally closed Switching 0 0 Battery negative 1 Battery positive Response delay 0 0 No delay 1 Delayed 4sec Program Group Input Configuration Spare 1 Input password level 2 Parameter Definition Unit Fac Set Description Action 2 0 Shutdown the engine stops immediately 1 Load Dump the engine stops after cooldown 2 Warning the horn relay operates 3 No operation Sampling 0 0 Always 1 Afte...

Page 38: ...ing Contact type 0 0 Normally open 1 Normally closed Switching 0 0 Battery negative 1 Battery positive Response delay 0 0 No delay 1 Delayed 4sec 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 Re...

Page 39: ... sender alarm 48 49 50 51 High battery voltage alarm 52 Charge fail alarm 53 54 55 56 Oil switch load_dump 57 Temp switch load_dump 58 59 60 Emerg Stop load_dump 61 Spare 1 load_dump 62 Spare 2 load_dump 63 64 Oil sender fail ldd 65 Temp sender fail ldd 66 Fuel Lev sender fail ldd 67 68 69 70 71 72 Overcurrent load_dump 73 Excess power ldd 74 Reverse power ldd 75 76 77 78 79 Genset Phase Order Fai...

Page 40: ...ect 18 Remote Start 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 2nd Volt Fre...

Page 41: ...n Factory Set Description Modem 2 SMS 2 telephone number 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 Program Group SMS 3 Telephone Number password level 2 Parameter Definition Factory Set D...

Page 42: ...nsformer 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 la...

Page 43: ...s 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...

Page 44: ... alternator excitation current min 150 mADC 10 to 30 VDC Current inputs from current transformers 5A Max load 0 7VA per phase Digital inputs input voltage 0 30 VDC 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 Polluti...

Page 45: ...DKG 119 User Manual V 27 20 04 2012 45 DATAKOM Electronics Ltd Tel 90 216 466 84 60 Fax 90 216 364 65 65 e mail datakom datakom com tr http www datakom com tr 15 CONNECTION DIAGRAM ...

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