Datakom DKG-307 User Manual
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Datakom DKG-307 User Manual

Automatic mains failure unit canbus and mpu versions
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DKG-307 User Manual
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.
The unit is able to initiate modem calls and send
SMS messages in fault conditions through external
modems.
The unit provides a comprehensive set of digitally
adjustable timers, threshold levels, input and output
configurations, operating sequences and engine
types. 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 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.
DKG-307 AUTOMATIC
MAINS FAILURE UNIT
CANBUS AND MPU VERSIONS
True RMS measurements
ECU connection through J1939 CAN option
MPU input option
Dual genset mutual standby operation
Event logging with time stamp and
measurements
Battery backed-up real time clock
Built in daily / weekly / monthly exerciser
Weekly operation schedule programs
Field adjustable parameters
RS-232 serial port
Free MS-Windows Remote monitoring SW
GSM and PSTN modem support
GSM SMS message sending on fault
MODBUS communications
Customer logo display capability
10ADC relay outputs
Configurable analogue inputs: 4
Configurable digital inputs: 7
Configurable relay outputs: 2
Total relay outputs: 6
I/O expansion capability
Plug-in connection system
V-37
(01.03.2012)
FEATURES

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  • Page 1 DKG-307 User Manual V-37 (01.03.2012) DKG-307 AUTOMATIC MAINS FAILURE UNIT CANBUS AND MPU VERSIONS DESCRIPTION FEATURES The controller is a comprehensive AMF unit for True RMS measurements single genset standby or dual genset mutual standby ECU connection through J1939 CAN option operations.

  • Page 2: Table Of Contents

    DKG-307 User Manual V-37 (01.03.2012) 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.

  • Page 3: Installation

    DKG-307 User Manual V-37 (01.03.2012) 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-307 User Manual V-37 (01.03.2012) 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: Inputs And Outputs

    DKG-307 User Manual V-37 (01.03.2012) 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 6 DKG-307 User Manual V-37 (01.03.2012) Term Function Technical data Description Connect the charge alternator‟s D+ terminal to CHARGE Input and output this terminal. This terminal will supply the excitation current and measure the voltage of the charge alternator. RELAY-2 (HORN RELAY)

  • Page 7: Led Displays

    DKG-307 User Manual V-37 (01.03.2012) 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 8: Digital Displays

    DKG-307 User Manual V-37 (01.03.2012) 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.

  • Page 9: Alarms And Warnings

    DKG-307 User Manual V-37 (01.03.2012) 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: Therelated ALARM led to be on steadily,...
  • Page 10 DKG-307 User Manual V-37 (01.03.2012) 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 11: Modes Of Operation

    DKG-307 User Manual V-37 (01.03.2012) 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.

  • Page 12: Other Features

    DKG-307 User Manual V-37 (01.03.2012) 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.

  • Page 13: Engine Heating Operation

    DKG-307 User Manual V-37 (01.03.2012) 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 14: Fuel Pump Control

    DKG-307 User Manual V-37 (01.03.2012) 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 15: Delayed Mains Simulation, Battery Charging

    DKG-307 User Manual V-37 (01.03.2012) 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 16: Dual Genset Mutual Standby Operation

    Also relays on an extension module may be assigned 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. Please contact DATAKOM for a complete application manual. - 16 -...

  • Page 17: Service Request Display

    DKG-307 User Manual V-37 (01.03.2012) 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 18: 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 19: 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 20: Remote Monitoring And Programming

    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. - 20 -...

  • Page 21: Resuming To Factory Set Parameters

    DKG-307 User Manual V-37 (01.03.2012) 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.

  • Page 22: Gas Engine Fuel Solenoid Control

    DKG-307 User Manual V-37 (01.03.2012) 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.

  • Page 23: Firmware Update

    DKG-307 User Manual V-37 (01.03.2012) 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”...
  • Page 24 DKG-307 User Manual V-37 (01.03.2012) 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.

  • Page 25: J1939 Engine Monitoring And Control Port

    Engine Type parameter should be set accordingly. The list of available engines is given at the programming section. Please contact DATAKOM for the most current list of engines. If the J1939 port is enabled then the oil pressure, coolant temperature and the engine rpm information are picked up from the ECU unit.
  • Page 26 DKG-307 User Manual V-37 (01.03.2012) Below is a basic list of fault conditions (x denotes any FMI) DESCRIPTION Fuel filter restriction Fuel pressure sensor fail Low oil level High oil level Oil level sensor fail Low oil pressure Oil pressure sensor fail...
  • Page 27 DKG-307 User Manual V-37 (01.03.2012) Below is a basic list of FMI codes. Please be aware that these codes may differ slightly depending on the engine brand and model. DESCRIPTION Value too high” Valid data, but above the normal working range “Value too low”...

  • 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: Weekly Operation Schedule

    DKG-307 User Manual V-37 (01.03.2012) 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.

  • Page 30: Event Logging

    DKG-307 User Manual V-37 (01.03.2012) 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 31: Maintenance

    DKG-307 User Manual V-37 (01.03.2012) 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 - 31 -...

  • Page 32: Programming

    DKG-307 User Manual V-37 (01.03.2012) 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.
  • Page 33 DKG-307 User Manual V-37 (01.03.2012) Parameter Definition Unit Fact.Set Description This is the rated value of current transformers. Current Transformer P_000 All transformers must have the same rating. Ratio The secondary of the transformer will be 5 Amps. If the current goes above this limit, during the...
  • Page 34 DKG-307 User Manual V-37 (01.03.2012) Parameter Definition Unit Fact.Set Description If the oil pressure measured from the analog input Low Oil Pressure P_018 falls below this limit, this will generate a LOW OIL Warning PRESSURE SENDER warning. If the oil pressure measured from the analog input...
  • Page 35 DKG-307 User Manual V-37 (01.03.2012) Parameter Definition Unit Fact.Set Description This parameter provides the mains and genset voltage limits with a hysteresis feature in order to prevent faulty decisions. For example, when the mains are present, the P_029 Hysteresis Voltage mains voltage low limit will be used as the programmed low limit.
  • Page 36 DKG-307 User Manual V-37 (01.03.2012) Parameter Definition Unit Fact.Set Description This is the period after the mains contactor has Genset Contactor P_043 been deactivated and before the generator Timer contactor has been activated. This is the period after the generator contactor has...
  • Page 37 DKG-307 User Manual V-37 (01.03.2012) Following parameters are in “high” priority group. Parameter Definition Unit Fact.Set Description If the genset power is negative and goes above Reverse power P_059 this limit then a REVERSE POWER warning will warning limit be generated.
  • Page 38 See chapter 6.8 for more info. Delayed Simulate Mains Operation: max genset running time after Simulate Mains signal disappears. P_086 Flashing Relay Timer hours Dual Genset Systems: flashing relay toggle timer. Please contact DATAKOM for dual genset mutual stanby operation. - 38 -...
  • Page 39 DKG-307 User Manual V-37 (01.03.2012) Parameter Definition Unit 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. The exercise may be selected to start at the beginning of the any hour of the week.
  • Page 40 DKG-307 User Manual V-37 (01.03.2012) Below parameters are applicable to J1939 enabled versions only. Parameter Definition Unit Fact.Set Description 0: The J1939 port is inoperative. 1: The analog measurements (oil, temp, rpm) are P_094 J1939 Enable picked_up from the ECU. If the ECU communication is lost, then the engine will be stopped.
  • Page 41 DKG-307 User Manual V-37 (01.03.2012) Parameter Definition Unit Fact.Set Description When secondary volt/freq limits are active: If the current goes above this limit, during the period defined in Overload Timeout then a P_098 2 Overcurrent Limit Overcurrent Load Dump alarm will be generated.
  • Page 42 DKG-307 User Manual V-37 (01.03.2012) Parameter Definition Unit Fact.Set Description When secondary volt/freq limits are active: Low rpm If the engine speed goes under this limit, a GENSET P_111 Shutdown LOW SPEED alarm is generated and the engine stops. When secondary volt/freq limits are active:...
  • Page 43 DKG-307 User Manual V-37 (01.03.2012) Oil Pressure Sender Characteristics Parameter Definition Unit Factory Set Description Oil Pressure Sender point 1, ohm value P_136 Oil Pressure Sender Ohms -1 Oil Pressure Sender point 1, bar value P_137 Oil Pressure Value -1...
  • Page 44 DKG-307 User Manual V-37 (01.03.2012) Program Group: Sender Characteristics (password level-2) Parameter Definition Unit Fact.Set Description Temperature Sender point 1, ohm value P_172 Oil Temperature Sender Ohms -1 ohm Temperature Sender point 1, °C value °C P_173 Oil Temperature Value -1...
  • Page 45 DKG-307 User Manual V-37 (01.03.2012) Coolant Level Switch Input Configuration Parameter Definition Unit Fac.Set Description 0: Shutdown (the engine stops immediately) 1: Load Dump (the engine stops after cooldown) P_196 Action 2: Warning (the horn relay operates) 3: No operation...
  • Page 46 DKG-307 User Manual V-37 (01.03.2012) Spare–1 Input Input Configuration Parameter Definition Unit Fac.Set Description 0: Shutdown (the engine stops immediately) 1: Load Dump (the engine stops after cooldown) P_214 Action 2: Warning (the horn relay operates) 3: No operation 0: Always...
  • Page 47 DKG-307 User Manual V-37 (01.03.2012) 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 RELAY- 2 have programmable functions, selected from a list.
  • Page 48 DKG-307 User Manual V-37 (01.03.2012) The function of a programmable relay output may be selected from below list. Fuel Oil switch alarm Oil switch warning Alarm Temp switch alarm Temp switch warn. Start Coolant Level switch Coolant Level switch alarm...

  • Page 49: Troubleshooting

    DKG-307 User Manual V-37 (01.03.2012) 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 50 DKG-307 User Manual V-37 (01.03.2012) 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 51: Declaration Of Conformity

    DKG-307 User Manual V-37 (01.03.2012) 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 52: Technical Specifications

    DKG-307 User Manual V-37 (01.03.2012) 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 53: Connection Diagrams

    DKG-307 User Manual V-37 (01.03.2012) 17. CONNECTION DIAGRAMS - 53 -...
  • Page 54 DKG-307 User Manual V-37 (01.03.2012) 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 - 54 -...

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