dkg-215 manual and remote start unit features
Contents
1. HIGH BATTERY Set if the battery voltage goes outside programmed limits During engine cranking this fault is not monitored Warning level for low battery voltage P_10 and both warning P_11 and alarm P_12 levels for high battery voltage are programmable BELT BROKEN Set if a charge alternator failure or broken belt occurs This fault condition may result to a warning or alarm following programming P_34 EMERGENCY STOP Set if a signal is detected at the emergency stop input LOW FUEL LEVEL Set if a signal is detected at the Low Fuel Level Switch input or the fuel level measured from the sender is below the programmed limit Warning P_17 and alarm P_18 limits are separately programmable for the fuel level sender input LOW COOLANT LEVEL Set if a signal is detected at the Low Coolant Level input SERVICE REQUEST Please rewiev chapter 6 6 DKG 215 User Manual V 01 20 10 2009 5 MODES OF OPERATION The unit will power up when the front panel RUN button is pressed It will turn off if the STOP button is pressed If no key is pressed it will power down automatically after approximately 4 minutes If needed the automatic power down feature may be disabled with the program parameter P_37 When the unit is powered up if the RUN button is pressed again then the genset will run When the engine is running the GENERATOR led will flash When the genset is ready for load it will turn on steadily If the STOP button is pressed the gense2. 1 Latching 68 Contact type 0 0 Normally open 1 Normally closed 69 Switching 0 0 Battery negative 1 Battery positive 70 Response delay 1 0 No delay 1 Delayed 4sec LOW FUEL LEVEL SWITCH INPUT Pgm Description Std 71 Operation 0 0 Alarm the engine stops and horn output operates 2 Warning the horn output operates 3 No operation 72 Fault monitoring 0 0 Always 1 After holdoff timer 73 Latching 1 0 Non latching 1 Latching 74 1 Contact type 0 0 Normally open 1 Normally closed 75 Switching 0 0 Battery negative 1 0 1 Delayed 4sec 20 DKG 215 User Manual EMERGENCY STOP INPUT V 01 20 10 2009 Pgm 1 Description Std 77 Operation 0 0 Alarm the engine stops and horn output operates 2 VVarning the horn output operates 3 No operation 78 Fault monitoring 0 0 Always 1 After holdoff timer 79 Latching 0 0 Non latching 1 Latching 80 Contact type 0 0 Normally open 1 Normally closed 81 Switching 0 0 Battery negative 1 Battery positive 82 Response delay 0 0 No delay 1 Delayed 4sec Parameters from P_83 to P_94 define the ohm bar characteristics of the oil pressure sender The sender characteristics will be defined using maximum 6 points The values should be entered in the increasing order of ohm values For unused points ohm values should be entered as 0 An example table is given below The sensor characteris
3. When the MENU key is released it will show the last 3 digits of the remaining days to service 6 7 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 by power supply failures The engine hours may be displayed via the statistics menu selected by pressing the MENU key for 1 second When the MENU key is pressed the display will show EnH engine hours When the MENU key is released it will show the first 3 digits of the engine hours When the MENU key is pressed again the display will show EnH engine hours When the MENU key is released it will show the last 3 digits of the engine hours 12 DKG 215 User Manual V 01 20 10 2009 6 8 Remote Monitoring and Programming Thanks to its serial port the unit offers the remote monitoring and programming feature The serial port has logic level outputs and is connected to the PC or modem with below RS 232 adapter and cable The adapter cable assembly is available at Datakom converter i DEL SERIAL The RAINBOW remote monitoring and programming PC software may be downloaded from www datakom com tr internet site The RAINBOW software allows the visualization and recording of all measured parameters The recorded parameters may then be analyzed graphically and printed The software also allows the programming of the unit and the storage of the program
4. are Fuel and Start The function of a programmable output may be selected from the below list DIGITAL OUTPUT FUNCTION LIST Pgm Description Std 00 Fuel 24 Oil sender alarm 50 RELAY 1 function 03 01 Horn 25 Temp sender alarm 52 RELAY 2 function 01 02 Start 26 Speed alarm 52 RELAY 3 function 07 03 Stop 27 Start fail alarm 04 Genset Contactor 28 Belt alarm 05 29 Overload alarm 06 Choke 30 1 Voltage alarm 07 Preheat 31 1 Battery High alarm 08 Shutdown alarm 32 1 Oil switch warning 09 Warning 33 Temp switch warn 10 Alarm Warning 34 Coolant level warn 11 35 Low fuel sw warn 12 36 1 Emerg Stop warn 13 37 14 Genset Voltage OK 38 15 Service Request 39 16 Oil switch alarm 40 Oil sender warning 17 Temp switch alarm 41 1 Temp sender warn 18 Coolant level alarm 42 Speed warning 19 Low fuel sw alarm 43 Fail to Stop 20 Emerg Stop alarm 44 Belt warning 21 l 45 Battery low warning 22 46 Fuel Sender Warn 23 47 Battery high warn Parameters from P 53 to P_82 program the functions of the digital inputs The programmable properties of digital inputs are action to be taken upon arrival of the fault signal alarm warning etc when the fault monitoring will be enabled latching of the fault signal contact type NO NC svvitch
5. output Connect the charge alternator s D terminal to this terminal This terminal will supply the excitation current and measure the voltage of the charge alternator 22 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 23 COOLANT TEMP SENDER Input 0 5000 ohms Analogue high temperature sender connection Do not connect the sender to other devices The input has programmable characteristics and connects to any kind of sender 24 FUEL LEVEL SENDER Input 0 5000 ohms Analogue fuel level sender connection Do not connect the sender to other devices The input has programmable ohm value DKG 215 User Manual V 01 20 10 2009 3 DISPLAY 3 1 Led Displays The unit has 20 LEDs grouped as belovv Function Color Description GENERATOR Yellovv The LED will flash when the generator is running It turns on when genset contactor output function is active genset ready for load AUTO OFF RUN Yellow The LED will turn on when the related operating mode is selected SERVICE REQUEST Red Engine periodic maintenance request indicator It turns on when the preset engine hours or time duration after previous service has elapsed ALARM GROUP Red If a warning condition has occurred the related led flashes f a fault condit
6. parameter number when the MENU key is released the display will show the program parameter value The first program number is P00 Each depression of the MENU key will cause the display to switch to the next program parameter If the MENU key is hold pressed the program numbers will increase by steps of 10 After the last parameter the display switches back to the first parameter The displayed parameter value may be increased or decreased using A and W keys If these keys are hold pressed the program value will be increased decreased by steps of 10 Program parameters are kept in a non volatile memory and are not affected from power failures To exit the program mode press one of the mode selection keys If no button is pressed during 1 minute the program mode will be cancelled automatically Pgm Definition Unit Std Val Description This is the rated value of the current transformer The secondary of the transformer will be 5 Amps For values over 990A use 10 0 Current Transformer A 500 of the value These values will be displayed as Primary K Amperes for ex 1 85KA Values under 100A may be used by multiplying with 10 in order to enable the current display with 0 1A precision for ex 35 7A This parameter determines the display range of current and active power Current Transformer p 1 f 0 0 000 999 Decimal Point 1 0 00 9 99 2 00 0 99 9 If the current goes above this limit during
7. parameters to PC or the downloading of stored parameters from PC to the unit 13 DKG 215 User Manual V 01 20 10 2009 7 STATISTICAL COUNTERS The unit provides a set of non resettable incremental counters for statistical purposes The counters consist on total engine cranks total genset runs total genset on load These counters are kept in a non volatile memory and are not affected from power failures The statistical counters are only displayed on the PC screen using the remote monitoring and programming software They can not be displayed on the unit 8 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 14 DKG 215 User Manual V 01 20 10 2009 9 PROGRAMMING The program mode is used to program the timers operational limits and the configuration of the unit To enter the program mode press the MENU button for 5 seconds The program mode is only allowed if the PROGRAM LOCK input terminal 5 is left open If this input is tied to GROUND the program value modification vvill be disabled to prevent unauthorized intervention lt is advised to keep the PROGRAM LOCK input tied to GROUND The program mode will not affect the operation of the unit Thus programs may be modified anytime even while the genset is running In program mode when the MENU key is pressed the display will show the program
8. program parameter P_33 29 Cooling Timer min This is the period that the generator runs for cooling purpose after the unloading 30 Stop Timer sec This is the maximum time duration for the engine to stop During this period the STOP output function is active 31 Start Attempts This is the maximum number of start attempts ve DKG 215 User Manual V 01 20 10 2009 Pgm Definition Unit Std Val Description 32 Horn Timer sec 30 This is the period during which the HORN output function is active If the period is set to 0 this will mean that the period is unlimited 33 Engine Heating Type 0 This parameter defines the engine heating method The genset will not take the load before engine heating is completed 0 engine is heated during the period defined by the Engine Heating Timer P_28 1 engine is heated until the coolant temperature reaches the temperature defined by Engine Heating Temperature P_22 and at least during the period defined by the Engine Heating Timer P_28 34 Charge input alarm 0 0 The charge input generates BELT warning and does not stop the engine 1 The charge input generates BELT alarm and stops the engine 35 Maintenance Period hours 50 The SERVICE REQUEST led indicator will turn Engine Hours on after this quantity of engine hours from the last service If the period is s
9. provides the genset voltage limits with a hysteresis feature in order to prevent faulty decisions For example when the genset voltage is present the genset voltage low limit will be used as the programmed low limit P_04 When the genset fails the low limit will be used as P_04 P_21 It is advised to set this value to 8 volts 22 Engine Heating Temperature 50 If it is requested that the engine runs without load until reaching a certain temperature this parameter defines the temperature 23 Holdoff timer sec This parameter defines the delay after the engine runs and before the fault monitoring is enabled 24 Overcurrent Excess Power Frequency Timer sec This is the period between the current or active power goes over the limits P_02 P_03 and OVERLOAD alarms occurs This is also the period between the frequency goes out of the limits P_06 P_09 and SPEED FAULT alarm occurs 25 Preheat timer sec This is the time after the fuel solenoid is energized and before the genset is started During this period the PREHEAT output function will be active 26 Start Timer sec This is the maximum start period Starting will be automatically cancelled if the genset fires before the timer 27 Wait between Starts sec This is the waiting period between two start attempts 28 Engine Heating Timer sec This is the period used for engine heating following the
10. the unit will start Optionally the oil pressure switch may be replaced The engine starts to run but the unit gives START FAIL alarm and then the engine stops The generator phase voltage is not connected to the unit Measure the AC voltage between terminals L1 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 The unit is late to remove engine cranking The generator voltage rises lately Also the generator remnant voltage is below 20 volts The unit removes starting with the generator frequency and needs at least 20 volts to measure the frequency If this situation is to be avoided the only solution is to add an auxiliary relay The coil of the relay will be between BATTERY and charging alternator D terminal The normally closed contact of the relay will be connected serially to the unit s START output So the starting will also be removed when the D pulls to battery positive 22 DKG 215 User Manual V 01 20 10 2009 The unit is inoperative Measure the DC supply voltage between terminals 12 and 15 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 Th
11. 1 Led Displays 3 2 Digital Display ALARMS AND WARNINGS MODES OF OPERATION OTHER FEATURES 6 1 Engine Control Mode 6 2 Remote start operation 6 3 Sender type selection 6 4 Engine Heating 6 5 Crank Cutting Options 6 6 Service Request Display 6 7 Engine Hour Meter 6 8 Remote Monitoring and Programming 7 STATISTICAL COUNTERS 8 MAINTENANCE 9 PROGRAMMING 10 TROUBLESHOOTING 11 DECLARATION OF CONFORMITY 12 TECHNICAL SPECIFICATIONS 13 CONNECTION DIAGRAM C N ou A DKG 215 User Manual V 01 20 10 2009 1 INSTALLATION 1 1 Introduction to the Control Panel The unit is a control and protection panel used in gensets t shovvs 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 Hovvever programmable parameters allovv the complete control 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 current phase L1 Gen frequency Gen KW phase L1 Gen power factor phase L1 Battery voltage Engine rpm Coolant temperature Oil pressure Fuel level 1 2 Mounting the Unit The unit is designed for panel mounting The user should not be able to access parts of t
12. AC voltage or frequeney displayed on the unit are not correct Check engine body grounding it is necessary The error margin of the unit is 3 volts f 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 f there are faulty measurements only when mains are present then the battery charger may be failed Turn off the rectifier fuse and check KW and cos readings are negative although the Amp readings are correct The current transformer is connected with reverse polarity Change the CT polarity VAN Short circuit the outputs of unused Current Transformers When the engine is to run the unit energizes the fuel solenoid but does not start and OIL PRESSURE led flashes 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 led flashes The oil pressure switch closes very lately As the unit senses an oil pressure it does not start When oil pressure switch closes
13. DKG 215 User Manual V 01 20 10 2009 D DATAKOM Tel 90 216 466 84 60 Fax 90 216 364 65 65 datakom datakom com tr http www datakom com tr D DATAKOM BEH v A H z rpm ENGINE RUNNING DKG 215 MANUAL AND REMOTE START UNIT DKG 215 FEATURES Manual and remote starting and stopping Zero power consumption at rest Engine control mode available Generator protection Built in alarms and warnings 1 phase genset voltage input 1 phase genset CT input Magnetic Pickup input Engine oil pressure measurement Engine coolant temperature measurement Engine fuel level measurement Genset active power measurement single phase Genset power factor measurement single phase Periodic maintenance request indicator Engine hours run counter Event logging Statistical counters Front panel configurable 100 adjustable parameters Logic level serial port Optional RS 232 adapter Free MS Windows Remote monitoring SW monitoring download of parameters LED displays Configurable analogue inputs 3 Configurable digital inputs 5 Digital outputs 5 Survives cranking dropouts Sealed front panel Plug in connection system for easy replacement Small dimensions 96x96x53mm Low cost DKG 215 User Manual V 01 20 10 2009 TABLE OF CONTENTS Section 1 INSTALLATION 1 1 Introduction to the Control Panel 1 2 Mounting the Unit 1 3 VViring the Unit INPUTS AND OUTPUTS DISPLAYS 3
14. _23 when the engine runs If P_42 1 then rpm 10 will be used instead of frequency High Speed Warning Hz rpm 54 If the genset frequency goes over this limit a SPEED warning will be generated This warning will be monitored after delay defined in P_23 when the engine runs If P_42 1 then rpm 10 will be used instead of frequency High Speed Alarm Hz rpm 57 If the genset frequency goes over this limit a SPEED alarm will be generated and the engine will stop This alarm will be monitored after delay defined in P_23 when the engine runs If P_42 1 then rpm 10 will be used instead of frequency 10 Low Battery Voltage Warning 9 0 If the battery voltage falls below this limit this will generate a BATTERY warning 11 High Battery Voltage Warning 31 0 If the battery voltage goes over this limit this will generate a BATTERY warning 12 High Battery Voltage Alarm 33 0 If the battery voltage goes over this limit this will generate a BATTERY alarm and the engine will stop 13 Low Oil Pressure Warning Bar If the oil pressure measured from the analog input falls below this limit this will generate an LOW OIL PRESSURE warning This input will be monitored after delay defined in P_23 when the engine runs 14 Low Oil Pressure Alarm Bar If the oil pressure measured from the analog input falls below this limit this will generate an LOW OIL PRESSURE al
15. a list See PROGRAMMING section for more details 11 REMOTE START Input In AUTO mode the battery positive voltage applied to this input will cause the engine to run If the unit is not in AUTO mode this signal will turn on the unit but the engine will not run 12 BATTERY POSITIVE 12 or 24VDC The positive terminal of the DC Supply shall be connected to this terminal The unit operates on both 12V and 24V battery systems 13 MAGNETIC PICKUP MAGNETIC PICKUP Inputs 1 30V 0 10KHz Connect the magnetic pickup signal to these inputs 15 GROUND O VDC Power supply negative connection DKG 215 User Manual V 01 20 10 2009 Term Function Technical data Description 16 RELAY 3 PREHEAT Output 10A 28VDC This digital output has programmable function selectable from a list 17 RELAY 2 ALARM Output 10A 28VDC This digital output has programmable function selectable from a list 18 RELAY 1 STOP RELAY Output 10A 28VDC This digital output has programmable function selectable from a list 19 START RELAY Output 10A 28VDC This digital output controls the engine cranking 20 FUEL RELAY Output 10A 28VDC This digital output is used for fuel solenoid control It is internally connected to terminal 21 for supplying the charge alternator s excitation current 21 CHARGE Input and
16. adapter module is needed V 01 20 10 2009 Term Function Technical data Description 1 L1 Generator phase input 0 300V AC Connect the generator phase to this input The generator phase voltage upper and lower limits are programmable GENERATOR NEUTRAL Input 0 300V AC Neutral terminal for the generator phases CURR_U CURR_U Current transformer inputs 5A AC Connect the generator current transformer terminals to these inputs Do not connect the 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 secondary winding rating shall be 5 Amperes For ex 200 5 Amps PROGRAM LOCK Input If this input is connected to Battery negative then Program mode entry will be disabled EMERGENCY STOP SW LOW FUEL LEVEL SWITCH LOW COOLANT LEVEL SW o 00 N HIGH TEMP SWITCH LOW OIL PRESSURE SW Digital inputs These inputs have programmable characteristics selected via the program menu Each input may be driven by a normally closed or normally open contact switching either battery or battery The effect of the switch is also selectable from
17. arity 1 bit stop Operating temperature range 20 C to 70 C 4 F to 158 F Storage temperature range 30 C to 80 C 22 F to 176 F Maximum humidity 95 non condensing IP protection IP65 from front panel IP30 from the rear Dimensions 96 x 96 x 53mm WxHxD Panel Cut out dimensions 91 x 91mm minimum Mounting Front panel mounted with rear retaining plastic brackets Weight 170 g approx Case material High temperature self extinguishing ABS UL94 V0 DKG 215 User Manual V 01 20 10 2009 13 CONNECTION DIAGRAM Charge Alt L s pu mnss ld Ho a 1 PU 19A 7 o L1 o L2 o L3 oN J N4 MOT ALTERNATOR 3UE1002 MOT eanjesodwiey ubiH ss HO yes l y Battery negative must be grounded wo d z N FO m s De t oN Sa Ba 3 T P 5 s 24
18. arm This input will be monitored after delay defined in P_23 when the engine runs 15 High Temperature Warning 90 If the coolant temperature measured from the analog input goes over this limit this will generate a HIGH ENG TEMP warning 16 High Temperature Alarm 98 If the coolant temperature measured from the analog input goes over this limit this will generate a HIGH ENG TEMP alarm and the engine will stop 17 Low Fuel Warning 20 If the fuel level measured from the analog input falls below this limit this will generate a LOW FUEL warning 18 Low Fuel Alarm 10 If the fuel level measured from the analog input falls below this limit this will generate a LOW FUEL alarm and the engine will stop 16 DKG 215 User Manual V 01 20 10 2009 Pgm Definition Unit Std Val Description 19 Oil pressure sender type This parameter selects the oil pressure sender type 0 Non standard sender The sender characteristics are defined in table using parameters P_83 to P_94 1 VDO 0 7 bars 10 180 ohms 2 VDO 0 10 bars 10 180 ohms 3 DATCON 0 7 bars 240 33 ohms 20 Temperature sender type This parameter selects the temperature sender type 0 The sender characteristics are defined in table using parameters P_95 to P_106 1 VDO 2 DATCON DAH type 3 DATCON DAL type 21 Hysteresis Voltage This parameter
19. e program lock input disables programming mode entry Disconnect the program lock input from battery negative before modification Do not forget to make this connection again to prevent unauthorized program modifications 11 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 12 TECHNICAL SPECIFICATIONS Alternator voltage 15 to 300 V AC Ph N Alternator frequency 0 100 Hz Current input from current transformer 5A Max load 0 7VA Digital inputs input voltage 0 30 V DC 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 Magnetic pickup input 1 30V AC 0 to 10 KHz Measurement category CAT II Air category Pollution degree l DC Supply range 9 0 V DC to 33 0 V DC Cranking dropouts survives 0 V for 100ms Typical standby current 0 mA DC Maximum operating current 100 mA DC digital outputs open Digital outputs 1A 28 V Negative pulling protected semiconductor outputs Charge alternator excitation current 150 mA DC minimum Serial port Logic levels 2400 bauds no p
20. et to 0 no SERVICE REQUEST will be generated depending on engine hours 36 Maintenance Period month 6 The SERVICE REQUEST led indicator will turn Months on after this amount of time from the last service If the period is set to 0 no SERVICE REQUEST will be indicated depending on time 37 Disable auto power_off 0 0 0 1 there is no alarm the unit powers down 4 minutes after engine stop 1 the unit does not power_down 38 Fuel Level Sender Ohms ohms 180 Fuel level sender max resistance 180 ohms and 300 ohms senders are common 39 1 Crank Teeth count 60 This is the number of pulses generated by the magnetic pickup sensing unit in one turn of the flywheel 40 1 Crank Stop with Oil 0 0 no crank stop vvith oil pressure Pressure 1 cranking is stopped when oil presure switch is open or the oil pressure measured is above shutdown limit 41 Crank Stop vvith Charge 0 0 no crank stop vvith charge input 1 cranking is stopped when the charge alternator voltage is established 42 Speed protection on MPU 0 speed protections on frequency 1 speed protections on rom 43 Unused 44 Unused 45 1 Unused 46 1 Unused 47 1 Unused 48 1 Unused 49 Unused 18 DKG 215 User Manual V 01 20 10 2009 The parameters P 050 to P 052 define the functions of digital outputs The unit has 5 digital outputs and 3 of them have programmable functions The fixed function outputs
21. he unit other than the front panel Mount the unit on a flat vertical surface The unit fits into a standard panel meter opening of 91x91 millimeters Before mounting remove the connectors from the unit then pass the unit through the mounting opening The unit will be maintained in its position by the mounting brackets Screw gently in the fixing screws Engine body must be grounded for correct operation of the unit otherwise incorrect voltage and frequency measurements may occur The output of the current transformer shall be 5 Amperes The input current rating of the current transformers may be selected as needed between 10 5 and 9000 5 amps Current transformer outputs shall be connected by separate cable pairs from each transformer to related inputs Never use common terminals or grounding The power rating of the transformer should be at least 5 VA It is recommended to use 1 precision transformers If analogue senders e g temperature or oil pressure are connected to the unit it is not possible to use auxiliary displays otherwise the unit may be destroyed If temperature or oil pressure 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
22. ing bat bat response delay LOW OIL PRESSURE SWITCH INPUT Pgm Description Std 53 1 Operation 0 Alarm the engine stops and horn output operates 0 2 VVarning the horn output operates 3 No operation 54 1 Fault monitoring 1 0 Alvvays 1 After holdoff timer 55 Latching 1 0 Non latching 1 Latching 56 1 Contact type 0 0 Normally open 1 Normally closed 57 1 Switching 0 0 Battery negative 1 Battery positive 58 Response delay 1 0 No delay 1 Delayed 4sec 07 DKG 215 User Manual HIGH TEMPERATURE SWITCH INPUT V 01 20 10 2009 Battery positive 64 Response delay Pgm Description Std 59 Operation 0 Alarm the engine stops and horn output operates 0 2 Warning the horn output operates 3 No operation 60 Fault monitoring 0 0 Always 1 After holdoff timer 61 Latching 1 0 Non latching 1 Latching 62 1 Contact type 0 0 Normally open 1 Normally closed 63 1 Switching 0 0 Battery negative 1 0 1 No delay Delayed 4sec LOW COOLANT LEVEL SWITCH INPUT Battery positive 76 Response delay No delay Pgm Description Std 65 Operation 0 0 Alarm the engine stops and horn output operates 2 Warning the horn output operates 3 No operation 66 1 Fault monitoring 0 0 Always 1 After holdoff timer 67 Latching 1 0 Non latching
23. ion resulting to the engine shutdown has occurred the related alarm led turns on steadily The alarms work on a first occurring basis The occurrence of a fault will disable other faults of lower or equal priority UNIT GROUP Red This group indicates the unit of the value displayed in the digital display By default the unit displays the genset frequency Different values may be scrolled by pressing the MENU key 3 2 Digital Display The unit has a three digit seven segment display It shows Measured parameters Parameter names Service counters Program parameters The navigation between different screens in a group is made with the MENU button When the MENU key is pressed the parameter name will be displayed By pressing the MENU key below values may be displayed generator phase L1 to neutral voltage generator phase L1 current generator frequency generator cos phase L1 generator active power phase L1 oil pressure bar coolant temperature C fuel level battery voltage Holding the MENU button pressed for 1 second makes the display to switch to the service counters group total engine hours engine hours to service time to service DKG 215 User Manual V 01 20 10 2009 4 ALARMS AND VVARNINGS Alarms indicate an abnormal situation in the generating set are divided into 2 priority levels 1 ALARMS These are the most important fault conditions and cause The re
24. lated alarm led to turn on steadily The engine to be stopped immediately The Horn Alarm and Alarm Warning output functions to become active 2 WARNINGS These conditions cause The related alarm led to flash The Horn and Alarm Warning output functions to become active If the ALARM MUTE button is pressed the Horn output function will be deactivated however the existing alarms will persist and disable the operation of the genset Alarms operate in a first occurring basis If an alarm is present following alarms 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 latching alarms even if the alarm condition is removed the alarms will stay on and disable the operation of the genset The existing alarms may be canceled by pressing one of the operating mode buttons AUTO RUN STOP Most of the alarms have programmable trip levels See the programming chapter for user 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 P_13 and alarm P_14 limits are separately programmable for the oil pressure sender input This fault will be monitored with holdoff timer P_23 delay after the engine is running Also if the oil pressure switch is open at the beginning of a start attemp
25. normally closed contacts switching either to BAT or BAT The charge alternator connection terminal provides also the excitation current thus it is not necessary to use an external charge lamp DKG 215 User Manual V 01 20 10 2009 1 3 VViring the Unit WARNING THE UNIT IS NOT FUSED Use external fuses for Generator phase L1 Battery positive BAT Install the fuses as nearly as possible to the unit in a place easily accessible for the user The fuse rating should be 6 Amps WARNING ELECTRICITY CAN KILL ALWAYS disconnect the power BEFORE connecting the unit 1 ALWAYS remove the plug connectors when inserting wires with a screwdriver 2 ALWAYS refer to the National Wiring Regulations when conducting installation 3 An appropriate and readily accessible set of disconnection devices e g automatic fuses MUST be provided as part of the installation 4 The disconnection device must NOT be fitted in a flexible cord 5 The building mains supply MUST incorporate appropriate short circuit backup protection e g a fuse or circuit breaker of High Breaking Capacity HBC at least 1500A 6 Use cables of adequate current carrying capacity at least 0 75mm and temperature range DKG 215 User Manual 2 INPUTS AND OUTPUTS SERIAL DATA This connector provides logic level serial data input and output for various purposes like remote monitoring and remote programming In order to connect to a PC an RS 232
26. quested temperature is reached the genset contactor output function will become active This operation mode may be used as a backup to the engine body heater If the engine body is warm the heating will be skipped 6 5 Crank Cutting Options The unit cuts cranking automatically when at least one of below conditions are met Genset frequency greater than 10 0 Hz Genset voltage greater than 80 volts Engine rpm greater than 511 rpm Additionally crank cutting with oil pressure and charge alternator voltage are available P_40 1 Crank is cut when oil pressure is established detected either from sender or switch input P_41 1 Crank is cut when charge alternator voltage is above 8 Volts Thus the total numbers of resources for crank cutting is 6 11 DKG 215 User Manual V 01 20 10 2009 6 6 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 The unit has both programmable engine hours and maintenance time limit The engine hours is programmable vvith 50 hour steps P 35 the time limit is programmable betvveen vvith 1 month steps P 36 f any of the programmed values i
27. ry and selectable from a list Hovvever non standard senders may also be used by entering their characteristics to the table Oil Pressure Sender Type Selection The oil pressure sender is selected using parameter P 19 The selectable sender types are 0 The sender characteristics are defined in table using parameters P 83 to P 94 1 VDO 0 7 bars 10 180 ohms 2 VDO 0 10 bars 10 180 ohms 3 DATCON 0 7 bars 240 33 ohms Temperature Sender Selection The temperature sender is selected using parameter P 20 The selectable sender types are 0 The sender characteristics are defined in table using parameters P 95 to P 106 1 VDO 2 DATCON DAH type 3 DATCON DAL iype 6 4 Engine Heating Operation Especially on engines vvithout a body heater or vvith 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 vvays of engine heating 1 Timer controlled heating This operation mode is selected when the parameter P_33 is set to 0 In this mode the engine will run during parameter P_28 and then the genset contactor output function will become active 2 Timer and temperature controlled heating This operation mode is selected when the parameter P_33 is set to 1 In this mode at first the engine will run during parameter P_28 then it will continue to run until the measured coolant temperature reaches the limit defined in parameter P_22 When the re
28. s zero this means that the parameter vvill not be used For example a maintenance period of 0 months indicates that the unit vvill 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 the SERVICE REQUEST display vvill be inoperative When the engine hours OR the time limit is over the SERVICE REQUEST led red will start to flash To turn off the led and reset the service period press together the ALARM MUTE and LAMP TEST keys for 5 seconds The display vvill shovv SER The remaining engine hours and the remaining time limit are kept stored in a non volatile memory and are not affected by power supply failures The remaining time and engine hours to service may be checked via the statistics menu selected by pressing the MENU key for 1 second When the MENU key is pressed the display will show HtS hours to service When the MENU key is released it will show the first 3 digits of the engine hours to service When the MENU key is pressed again the display will show HtS hours to service When the MENU key is released it will show the last 3 digits of the engine hours to service When the MENU key is pressed the display will show ttS time to service When the MENU key is released it will show the first 3 digits of the remaining days to service When the MENU key is pressed again the display will show ttS time to service
29. t then the engine will not be started and the oil pressure led will flash When the oil pressure switch closes normal operation will be resumed HIGH ENGINE TEMPERATURE Set if a signal is detected at the High Temperature Switch input or the coolant temperature value measured from the sender is above the programmed limit Warning P_15 and alarm P_16 limits are separately programmable for the temperature sender input OVER UNDER _ SPEED Set if the generator frequency is outside programmed limits overspeed Underspeed This fault will be monitored with holdoff timer P_23 delay after the engine is running Different low and high limits for warning and alarm are separately programmable P_06 P_07 P_08 P_09 FAIL TO START Set if the engine is not running after programmed number of start attempts P_31 OVERLOAD Set if the genset phase current goes over the Overcurrent Limit P_02 or if the genset phase active power KW measured on phase L1 goes over the Excess Power P_03 limit for Overcurrent Excess Power Timer P_24 If the current and power go below the limits before expiration of the timer then no alarm will be set If the Overcurrent Limit P_02 or Excess Power P_03 limit is set to zero then the corresponding check will be omitted LOVV HIGH VOLTAGE Set if any of the generator phase voltages goes outside programmed limits P_04 P_05 This fault will be monitored with holdoff timer P_23 delay after the engine is running LOW
30. t will stop but the unit will stay powered up If the STOP button is pressed again or no key is pressed during 4 minutes then it will power down automatically If an alarm occurs during any operation status the genset will stop and the related alarm led will turn on steadily The unit will not power down until the alarm is cancelled with the STOP button lf AUTO mode is selected then the REMOTE START 11 input is enabled lt does not need any programming Please check chapter 6 1 for the remote start operation POWER OFF RUN V A OFF POWER ON GENSET STOPPED RUN V A OFF RUN THE GENSET DKG 215 User Manual V 01 20 10 2009 6 OTHER FEATURES 6 1 Engine Control Mode The unit offers the possibility of engine speed protection through the magnetic pickup input instead of genset frequency This option enables the control of a diesel engine without alternator The engine control mode is entered by setting the parameter P_42 1 When P_42 1 the speed protection program parameters P 06 to P 09 apply to the engine rpm instead of the genset frequency In engine control mode when the engine runs the display switches automatically to rpm mode However all measurements can be visualized by pressing the MENU button The engine rpm is displayed with 3 digits in 10 rom steps As an example 1500 rpm is displayed as 1 50 x1000 rpm The engine cranking is cut at 512 rpm Crank cutting with oil pressure and charge alternator are also a
31. the period defined in P_24 an OVERLOAD alarm will be generated Enter this information with the same format as parameter P 00 If the parameter is set to 0 then the Overcurrent checking is skipped 2 Overcurrent Limit A 0 If the active power measured on phase U goes above this limit during the period defined in P_24 an OVERLOAD alarm will be generated Enter this information with the same format as parameter P 00 If the parameter is set to 0 then the Excess Power checking is skipped 3 Excess Power Limit KW 0 4 Gen Voltage Low Limit V 180 If the generator phase voltage goes under this limit when feeding the load this will generate a VOLTAGE alarm and the engine will stop 5 Gen Voltage High Limit V 270 If the generator phase voltage goes over this limit when feeding the load this will generate a VOLTAGE alarm and the engine will stop 15 DKG 215 User Manual V 01 20 10 2009 Pgm Definition Unit Std Val Description Lovv Speed Alarm Hz rpm 30 If the genset frequency goes under this limit a SPEED alarm will be generated and the engine will stop This alarm will be monitored after delay defined in P_23 when the engine runs If P_42 1 then rpm 10 will be used instead of frequency Low Speed Warning Hz rpm 40 If the genset frequency goes under this limit a SPEED warning will be generated This warning will be monitored after delay defined in P
32. tics used in this table are 0 0 bar 240 ohms 1 0 bar 218 ohms 5 0 bar 153 ohms 10 0 bar 103 ohms Pgm 1 Description Unit Value 83 Point 1 resistor ohm 103 84 Point 1 pressure bar 10 0 85 Point 2 resistor ohm 153 86 Point 2 pressure Bar 5 0 87 Point 3 resistor Ohm 218 88 Point 3 pressure Bar 1 0 89 Point 4 resistor Ohm 240 90 Point 4 pressure Bar 0 0 91 Point 5 resistor Ohm 0 92 Point 5 pressure Bar 0 0 93 Point 6 resistor Ohm 0 94 Point 6 pressure bar 0 0 Parameters from P 95 to P 106 define the ohm degrees characteristics of the temperature sender The sender characteristics vvill be defined using maximum 6 polnts The values should be entered in the increasing order of ohm values For unused polnis ohm values should be entered as 0 An example table is given belovv The sensor characteristics used in this table are Pgm 1 Description Unit Value 95 Point 1 resistor ohm 30 96 Point 1 temperature C 121 97 Point_2 resistor ohm 40 98 Point_2 temperature C 104 99 Point_3 resistor ohm 71 100 Point_3 temperature C 82 101 Point 4 resistor ohm 342 102 1 Point 4 temperature C 38 103 Point_5 resistor ohm 0 104 Point_5 temperature C 0 105 Point_6 resistor ohm 0 106 Point_6 temperature C 0 21 DKG 215 User Manual V 01 20 10 2009 10 TROUBLESHOOTING
33. vailable via parameters P_40 and P_41 In engine control mode genset voltage and current inputs can be left open However these inputs can be connected and measured as well Voltage and overload checks are still performed following parameter setting P_02 P_03 P_04 P 05 Below parameters must be programmed to adequate values in engine control mode P_04 0 genset voltage low limit P_06 low rpm shutdown limit P_07 low rpm warning limit P_08 high rom warning limit P 09 high rpm shutdown limit P 40 as desired P 41 as desired 6 2 Remote Start Operation The unit offers the possibility of REMOTE START mode of operation The REMOTE START 11 input is enabled only in AUTO mode and does not need any programming The REMOTE START signal is always the battery positive voltage Due to the zero power at rest structure power should be supplied to this input in order to wake up the unit WARNING Do not connect a voltage greater than the battery positive to this input otherwise permanent damage to the unit may occur The REMOTE START signal is equivalent to 2 successive depressions of the RUN button This means that upon arrival of the REMOTE START signal the unit will power up will run the engine 10 DKG 215 User Manual V 01 20 10 2009 6 3 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 memo
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