DKG-307 User Manual V-42 (24.05.2013) DKG-307 AUTOMATIC MAINS FAILURE UNIT CANBUS AND MPU VERSIONS DESCRIPTION The controller is a comprehensive AMF unit for single genset standby or dual genset mutual standby operations. The unit is available with MPU or CANBUS versions. The CANBUS version connects to ECU controlled electronic engines providing engine control, protection and instrumentation without extra senders.
DKG-307 User Manual V-42 (24.05.2013) TABLE OF CONTENTS Section 1. INSTALLATION 1.1. Introduction to the Control Panel 1.2. Mounting the Unit 1.3. Wiring the Unit 2. INPUTS AND OUTPUTS 3. DISPLAYS 3.1. Led Displays 3.2. Digital Displays 4. ALARMS AND WARNINGS 5. MODES OF OPERATION 6. OTHER FEATURES 6.1. Remote start operation 6.2. Sender type selection 6.3. Engine heating operation 6.4. Engine Idle Speed Operation 6.5. Engine Block Heater 6.6. Fuel Pump Control 6.7. Mains Simulation (Disable Start) 6.8.
DKG-307 User Manual V-42 (24.05.2013) 1. INSTALLATION 1.1 Introduction to the Control Panel The unit is a control and protection panel used in gensets. It shows the measured values on its displays. The unit is designed to provide user friendliness for both the installer and the user. Programming is usually unnecessary, as the factory settings have been carefully selected to fit most applications. However programmable parameters allow the complete control over the generating set.
DKG-307 User Manual V-42 (24.05.2013) 1.2 Mounting the Unit The unit is designed for panel mounting. The user should 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 the unit through the mounting opening. The unit will be maintained in its position by the mounting brackets spring.
DKG-307 User Manual V-42 (24.05.2013) 2. INPUTS AND OUTPUTS RS-232 SERIAL PORT: This connector provides serial data input and output for various purposes like remote monitoring and remote programming. EXTENSION CONNECTOR: This connector is intended for the connection to output extension modules. The optional relay extension module provides 8 programmable 16A relay outputs. The unit allows the use of up to 2 I/O extension modules.
DKG-307 User Manual V-42 (24.05.2013) Term Function 16 CHARGE Technical data Input and output 17 RELAY-2 (HORN RELAY) Output 10A/28VDC 18 RELAY-1 (STOP RELAY) Output 10A/28VDC 19 20 21 22 23 24 25 26 27 28 29 START RELAY FUEL RELAY EMERGENCY STOP SPARE-2 PROGRAM LOCK SPARE-1 COOLANT LEVEL HIGH TEMP LOW OIL PRESSURE RECTIFIER FAIL CURR_1+ Output 10A/28VDC Output 10A/28VDC Digital inputs 30 CURR_1- 31 CURR_2+ 32 CURR_2- 33 CURR_3+ 34 CURR_3- 35 OIL TEMP.
DKG-307 User Manual V-42 (24.05.2013) 3. DISPLAYS 3.1 Led Displays The unit has 12 LEDs, divided in 3 groups: -Group_1: Operating mode: This group indicates the genset function. -Group_2: Mimic diagram: This group indicates the current status of the mains and genset voltages and contactors. -Group_3: Warnings and alarms: This group indicates the existence of abnormal conditions encountered during operation.
DKG-307 User Manual V-42 (24.05.2013) 3.2 Digital Displays The unit has 3 seven segment displays. They show: -Measured parameters, -Service counters, -Statistical counters, -Program parameters. The navigation between different screens in a group is made with the MENU► button. Holding the MENU► button pressed for 1 second makes the display to switch to the next group.
DKG-307 User Manual V-42 (24.05.2013) 4.
DKG-307 User Manual V-42 (24.05.2013) 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 separately programmable for the oil pressure sender input. This fault will be monitored with Holdoff Timer delay after the engine is running.
DKG-307 User Manual V-42 (24.05.2013) 5. MODES OF OPERATION The modes of operation are selected by pushing the front panel keys. Changing the operation mode while the genset is running will result into a behavior suitable for the new operating mode. For example, if the TEST mode is selected when genset is running at RUN mode, then the genset will take the load. STOP: In this mode, the mains contactor will be energized if mains phase voltages are within the programmed limits. The engine will be stopped.
DKG-307 User Manual V-42 (24.05.2013) 6. OTHER FEATURES 6.1 Remote Start Operation The unit offers the possibility of REMOTE START mode of operation. The SPARE-2 input may be assigned as Remote Start Input using the program parameter P_083. The REMOTE START signal may be a NO or NC contact, switching to either battery positive or battery negative. These selections are made using programming menu.
DKG-307 User Manual V-42 (24.05.2013) 6.3 Engine Heating Operation Especially on engines without a body heater, or with a failing one, it may be desired that the genset should not take the load before reaching a suitable temperature. The unit offers 2 different ways of engine heating. 1. Timer controlled heating: This operation mode is selected when the Engine Heating Method parameter is set to 0.
DKG-307 User Manual V-42 (24.05.2013) 6.6 Fuel Pump Control The unit is able to provide a relay output in order to drive the fuel pump motor. The fuel pump is used in order to transfer fuel from the large capacity main tank (if exists) to the genset daily tank which is generally integrated in the chassis and has a limited capacity. The fuel level reference is measured through the analog fuel level sender.
DKG-307 User Manual V-42 (24.05.2013) 6.8 Delayed Mains Simulation, Battery Charging The Delayed Mains Simulation feature is used in battery backed up telecom systems where batteries are able to supply the load during a certain period. The genset is requested to run only when battery voltage drops below the critical level. Once the engine runs, the rectifier system starts charging the batteries and the battery voltage goes up immediately.
DKG-307 User Manual V-42 (24.05.2013) 6.9 Dual Genset Mutual Standby Operation Dual genset intermittent operation consists of regular switching of the load between 2 gensets. The use of 2 gensets instead of one is due either to safety purposes in case of a genset failure or to a continuous operation requesting service stops. The running period for each genset is adjustable using Flashing Relay Timer program parameter.
DKG-307 User Manual V-42 (24.05.2013) 6.10 Service Request Display This led is designed to help the periodic maintenance of the genset to be made consistently. The periodic maintenance is basically carried out after a given engine hours (for example 200 hours), but even if this amount of engine hours is not fulfilled, it is performed after a given time limit (for example 12 months). The SERVICE REQUEST led has no effect on the genset operation.
DKG-307 User Manual V-42 (24.05.2013) 6.11 Engine Hour Meter The unit features a non-erasable incremental engine hour meter. The hour meter information is kept in a non-volatile memory and is not affected from power supply failures. The engine hours may be displayed STATISTICAL COUNTERS menu. 6.12 Date & Time Display The date & time display is provided for verification. 6.13 Software Version Display Some additional features are installed within consecutive software releases.
DKG-307 User Manual V-42 (24.05.2013) 6.15 SMS Message Sending The GSM SMS sending is activated by setting the SMS Enable program parameter to 1. If Modem Enable or SMS Enable or MODBUS Address parameters are different from zero, the local PC connection will not work. When a fault condition occurs, the unit will compose an SMS message and will send it to up to 6 phone numbers. If modem is enabled, only 4 telephone numbers are available for SMS sending.
DKG-307 User Manual V-42 (24.05.2013) 6.16 Remote Monitoring and Programming Thanks to its standard serial RS-232 port, the unit offers the remote monitoring and programming feature. The remote monitoring and programming PC software is called RAINBOW and may be downloaded from www.datakom.com.tr internet site with password login. The modem, SMS and Modbus modes are not compatible with the local PC connection.
DKG-307 User Manual V-42 (24.05.2013) 6.17 Exerciser The unit offers automatic exerciser operation. The exercise operation may be done on a daily, weekly or monthly basis. The start day and time of the exercise is programmable as well as its duration. The exercise may be done with or without load following programming.
DKG-307 User Manual V-42 (24.05.2013) 6.19. Gas Engine Fuel Solenoid Control The unit provides a special function for the fuel solenoid control of a gas engine. The fuel solenoid of a gas engine is different from a diesel engine. It should be opened after the cranking has been started and should be closed between crank cycles. The delay between the crank start and solenoid opening is adjusted using the Gas Solenoid Delay program parameter.
DKG-307 User Manual V-42 (24.05.2013) 6.22. Firmware Update 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 mode, the display of the unit will show “DL V1.00” During firmware update process, the progress is visible through a percentage counter on the screen.
DKG-307 User Manual V-42 (24.05.2013) 6.25. Dual Voltage and Frequency The unit offers 2 sets of voltage and frequency protection limit values. The user is allowed to switch between these 2 sets anytime. This feature is especially usefull in dual voltage or frequency gensets for easy switching between 2 operating conditions. The switching to the second set of limit values is performed by applying signal to the SPARE-1 digital input.
DKG-307 User Manual V-42 (24.05.2013) 7. J1939 ENGINE MONITORING AND CONTROL PORT (ONLY CANBUS VERSIONS) The unit offers a special J1939 port in order to communicate with electronic engines controlled by an ECU (electronic control unit). The J1939 port consists of 2 terminals which are J1939+ and J1939-. The connection between the unit and the engine should be made with either a twisted cable pair or a coaxial cable. If a coaxial cable is used, the external conductor should be grounded at one end only.
DKG-307 User Manual V-42 (24.05.
DKG-307 User Manual V-42 (24.05.2013) Below is a basic list of FMI codes. Please be aware that these codes may differ slightly depending on the engine brand and model.
DKG-307 User Manual V-42 (24.05.2013) 8. MODBUS COMMUNICATION The unit offers the possibility of MODBUS communication via its RS232 serial port. The connection to the MODBUS master may be done in 3 ways: 1) RS232 connection using directly the RS232 port provided. 2) RS422/485 connection using external RS422/485 converter. 3) Modem connection using external modem. The MODBUS mode is activated by assigning a controller address to the unit using MODBUS Address program parameter.
DKG-307 User Manual V-42 (24.05.2013) 9. WEEKLY OPERATION SCHEDULE In most applications, the genset is requested to operate only in working hours. Thanks to the weekly program feature unwanted operation of the genset may be prohibited. The unit has one programmable turn-on/turn-off time pairs for each day of week. These programmable parameters allow the genset to operate automatically only in allowed time limits. The weekly operation schedule is only active in AUTO mode.
DKG-307 User Manual V-42 (24.05.2013) 10. EVENT LOGGING The unit keeps record of the last 100 events in order to supply information for the service personal. The genset status information and a comprehensive set of measured values are stored within the event memory. The events are recorded with a time stamp which comes from the internal real time clock circuit of the unit. The events are stored in a circular memory. This means that a new coming event will erase the oldest recorded event.
DKG-307 User Manual V-42 (24.05.2013) 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.
DKG-307 User Manual V-42 (24.05.2013) 13. PROGRAMMING The program mode is used to program timers, operational limits and the configuration of the unit. To enter the program mode, hold pressed the MENU►button for 5 seconds. When the program mode is entered, the upper display will show “PRGM” and the mid display will indicate the program parameter number. The lower display will show the parameter value.
DKG-307 User Manual V-42 (24.05.
DKG-307 User Manual PGM V-42 (24.05.2013) Parameter Definition Unit P_018 Low Oil Pressure Warning bar P_019 Low Oil Pressure Shutdown bar P_020 High Temperature Warning °C P_021 High Temperature Shutdown °C P_022 Low Fuel Warning % P_023 Low Fuel Shutdown % P_024 High Oil Temperature Warning °C P_025 High Oil Temperature Shutdown °C P_026 Oil Pressure Sender type - P_027 Coolant Temp. Sender Type - P_028 Oil Temp. Sender Type - Fact.
DKG-307 User Manual PGM Parameter Definition V-42 (24.05.2013) Unit P_029 Hysteresis Voltage V P_030 Engine Heating Temperature °C P_031 Fault Holdoff Timer sec P_032 Overload Timeout sec P_033 Engine Start Delay sec P_034 Preheat Timer sec P_035 Choke Timer sec P_036 Gas Solenoid Delay sec P_037 Crank Timer sec P_038 Wait Between Starts sec P_039 Idle Speed Timer sec P_040 Engine Heating Timer sec P_041 Mains Waiting Timer min P_042 Cooldown Timer min Fact.
DKG-307 User Manual PGM V-42 (24.05.
DKG-307 User Manual V-42 (24.05.2013) Following parameters are in “high” priority group.
DKG-307 User Manual PGM Parameter Definition V-42 (24.05.2013) Unit P_075 Single phase Enable - P_076 Emergency Backup Operation - P_077 Modem Enable - P_078 SMS Enable - P_079 MODBUS Address - P_080 SMS on Mains Change - P_081 Fuel Consumption per Hour % P_082 Real Time Clock Adjust - P_083 Remote Start Enable - P_084 Simulate Mains Enable - P_085 Delayed Simulate Mains - P_086 Flashing Relay Timer hours Fact.
DKG-307 User Manual PGM Parameter Definition V-42 (24.05.2013) Unit P_087 Exercise Day and Time - P_088 Exercise Duration min P_089 Exercise Off/On Load - P_090 Exercise Period - P_091 Language Selection - P_092 Secondary Volt/Freq - P_093 Engine Control Only - Fact.Set Description This parameter defines the start day and hour of the exerciser. Values higher or equal to 168 mean that the exerciser is off.
DKG-307 User Manual V-42 (24.05.2013) Below parameters are applicable to J1939 enabled versions only. PGM Parameter Definition Unit P_094 J1939 Enable - P_095 J1939 Engine Type - P_096 J1939 Speed Adjust % P_097 VOLVO Speed Toggle - Fact.Set Description 0: The J1939 port is inoperative. 1: The analog measurements (oil, temp, rpm) are 0 picked_up from the ECU. If the ECU communication is lost, then the engine will be stopped.
DKG-307 User Manual PGM Parameter Definition V-42 (24.05.
DKG-307 User Manual PGM V-42 (24.05.2013) Parameter Definition Unit P_111 2nd Low rpm Shutdown rpm P_112 2nd Low rpm Warning rpm P_113 2nd High rpm Warning rpm P_114 2nd High rpm Shutdown rpm P_115 Engine Run Password - Fact.Set Description When secondary volt/freq limits are active: If the engine speed goes under this limit, a GENSET 0 LOW SPEED alarm is generated and the engine stops.
DKG-307 User Manual V-42 (24.05.2013) Oil Pressure Sender Characteristics PGM P_136 P_137 P_138 P_139 P_140 P_141 P_142 P_143 P_144 P_145 P_146 P_147 Parameter Definition Oil Pressure Sender Ohms -1 Oil Pressure Value -1 Oil Pressure Sender Ohms -2 Oil Pressure Value -2 Oil Pressure Sender Ohms -3 Oil Pressure Value -3 Oil Pressure Sender Ohms -4 Oil Pressure Value -4 Oil Pressure Sender Ohms -5 Oil Pressure Value -5 Oil Pressure Sender Ohms -6 Oil Pressure Value -6 Unit Factory Set 10 ohm 0.
DKG-307 User Manual V-42 (24.05.
DKG-307 User Manual V-42 (24.05.2013) Coolant Level Switch Input Configuration PGM Parameter Definition P_196 Action P_197 Sampling P_198 Latching P_199 Contact type P_200 Switching P_201 Response delay Unit Fac.
DKG-307 User Manual V-42 (24.05.2013) Spare–1 Input Input Configuration PGM Parameter Definition P_214 Action P_215 Sampling P_216 Latching P_217 Contact type P_218 Switching P_219 Response delay Unit Fac.
DKG-307 User Manual V-42 (24.05.2013) The parameters below define the functions of relay outputs. The unit has 6 relay outputs. The fixed function relays are Fuel, Start, Mains Contactor and Generator Contactor. RELAY-1 and RELAY2 have programmable functions, selected from a list. The relays may be extended up to 22 using Relay Extension Modules.. Other relays are in the optional Extension Modules. Program Group: Relay Definitions (password level-2) PGM Parameter Definition Unit Fac.
DKG-307 User Manual V-42 (24.05.2013) The function of a programmable relay output may be selected from below list. 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Fuel Alarm Start Stop Gen. Contactor Mains Contactor Choke Preheat Shutdown alarm Shutdown or load_dump alarm Shutdown or load_dump or warning Automatic ready Week.
DKG-307 User Manual V-42 (24.05.2013) 14. TROUBLESHOOTING The genset operates while AC mains are OK or continues to operate after AC mains are OK: -Check engine body grounding. -AC mains voltages may be outside programmed limits, measure the phase voltages. -Check the AC voltage readings by pressing the MENU button. -Upper and lower limits of the mains voltages may be too tight. Check the parameters Mains Voltage Low Limit and Mains Voltage High Limit. Standard values are 170/270 volts.
DKG-307 User Manual V-42 (24.05.2013) 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.
DKG-307 User Manual V-42 (24.05.2013) 15. DECLARATION OF CONFORMITY The unit conforms to the 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. UL / CSA Conformity: certificate # 20110527-E314374 UL 508, Edition 17 UL 2200, 1st Edition.
DKG-307 User Manual V-42 (24.05.2013) 16. TECHNICAL SPECIFICATIONS Alternator voltage: 0 to 300 V-AC Phase to Neutral (0 to 520 V-AC Phase to Phase) Alternator frequency: 0-100 Hz. Mains voltage: 0 to 300 V-AC Phase to Neutral (0 to 520 V-AC Phase to Phase) Mains frequency: 0-100 Hz. DC Supply range: 9.0 VDC to 33.0 VDC Cranking dropouts: survives 0 V for 100ms Typical stand-by current consumption: 100 mADC. Maximum current consumption: 250 mADC. Generator/mains contactor outputs: 16 A @ 250 VAC.
DKG-307 User Manual V-42 (24.05.2013) 17.
DKG-307 User Manual V-42 (24.05.2013) 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.
