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1. Monday Turn_on 07 00 Monday Turn_off 18 00 Tuesday Turn_on 07 00 Tuesday Turn_off 18 00 Wednesday Turn_on 07 00 Wednesday Turn_off 18 00 Thursday Turn_on 07 00 Thursday Turn_off 18 00 Friday Turn_on 07 00 Friday Turn_off 18 00 Saturday Turn_on 07 00 Saturday Turn_off 13 00 Sunday Turn_on 24 00 Sunday no turn on time last operation mode continues Sunday Turn_off 24 00 Sunday no turn off time last operation mode continues If the same time is used for turn on and turn off then it will be considered as a turn on time The unit has a battery backed up precision real time clock circuit The real time clock circuit will continue its operation even in power failures The real time clock is precisely trimmed using the Real Time Clock Adjust program parameter For more details check the programming section ge DKG 519J User Manual V 27 14 04 2011 10 EVENT LOGGING The unit keeps record of the last 200 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 The events are always displayed starting from the most recent one Events are kept in a non volatile memory and are not affected from pow
2. ohm 38 Temperature Sender point 1 ohm value Temperature Value 1 C 100 Temperature Sender point 1 C value Temperature Sender Ohms 2 ohm 51 Temperature Sender point 2 ohm value Temperature Value 2 C 90 Temperature Sender point 2 C value Temperature Sender Ohms 3 ohm 134 Temperature Sender point 3 ohm value Temperature Value 3 C 60 Temperature Sender point 3 C value Temperature Sender Ohms 4 ohm 322 Temperature Sender point 4 ohm value Temperature Value 4 C 39 Temperature Sender point 4 C value Temperature Sender Ohms D ohm 650 Temperature Sender point 5 ohm value Temperature Value 5 C 20 Temperature Sender point 5 C value Temperature Sender Ohms 6 ohm 1630 Temperature Sender point 6 ohm value Temperature Value 6 C 02 Temperature Sender point 6 C value Program Group Sender Characteristics password level 2 Parameter Definition Unit Factory Description Set Oil Temperature Sender Ohms 1 ohm 38 Temperature Sender point 1 ohm value Oil Temperature Value 1 C 100 Temperature Sender point 1 C value Oil Temperature Sender Ohms 2 ohm 51 Temperature Sender point 2 ohm value Oil Temperature Value 2 S 90 Temperature Sender point 2 C value Oil Temperature Sender Ohms 3 ohm 134 Temperature Sender point 3 ohm value Oil Temperature Value 3 C 60 Temperature Sender point 3 C value Oil Temperature Sender Ohms 4 ohm 322
3. No delay Delayed 4sec 48 DKG 519J User Manual V 27 14 04 2011 Program Group Input Configuration Emergency Stop password level 2 Parameter Definition Unit Fac Set Description Action Shutdown the engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operation Sampling Always After holdoff timer When mains present Latching Non latching Latching Contact type Normally open Normally closed Switching Battery negative Battery positive Response delay Og Oos 0 2 ona olun No delay Delayed 4sec Program Group Input Configuration Spare 1 Input password level 2 Parameter Definition Unit Fac Set Description Action Shutdown the engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operation Sampling Always After holdoff timer When mains present Latching Non latching Latching Contact type Normally open Normally closed Switching Battery negative Battery positive Response delay Og Og 0 2 olna ovn No delay Delayed 4sec 49 DKG 519J User Manual V 27 14 04 2011 Program Group Input Configuration Remote Start Input password level 2 Parameter
4. The fuel level reference is measured through the analog fuel level sender When the measured fuel level falls below Fuel Pump Low Limit parameter the fuel pump relay output will operate When the fuel level reaches Fuel Pump High Limit parameter the relay will turn off Thus the chassis fuel tank level will be always kept between Fuel Pump Low Limit and Fuel Pump High Limit parameters The fuel pump relay function may be assigned to spare relays using Relay Definition program parameters Also relays on an extension module may be assigned to this function 6 7 Mains Simulation Disable Start The unit offers an optional SIMULATE MAINS signal input Any digital input may be assigned as Simulate Mains using Input Function Select program parameters It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarms generated from this input The SIMULATE MAINS signal may be a NO or NC contact switching to either battery positive or battery negative These selections are made using the programming menu If the Simulate Mains input is defined and the input signal is active the mains phases are not monitored and supposed to be inside limits This will prevent the genset from starting even in case of a mains failure If the genset is running when the signal is applied then usual Mains Waiting and Cooldown cycles will be performed before engine stop When the SIMULATE MAINS signal is present the front
5. 6 18 Automatic Exerciser 6 19 Resuming to factory set parameters 6 20 Gas engine fuel solenoid control 6 21 Load Shedding Dummy Load 6 22 Fuel Theft Fuelling Messages 6 23 Firmware Update 6 24 Changing the Default Engine Speed in Volvo Engines 6 25 Engine Control Mode 6 26 Dual Voltage and Frequency 6 27 Single Phase Operation 7 J1939 ENGINE MONITORING AND CONTROL PORT 8 MODBUS COMMUNICATION 9 WEEKLY OPERATION SCHEDULE 10 EVENT LOGGING 11 STATISTICAL COUNTERS 12 MAINTENANCE 13 PROGRAMMING 14 TROUBLESHOOTING 15 DECLARATION OF CONFORMITY 16 TECHNICAL SPECIFICATIONS 17 CONNECTION DIAGRAM DKG 519J User Manual V 27 14 04 2011 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 Programmed parameters are stored in a Non Volatile Memory and thus all information is retained even in the event of complete loss of power The measured parameters are Gen voltage phase L1 to neutral Gen voltage phase L2 to neutral Gen voltage phase L3 to neutral Gen voltage phase L1 L2 Gen voltage phase L2 L3 Gen voltage phase L3 L1 Gen curr
6. Definition Unit Fac Set Description Action Shutdown the engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operation Sampling Always After holdoff timer When mains present Latching Non latching Latching Contact type Normally open Normally closed Switching Battery negative Battery positive Response delay Og o o ona olun No delay Delayed 4sec 50 DKG 519J User Manual V 27 14 04 2011 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 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 Parameter Definition Unit Fac Set Description Relay 01 Definition 3 RELAY 1 function selected from list Relay 02 Definition 1 RELAY 2 function selected from list Relay 03 Definition 0 RELAY 3 function expansion module selected from list Relay 04 Definition 2 RELAY 4 function expansion module 1 selected from list Relay 05 Definition 4 RELAY 5 function expansion module 1 selected from list R
7. Fan load dump 105 Gen High voltge warn 28 2 volt frequency 59 Rectifier load dump 106 Reverse Power warn 29 Crank 1 2 Selector 60 Emerg Stop load dump 107 High oil temp warn 30 61 Spare 1 load dump 108 31 62 Spare 2 load dump 109 63 Fuel Level switch 110 load_dump 111 64 Oil sender fail Idd 112 Oil sender fail warn 65 Temp sender fail Idd 113 Temp sender fail warn 66 Fuel Lev sender fail Idd 114 Fuel sender fail warn 67 Oil Temp snd fail Idd 115 Oil temp snd fail warn 68 116 69 117 70 118 71 119 72 Overcurrent load dump 73 Excess power Idd 74 Reverse power Idd 75 76 77 78 79 Genset Phase Order Fail Loaddump 52 DKG 519J User Manual V 27 14 04 2011 The parameters below define the functions of digital inputs selected from a list Functions from 12 to 23 activate also the related operating sequence 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 Set Description Input 01 Function Select 0 Oil Pressure Switch Input 02 Function Select 1 High Temp Switch Input 03 Function Select 2 Low Coolant Level switch Input 04 Function Select 3 Rectifier Fail Input 05 Function Select 4 Emergen
8. It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarm from this input In this mode the mains phases are not monitored If the REMOTE START signal is present then the mains will be supposed to fail inversely if the REMOTE START signal is absent then mains voltages will be supposed to be present The front panels mimic diagram s mains LEDs will reflect the status of the REMOTE START input 6 2 Sender type Selection The unit has the ability to adapt to any type of oil pressure and temperature senders The commonly used standard sender characteristics are recorded in memory and selectable from a list However non standard senders may also be used by entering their characteristics to the table Oil Pressure Sender Type Selection Selectable sender types are 0 Sender characteristics are defined in Sender Characteristics table 1 VDO 0 7 bars 10 180 ohms VDO 0 10 bars 10 180 ohms DATCON 0 7 bars 240 33 ohms DATCON 0 10 bars 240 33 ohms DATCON 0 7 bars 0 90 ohms DATCON 0 10 bars 0 90 ohms DATCON 0 7 bars 75 10 ohms cl OD OO P WD Temperature Sender Selection Selectable sender types are 0 Sender characteristics are defined in Sender Characteristics table 1 VDO 2 DATCON DAH type 3 DATCON DAL type Fuel Level Sender Selection The Fuel Level Sender Ohms is also programmable Oil Temperature Sender Selection Selectable sender types
9. Limit that the mains are off and it starts the transfer to the genset in AUTO mode When secondary volt freg limits are active 2 2 Mains Frequency Hz 65 If the mains frequency goes above this limit it means High Limit that the mains are off and it starts the transfer to the genset in AUTO mode When secondary volt freg limits are active nd If one of the generator phase voltages goes under this SC SE voltage V 90 limit when feeding the load this will generate a GENSET LOW VOLTAGE shutdown alarm and the engine will stop When secondary volt freq limits are active 2 2 Genset Low Voltage V 94 If one of the generator phase voltages goes under this Warning Limit limit when feeding the load this will generate a GENSET LOW VOLTAGE warning When secondary volt freg limits are active 2 2 Genset High Voltage V 130 If one of the generator phase voltages goes above this Warning Limit limit when feeding the load this will generate a GENSET HIGH VOLTAGE warning When secondary volt freg limits are active nd i If one of the generator phase voltages goes over this ye GENE MoN vonage V 136 limit when feeding the load this will generate a Shutdown Limit GENSET HIGH VOLTAGE alarm and the engine will stop 39 DKG 519J User Manual V 27 14 04 2011 Program Group Electrical Parameters continued Parameter Definition Factor Ge Password Level oon Set Descripuion If any of the phase
10. Temperature Sender point 4 ohm value Oil Temperature Value 4 C 39 Temperature Sender point 4 C value Oil Temperature Sender Ohms 5 ohm 650 Temperature Sender point 5 ohm value Oil Temperature Value 5 GC 20 Temperature Sender point 5 C value Oil Temperature Sender Ohms 6 ohm 1630 Temperature Sender point 6 ohm value Oil Temperature Value 6 C 02 Temperature Sender point 6 C value 46 DKG 519J User Manual V 27 14 04 2011 Program Group Input Configuration Low Oil Pressure Switch password level 2 Parameter Definition Unit Ger Description 0 Shutdown the engine stops immediately Action 0 1 Load Dump the engine stops after cooldown 2 Warning the horn relay operates 3 No operation 0 Always Sampling 1 1 After holdoff timer 2 When mains present b 0 Non latching Latching 1 1 Latching 0 Normally open Contact type S 1 Normally closed DER 0 Battery negative Switching Q 1 Battery positive 0 No dela Response delay 0 1 Delaye f 4sec Program Group Input Configuration High Temperature Switch password level 2 Factory Parameter Definition Unit Set Description Shutdown the engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operation Action 0 Always After holdoff timer When mains present Sampling 1 Non latching Latching L
11. The delay between the crank start and solenoid opening is adjusted using the Gas Solenoid Delay program parameter The gas engine fuel solenoid relay function may be assigned to spare relays using Relay Definition program parameters Also relays on an extension module may be assigned to this function 6 21 Load Shedding Dummy Load The load shedding feature consists on the disconnection of the least crucial loads when the genset power approaches to its limits These loads will be supplied again when the genset power falls below the programmed limit The internal Load Shedding function is always active Any of the auxiliary relays may be used as the load shedding output The dummy load function consists on the connection of a dummy load if the total genset load is below a limit and to disconnection of the dummy load when the total power exceeds another limit The dummy load function is the inverse of the load shedding function thus the same output may be used for both purposes The parameters used in Load Shedding feature are in the Electrical Parameters Group Load Shedding Low Limit If the genset active power output goes below this limit then the Load Shedding relay will be deactivated Load Shedding High Limit If the genset active power output goes above this limit then the Load Shedding relay will be activated 24 DKG 519J User Manual V 27 14 04 2011 6 22 Fuel Theft Fuelling Messages The unit is able to send SMS messag
12. and OIL PRESSURE EXISTS message is displayed The oil pressure switch closes very lately As the unit senses an oil pressure it does not start When oil pressure switch closes the unit will start Optionally the oil pressure switch may be replaced When the AC mains fails the engine starts to run but the unit gives START FAIL alarm and then the engine stops The generator phase voltages are not connected to the unit Measure the AC voltage between terminals GEN L1 L2 L3 and Generator Neutral at the rear of the unit while the engine is running A fuse protecting the generator phases may be failed A misconnection may be occurred If everything is OK turn all the fuses off and then turn all the fuses on starting from the DC supply fuse Then test the unit again 55 DKG 519J User Manual V 27 14 04 2011 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 The unit is inoperative Measure the DC supply
13. are 0 Sender characteristics are defined in Sender Characteristics table 1 VDO 2 DATCON DAH type 3 DATCON DAL type 14 DKG 519J User Manual V 27 14 04 2011 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 In this mode the engine will run during parameter Engine Heating Timer and then the generator contactor will be activated 2 Timer and temperature controlled heating This operation mode is selected when the Engine Heating Method parameter is set to 1 In this mode at first the engine will run during parameter Engine Heating Timer then it will continue to run until the measured coolant temperature reaches the limit defined in parameter Engine Heating Temperature When the requested temperature is reached the generator contactor will be operated 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 4 Engine Idle Speed Operation It may be required that the engine runs at the idle speed for a programmed duration for engine heating The idle operation duration is adjusted with the parameter Idle Speed Timer The idle speed will be se
14. be masked causing the audible alarm relay to release and preventing consecutive 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 S DKG 519J User Manual V 27 14 04 2011 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 Modem Enable SMS Enable and MODBUS Address program parameters should be set to 0 before connection 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 parameters to PC or the downloading of stored parameters from PC to the unit For PCs without a serial port below USB to serial adapters are tested and approved DIGITUS USB 2 0 TO RS 232 ADAPTER PRODUCT CODE DA70146 REV 1 1 DIGITUS USB 1 1 TO RS 232 ADAPTER PRODUCT CODE DA70145 REV 1 1 FLEXY USB 1 1 TO SERIAL ADAPTER PRODUCT CODE BF 810 CASECOM US
15. current consumption 130 mADc Maximum current consumption 200 mADC DC outputs 10A 28 VDC relay outputs Charge alternator excitation current min 150 mADC 10 to 30 VDC Current inputs from current transformers 5A Max load 0 7VA per phase Digital inputs input voltage 0 30 VDC Internally connected to battery positive via 4700 ohm resistor Analog inputs Resistor input 0 to 5000 ohms connected to the battery negative Sources 10 mA when closed to battery negative Measurement category CAT II Air category Pollution degree II Communication port RS 232 9600 bauds no parity 1 stop bit Operating temperature range 20 C to 70 C 4 F to 158 F Storage temperature range 40 C to 80 C 40 F to 176 F Maximum humidity 95 non condensing Dimensions 190x135x48mm WxHxD Panel Cut out dimensions 176 x 121mm minimum Weight 350 g approx Case material High temperature self extinguishing ABS PC UL94 V0 IP protection IP65 from front panel IP30 from the rear 58 V 27 14 04 2011 DKG 519J User Manual 17 CONNECTION DIAGRAM Hod uolsua xy 3ndyno 3ndu Hod weiboig pue Duuouuow ajowsay ETE Q v lt ki a D E Ki ainjesodwiay YbIH 18487 JUE 00J yoo UIEIBOid LT 97 ST P ET 2 r E papunolb aq snw anIgbau AJayneg Jepuag dwea uo TT v ig kl lt O LAH J pu dua zuejoog NG JSpuag ANSS2 d WO e F6LS DMG
16. download of parameters networking via modems GSM and PSTN modem support GSM SMS sending in case of alarm Modem call in case of alarm MODBUS communication 128x64 graphic LCD display Triple language support Customer logo display capability Configurable analogue inputs 3 Configurable digital inputs 7 Configurable digital outputs 2 Total digital outputs 4 Output expansion capability Remote Start operation available Engine Idle speed control Survives cranking dropouts Sealed front panel Plug in connection system for easy replacement Dimensions 190x135x48mm DKG 519J User Manual V 27 14 04 2011 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 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 Delayed Mains Simulation Battery Charging 6 9 Dual Genset Mutual Standby Operation 6 10 Service Request Display 6 11 Engine Hours Meter 6 12 Date Time Display 6 13 Display of Software Version 6 14 Modem connection 6 15 SMS message sending 6 16 Remote Monitoring and Programming 6 17 External Control of the Unit
17. keys for 5 seconds The remaining engine hours and the remaining time limit are kept stored in a non volatile memory and are not affected from power supply failures The time and engine hours to service are displayed in the STATISTICAL COUNTERS menu 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 amp Time Display The date amp time display is provided for verification 6 13 Software Version Display Some additional features are installed within consecutive software releases In order to be sure of the validity of the status of the unit the software version needs to be known The software version of the unit is displayed together with the data time information The software version consists of 2 numbers The first number represent the operating software version of the unit 19 DKG 519J User Manual V 27 14 04 2011 6 14 Modem Connection The unit is capable of making modem calls in case of alarm as well as answering modem calls made from a remote location GSM modems and classic cable network PSTN modems are acceptable If the modem is connected to the unit the Modem Enable program parameter should be set to 1 otherwise faulty operation may occur A maximum of 2 telephone numbers can be defin
18. panels mimic diagram s mains LEDs will reflect the mains voltages as present When the signal is passive the unit will revert to normal operation and monitor the mains voltage status The REMOTE START operation overrides SIMULATE MAINS and FORCE TO START operations 16 DKG 519J User Manual V 27 14 04 2011 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 Thus the engine should continue to run a programmed period for effective charging The critical battery voltage level will be detected by an external unit which provides the digital Simulate Mains signal for the genset control unit The unit offers an optional SIMULATE MAINS signal input Any digital input may be assigned as Simulate Mains using Input Function Select program parameters It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarms generated from this input The SIMULATE MAINS signal may be a NO or NC contact switching to either battery positive or battery negative These selections are made using the programming menu If the Delayed Simulate Mains pro
19. to 9876 Passwords can only be modified through Rainbow program The program mode will not affect the operation of the unit Thus programs may be modified anytime even while the genset is running The program mode is driven with a two level menu system The top menu consists on program groups and each group consists of various program parameters When program mode is entered a list of available groups will be displayed Navigation between different groups are made with Wand A buttons Selected group is shown in reverse video blue on white In order to enter inside a group please press MENUP button In order to exit from the group to the main list please press MENU button Navigation inside a group is made also with Wand Abuttons A list of available parameters will be displayed Selected parameter is shown in reverse video blue on white In order display change the value of this parameter please press MENUP button Parameter value may be increased and decreased with Wand A buttons If these keys are hold pressed the program value will be increased decreased by steps of 10 When a program parameter is modified it is automatically saved in memory If MENUP button is pressed next parameter will be displayed If MENU button is pressed then the list of parameters in this group will be displayed Program parameters are kept in a non volatile memory and are not affected from power failures To exit the program mode press one of
20. voltage between terminals BAT and BAT at the rear of the unit If OK turn all the fuses off then turn all the fuses on starting from the DC supply fuse Then test the unit again Programming mode can not be entered The program lock input disables programming mode entry Disconnect the program lock input from battery negative before modification Do not forget to make this connection again to prevent unauthorized program modifications Some program parameters does not appear A higher password level is required AUTO led flashes and the genset does not run when REMOTE START signal arrives The unit is in Weekly Schedule OFF time Please check date and time setting of the unit Please check also Weekly Schedule program parameters 56 DKG 519J User Manual V 27 14 04 2011 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 57 DKG 519J User Manual V 27 14 04 2011 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 DC Supply range 9 0 VDC to 30 0 VDC Cranking dropouts survives 0 V for 100ms Typical stand by
21. voltages goes over under this limit compared to the average voltage then a Voltage ae balanco 0 Unbalance Warning will be generated If this limit is set to 0 then the voltage unbalance condition is not monitored If any of the phase currents goes over under this 1 Current Unbalance limit compared to the average current then a Current 0 Unbalance Warning will be generated Warning Limit If this limit is set to 0 then the current unbalance condition is not monitored 40 DKG 519J User Manual V 27 14 04 2011 Program Group Engine Parameters Parameter Definition a Factory ar Password Level Unit Set DESCHpHON 2 Low Frequency Hz 30 If the genset frequency goes under this limit a GENSET Shutdown LOW SPEED alarm is generated and the engine stops If the genset frequency goes under this limit a GENSET GU Low Frequency aring s 99 LOW SPEED warning is generated b If the genset frequency goes over this limit a GENSET 1 High Frequency Warning Hz 54 HIGH SPEED warning is generated 2 High Frequency Hz 55 If the genset frequency goes over this limit a GENSET Shutdown HIGH SPEED alarm is generated and the engine stops If the oil pressure measured from the analog input nigesure bar 1 4 falls below this limit this will generate a LOW OIL PRESSURE SENDER warning If the oil pressure measured from the analog input 2 Low Oil Pressur
22. warn 02 Start 34 Coolant Level switch 82 Coolant Level switch 03 Stop alarm warning 04 Gen Contactor 35 Rectifier alarm 83 Rectifier warning 05 36 Emerg Stop alarm 84 Emerg Stop warn 06 Choke 37 Spare 1 Alarm 85 Spare 1 warning 07 Preheat 38 Spare 2 Alarm 86 Spare 2 warning 08 Shutdown alarm 39 Fuel Level switch alarm 87 Fuel Level switch 09 Shutdown or 40 Oil sender alarm warning load dump alarm 41 Temp sender alarm 88 Oil sender warning 10 Shutdown or 42 Low speed alarm 89 Temp sender warn load dump or warning 43 High speed alarm 90 Low speed warning 11 Automatic ready 44 Low voltage alarm 91 High speed warning 12 Week on time 45 High voltagealarm 92 13 Exerciser on 46 Fail to start alarm 93 Low temp warning 14 Load dump alarm 47 Low fuel sender alarm 94 Fail to stop warning 15 48 High oil temp alarm 95 Low fuel sender 16 Mains Fail 49 warning 17 Block Heater 50 96 Service request 18 Service Request 51 High battery voltage warning 19 alarm 97 Mains Phase Order 20 Load Shedding Relay 52 Charge fail alarm Fail 21 Flashing Relay 53 98 Low battery warning 22 Gas Solenoid 54 99 High battery warning 23 Fuel Pump 55 100 Charge fail warning 24 56 Oil switch load dump 101 25 Genset Phase Order 57 Temp switch 102 Fail load dump 103 26 Idle Speed 58 Coolant Level switch 104 Gen Low voltge warn 27 Cooler
23. 2 Fuel Consumption per Hour This parameter is the threshold for sending FUEL THEFT and FUELLING sms messages If this parameter is set to 0 then no Fuel Theft and Fuelling sms messages will be sent If SMS is required set this parameter to a value above the hourly fuel consumption of the genset 2 Fuel Level sender Ohms ohms 180 Fuel level sender max resistance 180 ohms and 300 ohms senders are common 3 Crank Cut Frequency Hz 10 0 When the genset frequency reaches this limit the engine is supposed running and the crank output will release 42 DKG 519J User Manual V 27 14 04 2011 Program Group Engine Parameters continued Parameter Definition Unit Factory Description Password Level Set e i 0 no crank stop with oil pressure Ss Ge SES 0 1 cranking is stopped when oil presure switch is open een or the oil pressure measured is above shutdown limit 0 no crank stop with charge input 2 Crank Stop with Charge 0 1 cranking is stopped when the charge alternator voltage is established If the engine speed goes under this limit a GENSET 2 Low rpm Shutdown rpm Q LOW SPEED alarm is generated and the engine stops 2 Low rpm Warnin a 0 If the engine speed goes under this limit a GENSET H 9 H LOW SPEED warning is generated If the engine speed goes over this limit a GENSET AP ENGI DI arning es 0 HIGH SPEED warning is g
24. Abnormally high current or short circuit to battery negative 7 Mechanical fault Faulty response from mechanical system 8 Mechanical or electrical fault Abnormal frequency 9 Communication fault Abnormal updating rate or Open circuit in injector circuit 10 Mechanical or electrical fault Abnormally large variations 11 Unknown fault Unidentified fault 12 Component fault Faulty unit or component 13 Faulty calibration Calibration values outside the limits 14 Unknown fault Special instructions 15 Data valid but above normal operating range least severe level 16 Data valid but above normal operating range moderately severe level 17 Data valid but below normal operating range least severe level 18 Data valid but below normal operating range moderately severe level 19 Received network data in error 20 not used reserved 21 not used reserved 22 not used reserved 23 not used reserved 24 not used reserved 25 not used reserved 26 not used reserved 27 not used reserved 28 not used reserved 29 not used reserved 30 not used reserved 31 Condition exist V 27 14 04 2011 29 DKG 519J User Manual V 27 14 04 2011 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 ex
25. B 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 Each digital input may be programmed for below functions Force OFF mode Force AUTO mode Force TEST mode Force LOAD TEST mode Disable Auto Start Force to Start Fault Reset Alarm Mute Panel Lock External mode select signals have priority on mode buttons of the unit If the mode is selected by external signal it is impossible to change this mode with front panel keys However if the external mode select signal is removed the unit will revert to the last selected mode via pushbuttons It is also possible to lock the front panel completely for remote command 22 DKG 519J User Manual V 27 14 04 2011 6 18 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 Program parameters related to the exerciser are Exercise start day and hour Exercise duration Exercise off_load on_load Exerciser Period Daily Weekly Monthly Please refer to the programming section for a more detailed description of the above parameters W
26. DKG 519J User Manual V 27 14 04 2011 D DATAKOM Tel 90 216 466 84 60 Fax 90 216 364 65 65 datakom datakom com tr http www datakom com tr STATUS Ae WE ER e 5 S 4 warnina I d D navest KO DKG 519 MANUAL AND REMOTE START UNIT WITH J1939 PORT rem FEATURES True RMS measurements ECU control and monitoring through J1939 CAN J1939 ECU warnings displayed as text Various engine brands and models available Engine control Generator protection Built in alarms and warnings Dual genset mutual standby operation Load shedding dummy load Gas engine support Engine idle speed control 3 phase genset voltage inputs 3 phase genset CT inputs Engine oil pressure measurement Engine coolant temperature measurement Fuel level measurement Genset active power measurement Genset power factor measurement Engine rpm display Periodic maintenance request indicator Daily weekly monthly exerciser Engine hours counter Event logging with date time stamp and complete measurement values Stores last 200 events Statistical counters Battery backed up real time clock Weekly operation schedule programs 3 level password protection Programmable parameters All parameters field adjustable Return to factory settings enabled RS 232 serial port Optional RS 485 serial port Firmware downloadable from serial port Free MS Windows Remote monitoring SW local and modem connection monitoring
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28. U unit 97 VOLVO without CIU unit 112 CATERPILLAR ADEM II 128 SCANIA S6 144 IVECO Other values Reserved Do not use 2 J1939 Speed Adjust 50 This parameter adjusts the speed of an ECU controlled engine by 8 2 VOLVO Speed Toggle This program parameter is not stored but only used in order to activate the primary or secondary speed selection operation of a Volvo EMS II engine control unit 0 Initiate the primary speed select operation 1 Initiate the secondary speed select operation 44 DKG 519J User Manual V 27 14 04 2011 Program Group Adjust Date and Time password level 2 Parameter Definition Unit Factory Description Set Date 01 31 Current day of the month Month 01 12 Current month Year i 00 99 Last two digits of the current year Hours 00 23 Current hour of the day Minutes gt 00 59 Current minute of the hour Seconds 00 59 Current second of the minute Program Group Weekly Schedule password level 2 Description Parameter Definition Unit Factory Set Monday Turn on 24 00 Monday Turn off 24 00 Tuesday Turn on 24 00 Tuesday Turn off 24 00 Wednesday Turn on 24 00 Wednesday Turn off 24 00 Thursday Turn on 24 00 Thursday Turn off 24 00 Friday Turn on 24 00 Friday Turn off 24 00 Saturday Turn on 24 00 Saturday Turn o
29. ammed as the generator contactor signal When the REMOTE START signal goes off the engine will continue to run for the mains waiting period At the end of this period the generator contactor is deactivated If a cooldown period is given the generator will continue to run during cooldown period At the end of the period the fuel solenoid will be de energized and the diesel will stop The unit will be ready for the next REMOTE START signal then the AUTO led will flash and the genset operates as in the OFF If the operation of the genset is disabled by the WEEKLY SCHEDULE mode TEST It is used to run the genset when the REMOTE START signal is off or keep the generator running in the emergency backup mode The operation of the generator is similar to the AUTO mode If the REMOTE START signal arrives the generator contactor will be activated If the REMOTE START signal goes off the generator contactor will release but the engine will run until another mode is selected To stop the engine select AUTO or OFF mode 13 DKG 519J User Manual V 27 14 04 2011 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 These selections are made using programming menu
30. atching Normally open Contact type 0 Normally closed Battery negative Switching S Battery positive No delay Response delay 0 Delayed 4sec aA OA O H Ol ON A 0 MN 0 47 DKG 519J User Manual V 27 14 04 2011 Program Group Input Configuration Coolant Level Switch password level 2 Parameter Definition Unit Fac Set Description Action Shutdown the engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operation Sampling Always After holdoff timer When mains present Latching Non latching Latching Contact type Normally open Normally closed Switching Battery negative Battery positive Response delay Og Og Oo ona ovn No delay Delayed 4sec Program Group Input Configuration Rectifier Fail password level 2 Parameter Definition Unit Fac Set Description Action Shutdown the engine stops immediately Load Dump the engine stops after cooldown Warning the horn relay operates No operation Sampling Always After holdoff timer When mains present Latching Non latching Latching Contact type Normally open Normally closed Switching Battery negative Battery positive Response delay Og Og og ON ouno
31. ation in other then programming mode the display will automatically switch to ALARM LIST position The MENU or MENUP buttons will not function To enable display navigation and mute the internal buzzer press ALARM MUTE button first If there is more than one alarm the next alarm is displayed by pressing the W button Thus all existing alarms can be scanned END OF ALARM LIST will be displayed when there is no more alarm to display The display has a backlight illumination feature The backlight turns on with the depression of any button or when the genset runs It turns off after 4 hours to allow power economy DKG 519J User Manual V 27 14 04 2011 Screen Description Contents 1 Genset parameters phase to neutral Genset status Genset Current L1 Genset Current L2 Genset Current L3 Genset Frequency Genset Active Power KW Genset Volts L1 2 Genset parameters phase to phase Genset status Genset Current L1 Genset Current L2 Genset Current L3 Genset Frequency Genset Active Power KW Genset Volts L1 L2 3 Engine parameters Genset status Oil Pressure Coolant Temperature Fuel Level Engine rpm Battery Voltage 4 Complete Genset parameters phase to neutral Genset status Genset Volts L1 Genset Volts L2 Genset Volts L3 Genset Current L1 Genset Current L2 Genset Current L3 Genset Frequency Oil Pressure Genset Active Power KW Coolant Temperature Genset
32. cial 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 The 120 ohms termination resistor is included inside the unit Please do not connect external resistor The J1939 port is activated by setting the program parameter J1939 Enable to 1 The J1939 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 Other available measurements are displayed for information but they have no effect on engine operation In total the unit is capable of displaying 21 parameters from the J1939 The J1939 measurements are also available for Modbus operation Please check chapter 8 for more details When the fuel output is active if no information is received from the ECU during last 3 seconds then the unit will give a ECU FAIL alarm and stop the engine This feature prevents uncontrolled engine operation The fault conditions of an electronic engine are considered by the unit as warning
33. cy Stop Input 06 Function Select 11 Spare 1 Input Input 07 Function Select 18 Remote Start Input Function Select List Number Description 0 Oil Pressure Switch 1 High Temp Switch 2 Low Coolant Level switch 3 Rectifier Fail 4 Emergency Stop 5 Alternator High Temp 6 Door Open 7 Low Fuel Level Switch 8 Earthquake Detector 9 Spare 3 Input 10 Spare 2 Input 11 Spare 1 Input 12 Force AUTO Mode 13 Force OFF Mode 14 Force TEST Mode 15 Force LOAD TEST Mode 16 2nd Volt Freq Select 17 Priority Input 18 Remote Start Input 19 Disable Auto Start 20 Force to Start 21 Fault Reset 22 Alarm Mute 23 Panel Lock 53 DKG 519J User Manual V 27 14 04 2011 Program Group Site Id password level 2 Parameter Definition Factory Set Description This is the site Id string sent at the beginning of an DATAKOM SITE SMS message for the identification of the genset ID sending the SMS message Any 20 character long string may be entered Site Id String Program Group Modem 1 SMS 1 Telephone Number password level 2 Parameter Definition Factory Set Description This telephone number buffer accepts up to 16 digits including the wait charater in order to enable dialing through a pabx If Modem Enabled This is the first telephone number used for modem calls If Modem Disabled This is the firs
34. e through the J1939 CANBUS The unit offers the possibility to the user to switch between the primary and secondary speed using the programming menu If the program parameter Volvo Speed Toggle is increased the unit will freeze for a few seconds and switch the engine to 1800 rpm which is generally the secondary speed When the parameter is decreased the speed is set to the primary speed which is generally 1500 rpm Please note also that a fine adjustment of the engine speed in the 8 range may be done using the program parameter J1939 Speed Adjust 25 DKG 519J User Manual V 27 14 04 2011 6 25 Engine Control Mode In engine control mode the unit is supposed to control an engine without alternator The engine control mode is activated by a program parameter in the Controller Configuration group When the Engine Control Mode is activated the unit will not display genset AC parameters volts amps kW and pf genset voltage and frequency protections are disabled However engine rpm protections will be active 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 The switching to the second set of limit values can be done in 2 ways by setting the program parameter Seconda
35. e fault re is enabled This is the period during which the ALARM relay is 1 Alarm Relay Timer sec 60 active If the period is set to 0 this will mean that the period is unlimited 0 continuous Oen am Polay i Q 1 intermittent turns on and off every second 0 The charge input generates CHARGE FAIL 2 Charge Alternator g 0 warning and does not stop the engine Shutdown 1 The charge input generates CHARGE FAIL alarm and stops the engine 0 In TEST mode the load will not be transferred to 1 Emergency Backup 0 the genset even if the mains fail Operation 1 In TEST mode the load will be transferred to the genset if the mains fail 35 DKG 519J User Manual V 27 14 04 2011 Program Group Controller Configuration continued Parameter Definition Password Level Unit Factory Set Description 1 Exercise Day and Time 168 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 The parameter value is the hour count of the start time Examples 0 exercise starts at Monday 00 00 8 exercise starts at Monday 08 00 24 exercise starts at Tuesday 00 00 167 exercise starts at Sunday 23 00 168 exerciser off If a daily exercise is selected then the day information is don t care and the exercise will be performed ever
36. e h r 10 falls below this limit this will generate a LOW OIL Shutdown PRESSURE SENDER alarm is generated and the engine stops 1 High Temperature If the coolant temperature measured from the analog Warning C 95 input goes over this limit this will generate a HIGH TEMPERATURE SENDER warning f the coolant temperature measured from the analog 2 High Temperature C 98 input goes over this limit this will generate a HIGH Shutdown TEMPERATURE SENDER alarm and the engine will stop This parameter selects the oil pressure sender type 0 Non standard sender The sender characteristics are defined in Sender Characteristics table 1 VDO 0 7 bars 10 180 ohms e 2 VDO 0 10 bars 10 180 ohms 2 Ol Pressure Sender type 1 13 DATCON 0 7 bars 240 33 ohms 4 DATCON 0 10 bars 240 33 ohms 5 DATCON 0 7 bars 0 90 ohms 6 DATCON 0 10 bars 0 90 ohms 7 DATCON 0 7 bars 75 10 ohms This parameter selects the temperature sender type 0 The sender characteristics are defined in Sender 2 Coolant Temp Sender i 1 Characteristics table Type 1 VDO 2 DATCON DAH type 3 DATCON DAL type If it is requested that the engine runs without load until d reaching a certain temperature this parameter defines eee C 0 the temperature If the coolant temperature falls below this parameter an Engine Low Temperature warning will occur This is the time between the mains fails and the fuel solenoid turns on before starting the genset It 2 Eng
37. eased after this delay or when engine runs whichever occurs first 2 Engine Heating Method This parameter defines the engine heating method The genset will not take the load before engine heating is completed 0 engine is heated during Engine Heating Timer 1 engine is heated until the coolant temperature reaches the Engine Heating Temperature and at least during the Engine Heating Timer 1 Service Engine Hours hour 50 The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last service If the period is set to 0 no SERVICE REQUEST will be generated depending on engine hours 1 Service Period month The SERVICE REQUEST led indicator will turn 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 2 Idle Speed Timer sec When the engine runs the Idle output relay function will be active during this timer 2 Gas Solenoid Delay sec The gas solenoid of the gas engine will be opened after this delay during cranking 1 Low Fuel Warning 20 If the fuel level measured from the analog input falls below this limit a LOW FUEL LEVEL SENDER warning is generated 2 Low Fuel Shutdown 10 the fuel level measured from the analog input falls below this limit a LOW FUEL LEVEL SENDER shutdown alarm is generated and the engine stops
38. ed for outgoing modem calls In case of alarm the unit will attempt to reach control centers associated with each number In case of modem connection failure the call will be repeated up to 30 times with 2 minute intervals When the modem call is in progress a telephone icon M will appear at the upper right corner of the screen If Modem Enable or SMS Enable or MODBUS Address parameters are different from zero the local PC connection will not work Advised modems are DATAKOM types which are powered up from the same DC battery voltage than the unit Most of other desktop modems with standard AT commands are also usable but it is the user s responsibility to provide an uninterrupted AC supply source to the modem The necessary modem cable will be supplied by DATAKOM Modem calls are always terminated by the central RAINBOW software However the unit does not allow connection durations exceeding 2 minutes and hangs up the modem when this period expires The PC program used for remote monitoring and programming is the same RAINBOW software used for RS 232 connection Please note that the modem operation is also compatible with the MODBUS communication Thus the unit can iniate and receive calls to from a MODBUS masier station Please review chapter_8 for more details on MODBUS communication 20 DKG 519J User Manual V 27 14 04 2011 6 15 SMS Message Sending The GSM SMS sending is activated by setting the SMS Enable prog
39. ed sensor loss of signal Speed sensor mechanical failure 228 D Timing calibration required 234 X Incorrect ecm software 620 D ECU internal 5V fail 629 D ECU hardware fail 651 D Injector cylinder 1 fault 652 D Injector cylinder 2 fault 653 X Injector cylinder 3 fault 654 X Injector cylinder 4 fault 655 X Injector cylinder 5 fault 656 X Injector cylinder 6 fault 657 X Injector cylinder 7 fault 657 X Injector cylinder 8 fault 678 D ECU internal power supply fail 723 D Secondary engine speed sensor fail 1108 D Critical override enabled 1111 D Check configuration parameters 2000 X ECU failure 28 DKG 519J User Manual model Below is a basic list of FMI codes Please be aware that these codes may differ slightly depending on the engine brand and FMI DESCRIPTION 0 Value too high Valid data but above the normal working range 1 Value too low Valid data but below the normal working range 2 Faulty data Intermittent or faulty data or Short circuit to battery voltage injector high voltage side 3 Electrical fault Abnormally high voltage or short circuit to battery voltage injector low voltage side 4 Electrical fault Abnormally low voltage or short circuit to battery negative injector low voltage or high voltage side 5 Electrical fault Abnormally low current or open circuit 6 Electrical fault
40. elay 06 Definition 5 RELAY 6 function expansion module 1 selected from list Relay 07 Definition 0 RELAY 7 function expansion module 1 selected from list Relay 08 Definition 2 RELAY 8 function expansion module 1 selected from list Relay 09 Definition 4 RELAY 9 function expansion module 1 selected from list Relay 10 Definition 5 RELAY 10 function expansion module 1 selected from list Relay 11 Definition 0 RELAY 11 function expansion module 2 selected from list Relay 12 Definition 2 RELAY 12 function expansion module 2 selected from list Relay 13 Definition 4 RELAY 13 function expansion module 2 selected from list Relay 14 Definition 5 RELAY 14 function expansion module 2 selected from list Relay 15 Definition 0 RELAY 15 function expansion module 2 selected from list Relay 16 Definition 2 RELAY 16 function expansion module 2 selected from list Relay 17 Definition 4 RELAY 17 function expansion module 2 selected from list Relay 18 Definition 5 RELAY 18 function expansion module 2 selected from list 54 DKG 519J User Manual V 27 14 04 2011 The function of a programmable relay output may be selected from the below list 00 Fuel 32 Oil switch alarm 80 Oil switch warning 01 Alarm 33 Temp switch alarm 81 Temp switch
41. emperature 13 CANBUS Measurements Boost Pressure 5 6 Air Filter Differential Pressure Crank Case Pressure 14 CANBUS Measurements Coolant Level 6 6 Oil Level Coolant Pressure 15 Company Logo DATAKOM 16 Alarm List If no alarm exists END OF ALARM LIST will be displayed Existing alarms load_dumps warnings and J1939 ECU warnings will be displayed as one screen for each entry Switching to the next entry will be made with the V button 17 Date Time Date and time Software Version Operating software version J1939 software version 18 Statistical Counters 1 3 Engine Hours Run Total Genset Active Power KW h 19 Statistical Counters 2 3 Engine Hours to Service Time to Service 20 Statistical Counters 3 3 Total Engine Cranks Total Engine Runs 21 Event Records The unit provides information about last 200 events starting from the most recent one Please review chapter 10 for detailed information about event logging 10 DKG 519J User Manual V 27 14 04 2011 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 The genset contactor to be released immediately The engine to be stopped immediately The Horn Alarm Alarm Load_dump and Alarm Load_dump Warning digital outputs to operate if selected via programming me
42. enerated If the engine speed goes over this limit a GENSET 2 High rpm Shutdown rom 0 HIGH SPEED alarm is generated and the engine stops If the coolant temp is above this limit then the fan relay el E 20 function will become active If the coolant temp is below this limit then the fan relay 2 Pan Un Otome i 80 function will become inactive e If the oil temperature measured from the analog input e GH O Temperature 100 goes over this limit this will generate a HIGH eng OILTEMPERATURE SENDER warning f the oil temperature measured from the analog input 2 High Oil Temperature 120 goes over this limit this will generate a HIGH OIL Shutdown TEMPERATURE SENDER alarm and the engine will stop 2 Oil Temp Sender Type This parameter selects the oil temperature sender type 0 The sender characteristics are defined in Sender Characteristics table 1 VDO 2 DATCON DAH type 3 DATCON DAL type 43 DKG 519J User Manual V 27 14 04 2011 Program Group Engine Parameters continued Parameter Definition Password Level Unit Factory Set Description 2 2 Low Frequency Shutdown Hz 40 When secondary volt freg limits are active If the genset frequency goes under this limit a GENSET LOW SPEED alarm is generated and the engine stops 1 2 Low Frequency Warning Hz 45 When secondary volt freg limits are active If the genset frequency goes under th
43. ent phase L1 Gen current phase L2 Gen current phase L3 Gen frequency Engine speed rpm Gen KW phase L1 Gen KW phase L2 Gen KW phase L3 Gen total KW Gen pf phase L1 Gen pf phase L2 Gen pf phase L3 Gen total pf Battery voltage Coolant temperature Oil pressure Fuel level Gen frequency DKG 519J User Manual V 27 14 04 2011 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 Engine body must be grounded for correct operation of the unit otherwise incorrect voltage and frequency measurements may occur The output of the current transformers 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 oil pressure or fuel level are connected to the unit it is not possible to use auxiliary displays otherwise
44. er failures Switching from one menu screen to another is made with the MENU and MENUP buttons When the EVENT RECORD screen is displayed each depression on the MENU button makes the display switch to the previous event and MENUP button makes the display switch to the next event To exit event record pages please hold pressed MENU or MENUP buttons Each event is displayed in 4 pages Event and page numbers are shown at the top right corner of the display Events are numbered starting from 1 number 1 being the latest one Pages are listed from A to D Navigation between different pages of the same event is done with V and A buttons Event sources are Shutdown alarms Load dump alarms Warnings Operating mode change OFF AUTO etc Periodic records Event record contents are Event type alarms mode change periodic etc Date and time Genset operating mode AUTO MANUAL OFF TEST LOAD TEST Genset operation status mains ok running cooldown etc Genset phase voltages L1 L2 L3 Genset phase currents L1 L2 L3 Genset frequency Genset active power KW Genset power factor Engine rom Oil pressure Coolant temperature Fuel level Battery voltage Digital input statuses Charge input status SE DKG 519J User Manual V 27 14 04 2011 11 STATISTICAL COUNTERS The unit provides a set of non resettable incremental counters for statistical purposes The counters consist on total engine hours total gen
45. es 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 gt Fuel Consumption Hour to a value other than 0 The Fuel Consumption Hour parameter should be set to a value clearly greater than the maximum fuel consumption of the engine If the fuel level measured from the sender input is decreased more than this parameter in 1 hour period then a FUEL THEFT sms message is sent to programmed telephone numbers If the fuel level measured from the sender input is increased more than this parameter in 1 hour period then a FUELLING sms message is sent to programmed telephone numbers 6 23 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 completion bar on the screen The firmware update operation will take around 3 minutes After completion of the update a special command will set back the unit to normal operation mode 6 24 Changing the Default Engine Speed in Volvo Engines Volvo engines equipped with EMS II engine control unit have the engine speed selectabl
46. et if the battery voltage goes above programmed limits Both warning and alarm levels for high battery voltage are programmable CHARGE Set if a charge alternator failure or broken belt occurs This fault condition may result to a warning or alarm following programming MAINS PHASE ORDER FAIL warning Set if the mains phase order checking is enabled mains phases are present and mains phase order is reversed This fault prevents the Mains Contactor to close 12 DKG 519J User Manual V 27 14 04 2011 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 AUTO mode is selected when genset is running at TEST mode if the REMOTE START signal is not present then the genset will stop OFF If this mode is selected the engine will be stopped immediately AUTO It is used for the automatic genset operation If the REMOTE START signal arrives the engine will be started for programmed times after the preheat timer When the engine runs the crank relay will be immediately deactivated The engine will run without load during engine heating period After this if alternator phase voltages and frequency are within limits then the unit will wait for the generator contactor period and the generator contactor will be energized Any of the spare digital outputs can be progr
47. evices The input has programmable characteristics and connects to any kind of sender 16 CHARGE Input and 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 17 RELAY 2 HORN RELAY Output 10A 28VDC This relay has programmable function selectable from a list 18 RELAY 1 STOP RELAY Output 10A 28VDC This relay has programmable function selectable from a list 19 START RELAY Output 10A 28VDC This relay controls the engine cranking 20 FUEL RELAY Output 10A 28VDC This relay is used for fuel solenoid control It is internally connected to terminal 16 for supplying the charge alternators excitation current DKG 519J User Manual V 27 14 04 2011 Term Function Technical data Description 21 EMERGENCY STOP Digital inputs These inputs have programmable 22 SPARE 2 characteristics selected via the program 23 PROGRAM LOCK menu Each input may be driven by a 24 SPARE 1 normally closed or normally open contact 25 COOLANT LEVEL switching either battery or battery The effect 26 HIGH TEMP of the switch is also selectable from a list See 27 LOW OIL PRESSURE PROGRAMMING section for more details 28 RECTIFIER FAIL 29 CURR 1 Current transformer Connect the generator current transformer inputs SA AC terminals to these inputs Do not c
48. ff 24 00 Sunday Turn on 24 00 Sunday Turn off 24 00 Please review chapter 9 for a detailed description of weekly programming schedule operation 45 DKG 519J User Manual V 27 14 04 2011 Program Group Sender Characteristics password level 2 Parameter Definition Unit Factory Description Set Oil Pressure Sender Ohms 1 ohm 10 Oil Pressure Sender point 1 ohm value Oil Pressure Value 1 bar 0 0 Oil Pressure Sender point 1 bar value Oil Pressure Sender Ohms 2 ohm 52 Oil Pressure Sender point 2 ohm value Oil Pressure Value 2 bar 2 0 Oil Pressure Sender point 2 bar value Oil Pressure Sender Ohms 3 ohm 90 Oil Pressure Sender point 3 ohm value Oil Pressure Value 3 bar 4 0 Oil Pressure Sender point 3 bar value Oil Pressure Sender Ohms 4 ohm 140 Oil Pressure Sender point 4 ohm value Oil Pressure Value 4 bar 7 0 Oil Pressure Sender point 4 bar value Oil Pressure Sender Ohms 5 ohm 156 Oil Pressure Sender point 5 ohm value Oil Pressure Value 5 bar 8 0 Oil Pressure Sender point 5 bar value Oil Pressure Sender Ohms 6 ohm 184 Oil Pressure Sender point 6 ohm value Oil Pressure Value 6 bar 10 0 Oil Pressure Sender point 6 bar value Program Group Sender Characteristics password level 2 Parameter Definition Unit Factory Description Set Temperature Sender Ohms 1
49. gram parameter is set to 1 and the input signal is active when the genset is not feeding the load then the genset will not run This will prevent the genset from starting when the simulate mains signal is present batteries charged The genset will start when the simulate mains signal disappears If the genset is running when the signal is applied then MAINS SIMULATION will be prevented during Flashing Relay Timer program parameter After this usual Mains Waiting and Cooldown cycles will be performed before engine stop When the SIMULATE MAINS signal is present the front panels mimic diagram s mains LEDs will reflect the mains voltages as present When the signal is passive the unit will revert to normal operation and monitor the mains voltage status The REMOTE START operation overrides DELAYED SIMULATE MAINS operation When both parameters Remote Start Operation and Delayed Simulate Mains are set then REMOTE START operation mode is performed 17 DKG 519J User Manual V 27 14 04 2011 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 If the time is adjusted as 0 hours it will be actual
50. hen the start day and hour of exercise has come the unit will automatically switch to either TEST or LOAD TEST mode The engine will run and if the on_load exercise is selected then the load will be transferred to the genset If a mains failure occurs during the off load exercise the load will not be transferred to the genset unless the Emergency Backup Operation is allowed by setting the related program parameter to 1 Thus it is highly recommended that the Emergency Backup mode enabled with off load exerciser At the end of the exercise duration the unit will switch back to the initial mode of operation If any of the mode selection keys are pressed during exercise then the exercise will be terminated 23 DKG 519J User Manual V 27 14 04 2011 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 will be displayed immediately press and hold pressed the ALARM MUTE button for 5 seconds factory set values will be reprogrammed to the parameter memory It is not possible to restore user parameters 6 20 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
51. imits These faults will be monitored with Holdoff Timer delay after the engine is running Low and high limits for warning and alarm are separately programmable Another high frequency shutdown limit which is 12 above the high limit is always monitored and stops the engine immediately START FAIL alarm Set if the engine is not running after programmed number of start attempts STOP FAIL warning Set if the engine has not stopped before the expiration of the Stop Timer OVERLOAD load dump Set if at least one of the genset phase currents goes over the Overcurrent Limit for Overload Timer If currents goes below the limit before expiration of the timer then no alarm will be set EXCESS POWER load dump Set if the genset power KW supplied to the load goes over the Excess Power limit for Overload Timer If the power goes below the limit before expiration of the timer then no alarm will be set GENSET LOW VOLTAGE Set if any of the generator phase voltages goes outside programmed limits for Overload Timer This fault will be monitored with holdoff timer delay after the engine is running GENSET HIGH VOLTAGE Set if any of the generator phase voltages goes outside programmed limits for Overload Timer This fault will be monitored with holdoff timer delay after the engine is running LOW BATTERY VOLTAGE warning Set if the battery voltage goes below the programmed limit During engine cranking this fault is not monitored HIGH BATTERY VOLTAGE S
52. ine Start Delay SES S prevents unwanted genset operation in battery backed up loads This is the time after the fuel solenoid is energized and before the genset is started During this period eee mer SS the PREHEAT E output is energized if assigned by Relay Definitions This is the maximum start period Starting will be 2 Crank Timer sec 10 automatically cancelled if the genset fires before the timer 41 DKG 519J User Manual V 27 14 04 2011 Program Group Engine Parameters continued Parameter Definition Password Level Unit Factory Set Description 2 Wait Between Starts sec 10 This is the waiting period between two start attempts 1 Engine Heating Timer sec 4 This is the period used for engine heating following the program parameter 1 Cooldown Timer min 1 0 This is the period that the generator runs for cooling purpose after the load is transferred to mains 1 Stop Solenoid Timer sec 10 This is the maximum time duration for the engine to stop During this period the STOP relay output is energized if assigned by Relay Definitions If the genset has not stopped after this period a FAIL TO STOP warning occurs 2 Number of Starts This is the maximum number of start attempts 2 Choke Timer sec This is the control delay of CHOKE output The choke output is activated together with the crank output It is rel
53. is limit a GENSET LOW SPEED warning is generated 1 2 High Frequency Warning Hz 65 When secondary volt freg limits are active If the genset frequency goes over this limit a GENSET HIGH SPEED warning is generated 2 2 High Frequency Shutdown Hz 69 When secondary volt freg limits are active If the genset frequency goes over this limit a GENSET HIGH SPEED alarm is generated and the engine stops 2 2 Low rpm Shutdown rpm When secondary volt freq limits are active If the engine speed goes under this limit a GENSET LOW SPEED alarm is generated and the engine stops 2 2 Low rpm Warning rpm When secondary volt freg limits are active If the engine speed goes under this limit a GENSET LOW SPEED warning is generated 2 2 High rom Warning rpm If the engine speed goes over this limit a GENSET HIGH SPEED warning is generated 2 2 High rom Shutdown rpm When secondary volt freg limits are active If the engine speed goes over this limit a GENSET HIGH SPEED alarm is generated and the engine stops 2 J1939 Enable 0 The J1939 port is inoperative 1 The analog measurements oil temp rpm are picked_up from the ECU If the ECU communication is lost then the engine will be stopped 2 J1939 Engine Type 00 GENERIC ENGINE TYPE 16 CUMMINS CM850 32 DETROIT DIESEL 48 DEUTZ EMR3 64 JOHN DEERE 80 PERKINS 96 VOLVO with CI
54. is negative and goes above this iene dB dl kw 0 limit then a REVERSE POWER warning will be generated If the genset power is negative and goes above this na te KW 0 limit then a REVERSE POWER loaddump will be generated vk If the genset power goes below this limit then the FE Shedding Dow iat E S load shedding er be deactivated 2 Load Shedding High KW 0 If the genset power goes above this limit then the Limit load shedding relay will be activated 0 genset phase order checking disabled Ge Phase Order 0 1 if genset phase order is faulty then a loaddump is generated and the genset stops after cooldown When secondary volt freg limits are active If the current goes above this limit during the period nd DE defined in Overload Timeout then a Overcurrent 2 2c Overcurrent S 0 Load Dump alarm will be generated If this parameter is 0 then Overcurrent check is disabled When secondary volt freg limits are active 1 2 Mains Voltage Low V 84 If one of the mains phases goes under this limit it Limit means that the mains are off and it starts the transfer to the genset in AUTO mode When secondary volt freg limits are active 1 2 Mains Voltage High V 136 If one of the mains phases goes over this limit it Limit means that the mains are off and it starts the transfer to the genset in AUTO mode When secondary volt freg limits are active 2 2 Mains Frequency Low Hz 55 If the mains frequency goes under this limit it means
55. ly set to 2 minutes for faster testing purposes A flashing relay output function is provided based on the parameter Flashing Relay Timer Each time the period programmed using Flashing Relay Timer elapses the relay output will change position The flashing relay function may be assigned to spare relays using Relay Definition program parameters Also relays on an extension module may be assigned to this function The dual genset intermittent operation uses also the Mains Simulation feature Please review chapter 6 7 for a detailed explanation of this feature Priority In Dual Genset Mutual Standby Operation It may be required that the dual genset system starts the same genset at every mains failure This is achieved using the PRIORITY input Any digital input may be assigned as Priority using Input Function Select program parameters It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarms generated from this input The Priority signal may be a NO or NC contact switching to either battery positive or battery negative These selections are made using the programming menu If a Priority input is defined then the system will work in priority mode If the priority signal is applied the unit will become master after each mains failure 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 co
56. mplete application manual 18 DKG 519J User Manual V 27 14 04 2011 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 The unit has both programmable engine hours and maintenance time limit The engine hours is programmable with 50 hour steps the time limit is programmable with 1 month steps If any of the programmed values is zero this means that the parameter will not be used For example a maintenance period of 0 months indicates that the unit will 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 will be inoperative When the engine hours OR the time limit is over the SERVICE REQUEST led red will start to flash and the service request relay function will be active The service request relay function may be assigned to spare relays using Relay Definition program parameters Also relays on an extension module may be assigned to this function To turn off the SERVICE REQUEST led and reset the service period press together the ALARM MUTE and LAMP TEST
57. n Overload Timeout then a Overcurrent Load Dump alarm will be generated If this parameter is 0 then Overcurrent check is disabled 2 Excess Power Limit KW If the active power goes above this limit during the period defined in Overload Timeout then an Excess Power Load Dump alarm will be generated If this parameter is 0 then Excess Power check is disabled 2 Overload Timeout sec This is the period between the current or active power go over the limits and OVERCURRENT or EXCESS POWER Load Dump alarms occur This is also the period between the frequency goes out of the limits and OVERSPEED or UNDERSPEED alarms occur This is also the period between the genset voltage goes out of the limits and HIGH VOLTAGE or LOW VOLTAGE alarms occur 2 Genset Low Voltage Shutdown Limit 190 If one of the generator phase voltages goes under this limit when feeding the load this will generate a GENSET LOW VOLTAGE shutdown alarm and the engine will stop 2 Genset Low Voltage Warning Limit 200 If one of the generator phase voltages goes under this limit when feeding the load this will generate a GENSET LOW VOLTAGE warning 2 Genset High Voltage Warning Limit 250 If one of the generator phase voltages goes above this limit when feeding the load this will generate a GENSET HIGH VOLTAGE warning 2 Genset High Voltage Shutdown Limit 260 If one of the generator phase voltages goes over
58. nit are not correct Check engine body grounding it is necessary The error margin of the unit is 3 volts If there are faulty measurements only when the engine is running there may be a faulty charging alternator or voltage regulator on the engine Disconnect the charging alternator connection of the engine and check if the error is removed If there are faulty measurements only when mains are present then the battery charger may be failed Turn off the rectifier fuse and check again KW and cos readings are faulty although the Amp readings are correct Current transformers are not connected to the correct inputs or some of the CTs are connected with reverse polarity Determine the correct connections of each individual CT in order to obtain correct KW and cos for the related phase and then connect all CTs Short circuit the outputs of unused Current Transformers When REMOTE START signal arrives the unit energizes the fuel solenoid but does not start and OIL PRESSURE EXISTS message is displayed The unit is not supplied with battery voltage at the oil pressure input Oil pressure switch not connected Oil pressure switch connection wire cut Oil pressure switch faulty Oil pressure switch closes too lately If oil pressure switch closes the unit will start Optionally oil pressure switch may be replaced The engine does not run after the first start attempt then the unit does not start again
59. ns encountered during operation Function Color Description MAINS ON Green The LED will turn on when all 3 mains phase voltages are within the limits MAINS OFF Red The LED will turn on when at least one of the mains phase voltages is outside limits LOAD MAINS Green It turns on when the mains contactor is activated LOAD GENERATOR Yellow It turns on when the generator contactor is activated GENERATOR Yellow The LED will flash when the engine is running It will turn on steadily when all 3 generator phase voltages are within the programmed limits TEST Yellow It turns on when the related operation mode is selected One of these LEDs is always on and OFF Yellow indicates which operation mode is selected If the operation of the genset is disabled by the AUTO Green weekly operation schedule then the AUTO led will flash ALARM Red If a fault condition resulting to the engine shutdown has occurred the alarm led turns on steadily If a loaddump condition occurs this led will flash Alarms work on a first occurring basis The occurrence of a fault will disable other faults of lower or equal priority WARNING Red If a warning condition has occurred this led turns on steadily The warnings work on a first occurring basis The occurrence of a warning will disable other warnings however shutdown and loaddump alarms are still allowed SERVICE REQUEST Red Engine periodic maintenance request indicator It tu
60. nu 2 LOAD_DUMPS These fault conditions cause The ALARM led to flash The genset contactor to be released immediately The engine to be stopped after Cooldown period The Horn Alarm Load dump and Alarm Load dump Warning digital outputs to operate if selected via programming menu 3 WARNINGS These conditions cause The WARNING led to be on steadily The Horn and Alarm Load_dump Warning digital outputs to operate if selected via programming menu If the ALARM MUTE button is pressed the Horn output 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 load_dumps and warnings will not be accepted If a load_dump is present following load_dumps 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 LOAD TEST TEST OFF AUTO Most of the alarms have programmable trip levels See the programming chapter for adjustable alarm limits LOW OIL PRESSURE Set if a signal is detected at the Low Oil Pressure Switch input or the oil pressure value measured from the sender is below the
61. onnect the 30 CURR 1 same current transformer to other instruments 8 otherwise a unit fault will occur Connect each 31 CURR_2 terminal of the transformer to the unit s related terminal Do not use common terminals Do not use grounding Correct polarity of 8 CURR 2 connection is vital If the measured power is negative then change the polarity of each 3 33 CURR_3 current transformers The rating of the transformers should be the same for each of 34 CURR 3 the 3 phases The secondary winding rating shall be 5 Amperes For ex 200 5 Amps 35 OIL TEMP SENDER Input 0 5000 ohms Analogue oil temperature sender connection Do not connect the sender to other devices The input has programmable characteristics and connecis to any kind of sender 36 J1939 37 J1939 Digital communication port Connect the J1939 port of an electronic engine to these terminals The 120 ohm terminating resistors are inside the unit Please do not connect external resistors Use a twisted cable pair or coaxial cable for best results DKG 519J User Manual V 27 14 04 2011 3 DISPLAYS 3 1 Led Displays The unit has 8 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 conditio
62. power factor Fuel Level Engine rpm Battery Voltage 5 Complete Genset parameters phase to phase Genset status Genset Volts L1 L2 Genset Volts L2 L3 Genset Volts L3 L1 Genset Current L1 Genset Current L2 Genset Current L3 Genset Frequency Oil Pressure Genset Active Power KW Coolant Temperature Genset power factor Fuel Level Engine rpm Battery Voltage 6 Graphical Genset parameters phase to neutral Genset status Genset Active Power Genset Current L1 Genset Volts L1 Genset Frequency Oil Pressure Coolant Temperature Fuel Level 7 Graphical Genset parameters phase to phase Genset status Genset Active Power Genset Current L1 Genset Volts L1 L2 Genset Frequency Oil Pressure Coolant Temperature Fuel Level 8 Genset Phase Power parameters Genset status Genset Phase L1 Genset Phase L2 Genset Phase L3 Active Power KW Power Factor Active Power KW Power Factor Active Power KW Power Factor DKG 519J User Manual V 27 14 04 2011 Screen Description Contents 9 CANBUS Measurements Percent Torque 1 6 Percent Load Fuel Pressure 10 CANBUS Measurements Fuel Rate 2 6 Average Fuel Economy Total Engine Hours 11 CANBUS Measurements Air Pressure 3 6 Ambient Air Temperature Oil Temperature 12 CANBUS Measurements Intake Manifold 1 Temperature 4 6 Exhaust Gas Temperature Fuel T
63. 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 Also if the oil pressure switch is open at the beginning of a start attempt then the engine will not be started and Oil Pressure Exists information is displayed When the oil pressure switch closes normal operation will be resumed HIGH 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 and alarm limits are separately programmable for the temperature sender input LOW TEMPERATURE warning Set if the coolant temperature value measured from the sender is blow the Engine Heating Temperature limit LOW FUEL Set if a signal is detected at the low fuel level input or the the fuel level measured from the sender is below the programmed limit Warning and alarm limits are separately programmable for the fuel level sender input RECTIFIER FAIL Set if a signal is detected at the rectifier fail input This input is only monitored when mains voltages are present EMERGENCY STOP Set if a signal is detected at the emergency stop input SPARE 1 SPARE 2 Set if a signal is detected from the related spare fault input 11 DKG 519J User Manual V 27 14 04 2011 LOW SPEED HIGH SPEED Set if the generator frequency is outside programmed l
64. ram 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 The unit is also able to send SMS messages in below conditions without creating a visible alarm or warning Mains Fail Mains Restored enabled via SMS on Mains Change program parameter Fuel Theft Fuelling enabled by setting the Fuel Consumption Hour parameter to other than 0 If both modem and SMS are enabled the unit will send SMS messages first and attempt modem connection afterwards When SMS sending is in progress an SMS icon will appear at the upper right corner of the screen The maximum number of alarms transmitted in a SMS message is 4 This limitation is due to the maximum length of an SMS message which is 160 characters A sample GSM SMS message is given below DKGxxx lt SITE ID gt STOP LOW OIL PRESSURE SW END OF ALARM LIST The first line of the message carries information about the unit type and the site identity string This line is intended for the identification of the genset sending the SMS message Each following line will give one fault information The message will always be terminated by the END OF ALARM LIST string When the message is sent the existing alarms will
65. rees F 2 Flashing Relay Timer hours Delayed Simulate Mains Operation max genset running time after Simulate Mains signal disappears Dual Genset Systems flashing relay toggle timer Please contact DATAKOM for dual genset mutual stanby operation 36 DKG 519J User Manual V 27 14 04 2011 Program Group Controller Configuration continued Parameter Definition Unit Factory Description Password Level Set This parameter trims precisely the real time clock circuit f Values from 0 to 63 speed up the clock with 1 Real Time Clock Adjust 117 0 25sec day steps Values from 127 to 64 slow down the clock with 0 25sec day steps This parameter provides the mains and genset voltage limits with a hysteresis feature in order to prevent faulty decisions f For example when the mains are present the mains 2 Hysteresis Voltage x S voltage low limit will be used as the programmed low limit When the mains fail the low limit will be incremented by this value It is advised to set this value to 8 volts This parameter is used in the conversion of the 2 RPM from genset 1 genset frequency to engine rpm frequency 0 read rpm from the optional MPU input 1 convert frequency to rpm using crank teeth count This is the number of pulses generated by the magnetic pickup sensing unit in one turn of the flywheel 2 Crank Teeth Count 30 This parameter i
66. rns on when the preset engine hours or time duration after previous service has elapsed DKG 519J User Manual V 27 14 04 2011 3 2 Language Selection The unit is able to display information in 3 languages Language selection is made through program parameter CONTROLLER CONFIGURATION gt LANGUAGE SELECTION Below selections are available 0 English language 1 Turkish language 2 Chinese language 3 ask selection at power up If language is set to 3 below screen will come at power on TY Enslish 4 Turkce a FY Left Up Down arrow pushbuttons will select the screen language The language will be asked everytime power is turned on With selections of 0 1 2 this screen will not appear and the selected language is enabled 3 3 Digital Display The unit has a graphical 128x64 pixel LCD display It shows Measured parameters The company logo The alarm list Software version and date time information Statistical counters Event records Program parameters Navigation between different screens s made with the MENU and MENUP buttons Each depression of the MENUP button switches the display to the next screen Each depression of the MENU button switches the display to the previous screen During operation the unit will switch automatically between different screens displaying always the most important parameters for the current operating status If an alarm or warning occurs during oper
67. ry Volt Freq to 1 with digital input signal Thus the user has full flexibility for manual or external switching If switching is done with digital input signal one of digital inputs has to be defined as 2 Volt Freq Select using INPUT FUNCTION SELECT program group Below parameters are available for second voltage frequency selection Mains Low Voltage Limit Genset Low Voltage Shutdown Limit Mains High Voltage Limit Genset Low Voltage Warning Limit Mains Low Frequency Limit Genset High Voltage Warning Limit Mains High Frequency Limit Genset High Voltage Shutdown Limit Genset Low Frequency Shutdown Limit Genset Low Frequency Warning Limit Genset High Frequency Warning Limit Genset High Frequency Shutdown Limit Genset Low RPM Shutdown Limit Genset Low RPM Warning Limit Genset High RPM Warning Limit Genset High RPM Shutdown Limit 26 DKG 519J User Manual V 27 14 04 2011 6 27 Single Phase Operation If the unit is used in a single phase electrical network it is advised t set the Single Phase Enable program parameter in CONTROLLER CONFIGURATION group to 1 When Single Phase Enable is set to 1 then the unit will measure electrical parameters only on phases L1 of genset and mains Voltage and overcurrent checks will be performed on phases L1 only Phases L2 and L3 parameters as well as phase to phase voltages are removed from display screens 7 J1939 ENGINE MONITORING AND CONTROL PORT The unit offers a spe
68. s also used in the conversion of the genset frequency to engine rpm The frequency in Hz is multiplied with this parameter during conversion to rpm This parameter controls SMS sending when mains voltages status is changed No warning is generated 2 SMS on Malis Change g 0 no SMS when mains failed or restored 1 SMS sent when mains failed or restored If the fuel level measured from the sender input falls 2 Fuel Pump Low Limit 20 below this level then the FUEL PUMP function will become active If the fuel level measured from the sender input goes 2 Fuel Pump High Limit 80 above this level then the FUEL PUMP function will become passive 0 no effect e pressure sender fault 0 1 warning 2 loaddump 0 no effect or temp sender fault _ 0 1 warning 2 loaddump 0 no effect reg level sender fault i 0 1 warning 2 loaddump 0 no effect A temp sender fault 0 warning 2 loaddump 2 RS 485 Enable 0 0 RS 232 communication 1 RS 485 communication 37 DKG 519J User Manual V 27 14 04 2011 Program Group Electrical Parameters Parameter Definition Password Level Unit Factory Set Description 2 Current Transformer Ratio 500 This is the rated value of current transformers All transformers must have the same rating The secondary of the transformer will be 5 Amps 2 Overcurrent Limit If the current goes above this limit during the period defined i
69. s and do not cause engine stop The engine is supposed protected by the ECU which will stop it when necessary The electronic engine fault codes are displayed within the alarm list table in text together with their SPN FMI codes A maximum of 8 fault codes can be displayed The complete list of fault codes is given in the engine manufacturer s user manual 27 DKG 519J User Manual Below is a basic list of fault conditions x denotes any FMI V 27 14 04 2011 SPN FMI DESCRIPTION 94 x Fuel filter restriction Fuel pressure sensor fail 98 X Low oil level High oil level Oil level sensor fail 100 D Low oil pressure Oil pressure sensor fail 102 xX High boost pressure Turbo outlet pressure sensor fail 105 D Intake manifold temp high Intake manifold temp sensor fail 107 X Air filter restriction Air filter sensor fail 108 D Athmospheric pressure sensor fail 110 X High coolant temperature Coolant temperature sensor fail 111 x Low coolant level Coolant level sensor fail 164 x High injector activation pressure Injector activation pressure sensor fail 168 X Battery voltage failure 172 D High inlet air temperature High inlet manifold air temperature Inlet manifold air temperature sensor fail 174 D High fuel temperature Fuel temperature sensor fail 175 X High oil temperature Oil temperature sensor fail 190 Xx Overspeed Spe
70. set KWh engine hours to service time to service total engine cranks total genset runs These counters are kept in a non volatile memory and are not affected from power failures 12 MAINTENANCE DO NOT OPEN THE UNIT There are NO serviceable parts inside the unit Wipe the unit if necessary with a soft damp cloth Do not use chemical agents 33 DKG 519J User Manual V 27 14 04 2011 13 PROGRAMMING The program mode is used to program timers operational limits and the configuration of the unit To enter the program mode press together MENU and MENUP buttons for 1 second The program mode is only allowed if the PROGRAM LOCK input is left open If this input is tied to GROUND the program value modification will be disabled to prevent unauthorized intervention It is advised to keep the PROGRAM LOCK input tied to GROUND When the program mode is entered below password entry screen will be displayed E ENTER PASSWORD MI 81 8 8 A 4 digit password must be entered using V MENUP and MENU buttons The unit stores 3 different passwords Each password allows access to a different level of program parameters 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
71. t SMS telephone number Modem 1 SMS 1 telephone number Program Group Modem 2 SMS 2 Telephone Number password level 2 Parameter Definition Factory Set Description This telephone number buffer accepts up to 16 digits including the wait charater in order to enable dialing through a pabx If Modem Enabled This is the second telephone number used for modem calls If Modem Disabled This is the second SMS telephone number Modem 2 SMS 2 telephone number Program Group SMS 3 Telephone Number password level 2 Parameter Definition Factory Set Description This SMS telephone number accepts up to 16 digits SMS 3 telephone number Program Group SMS 4 Telephone Number password level 2 Parameter Definition Factory Set Description This SMS telephone number accepts up to 16 digits SMS 3 telephone number Program Group SMS 5 Telephone Number password level 2 Parameter Definition SMS 3 telephone number This SMS telephone number accepts up to 16 digits Factory Set Description Program Group SMS 6 Telephone Number password level 2 Parameter Definition Factory Set Description SMS 3 telephone number This SMS telephone number accepts up to 16 digits 54 DKG 519J User Manual V 27 14 04 2011 14 TROUBLESHOOTING AC voltages or frequency displayed on the u
72. t by the governor control unit of the engine Any of the spare relay outputs may be assigned as IDLE output using Relay Definition program parameters Also relays on an extension module may be assigned to this function The Idle speed operation is performed both in engine start up and cool down sequences Speed and voltage protections are disabled during idle speed operation 6 5 Engine Block Heater The unit is able to provide a relay output in order to drive the block heater resistor The temperature reference is the coolant temperature measured from the the analog sender input The block heater relay function may be assigned to spare relays using Relay Definition program parameters Also relays on an extension module may be assigned to this function The engine body temperature limit is adjusted using the parameter Engine Heating Temperature The same parameter is used for engine heating operation The relay will become active if the body temperature falls to 4 degrees below the limit set by Engine Heating Temperature It turns off when the body temperature exceeds Engine Heating Temperature 15 DKG 519J User Manual V 27 14 04 2011 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
73. ter holds the genset active power multiplied by 256 Least significant 16 bits are in the register 0016h Most significant 8 bits are in the LSB of the register 0017h 0018 R 8bit x100 Power factor multiplied by 100 signed byte Negative values indicate a capacitive power factor 002A R 16bit x1 Engine speed rpm 002B R 16bit x10 Oil pressure in bars 002C R 16bit x1 Coolant temperature in degrees C 002D R 16bit x1 Fuel level as 002F R 16bit x10 Battery voltage 003D R 8bit Operating mode bit_3 manual mode bit_4 auto mode bit_5 off mode bit_6 test mode bit_7 load test mode 280 DKG 519J User Manual V 27 14 04 2011 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 In other modes it will not affect the genset operation In AUTO mode if the operation of the genset is disabled by the weekly schedule then the AUTO led will flash instead of a steady on state Each turn on turn off time is defined in 10 minute steps Unused programs should be set to 24 00 An example setup may be as follows
74. ternal 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 The possible address range is 1 to 144 Setting the address to 0 will disable the MODBUS mode and allow communication under RAINBOW protocol The MODBUS properties of the unit are Data transfer mode RTU Serial data 9600 bps 8 bit data no parity 1 bit stop Supported functions Function 3 Read multiple registers Function 6 Write single register 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 R DATA COEFFICIENT DESCRIPTION Moen w Leize 0003 R 16bit x1 Genset Phase L1 voltage 0004 R 16bit x1 Genset Phase L2 voltage 0005 R 16bit x1 Genset Phase L3 voltage 0006 R 16bit x1 Genset Phase L1 current 0007 R 16bit x1 Genset Phase L2 current 0008 R 16bit x1 Genset Phase L3 current 000F R 16bit x1 Genset Phase L12 voltage 0010 R 16bit x1 Genset Phase L23 voltage 0011 R 16bit x1 Genset Phase L31 voltage 0013 R 16bit x10 Genset frequency 0016 0017 R 32bit x256 Genset active power this 24 bit signed regis
75. the mode selection keys If no button is pressed during 1 minute the program mode will be cancelled automatically 34 DKG 519J User Manual V 27 14 04 2011 Program Group Controller Configuration Parameter Definition Unit Factory Description Password Level Set 1 LCD Contrast p 22 This parameter is used to set LCD contrast Adjust for the best viewing angle 0 English language selected 1 Turkish language selected This language may depend on the country where the unit is intended to 2 Language 0 be used 2 Chinese language selected 3 The unit will ask for manual language selection at power on 2 Secondary Volt Freq 0 0 Use primary voltage frequency limits 1 Use secondary voltage frequency limits 0 3 phase system 2 Single phase Enable 0 1 Single phase system 0 Display Line to Neutral voltages as default CE ge EG 0 1 Display Line to Line voltages as default This parameter selects the screen which is displayed during genset on load operation 0 screen 3 or 4 electrical large characters 1 screen 5 engine parameters large characters 1 Genser Default Display S 2 screen 6 or 7 P EE small characters 3 screen 8 or 9 Details of each screen are explained in chapter 3 2 0 Genset control 2 Engine Control Only j 9 1 Engine control no alternator This parameter defines the delay after the engine A FAU Odo Firar ci 5 runs a before th
76. the unit may be damaged If temperature or oil pressure or fuel level displays are already present on the generator control panel do not connect the senders to the unit The unit is factory programmed for VDO type senders However different types of senders are selectable via programming menu Please check the programming section The programmable digital inputs are compatible with both normally open and normally closed contacts switching 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 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 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 Anappropriate and readily accessible set of disconnection devices e g automatic fuses MUST be provided as part of the installation 3 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 4 Use cables of adequate current carrying capacity at least 0 75mm and tempera
77. this limit when feeding the load this will generate a GENSET HIGH VOLTAGE alarm and the engine will stop 2 Low Battery Voltage Warning 9 0 If the battery voltage falls below this limit this will generate a LOW BATTERY warning 2 High Battery Voltage Warning If the battery voltage goes over this limit this will generate a HIGH BATTERY warning 2 High Battery Voltage Shutdown 33 0 If the battery voltage goes over this limit this will generate a HIGH BATTERY shutdown alarm and the engine will stop 1 Mains Waiting Timer min 0 5 This is the time between the mains voltages entered within the limits and the generator contactor is deactivated 2 Genset Contactor Timer SEC This is the period after the mains contactor has been deactivated and before the generator contactor has been activated 2 Mains Contactor Timer SEC This is the period after the generator contactor has been deactivated and before the mains contactor has been activated 2 Mains Phase Order Enable 0 mains phase order checking disabled 1 if mains phase order is faulty then a warning is given and mains contactor deenergized 38 DKG 519J User Manual V 27 14 04 2011 Program Group Electrical Parameters continued Parameter Definition Factor SES Password Level gul Set Description If the genset power
78. ture range DKG 519J User Manual V 27 14 04 2011 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 Term Function Technical data Description 1 s 2 GEN L1 Generator phase Connect the generator phases to these inputs 3 GEN L2 inputs 0 300V AC The generator phase voltages upper and 4 GEN L3 lower limits are programmable 5 GENERATOR NEUTRAL Input 0 300V AC Neutral terminal for the generator phases 6 7 8 8 9 10 11 GROUND O VDC Power supply negative connection 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 FUEL LEVEL SENDER Input 0 5000 ohms No connection to this terminal 14 OIL PRESSURE SENDER Input 0 5000 ohms Analogue oil pressure sender connection Do not connect the sender to other devices The input has programmable characteristics and connects to any kind of sender 15 COOLANT TEMP SENDER Input 0 5000 ohms Analogue high temperature sender connection Do not connect the sender to other d
79. y day regardless of the day selection If the monthly exerciser is selected then the exercise will be performed during the first 7 days of each month at the programmed day and hour 1 Exercise Duration min This parameter defines the exercise duration and programmed in 10 minute steps up to 24 hours 1 Exercise Off On Load 0 Exercise at TEST mode 1 Exercise at LOAD TEST mode 1 Exercise Period 0 exercise every day the exercise will be performed every day regardless of the day selection of Exercise Dat and Time parameter 1 exercise once per week 2 exercise once per month the exercise will be performed during the first 7 days of each month at the programmed day and hour 2 Delayed Simulate Mains 0 The SPARE 2 input has normal function 1 The SPARE 2 input has delayed simulate mains function See chapter 6 8 for more info 2 Modem Enable 0 No modem connection the serial port is connected to PC 1 Modem connected 2 SMS Enable 0 SMS not enabled 1 SMS enabled 2 GPRS Call Enable 0 standard modem calls 1 GPRS modem calls 2 MODBUS Address 0 RAINBOW communication protocol 1 144 MODBUS communication This parameter is also the MODBUS controller address of the unit 1 Oil Pressure in psi 0 oil pressure display in bars 1 oil pressure display in psi 1 Temperature in F 0 temperature display in degrees C 1 temperature display in deg

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