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DKG-379 User Manual Rev_02

V-15

(24-12-2012)

K43D01-EN - 2 -

Any unauthorized use or copying of the contents or any part of this document is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.

This document describes minimum requirements and necessary steps for the successful installation of the
DKG-379 unit.
Follow carefully advices given in the document. These are often good practices for the installation of genset
control units which reduce future issues.
For all technical queries please contact Datakom at below e-mail address:

[email protected]

FILENAME

DESCRIPTION

379_INSTE

DKG-379 Installation Guide

REVISION

DATE

AUTHOR

DESCRIPTION

01

04.04.2012

MH

First issue, firmware version 12, hardware version 02

02

24.12.2012

MH

Updated for firmware version 15, hardware version 03

CAUTION:

Potential risk of injury or death.

WARNING:

Potential risk of malfunction or material damage.

ATTENTION:

Useful hints for the understanding of device operation.

TERMINOLOGY

REVISION HISTORY

RELATED DOCUMENTS

ABOUT THIS DOCUMENT

COPYRIGHT NOTICE

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Summary of Contents for DKG-379

Page 1: ...started the controller will perform an optimal battery charging cycle and will stop the genset when batteries are fully charged The optimal charge algorithm allows maximum battery life and minimal eng...

Page 2: ...installation of genset control units which reduce future issues For all technical queries please contact Datakom at below e mail address datakom datakom com tr FILENAME DESCRIPTION 379_INSTE DKG 379 I...

Page 3: ...rdering the correct version DKG 379 MPU G T 00 Screw type bracket Stock Code J10P01 per unit Self Retaining type bracket Stock Code K16P01 per unit Sealing Gasket Stock Code K44P01 SPARE PARTS ORDERIN...

Page 4: ...of the unit Fuses must be of fast type FF with a maximum rating of 6A Disconnect all power before working on equipment Any electrical parameter applied to the device must be in the range specified in...

Page 5: ...NBUS PORT 3 13 RS 232 PORT OPTIONAL 4 CONNECTION DIAGRAM 5 TERMINAL DESCRIPTION 6 TECHNICAL SPECIFICATIONS 7 DESCRIPTION OF CONTROLS 7 1 FRONT PANEL FUNCTIONALITY 7 2 PUSHBUTTON FUNCTIONS 7 3 DISPLAY...

Page 6: ...FINITIONS 15 9 INPUT FUNCTION SELECT 15 10 SITE ID STRING 15 11 MODEM1 2 SMS1 2 3 4 TELEPHONE NUMBERS 16 CRANK CUTTING 17 J1939 CANBUS ENGINE SUPPORT 18 SOFTWARE FEATURES 18 1 Charging the Engine Batt...

Page 7: ...perature in any case Below conditions may damage the device Incorrect connections Incorrect power supply voltage Voltage at measuring terminals beyond specified range Voltage applied to digital inputs...

Page 8: ...DKG 379 User Manual Rev_02 V 15 24 12 2012 K43D01 EN 8 Dimensions 172x134x76mm 6 8 x5 3 x3 0 Panel Cutout 151x111mm minimum 6 0 x4 4 Weight 450g 1 lb 2 1 DIMENSIONS 2 MOUNTING...

Page 9: ...ould 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 th...

Page 10: ...2012 K43D01 EN 10 Two different types of brackets are provided Screw type bracket Self retaining type bracket Installation of screw type bracket Installation of self retaining type bracket Do not tig...

Page 11: ...oreign objects of 1 0 mm diameter and greater 5 Protected from the amount of dust that would interfere with normal operation 6 Dust tight 2nd Digit Description of Protection Level 0 Not protected 1 Pr...

Page 12: ...rature range Use adequate cable section at least 0 75mm2 AWG18 Follow national rules for electrical installation Current shunts must have 60mV output at nominal current For the correct operation of th...

Page 13: ...voltage protection Withstands 150VDC continuously Reverse voltage 33VDC continuous Maximum operating current 250mA 12 24VDC All options included digital outputs open Typical operating current 200mA 12...

Page 14: ...50VDC Measurement method Isolated DC voltage measurement Sampling rate 100 Ks s Input voltage range 0 to 100 mVDC Measurement range 0 to 100 mVDC Input impedance 1000 ohms Isolation 500VAC 1minute Ac...

Page 15: ...hold 35 of battery voltage High level threshold 85 of battery voltage Maximum input voltage 100VDC with respect to battery negative Minimum input voltage 70VDC with respect to battery negative Noise f...

Page 16: ...y 2 0 1V 0 9V 30VDC Charge Fail Warning Threshold adjustable Charge Fail Shutdown Alarm Threshold adjustable Open circuit voltage battery positive Overvoltage protection 500VDC continuous with respect...

Page 17: ...switching power 4000VA Structure linear output for rpm voltage control Functionality Precision PID control output regulating rpm voltage for voltage matching current control temperature and rpm limiti...

Page 18: ...S to 100VAC RMS Frequency range 10Hz to 10 kHz Resolution 1 rpm Accuracy 0 2 1 rpm 3rpm 1500 rpm Flywheel teeth range 1 to 500 Do not share MPU with other devices If charge alternator pulses are used...

Page 19: ...must be battery negative Any function can be assigned to digital inputs Digital outputs can be extended using DKG 186 Fet Extension modules each one providing 8 outputs Digital outputs have the same...

Page 20: ...ance 200m with 120 ohm balanced cable Description RS 232 non isolated Functionality External modem PC connection PLC connection Connector RJ11 6pin Connection 6 wires Rx Tx DTR CxD GND 10V Full duplex...

Page 21: ...DKG 379 User Manual Rev_02 V 15 24 12 2012 K43D01 EN 21 4 CONNECTION DIAGRAM...

Page 22: ...an 70VDC otherwise the unit may get damaged 4 DC LOAD POSITIVE TERMINAL 5 DC ALTERNATOR OUTPUT POSITIVE 6 LOAD CONTACTOR NO TERMINAL Relay output 16A DC This output provides energy to the load contact...

Page 23: ...sender connection Do not connect the sender to other devices The input has programmable ohms for VDO senders 19 OIL PRESSURE SENDER Input 0 5000 ohms Analogue oil pressure sender connection Do not co...

Page 24: ...mally open contact switching either battery or battery The effect of the switch is also selectable from a list See PROGRAMMING section for more details 27 SPARE 2 28 PROGRAM LOCK 29 SPARE 1 30 COOLANT...

Page 25: ...max Alternator voltage 0 to 70V DC Battery bank voltage 0 to 70V DC Current input from DC shunt 60mV at rated current Rated Current range 1 to 5000 ADC at 60mV Actuator Output Voltage 0 to 12 24V Actu...

Page 26: ...FUNCTIONALITY 7 DESCRIPTION OF CONTROLS Fault condition indicators Service request indicator TEST mode button RUN mode button AUTO mode button STOP mode button Graphic LCD screen LAMP TEST if held pre...

Page 27: ...The genset runs when necessary and starts charging Selects OFF mode The genset stops BUTTON FUNCTION LAMP TEST when held pressed Selects next item or decrease value in program mode Selects previous di...

Page 28: ...ss 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 When there is no more alarm to display END OF ALAR...

Page 29: ...ist If no alarm exists END OF ALARM LIST will be displayed Existing alarms load_dumps warnings and J1939 ECU warnings will be displayed as one screen for each entry Switching to the next entry will be...

Page 30: ...pired MODE LEDS Each led turns on when the related mode is selected either locally or remotely MIMIC DIAGRAM LEDS LOAD CONTACTOR ON Turns on when the load contactor is activated GENSET RUNNING This le...

Page 31: ...voltages L1 L2 L3 Mains frequency Digital input statuses Charge input status J1939 VAlues if applicable event number event type fault definition see below for various event sources date and time oper...

Page 32: ...displayed Skip the password entry screen by pressing the button 4 times The screen below left will come Press again button The last event is displayed The first page will display the event number even...

Page 33: ...incremental counters for statistical purposes The counters consist on total genset kWh total engine hours total engine cranks total engine runs engine hours to service time to service These counters...

Page 34: ...g under load then it will be immediately unloaded The engine will continue to run during Cooldown Timer and will stop afterwards If the STOP button is pressed again then the engine will immediately st...

Page 35: ...s during crank timer When the engine fires the crank relay will be immediately deactivated See section Crank Cutting for more details The engine will run at idle speed during Idle Speed Timer The engi...

Page 36: ...op the engine press button or select another mode of operation The TEST mode is entered by pressing the button The TEST mode is used in order to test the genset under load Once this mode is selected t...

Page 37: ...le Even if the charge cycle is not completed at the expiration of this timer the engine will stop 1 Nominal Charge Volt V 27 4 This is the float charge voltage of the battery bank The default value is...

Page 38: ...loop A high value will cause slower but more stable operation A low value will cause faster operation but may cause instability 1 RPM High Limit rpm 2000 This is the maximum allowed rpm of the engine...

Page 39: ...r is closed Thus load switching is performed with zero current This provides longer contactor life Step_C The controller increases the rpm slowly until reaching the maximum charging current Step_D The...

Page 40: ...oltage If connected the controller will take into account the battery bank temperature The temperature sensor is of industry standard PT100 type not provided with the controller During the charging cy...

Page 41: ...nt 0 If this value is different from zero when the charge current falls below this percentage of the max charge current then the charge cycle will be supposed to be terminated If this parameter is set...

Page 42: ...s closed The genset starts the charging of the battery bank The charge current is not controlled Step_D The battery bank voltage increases slowly until reaching the nominal genset DC output voltage St...

Page 43: ...e Alarms operate in a first occurring basis If a shutdown alarm is present following shutdown alarms loaddumps and warnings will not be accepted If a loaddump is present following loaddumps and warnin...

Page 44: ...LOW OIL PRESSURE Set if a signal is detected 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 separat...

Page 45: ...he timer then no alarm will be set EXCESS POWER Set if the genset power KW supplied to the load goes over the Excess Power limit for Overload Timer If the power goes below the limit before expiration...

Page 46: ...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...

Page 47: ...EST and ALARM MUTE Hold pressed ALARM MUTE The program mode is used to adjust timers operational limits and the configuration of the unit Although a free PC program is provided for programming every p...

Page 48: ...t supports 3 password levels The level_1 is designed for field adjustable parameters The level_2 is designed for factory adjustable parameters The level_3 is reserved It allows recalibration of the un...

Page 49: ...vailable parameters will be displayed Selected parameter 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 inc...

Page 50: ...election keys If no button is pressed during 2 minutes the program mode will be cancelled automatically 14 4 MODIFYING PARAMETER VALUE 14 5 PROGRAMMING MODE EXIT Press any mode button Decrease paramet...

Page 51: ...on small characters 3 screen 8 or 9 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 monitor...

Page 52: ...ST mode 1 Exercise at LOAD TEST mode 1 Exercise Period 1 0 exercise every day the exercise will be performed every day regardless of the day selection of Exercise Dat and Time parameter 1 exercise onc...

Page 53: ...S on Load Status Change 0 This parameter controls SMS sending when load contactor status is changed No warning is generated 0 no SMS when load contactor status is changed 1 SMS sent when load contacto...

Page 54: ...s above this limit this will generate a GENSET HIGH VOLTAGE warning 2 Genset High Voltage Shutdown Limit V 66 0 If the battery bank DC voltage goes under this limit this will generate a GENSET HIGH VO...

Page 55: ...ines the reaction speed of the actuator output A high gain will cause faster reaction but brings a risk of instability A low gain is slower to react but more stable 2 PID Stability Percent 10 This par...

Page 56: ...alls below the Battery Start to Charge Voltage during this timer then the controller will initiate an automatic charging cycle 1 Must Start Voltage V 0 0 When the battery bank voltage falls below this...

Page 57: ...6 DATCON 0 10 bars 0 90 ohms 7 DATCON 0 7 bars 75 10 ohms 2 Coolant Temp Sender Type 1 This parameter selects the temperature sender type 0 The sender characteristics are defined in Sender Characteris...

Page 58: ...ne hours 1 Service Period month 6 The SERVICE REQUEST led indicator will turn on after this amount of time from the last service If the period is set to 0 no SERVICE REQUEST will be indicated dependin...

Page 59: ...ctive 2 High Oil Temperature Warning C 100 If the oil temperature measured from the analog input goes over this limit this will generate a HIGH OILTEMPERATURE SENDER warning 2 High Oil Temperature Shu...

Page 60: ...4 112 CATERPILLAR ADEM II III 128 SCANIA S6 129 SCANIA Single Speed 130 SCANIA All Speed 144 IVECO 160 MTU MDEC 302 161 MTU MDEC 201 162 MTU MDEC 303 163 MTU MDEC 304 164 MTU MDEC 505 176 BOSCH Generi...

Page 61: ...hour Seconds 00 59 Current second of the minute Parameter Definition Unit Factory Set Description Monday Turn_on 24 00 Please review chapter 9 for a detailed description of weekly programming schedule...

Page 62: ...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...

Page 63: ...Level Sender point 2 value Fuel Level Sender Ohms 3 ohm 67 Fuel Level Sender point 3 ohm value Fuel Level Value 3 50 Fuel Level Sender point 3 value Fuel Level Sender Ohms 4 ohm 110 Fuel Level Sender...

Page 64: ...1 Battery positive Response delay 0 0 No delay 1 Delayed 4sec Parameter Definition Unit Fac Set Description Action 0 0 Shutdown the engine stops immediately 1 Load Dump the engine stops after cooldown...

Page 65: ...ative 1 Battery positive Response delay 0 0 No delay 1 Delayed 4sec Parameter Definition Unit Fac Set Description Action 0 0 Shutdown the engine stops immediately 1 Load Dump the engine stops after co...

Page 66: ...negative 1 Battery positive Response delay 0 0 No delay 1 Delayed 4sec Parameter Definition Unit Fac Set Description Action 0 0 Shutdown the engine stops immediately 1 Load Dump the engine stops afte...

Page 67: ...ne stops after cooldown 2 Warning the horn relay operates 3 No operation Sampling 1 0 Always 1 After holdoff timer 2 When mains present Latching 1 0 Non latching 1 Latching Contact type 0 0 Normally o...

Page 68: ...nction expansion module 1 selected from list Relay 07 Definition 0 RELAY 7 function expansion module 1 selected from list Relay 08 Definition 2 RELAY 8 function expansion module 1 selected from list R...

Page 69: ...larm 55 Low fuel sender alarm 56 High oil temp alarm 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 Coolant Level switch load_dum...

Page 70: ...lant Level switch Input 04 Function Select 3 Rectifier Fail Input 05 Function Select 4 Emergency Stop Input 06 Function Select 11 Spare 1 Input Input 07 Function Select 10 Spare 2 Input Input Function...

Page 71: ...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 Program Group Modem 2 SMS 2...

Page 72: ...d level 2 Parameter Definition Factory Set Description SMS 3 telephone number This SMS telephone number accepts up to 16 digits Program Group SMS 5 Telephone Number password level 2 Parameter Definiti...

Page 73: ...Parameters Charge Input Connected 1 If the charge alternator voltage reaches Engine Parameters Crank Cut Charge Voltage then cranking is immediately stopped Oil pressure above threshold Following set...

Page 74: ...1 Engine Brand ECU Type J1939 SW version 2 Engine Coolant Level 3 Engine Oil Level 4 Engine Coolant Pressure 5 Engine Fuel Delivery Pressure 6 Barometric Pressure 7 Engine Crankcase Pressure 8 Engine...

Page 75: ...essure sensor fail 168 x Battery voltage failure 172 x High inlet air temperature High inlet manifold air temperature Inlet manifold air temperature sensor fail 174 x High fuel temperature Fuel temper...

Page 76: ...ve 7 Mechanical fault Faulty response from mechanical system 8 Mechanical or electrical fault Abnormal frequency 9 Communication fault Abnormal updating rate or Open circuit in injector circuit 10 Mec...

Page 77: ...output functions of the Relay Definitions group should be set properly RELAY 1 terminal_23 and RELAY 2 terminal_22 have programmable functions selected from a list Digital outputs may be increased usi...

Page 78: ...Start signal input Any digital input may be assigned as Disable Auto Start using Input Function Select program parameters It is also necessary to set the ACTION program parameter of the related input...

Page 79: ...also the Disable Auto Start feature Please review related chapter for a detailed explanation of this feature Priority In Dual Genset Mutual Standby Operation It may be required that the dual genset sy...

Page 80: ...o the exerciser are Exercise start day and hour Exercise duration Exercise off_load on_load Please refer to the programming section for a more detailed description of the above parameters When the sta...

Page 81: ...eating 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 operat...

Page 82: ...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 o...

Page 83: ...n Modbus Protocol Reference Guide This document may be downloaded at www modbus org docs PI_MBUS_300 pdf ADDRESS hex R W DATA SIZE COEFFICIENT DESCRIPTION 0003 R 16bit x10 Genset DC voltage 0004 R 16b...

Page 84: ...oaddump alarm bits bit_0 oil pressure switch loaddump alarm bit_1 high temperature switch loaddump alarm bit_2 coolant level switch loaddump alarm bit_3 rectifier fail loaddump alarm bit_4 emergency s...

Page 85: ...contactor bit_1 crank relay bit_2 spare_2 bit_3 spare_1 bit_5 fuel 003A R 16bit Relay extension module relay statuses bit_0 module_1 relay_1 status bit_1 module_1 relay_2 status bit_2 module_1 relay_...

Page 86: ...aiting before between cranks 3 cranking 4 engine heating 5 load contactor timer 6 load on genset 8 cooldown operation 9 stopping 0040 R W 8bit Last pressed key This byte is also used in order to chang...

Page 87: ...1460 days 0060 R 16bit x8 J1939 Engine speed 0061 R 16bit x1 J1939 Coolant temperature 40 C offset 0062 R 16bit x10 J1939 Oil pressure 0063 0064 R 16bit x20 J1939 Total engine hours 0065 R 16bit x100...

Page 88: ...utput 1026 R 8bit x1 Operation mode_2 bits bit_0 modem connected bit_1 exercise on load bit_3 2 bit_4 bit_5 rpm from genset frequency bit_6 sms enable bit_7 GPRS connectio006E 1027 R 8bit x50 Engine h...

Page 89: ...electronic equipment WEEE this unit should be stored and disposed separately from the usual waste The european ROHS directive restricts and prohibits the use of some chemical materials in electronic d...

Page 90: ...e 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 The...

Page 91: ...d Check that the genset Yellow led is on steadily Adjust genset voltage and frequency limits if necessary Check that the digital output 8 is configured as Genset Contactor Check Genset Contactor Timer...

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