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DKG-209 User Manual V-29

(20.08.2013)

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Summary of Contents for DKG-209

Page 1: ...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 operat...

Page 2: ...attery 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 Fue...

Page 3: ...3 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 L...

Page 4: ...uld 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 facto...

Page 5: ...rt 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 In...

Page 6: ...hases 7 MAINS L3 Mains phase inputs 0 300V AC Connect the mains phases to these inputs The mains voltages upper and lower limits are programmable 8 MAINS L2 9 MAINS L1 10 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 c...

Page 7: ...t 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 shal...

Page 8: ... 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...

Page 9: ...th 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 th...

Page 10: ...grees F large characters 3 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 4 Engine Speed Displayed in RPMs 5 Battery Voltage Minimum battery voltage Displayed in Volts DC The Minimum Battery Voltage is reset before each engine crank cycle Th...

Page 11: ...ll cause the screen to switch to the next alarm Group Screen Contents Description GENSET STATUS 1 Genset Status Ascii explanation of the current status 2 Company Logo 3 Site Id String The generator site id string displayed in large characters 4 Software Version The unit firmware version number displayed in large characters 5 Maintenance Counters Time to maintenance days and engine hours to mainten...

Page 12: ...G 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 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...

Page 13: ...m 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 at least one of the genset phase cur...

Page 14: ...ed When all the mains phase voltages are within the limits the engine will continue to run for the mains waiting period At the end of this period the generator contactor is deactivated and 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 s...

Page 15: ... status of the REMOTE START input 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...

Page 16: ...grammed duration for engine heating 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 ...

Page 17: ... 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 3 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 men...

Page 18: ...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 19: ...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 20: ... hours there will be no time limit If the engine hours is also selected as 0 hours this will mean that the SERVICE REQUEST display will be inoperative When the engine hours OR the time limit is over the SERVICE REQUEST led red will start to flash and the service request relay function will be active The service request relay function may be assigned to spare relays using Relay Definition program p...

Page 21: ...l will be repeated up to 30 times with 2 minute intervals When the modem call is in progress a telephone icon will appear at the upper right corner of the screen Advised modems are DATAKOM types which are powered up from the same DC battery voltage than the unit Most of other desktop modems with standard AT commands are also usable but it is the user s responsibility to provide an uninterrupted AC...

Page 22: ...n a SMS message is 4 This limitation is due to the maximum length of an SMS message which is 160 characters A sample GSM SMS message 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 followi...

Page 23: ... 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 The cable length should not be over 3 meters The unit offers total external control through pro...

Page 24: ...edding 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 ...

Page 25: ...the sender input is increased more than this parameter in 1 hour period then a FUELLING sms message is sent to programmed telephone numbers The unit offers possibility of updating the firmware in the field The firmware is updated through the RS 232 serial port using Rainbow or a special DOS program The unit will go to firmware download mode with a special command from the PC program In download mo...

Page 26: ... 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 Warning...

Page 27: ...DKG 209 User Manual V 29 20 08 2013 27 This chapter is intentionally left blank 7 ...

Page 28: ...ENT 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 0004 R 16bit x1 Genset Phase L2 voltage 0005 R 16bit x1 Genset Phase L3 voltage 0006 R 16bit x1 Genset Phase L1 current 0007 R 16bit x1 Genset Phase L2 current 0008 R 16bit x1 Genset Phase L3 current 000C R 16bit x1 Mains Phase...

Page 29: ...ORD screen is displayed each depression on the MENU button makes the display switch to the previous event and MENU button makes the display switch to the next event Each event is displayed in 4 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 Navigation between different page...

Page 30: ...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 12 MAINTENANCE 11 STATISTICAL COUNTERS ...

Page 31: ... 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 and buttons Selected group is shown in reverse video blue on white In order to enter inside a group please ...

Page 32: ...ult 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 0 continuous 1 intermittent turns on and off every second 2 Charge Alternator Shutdown 1 0 Th...

Page 33: ... Teeth Count 30 This parameter is used in the conversion 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 0 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...

Page 34: ... 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 V 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 Mains Frequency Low Limit Hz 45 If the mains frequency goes under this limit it means that the mai...

Page 35: ...actor has been activated 2 Mains Contactor Timer sec 1 This is the period after the generator contactor has been deactivated and before the mains contactor has been activated 2 Mains Phase Order Enable 0 0 mains phase order checking disabled 1 if mains phase order is faulty then a warning is given and mains contactor deenergized 2 Reverse power warning limit kW 0 If the genset power is negative an...

Page 36: ...in AUTO mode 2 2nd Genset Low Voltage Shutdown Limit V 90 When secondary volt freq limits are active If one of the generator phase voltages goes under this limit when feeding the load this will generate a GENSET LOW VOLTAGE shutdown alarm and the engine will stop 2 2nd Genset Low Voltage Warning Limit V 94 When secondary volt freq limits are active If one of the generator phase voltages goes under...

Page 37: ...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 38: ...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 dependin...

Page 39: ...d when the charge alternator voltage is established 3 Low rpm Shutdown rpm 0 If the engine speed goes under this limit a GENSET LOW SPEED alarm is generated and the engine stops 3 Low rpm Warning rpm 0 If the engine speed goes under this limit a GENSET LOW SPEED warning is generated 3 High rpm Warning rpm 0 If the engine speed goes over this limit a GENSET HIGH SPEED warning is generated 3 High rp...

Page 40: ...generated 2 2nd High Frequency Shutdown Hz 69 When secondary volt freq limits are active If the genset frequency goes over this limit a GENSET HIGH SPEED alarm is generated and the engine stops 2 2nd Low rpm Shutdown rpm 0 When secondary volt freq limits are active If the engine speed goes under this limit a GENSET LOW SPEED alarm is generated and the engine stops 1 2nd Low rpm Warning rpm 0 When ...

Page 41: ...rature 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 ...

Page 42: ...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 Fac 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 Alw...

Page 43: ...lly 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 Fuel Levl 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 2 0 Always 1 Aft...

Page 44: ...tching 0 0 Non latching 1 Latching 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 5 relay outputs The fixed function relays are Fuel Start Mains Contactor and Generator Contactor ALARM RELAY has programmable functions selected from a...

Page 45: ... start alarm 55 Low fuel sender alarm 56 57 58 59 High battery voltage alarm 60 Charge fail alarm 61 62 63 64 Oil switch load_dump 65 Temp switch load_dump 66 67 68 Emerg Stop load_dump 69 Spare 1 load_dump 70 71 Fuel Level switch load_dump 72 Oil sender fail ldd 73 Temp sender fail ldd 74 Fuel Lev sender fail ldd 75 76 77 78 79 80 Overcurrent load_dump 81 Excess power ldd 82 Reverse power ldd 83 ...

Page 46: ...y Stop Input 04 Function Select 7 Low Fuel Switch Input 05 Function Select 11 Spare 1 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 Belt Rupture 10 Spare 2 Input 11 Spare 1 Input 12 Force AUTO Mode 13 Force OF...

Page 47: ...on 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 ...

Page 48: ...ailed Turn off the rectifier fuse and check again KW and cosΦ readings are faulty although the Amp readings are correct Current transformers are not connected to the correct inputs or some of the CTs are connected with reverse polarity Determine the correct connections of each individual CT in order to obtain correct KW and cosΦ for the related phase and then connect all CTs Short circuit the outp...

Page 49: ...ately 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...

Page 50: ...ow 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 15 DECLARATION OF CONFORMITY ...

Page 51: ... 1A 28 VDC protected semiconductor outputs Charge alternator excitation min 2W 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 47 000 ohm resistor Analog inputs Resistor input 0 to 5000 ohms connected to the battery negative Sources 5 mA when closed to battery negative Measurement category CAT I...

Page 52: ...DKG 209 User Manual V 29 20 08 2013 52 17 CONNECTION DIAGRAMS ...

Page 53: ...DKG 209 User Manual V 29 20 08 2013 53 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 ...

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