Datakom DKG-209 User Manual

Datakom DKG-209 User Manual

Automatic mains failure unit

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DKG-209 User Manual
DESCRIPTION
The controller is a comprehensive low cost AMF
unit for single genset standby or dual genset
mutual standby operations.
The unit is able to initiate modem calls and send
SMS messages in fault conditions through
external modem.
The unit provides a comprehensive set of
digitally adjustable timers, threshold levels, input
and output configurations and operating
sequences. All programs may be modified via
front panel pushbuttons, and do not require an
external unit.
Last 100 faults are stored in the event log file.
The event log includes not only the engine-hours
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.
The unit offers multiple language support.
DKG-209 AUTOMATIC
MAINS FAILURE UNIT
 Low cost
 True RMS measurements
 Dual genset mutual standby operation
 Event logging with engine run hours
stamp and measurements
 Field adjustable parameters
 Logic level serial port
 Free MS-Windows Remote monitoring
SW
 GSM and PSTN modem support
 GSM SMS message sending on fault
 MODBUS communications
 Multiple language support
 Customer logo display capability
 1A protected semiconductor outputs
 Configurable analogue inputs: 3
 Configurable digital inputs: 5
 Configurable relay outputs: 1
 Total relay outputs: 5
 Plug-in connection system
V-29
(20.08.2013)
FEATURES

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  • Page 1 DKG-209 User Manual V-29 (20.08.2013) DKG-209 AUTOMATIC MAINS FAILURE UNIT DESCRIPTION FEATURES  Low cost The controller is a comprehensive low cost AMF unit for single genset standby or dual genset  True RMS measurements mutual standby operations.  Dual genset mutual standby operation The unit is able to initiate modem calls and send ...
  • Page 2: Table Of Contents

    DKG-209 User Manual V-29 (20.08.2013) 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. Language Selection 3.3. Digital Displays 4.
  • Page 3: Installation

    DKG-209 User Manual V-29 (20.08.2013) 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.
  • Page 4: Mounting The Unit

    DKG-209 User Manual V-29 (20.08.2013) 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.
  • Page 5: Wiring The Unit

    DKG-209 User Manual V-29 (20.08.2013) 1.3 Wiring the Unit WARNING: THE UNIT IS NOT FUSED. Use external fuses for Mains phases: L1,L2,L3, Generator phase: L1,L2,L3, Battery positive: BAT(+). Install the fuses as nearly as possible to the unit in a place easily accessible for the user.
  • Page 6: Inputs And Outputs

    DKG-209 User Manual V-29 (20.08.2013) 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.
  • Page 7 DKG-209 User Manual V-29 (20.08.2013) Term Function Technical data Description 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.
  • Page 8: Displays

    DKG-209 User Manual V-29 (20.08.2013) 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.
  • Page 9: Language Selection

    DKG-209 User Manual V-29 (20.08.2013) 3.2 Language Selection The unit is able to display information in 3 or 4 languages, following versions. Language selection is made through program parameter CONTROLLER CONFIGURATION > LANGUAGE SELECTION. Below selections are available in the standard version:...
  • Page 10 DKG-209 User Manual V-29 (20.08.2013) Group Screen Contents Description Genset Volts L1, Genset Volts L1-L2, Presented as a table. GENSET Genset Volts L2 , Genset Volts L2-L3, PARAMETERS Genset Volts L3, Genset Volts L3-L1, Genset Current L1, Genset Frequency Presented as a table.
  • Page 11 DKG-209 User Manual V-29 (20.08.2013) Group Screen Description ALARM LIST If no alarm exists, then END OF ALARM LIST is displayed. Otherwise the first alarm is displayed. Each depression of the ▼ button will cause the screen to switch to the next alarm.
  • Page 12: Alarms And Warnings

    DKG-209 User Manual V-29 (20.08.2013) 4. ALARMS AND WARNINGS Alarms indicate an abnormal situation in the generating set are divided into 3 priority levels: 1- ALARMS: These are the most important fault conditions and cause: The ALARM led to be on steadily,...
  • Page 13 DKG-209 User Manual V-29 (20.08.2013) 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.
  • Page 14: Modes Of Operation

    DKG-209 User Manual V-29 (20.08.2013) 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 LOAD TEST mode is selected when genset is running at TEST mode, then the genset will take the load.
  • Page 15: Other Features

    DKG-209 User Manual V-29 (20.08.2013) 6. OTHER FEATURES 6.1 Remote Start Operation The unit offers the possibility of REMOTE START mode of operation. Any digital input may be assigned as Remote Start Input using Input Function Select program parameters. The REMOTE START signal may be a NO or NC contact, switching to either battery positive or battery negative.
  • Page 16: Engine Heating Operation

    DKG-209 User Manual V-29 (20.08.2013) 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.
  • Page 17: Fuel Pump Control

    DKG-209 User Manual V-29 (20.08.2013) 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.
  • Page 18: Delayed Mains Simulation, Battery Charging

    DKG-209 User Manual V-29 (20.08.2013) 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.
  • Page 19: Dual Genset Mutual Standby Operation

    If the priority signal is not applied, then the unit will become the slave one and the other genset will start. Please contact DATAKOM for a complete application manual. - 19 -...
  • Page 20: Service Request Display

    DKG-209 User Manual V-29 (20.08.2013) 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).
  • Page 21: Engine Hours Meter

    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.
  • Page 22: Sms Message Sending

    GSM SMS messages. Any new upcoming alarm will result in a new GSM SMS message. The new message will indicate all existing alarms, even masked ones. The necessary GSM modem cable will be supplied by DATAKOM. This is the same cable as PSTN (land) modems.
  • Page 23: Remote Monitoring And Programming

    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 Control of the Unit The unit offers total external control through programmable digital inputs.
  • Page 24: Resuming To Factory Set Parameters

    DKG-209 User Manual V-29 (20.08.2013) 6.18 - This chapter is intentionally left blank. 6.19. Resuming to factory set parameters In order to resume to the factory set parameter values: -hold pressed the OFF, LAMP TEST and ALARM MUTE buttons for 5 seconds, -“RETURN TO FACTORY SET”...
  • Page 25: Fuel Theft / Fuelling Messages

    DKG-209 User Manual V-29 (20.08.2013) 6.22. Fuel Theft / Fuelling Messages The unit is able to send SMS messages in fuel theft or fuelling conditions. These SMS messages are sent without creating visible fault condition. These features are enabled by setting the program parameter Engine Parameters > Fuel Consumption / Hour to a value other than 0%.
  • Page 26 DKG-209 User Manual V-29 (20.08.2013) 6.26. 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.
  • Page 27 DKG-209 User Manual V-29 (20.08.2013) 7. - This chapter is intentionally left blank. - 27 -...
  • Page 28: Modbus Communication

    Detailed description about the MODBUS protocol is found in the document “Modicon Modbus Protocol Reference Guide”. The web address is: www.modbus.org/docs/PI_MBUS_300.pdf Below is a limited shortlist of readable registers. For the detailed Modbus Application Manual and a complete list of registers please contact DATAKOM. ADDRESS DATA...
  • Page 29: Event Logging

    DKG-209 User Manual V-29 (20.08.2013) 9. - This chapter is intentionally left blank. 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.
  • Page 30: Statistical Counters

    DKG-209 User Manual V-29 (20.08.2013) 11. STATISTICAL COUNTERS The unit provides a set of non resettable incremental counters for statistical purposes. The counters consist 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.
  • Page 31: Programming

    The password level-1 allows access to field adjusted parameters. The level-2 allows access to factory setup. The password level-3 is reserved to Datakom and allows access to calibration parameters. The password level-1 is factory set to ‘1234’ and the password level-2 is factory set to ‘9876’.
  • Page 32 DKG-209 User Manual V-29 (20.08.2013) Program Group: Controller Configuration Parameter Definition, Unit Factory Description (Password Level) This parameter is used to set LCD contrast. Adjust (1) LCD Contrast for the best viewing angle. 0: English language selected. 1: Turkish language selected. This language may...
  • Page 33 Simulate Mains signal disappears. (2) Flashing Relay Timer hours Dual Genset Systems: flashing relay toggle timer. Please contact DATAKOM for dual genset mutual stanby operation. This parameter provides the mains and genset voltage limits with a hysteresis feature in order to prevent faulty decisions.
  • Page 34 DKG-209 User Manual V-29 (20.08.2013) Program Group: Electrical Parameters Parameter Definition, Unit Facto Description (Password Level) ry Set This is the rated value of current transformers. (2) Current Transformer All transformers must have the same rating. Ratio The secondary of the transformer will be 5 Amps.
  • Page 35 DKG-209 User Manual V-29 (20.08.2013) Program Group: Electrical Parameters (continued) Parameter Definition, Factor Unit Description (Password Level) y Set (2) Low Battery Voltage If the battery voltage falls below this limit, this will generate a LOW BATTERY warning. Warning (2) High Battery Voltage If the battery voltage goes over this limit, this will 31.0...
  • Page 36 DKG-209 User Manual V-29 (20.08.2013) Program Group: Electrical Parameters (continued) Parameter Definition, Factory Unit Description (Password Level) When secondary volt/freq limits are active: If the current goes above this limit, during the period defined in Overload Timeout then a Overcurrent...
  • Page 37 DKG-209 User Manual V-29 (20.08.2013) Program Group: Engine Parameters Parameter Definition, Factory Unit Description (Password Level) (2) Low Frequency If the genset frequency goes under this limit, a GENSET LOW SPEED alarm is generated and the engine stops. Shutdown If the genset frequency goes under this limit, a GENSET (1) Low Frequency Warning LOW SPEED warning is generated.
  • Page 38 DKG-209 User Manual V-29 (20.08.2013) Program Group: Engine Parameters (continued) Parameter Definition, Unit Factory Description (Password Level) This is the maximum start period. Starting will be (2) Crank Timer automatically cancelled if the genset fires before the timer. (2) Wait Between Starts This is the waiting period between two start attempts.
  • Page 39 DKG-209 User Manual V-29 (20.08.2013) Program Group: Engine Parameters (continued) Parameter Definition, Unit Factory Description (Password Level) When the genset frequency reaches this limit, the (3) Crank Cut Frequency 10.0 engine is supposed running and the crank output will release.
  • Page 40 DKG-209 User Manual V-29 (20.08.2013) Program Group: Engine Parameters (continued) Parameter Definition, Unit Factory Description (Password Level) When secondary volt/freq limits are active: (2) 2nd Low Frequency If the genset frequency goes under this limit, a Shutdown GENSET LOW SPEED alarm is generated and the engine stops.
  • Page 41 DKG-209 User Manual V-29 (20.08.2013) Program Group: Sender Characteristics (password level-2) Parameter Definition Unit Factory Description Oil Pressure Sender point 1, ohm value Oil Pressure Sender Ohms -1 Oil Pressure Sender point 1, bar value Oil Pressure Value -1 Oil Pressure Sender point 2, ohm value...
  • Page 42 DKG-209 User Manual V-29 (20.08.2013) Program Group: Input Configuration (Low Oil Pressure Switch) (password level-2) Parameter Definition Unit Fac.Set Description 0: Shutdown (the engine stops immediately) 1: Load Dump (the engine stops after cooldown) Action 2: Warning (the horn relay operates)
  • Page 43 DKG-209 User Manual V-29 (20.08.2013) Program Group: Input Configuration (Emergency Stop) (password level-2) Parameter Definition Unit Fac.Set Description 0: Shutdown (the engine stops immediately) 1: Load Dump (the engine stops after cooldown) Action 2: Warning (the horn relay operates) 3: No operation...
  • Page 44 DKG-209 User Manual V-29 (20.08.2013) Program Group: Input Configuration (Spare-1 Input) (password level-2) Parameter Definition Unit Fac.Set Description 0: Shutdown (the engine stops immediately) 1: Load Dump (the engine stops after cooldown) Action 2: Warning (the horn relay operates) 3: No operation...
  • Page 45 DKG-209 User Manual V-29 (20.08.2013) The function of a programmable relay output may be selected from the below list. Fuel Oil switch alarm Oil switch warning Alarm Temp switch alarm Temp switch warn. Start Stop Gen. Contactor Emerg.Stop alarm Emerg Stop warn.
  • Page 46 DKG-209 User Manual V-29 (20.08.2013) The related input configuration parameters apply for each input, thus any signal can be programmed for NO or NC contact, closing to BAT+ or BAT-. Program Group: Input Function Select (password level-2) Fact. Parameter Definition...
  • Page 47 DKG-209 User Manual V-29 (20.08.2013) Program Group: Site Id (password level-2) Parameter Definition Factory Set Description This is the site Id string sent at the beginning of an GENERATOR SMS message for the identification of the genset Site Id String SITE-ID sending the SMS message.
  • Page 48: Troubleshooting

    DKG-209 User Manual V-29 (20.08.2013) 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.
  • Page 49 DKG-209 User Manual V-29 (20.08.2013) 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.
  • Page 50: Declaration Of Conformity

    DKG-209 User Manual V-29 (20.08.2013) 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.
  • Page 51: Technical Specifications

    DKG-209 User Manual V-29 (20.08.2013) 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.
  • Page 52: Connection Diagrams

    DKG-209 User Manual V-29 (20.08.2013) 17. CONNECTION DIAGRAMS - 52 -...
  • Page 53 DKG-209 User Manual V-29 (20.08.2013) 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.tr - 53 -...

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