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DKG-225 User Manual Firmware V-01

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1. INSTALLATION INSTRUCTIONS
2. MOUNTING

2.1 DIMENSIONS

2.2 SEALING, GASKET

2.3 ELECTRICAL INSTALLATION

3. TERMINAL DESCRIPTIONS

3.1. BATTERY VOLTAGE INPUT / OUTPUT

3.2. AC VOLTAGE INPUTS

3.3. AC CURRENT INPUTS

3.4. DIGITAL INPUTS

3.5. ANALOG SENDER INPUTS

3.6. CHARGE INPUT TERMINAL

3.7. MAINS CONTACTOR OUTPUT

3.8. GENERATOR CONTACTOR OUTPUT

3.9. DIGITAL OUTPUTS

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 SCREEN ORGANIZATION

7.4. MEASURED PARAMETERS

7.5. LED INDICATORS

8. OPERATION OF THE UNIT

8.1. QUICK START GUIDE

8.2. STOP MODE

8.3. MANUAL RUN MODE

8.4. AUTO MODEN

9. PROTECTIONS AND ALARMS

9.1. SERVICE REQUEST ALARM

9.2. ALARMS

10. PROGRAMMING

11. CRANK CUTTING

TABLE OF CONTENTS

Содержание DKG-225

Страница 1: ...float charging of the engine start battery Timers threshold levels input and output configurations are digitally programmable Programs are modified through front panel pushbuttons and do not require an additional unit The fault conditions are considered in 2 categories as Warnings and Alarms Measured values have separate programmable limits for warning and alarm conditions Automatic mains monitori...

Страница 2: ...l is required please contact the manufacturer directly at below e mail address datakom datakom com tr Please provide following information in order to get answers to any question Device model name see the back panel of the unit Complete serial number see the back panel of the unit Firmware version read from the display screen Measuring circuit voltage and power supply voltage Precise description o...

Страница 3: ...DKG 225 User Manual Firmware V 01 3 Screw Type Bracket Stock Code J10P01 1 unit Spring Type Bracket Stock Code K16P01 1 unit Watertight Gasket Stock Code K96P01 SPARE PARTS ...

Страница 4: ... When the unit is connected to the network do not touch terminals Short circuit terminals of unused current transformers Any electrical parameter applied to the device must be in the range specified in the user manual Although the unit is designed with a wide safety margin over range parameters may reduce lifetime alter operational precision or even damage the unit Do not try to clean the device w...

Страница 5: ... 7 MAINS CONTACTOR OUTPUT 3 8 GENERATOR CONTACTOR OUTPUT 3 9 DIGITAL OUTPUTS 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 SCREEN ORGANIZATION 7 4 MEASURED PARAMETERS 7 5 LED INDICATORS 8 OPERATION OF THE UNIT 8 1 QUICK START GUIDE 8 2 STOP MODE 8 3 MANUAL RUN MODE 8 4 AUTO MODEN 9...

Страница 6: ...ED MAINS SIMULATION BATTERY CHARGING 12 4 SERVICE REQUEST DISPLAY 12 5 ENGINE HOUR METER 12 6 SOFTWARE VERSION DISPLAY 12 7 GAS ENGINE FUEL SOLENOID CONTROL 12 8 SINGLE PHASE OPERATION 13 DECLARATION OF CONFORMITY 14 MAINTENANCE 15 DISPOSAL OF THE UNIT 16 ROHS COMPLIANCE 17 TROUBLESHOOTING TABLE OF CONTENTS continued ...

Страница 7: ...ment will not exceed the maximum operating temperature in any case Below conditions may damage the device Incorrect connections Incorrect battery voltage Reverse battery voltage Voltage at measuring terminals beyond specified range Voltage applied to digital inputs over specified range Current at measuring terminals beyond specified range Overload or short circuit at relay outputs Excessive vibrat...

Страница 8: ...min 60mm 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 Place and tighten mounting brackets The unit is designed for panel mounting The user should not be able to access parts of the unit other than the front panel 2 1 DIMENSIONS 2 MOUNTING ...

Страница 9: ... Firmware V 01 9 The module will come with one of below bracket types Screw type bracket Spring type bracket Screw type bracket installation Spring type bracket installation Do not tighten too much this may break the unit ...

Страница 10: ...jects 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 Protected against vertically falling water drops 2 Protected against vertically falling water drops when enclosure is tilted up to 15 3 Protected against water sprayed at an angle up to 60 on either side of the ...

Страница 11: ...Use adequate cable section at least 0 75mm2 AWG18 Follow national rules for electrical installation Current transformers must have 5A output The current transformer cable length should not exceed 1 5 meters If longer cable is used increase the cable section proportionally Current Transformers must be used for current measurement No direct connection allowed For the correct operation engine body mu...

Страница 12: ...ll features passive digital outputs open Measurement range 0 36VDC Display resolution 0 1VDC Accuracy 1 0 1 digit 12VDC Measurement method True RMS Input voltage range 14 to 300 VAC phase neutral Min voltage for frequency detect 14 VAC Ph N Measurement range 0 to 330VAC ph N 0 to 570VAC ph ph Common mode offset Max 100V between neutral and battery negative Input impedance 4 5M ohms Display resolut...

Страница 13: ... order to minimize phase shift effect of the current transformer Phase shift in a CT will cause erroneous power and power factor readings although amp readings are correct Datakom advises CT rating to be selected following this table for the best measurement accuracy SELECTING THE CT ACCURACY CLASS The CT accuracy class should be selected in accordance with the required measurement precision The a...

Страница 14: ...ections are possible so check both order of CTs and their polarity Reactive power measurement is affected by incorrect CTs connection in similar way as active power measurement CORRECT CT CONNECTIONS Let s suppose that the genset is loaded with 10 kW on each phase The load Power Factor PF is 1 Measured values are as follows kW kVAr kVA pf Phase L1 10 0 0 0 10 1 00 Phase L2 10 0 0 0 10 1 00 Phase L...

Страница 15: ...L1 10 0 0 0 10 1 00 Phase L2 10 0 0 0 10 1 00 Phase L3 10 0 0 0 10 1 00 Total 10 0 0 0 30 0 33 EFFECT OF PHASE SWAPPING The generator is still loaded with 10 kW on each phase The load Power Factor PF is 1 PF in phases L2 and L3 will show 0 50 due to phase shift between voltages and currents which is caused by CT swapping The result is that total generator power displayed by controller is 0 kW Meas...

Страница 16: ... 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 filtering yes Structure 667 ohms resistor polarizing to 3 3VDC Measurement Analog resistor measurement Open circuit voltage 3 3VDC Short circuit current 5mA Measurement range 0 to 5000 ohms Open circuit threshol...

Страница 17: ...ative Structure Relay output normally closed contact One terminal is internally connected to mains phase L1 input Max switching current 16A 250VAC Max switching voltage 440VAC Max switching power 3000VA Structure Relay output normally open contact One terminal is internally connected to genset phase L1 input Max switching current 16A 250VAC Max switching voltage 440VAC Max switching power 4000VA T...

Страница 18: ...DKG 225 User Manual Firmware V 01 18 4 CONNECTION DIAGRAM ...

Страница 19: ... PRESSURE SWITCH Connect to the low oil pressure switch to this terminal 10 COOLANT TEMP SENDER Resistor measuring inputs 0 5000 ohms Connect to the coolant temperature sender Do not connect the sender to other devices The input is programmable in order to use to any sender type 11 OIL PRESSURE SENDER Connect to the oil pressure sender Do not connect the sender to other devices The input is progra...

Страница 20: ...e 3 phases The secondary winding rating shall be 5 Amperes ex 200 5 Amps 60 CURR_1 61 CURR_2 62 CURR_2 63 CURR_3 64 CURR_3 Term Function Technical data Description 65 MAINS NEUTRAL Input 0 300V AC Neutral terminal for the mains phases 67 MAINS L3 Mains phase inputs 0 300V AC Connect the mains phases to these inputs The mains voltages upper and lower limits are programmable 69 MAINS L2 71 MAINS L1 ...

Страница 21: ...min 1A 13 7V DC 195 300V AC Current Inputs CT inputs xxx 5A opt xxx 0 1A Analog Input Range 0 5000 ohms Digital Inputs 0 to 36V DC Operating temp 40 C 40 F to 70 C 158 F Storage temp 55 C 67 F to 80 C 176 F Maximum humidity 95 non condensing Dimensions 133x 107 x 46 mm WxHxD Panel Cutout 117 x 87mm minimum Weight 200 g approx Enclosure Flame retardant high temp ABS PC UL94 V0 IP Protection IP65 fr...

Страница 22: ...seconds resets service counters Selects next display parameter If held pressed select the LAMP TEST then PROGRAMMING functions When held pressed for 5 seconds enters a special PROGRAMMING mode where high level parameters may also be adjusted 7 2 PUSHBUTTON FUNCTIONS 7 1 FRONT PANEL FUNCTIONALITY 7 DESCRIPTION OF CONTROLS RUN mode button STOP mode button AUTO mode button Menu selection button Mimic...

Страница 23: ...un hours Engine run hours to service Time to service Firmware version The unit performs a detailed set of AC measurements The list of measured AC parameters is below 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 Mains frequency Mains current phase L1 Mains current p...

Страница 24: ...et frequency are within limits Turns on when the load is fed by the genset If a REMOTE START input is defined the MAINS led will reflect the status of the REMOTE START signal The led is also affected by MAINS SIMULATION and FORCE TO START signals 7 5 LED INDICATORS RUN mode indicator AUTO mode indicator Display unit leds Mains led Flashes when mains is OK turns on steady when load is fed by mains ...

Страница 25: ...oltages and frequency are within the programmed limits If enabled the mains phase order is also checked The RUN mode is entered by pressing the button When the RUN mode is selected the engine will be started regardless of the mains availability In order to stop the genset please press button or select another operating mode If Emergency Backup mode is enabled and if the mains are off then the main...

Страница 26: ...turns on the fuel and preheat glow plugs if any and waits for preheat timer The engine will be cranked for programmed times 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 unloaded during engine heating timer If alternator phase voltages frequency and phase order are correct the unit will wait f...

Страница 27: ... on the display The Alarm digital output to operate 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 warnings will not be accepted If a warning is present following warnings will not be accepted Alarms may be of LATCHING type following programming For latch...

Страница 28: ...ntenance period of 0 months indicates that the unit will request maintenance only based on engine hours there will be no time limit If the engine hours is also selected as 0 hours this will mean that this service counter set is not operative When the engine hours OR the time limit is over the unit will give A14 SERVICE REQUEST warning The remaining engine hours and the remaining time limits are ke...

Страница 29: ...gine has not stopped before the expiration of the Stop Timer A09 OVERLOAD load_dump Set if at least one of the genset phase currents goes over the Overcurrent Limit for Overload Timer Set also if the genset total active power kW supplied to the load goes over the Excess Power limit for Overload Timer If currents and power go below the limit before expiration of the timer then no alarm will be set ...

Страница 30: ...ogram parameter number to increase faster Parameter value may be increased and decreased with RUN and AUTO 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 will be displayed Program parameters are kept in a non volatile memory and are not affe...

Страница 31: ...the time after the fuel solenoid is energized and before the genset is started During this period the PREHEAT relay function is active P_08 Choke timer Sec 5 This is the control delay of CHOKE output The choke output is activated together with the crank output It is released after this delay or when engine runs whichever occurs first P_09 Engine heating timer Sec 4 This is the period used for engi...

Страница 32: ...mit a GENSET HIGH SPEED alarm is generated and the engine stops P_23 Low Battery Voltage Warning V 9 0 If the battery voltage falls below this limit this will generate a LOW BATTERY warning P_24 High Battery Voltage Warning V 15 0 If the battery voltage goes over this limit this will generate a HIGH BATTERY warning P_25 High Battery Voltage Shutdown V 16 0 If the battery voltage goes over this lim...

Страница 33: ...it the engine is supposed running and the crank output will release P_40 Crank Stop with Oil Pressure 0 0 no crank stop with oil pressure 1 cranking is stopped when oil presure switch is open or the oil pressure measured is above shutdown limit P_41 Crank Stop with Charge 0 0 no crank stop with charge input 1 cranking is stopped when the charge alternator voltage is established P_42 Charge Alterna...

Страница 34: ...pressure measured from the analog input falls below this limit this will generate a LOW OIL PRESSURE SENDER alarm is generated and the engine stops P_51 High Temperature Warning C 95 If the coolant temperature measured from the analog input goes over this limit this will generate a HIGH TEMPERATURE SENDER warning P_52 High Temperature Shutdown C 98 f the coolant temperature measured from the analo...

Страница 35: ...perature Sender Ohms 1 ohm 38 Temperature Sender point 1 ohm value P_66 Temperature Value 1 C 100 Temperature Sender point 1 C value P_67 Temperature Sender Ohms 2 ohm 51 Temperature Sender point 2 ohm value P_68 Temperature Value 2 C 90 Temperature Sender point 2 C value P_69 Temperature Sender Ohms 3 ohm 134 Temperature Sender point 3 ohm value P_70 Temperature Value 3 C 60 Temperature Sender po...

Страница 36: ...eed 27 28 29 30 31 32 Oil switch alarm 33 Temp switch alarm 34 35 36 37 38 Spare Alarm 39 40 Oil sender alarm 41 Temp sender alarm 42 Low speed alarm 43 High speed alarm 44 Low voltage alarm 45 High voltagealarm 46 Fail to start alarm 47 48 49 50 51 High battery voltage alarm 52 Charge fail alarm 53 54 55 56 57 58 59 60 61 62 Spare load_dump 63 64 65 66 67 68 69 70 71 72 Overcurrent load_dump 73 E...

Страница 37: ... If the genset phase L1 frequency reaches Crank Cut Frequency then cranking is immediately stopped Charge alternator voltage over threshold Following setting is necessary Crank Stop with Charge 1 If the charge alternator voltage reaches 6 volts then cranking is immediately stopped Oil pressure above threshold Following setting is necessary Crank Cut with Oil Pressure 1 The crank cutting with oil p...

Страница 38: ...imulate Mains using program parameter P_46 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 using the program parameter P_77 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 the Simulate Mains ...

Страница 39: ...er battery positive or battery negative These selections are made using the programming menu If the Delayed Simulate Mains program parameter P_47 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 ...

Страница 40: ...EQUEST warning will occur and the service request relay function will be active The service request relay function may be assigned to the auxiliary relay using Relay Definition program parameter 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 by pressi...

Страница 41: ... The gas engine fuel solenoid relay function may be assigned to the auxiliary relaysusing Relay Definition program parameter If the unit is used in a single phase electrical network it is advised t set the Single Phase Enable program parameter to 1 When Single Phase Enable is set to 1 then the unit will measure electrical parameters only on phases L1 of genset and mains Voltage and overcurrent che...

Страница 42: ...y from the usual waste The european ROHS directive restricts and prohibits the use of some chemical materials in electronic devices Following the DIRECTIVE 2011 65 EU OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 8 June 2011 on the restriction of the use of certain hazardous substances in electrical and electronic equipment this product is listed in annex I under category Monitoring and control...

Страница 43: ...f the engine and check if the error is removed If there are faulty measurements only when mains are present then the battery charger may be failed Turn off the rectifier fuse and check again When the AC mains fails the unit energizes the fuel solenoid but does not start and A01 OIL PRESSURE warning occurs The unit is not supplied with battery voltage at the oil pressure input Oil pressure switch n...

Страница 44: ...gine cranking The generator voltage rises lately Also the generator remnant voltage is below 14 volts The unit removes starting with the generator frequency and needs at least 14 volts to measure the frequency If this situation is to be avoided please enable crank cutting with oil pressure and charge alternator voltage The unit is inoperative Measure the DC supply voltage between terminals 2 and 4...

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