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DKG-519 User Manual V-27

(14.04.2011)

- 51 -

14. TROUBLESHOOTING

AC voltages or frequency displayed on the unit are not correct:

-Check engine body grounding, it is necessary.
-The error margin of the unit is +/- 3 volts.
-If  there  are  faulty  measurements  only  when  the  engine  is  running,  there  may  be  a  faulty  charging
alternator  or  voltage  regulator  on  the  engine.  Disconnect  the  charging  alternator  connection  of  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.

KW and cos

Φ

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 cos

Φ

for the related phase, and then connect all CTs.

Short circuit the outputs of unused Current Transformers.

When REMOTE START signal arrives 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 lately. If oil pressure switch closes, the unit will start. Optionally oil
pressure switch may be replaced.

The engine does not run after the first start attempt, then the unit does not start again and OIL
PRESSURE EXISTS ! message is displayed:

-The 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.

When the AC mains fails, the engine starts to run but the unit gives START FAIL alarm and
then the engine stops:

-The generator phase voltages are not connected to the unit. Measure the AC voltage between
terminals GEN L1-L2-L3 and Generator Neutral at the rear of the unit while the engine is running. A
fuse protecting the generator phases may be failed. A misconnection may be occurred. If everything is
OK, turn all the fuses off, and then turn all the fuses on, starting from the DC supply fuse. Then test
the unit again.

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Содержание DKG-519

Страница 1: ...asurement values Stores last 100 events Statistical counters Battery backed up real time clock Weekly operation schedule programs 3 level password protection Programmable parameters All parameters field adjustable Return to factory settings enabled RS 232 serial port Firmware downloadable from serial port Free MS Windows Remote monitoring SW local and modem connection monitoring download of parame...

Страница 2: ...ual Genset Mutual Standby Operation 6 10 Service Request Display 6 11 Engine Hours Meter 6 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 External Control of the Unit 6 18 Automatic Exerciser 6 19 Resuming to factory set parameters 6 20 Gas engine fuel solenoid control 6 21 Load Shedding Dummy Load 6 ...

Страница 3: ...ol over the generating 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 Gen voltage phase L1 to neutral Gen voltage phase L2 to neutral Gen voltage phase L3 to neutral Gen voltage phase L1 L2 Gen voltage phase L2 L3 Gen voltage phase L3 L1 Gen current phase L1 Gen current phase...

Страница 4: ...il pressure or fuel level displays are already present on the generator control panel 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 eithe...

Страница 5: ...4V battery systems 13 FUEL LEVEL SENDER Input 0 5000 ohms No connection to this terminal 14 OIL PRESSURE SENDER Input 0 5000 ohms Analogue oil pressure sender connection Do not connect the sender to other devices The input has programmable characteristics and connects to any kind of sender 15 COOLANT TEMP SENDER Input 0 5000 ohms Analogue high temperature sender connection Do not connect the sende...

Страница 6: ...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 each 3 current transformers The rating of the transformers should be the same for each of the 3 p...

Страница 7: ...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 OFF Yellow AUTO Green ALARM Red If a fault condition resulting ...

Страница 8: ...gation between different screens s made with 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 w...

Страница 9: ...Coolant Temperature Genset power factor Fuel Level Engine rpm Battery Voltage 5 Complete Genset parameters phase to phase Genset status Genset Volts L1 L2 Genset Volts L2 L3 Genset Volts L3 L1 Genset Current L1 Genset Current L2 Genset Current L3 Genset Frequency Oil Pressure Genset Active Power KW Coolant Temperature Genset power factor Fuel Level Engine rpm Battery Voltage 6 Graphical Genset par...

Страница 10: ...ade with the button 11 Date Time Software Version Date and time Operating software version 12 Statistical Counters 1 3 Engine Hours Run Total Genset Active Power KW h 13 Statistical Counters 2 3 Engine Hours to Service Time to Service 14 Statistical Counters 3 3 Total Engine Cranks Total Engine Runs 15 Event Records The unit provides information about last 100 events starting from the most recent ...

Страница 11: ... of the genset The existing alarms may be canceled by pressing one of the operating mode buttons LOAD TEST TEST OFF AUTO Most of the alarms have programmable trip levels See the programming chapter for adjustable alarm limits 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...

Страница 12: ...load Timer If the power goes below the limit before expiration of the timer then no alarm will be set GENSET LOW VOLTAGE Set if any of the generator phase voltages goes outside programmed limits for Overload Timer This fault will be monitored with holdoff timer delay after the engine is running GENSET HIGH VOLTAGE Set if any of the generator phase voltages goes outside programmed limits for Overlo...

Страница 13: ...enerator contactor will be energized Any of the spare digital outputs can be programmed as the generator contactor signal When the REMOTE START signal goes off the engine will continue to run for the mains waiting period At the end of this period the generator contactor is deactivated If a cooldown period is given the generator will continue to run during cooldown period At the end of the period t...

Страница 14: ... 6 2 Sender type Selection 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 are de...

Страница 15: ...t may be required that the engine runs at the idle speed for a programmed 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 assign...

Страница 16: ...t The unit offers an optional SIMULATE MAINS signal input 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 neg...

Страница 17: ... 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 the Delayed Simulate Mains program parameter is set to 1 and the input signal is active when the genset is not feeding the load then the genset will not run This will prevent the genset from starting when the simulate mains...

Страница 18: ...d to this function The dual genset intermittent 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 usin...

Страница 19: ...y function will be active 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 To turn off the SERVICE REQUEST led and reset the service period press together the ALARM MUTE and LAMP TEST keys for 5 seconds The remaining engine hours and the remaining time limit are kept stor...

Страница 20: ...able or SMS Enable or MODBUS Address parameters are different from zero the local PC connection will not work 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 supply source to the modem The necessary modem cabl...

Страница 21: ...erwards When SMS sending is in progress an SMS icon will appear at the upper right corner of the screen The maximum number of alarms transmitted in 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 informatio...

Страница 22: ...port below USB to serial adapters are 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 6 17 External...

Страница 23: ...ription of the above parameters When the start day and hour of exercise has come the unit will automatically switch to either TEST or LOAD TEST mode The engine will run and if the on_load exercise is selected then the load will be transferred to the genset If a mains failure occurs during the off load exercise the load will not be transferred to the genset unless the Emergency Backup Operation is ...

Страница 24: ...inition program parameters Also relays on an extension module may be assigned to this function 6 21 Load Shedding Dummy Load The load shedding 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 An...

Страница 25: ...y 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 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 operat...

Страница 26: ... Mains High 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 ...

Страница 27: ...st 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 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 Pha...

Страница 28: ...ed in 10 minute steps Unused 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...

Страница 29: ...n makes the display switch to the previous event and MENU button makes the display switch to the next event To exit event record pages please hold pressed MENU or MENU buttons 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 dif...

Страница 30: ...ist on total engine hours 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 12 MAINTENANCE DO NOT OPEN THE UNIT There are NO serviceable parts inside the unit Wipe the unit if necessary with a soft damp cloth Do not use chemical agents ...

Страница 31: ... even while the 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 ...

Страница 32: ...genset on load operation 0 screen 3 or 4 electrical large characters 1 screen 5 engine parameters large characters 2 screen 6 or 7 maximum information small characters 3 screen 8 or 9 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 befo...

Страница 33: ...se at TEST 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 once per week 2 exercise once per month the exercise will be performed during the first 7 days of each month at the programmed day and hour 2 Delayed Simulate Mains 0 0 The SPARE 2 input has norm...

Страница 34: ...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 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 2 SMS on Mains Change 0 This parameter controls SMS sending when mains...

Страница 35: ... 2 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 2 Genset High Voltage Warning Limit V 250 If one of the generator phase voltages goes above this limit when feeding the load this will generate a GENSET HIGH VOLTAGE warning 2 Genset High Voltage Shutdown Limit V 260 If one of ...

Страница 36: ...Limit V 136 When secondary volt freq limits are active 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 2 nd Mains Frequency Low Limit Hz 55 When secondary volt freq limits are active If the mains frequency goes under this limit it means that the mains are off and it starts the transfer to the genset in AUTO mod...

Страница 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...

Страница 38: ... 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 month 6 The SERVIC...

Страница 39: ...erated 2 High rpm Warning rpm 0 If the engine speed goes over this limit a GENSET HIGH SPEED warning is generated 2 High rpm Shutdown rpm 0 If the engine speed goes over this limit a GENSET HIGH SPEED alarm is generated and the engine stops 2 Fan turn on temp C 90 If the coolant temp is above this limit then the fan relay function will become active 2 Fan turn off temp C 80 If the coolant temp is ...

Страница 40: ...IGH SPEED warning is generated 2 2 nd 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 2 nd 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 2 2 nd Low...

Страница 41: ... 59 Current second of the minute Program Group Weekly Schedule password level 2 Parameter Definition Unit Factory Set Description Monday Turn_on 24 00 Please review chapter 9 for a detailed description of weekly programming schedule operation Monday Turn_off 24 00 Tuesday Turn_on 24 00 Tuesday Turn_off 24 00 Wednesday Turn_on 24 00 Wednesday Turn_off 24 00 Thursday Turn_on 24 00 Thursday Turn_off ...

Страница 42: ... 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 Sender point 5 ohm value Temperature Value 5 C 20...

Страница 43: ...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...

Страница 44: ...ormally open 1 Normally closed Switching 0 0 Battery negative 1 Battery positive Response delay 1 0 No delay 1 Delayed 4sec Program Group Input Configuration Rectifier Fail 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 ...

Страница 45: ...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...

Страница 46: ...utdown 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 After holdoff timer 2 When mains present Latching 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 ...

Страница 47: ...ed from list Relay 06 Definition 5 RELAY 6 function 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 Relay 09 Definition 4 RELAY 9 function expansion module 1 selected from list Relay 10 Definition 5 RELAY 10 function expansion module 1 selected from list R...

Страница 48: ...ge 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 Fuel Level switch load_dump 64 Oil sender fail ldd 65 Temp sender fail ldd 66 Fuel Lev sender fail ldd 67 Oil Temp snd fail ldd 68 69 70 71 72 Overcurrent load_dump 73 Excess power ldd 7...

Страница 49: ...ut 03 Function Select 2 Low Coolant 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 18 Remote Start 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...

Страница 50: ...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...

Страница 51: ...l 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 lately If oil pressure switch closes the unit will start Optionally oil pressure switch may be replaced The engine does n...

Страница 52: ...to battery positive The unit is inoperative Measure the DC supply voltage between terminals BAT and BAT at the rear of the unit If OK turn all the fuses off then turn all the fuses on starting from the DC supply fuse Then test the unit again Programming mode can not be entered The program lock input disables programming mode entry Disconnect the program lock input from battery negative before modi...

Страница 53: ...he EU directives 2006 95 EC low 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 ...

Страница 54: ... 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 II Air category Pollution degree II Communication port RS 232 9600 bauds no parity 1 stop bit Operating temperature range 20 C to 70 C 4 ºF to 158 ºF...

Страница 55: ...DKG 519 User Manual V 27 14 04 2011 55 17 CONNECTION DIAGRAM ...

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