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DKG-507 User Manual V-42

(24.05.2013)

- 26 -

Below is a basic list of fault conditions (x denotes any FMI)

SPN

FMI

DESCRIPTION

Fuel filter restriction
Fuel pressure sensor fail

Low oil level
High oil level
Oil level sensor fail

100

Low oil pressure
Oil pressure sensor fail

102

High boost pressure
Turbo outlet pressure sensor fail

105

Intake manifold temp high
Intake manifold temp sensor fail

107

Air filter restriction
Air filter sensor fail

108

Athmospheric pressure sensor fail

110

High coolant temperature
Coolant temperature sensor fail

111

Low coolant level
Coolant level sensor fail

164

High injector activation pressure
Injector activation pressure sensor fail

168

Battery voltage failure

172

High inlet air temperature
High inlet manifold air temperature
Inlet manifold air temperature sensor fail

174

High fuel temperature
Fuel temperature sensor fail

175

High oil temperature
Oil temperature sensor fail

190

Overspeed
Speed sensor loss of signal
Speed sensor mechanical failure

228

Timing calibration required

234

Incorrect ecm software

620

ECU in5V fail

629

ECU hardware fail

651

Injector cylinder #1 fault

652

Injector cylinder #2 fault

653

Injector cylinder #3 fault

654

Injector cylinder #4 fault

655

Injector cylinder #5 fault

656

Injector cylinder #6 fault

657

Injector cylinder #7 fault

657

Injector cylinder #8 fault

678

ECU internal power supply fail

723

Secondary engine speed sensor fail

1108

Critical override enabled

1111

Check configuration parameters

2000

ECU failure

Summary of Contents for DKG-507

Page 1: ... the date time 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 True RMS measurements ECU connection ...

Page 2: ... 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 Automatic Exerciser 6 18 Resuming to factory set parameters 6 19 Gas engine fuel solenoid control 6 20 Load Shedding Dummy Load 6 21 Fuel Theft Fuelling Messages 6 22 Firmware Update 6 23 Changing the Default Engine Speed in Volvo Engines 6 24 Engine Con...

Page 3: ...l 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 voltage phase L2 to neutral Gen voltage phase L3 to neutral Gen voltage phase L1 L2 Ge...

Page 4: ...nit 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 t...

Page 5: ...he mains phases 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 ...

Page 6: ...puts 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...

Page 7: ...R 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 ...

Page 8: ... L2 L3 generator phase to neutral voltages L12 L23 L31 mains phase to phase voltages L12 L23 L31 generator phase to phase voltages If the service counters group is displayed then this display will show the counter name In programming mode it displays PGM CURRENT DISPLAY This display will show the current values measured using the current transformers Using the programming menu current transformers...

Page 9: ...se Therelated ALARM led to flash 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...

Page 10: ...will not cause an engine stop If necessary the engine will be stopped by the ECU ECU FAIL alarm Set if no information has been received during 3 seconds from the ECU of the electronic engine This fault condition is only controlled if fuel is on OVERLOAD load_dump Set if at least one of the genset phase currents goes over the Overcurrent Limit for Overload Timer If currents go below the limit befor...

Page 11: ...nue 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 stop The unit will be ready for the next mains failure If the operation of the ge...

Page 12: ...re 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 are defined in Sender Characteristics table 1 VDO 0 7 bars 10 180 ohms 2 VDO 0 10 bars 10 18...

Page 13: ...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 14: ...input The SPARE 2 digital input may be assigned as Simulate Mains using program parameter P_084 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 menu If...

Page 15: ...itive or battery negative These selections are made using the programming menu If the Delayed Simulate Mains program parameter P_085 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 genset wi...

Page 16: ...minutes for faster testing purposes A flashing relay output function is provided based on the parameter Flashing Relay Timer Each time the period programmed using Flashing Relay Timer elapses the relay output will change position The flashing 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 ...

Page 17: ... 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 18: ... modem calls In case of alarm the unit will attempt to reach control centers associated with each number In case of modem connection failure the call will be repeated up to 30 times with 2 minute intervals 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 r...

Page 19: ...he 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 following line will give one fault information The mess...

Page 20: ...d recording of all measured parameters The recorded parameters may then be analyzed graphically and printed The software also allows the programming of the unit and the storage of the program parameters to PC or the downloading of stored parameters from PC to the unit For PCs without a serial port below USB to serial adapters are tested and approved DIGITUS USB 2 0 TO RS 232 ADAPTER PRODUCT CODE D...

Page 21: ...ise the load will not be transferred to the genset unless the Emergency Backup Operation is allowed by setting the related program parameter to 1 Thus it is highly recommended that the Emergency Backup mode enabled with off load exerciser At the end of the exercise duration the unit will switch back to the initial mode of operation If any of the mode selection keys are pressed during exercise then...

Page 22: ...her limit The dummy load function is the inverse of the load shedding function thus the same output may be used for both purposes The parameters used in Load Shedding feature are in the Electrical Parameters Group Load Shedding Low Limit If the genset active power output goes below this limit then the Load Shedding relay will be deactivated Load Shedding High Limit If the genset active power outpu...

Page 23: ...le is increased the unit will freeze for a few seconds and switch the engine to 1800 rpm which is generally the secondary speed When the parameter is decreased the speed is set to the primary speed which is generally 1500 rpm Please note also that a fine adjustment of the engine speed in the 8 range may be done using the program parameter J1939 Speed Adjust In engine control mode the unit is suppo...

Page 24: ...uency Warning Limit Genset High Frequency Warning Limit Genset High Frequency Shutdown Limit Genset Low RPM Shutdown Limit Genset Low RPM Warning Limit Genset High RPM Warning Limit Genset High RPM Shutdown Limit If the unit is used in a single phase electrical network it is advised t set the Single Phase Enable program parameter in CONTROLLER CONFIGURATION group to 1 When Single Phase Enable is s...

Page 25: ...l pressure coolant temperature and the engine rpm information are picked up from the ECU unit Other available measurements have no effect on engine operation In total the unit is capable of receiving 21 parameters from the J1939 The J1939 measurements are also available for Modbus operation Please check chapter 8 for more details When the fuel output is active if no information is received from th...

Page 26: ...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 temperature sensor fail 175 x High oil temperature Oil temperature sensor fail 190 x Overspeed Speed sensor loss of signal Speed sensor mechanical failure 228 x Timing calibration required 234 x Incorrect ecm soft...

Page 27: ...hanical 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 Mechanical or electrical fault Abnormally large variations 11 Unknown fault Unidentified fault 12 Component fault Faulty unit or component 13 Faulty calibration Calibration values outside the limits 14 Unknown f...

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: ... programs should be set to 24 00 An example setup may be as follows Monday Turn_on 07 00 Monday Turn_off 18 00 Tuesday Turn_on 07 00 Tuesday Turn_off 18 00 Wednesday Turn_on 07 00 Wednesday Turn_off 18 00 Thursday Turn_on 07 00 Thursday Turn_off 18 00 Friday Turn_on 07 00 Friday Turn_off 18 00 Saturday Turn_on 07 00 Saturday Turn_off 13 00 Sunday Turn_on 24 00 Sunday no turn on time last operation...

Page 30: ... alarms Warnings Engine crank starts Periodic records Event record contents are Event type alarms mode change periodic etc Date and time Genset operating mode AUTO MANUAL OFF TEST LOAD TEST Genset operation status mains ok running cooldown etc Genset phase voltages L1 L2 L3 Genset phase currents L1 L2 L3 Genset frequency Genset active power KW Genset power factor Engine rpm Oil pressure Coolant te...

Page 31: ...DKG 507 User Manual V 42 24 05 2013 31 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 ...

Page 32: ...program parameters is performed via the MENU button Holding the button pressed will cause the program parameter number to increase faster Parameter value may be increased and decreased with and buttons If these keys are held pressed the program value will be increased decreased faster When a program parameter is modified it is automatically saved in memory If MENU button is pressed next parameter ...

Page 33: ...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 P_008 Genset Low Voltage Warning Limit V 200 If one of the generator phase voltages goes under this limit when feeding the load this will generate a GENSET LOW VOLTAGE warning P_009 Genset High Voltage Warning Limit V 250 If one of the gene...

Page 34: ...ls below this limit a LOW FUEL LEVEL SENDER shutdown alarm is generated and the engine stops P_024 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 P_025 High Oil Temperature Shutdown C 120 f the oil temperature measured from the analog input goes over this limit this will generate ...

Page 35: ...ccur P_033 Engine Start Delay sec 0 This is the time between the mains fails and the fuel solenoid turns on before starting the genset It prevents unwanted genset operation in battery backed up loads P_034 Preheat Timer sec 1 This is the time after the fuel solenoid is energized and before the genset is started During this period the PREHEAT relay output is energized if assigned by Relay Definitio...

Page 36: ...t P_050 Crank Teeth Count 30 This is the number of pulses generated by the magnetic pickup sensing unit in one turn of the flywheel This parameter is also used in the conversion of the genset frequency to engine rpm The frequency in Hz is multiplied with this parameter during conversion to rpm P_051 Low rpm Shutdown rpm 0 If the engine speed goes under this limit a GENSET LOW SPEED alarm is genera...

Page 37: ...n will become inactive P_067 Engine Heating Method 0 This parameter defines the engine heating method The genset will not take the load before engine heating 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 P_068 Crank Cut Frequency Hz 10 0 When the genset...

Page 38: ... Hour 0 This parameter is the threshold for sending FUEL THEFT and FUELLING sms messages If this parameter is set to 0 then no Fuel Theft and Fuelling sms messages will be sent If SMS is required set this parameter to a value above the hourly fuel consumption of the genset P_082 Real Time Clock Adjust 117 This parameter trims precisely the real time clock circuit Values from 0 to 63 speed up the c...

Page 39: ...he exercise will be performed during the first 7 days of each month at the programmed day and hour P_088 Exercise Duration min 10 This parameter defines the exercise duration and programmed in 10 minute steps up to 24 hours P_089 Exercise Off On Load 0 0 Exercise at TEST mode 1 Exercise at LOAD TEST mode P_090 Exercise Period 1 0 exercise every day the exercise will be performed every day regardle...

Page 40: ...O EDC4 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 Generic 177 BOSCH EDC 731 178 BOSCH EDC 9 3 Other values Reserved Do not use P_096 J1939 Speed Adjust 50 This parameter adjusts the speed of an ECU controlled engine by 8 P_097 VOLVO Speed Toggle This ...

Page 41: ... phase voltages goes under this limit when feeding the load this will generate a GENSET LOW VOLTAGE shutdown alarm and the engine will stop P_104 2nd Genset Low Voltage Warning Limit V 94 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 warning P_105 2nd Genset High Voltage Warning ...

Page 42: ...s set to a value other than zero then when AUTO or RUN mode is selected the unit will ask for this password Date Time P_116 Date Current day of the month P_117 Month Current month P_118 Year Last two digits of the current year P_119 Hours Current hour of the day P_120 Minutes Current minute of the hour P_121 Seconds Current second of the minute Weekly Schedule Programs PGM Parameter Definition Uni...

Page 43: ... ohm value P_151 Temperature Value 2 C 90 Temperature Sender point 2 C value P_152 Temperature Sender Ohms 3 ohm 134 Temperature Sender point 3 ohm value P_153 Temperature Value 3 C 60 Temperature Sender point 3 C value P_154 Temperature Sender Ohms 4 ohm 322 Temperature Sender point 4 ohm value P_155 Temperature Value 4 C 39 Temperature Sender point 4 C value P_156 Temperature Sender Ohms 5 ohm 6...

Page 44: ...1630 Temperature Sender point 6 ohm value P_183 Oil Temperature Value 6 C 02 Temperature Sender point 6 C value Low Oil Pressure Switch Input Configuration PGM Parameter Definition Unit Fac Set Description P_184 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 P_185 Sampling 1 0 Always 1 After holdoff time...

Page 45: ...mmediately 1 Load Dump the engine stops after cooldown 2 Warning the horn relay operates 3 No operation P_203 Sampling 2 0 Always 1 After holdoff timer 2 When mains present P_204 Latching 1 0 Non latching 1 Latching P_205 Contact type 0 0 Normally open 1 Normally closed P_206 Switching 0 0 Battery negative 1 Battery positive P_207 Response delay 0 0 No delay 1 Delayed 4sec Emergency Stop Input Con...

Page 46: ...Normally closed P_218 Switching 0 0 Battery negative 1 Battery positive P_219 Response delay 0 0 No delay 1 Delayed 4sec Spare 2 Input Input Configuration PGM Parameter Definition Unit Fac Set Description P_220 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 P_221 Sampling 0 0 Always 1 After holdoff timer...

Page 47: ...ay 06 Definition 5 RELAY 6 function expansion module 1 selected from list P_232 Relay 07 Definition 0 RELAY 7 function expansion module 1 selected from list P_233 Relay 08 Definition 2 RELAY 8 function expansion module 1 selected from list P_234 Relay 09 Definition 4 RELAY 9 function expansion module 1 selected from list P_235 Relay 10 Definition 5 RELAY 10 function expansion module 1 selected fro...

Page 48: ...age alarm 45 High voltagealarm 46 Fail to start alarm 47 Low fuel sender alarm 48 High oil temp alarm 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 Coolant Level switch load_dump 59 Rectifier load_dump 60 Emerg Stop load_dump 61 Spare 1 load_dump 62 Spare 2 load_dump 63 64 65 66 67 68 69 70 71 72 Overcurrent load_dump 73 Exces...

Page 49: ...ot correct although Phase to Neutral voltages are correct Incorrect phase order Please connect phase voltages in the correct order 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 ...

Page 50: ... 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 the unit s START output So the starting will also be removed when the D pulls to battery positive The unit is inoperative Measure the DC supply voltage between terminals 19 and 22 at the rear of the unit If OK turn all the fuses...

Page 51: ...ference 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 UL CSA Conformity certificate 20110527 E314374 UL 508 Edition 17 UL 2200 1st Edition UL 840 Edition 3 CSA C22 2 NO 14 Edition 10 15 DECLARATION OF CONFORMITY ...

Page 52: ...urrent 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 II Air category Pollution degree II Communication port RS 232 9600 bauds no parit...

Page 53: ...DKG 507 User Manual V 42 24 05 2013 53 17 CONNECTION DIAGRAMS ...

Page 54: ...DKG 507 User Manual V 42 24 05 2013 54 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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