User Manual KG 545
Contents
1. 0 and Input Function IN 04 should be other than Remote Start Input 6 2 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 genset will take the load 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 load will be transferred to the genset 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 3 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 set by the governor control unit of the engine Any of the spare relay outputs may be assigned as IDLE output us2. Genset phase currents L1 L2 L3 Genset frequency Genset active power KW Genset power factor Engine rpm Oil pressure Coolant temperature Fuel level Battery voltage Mains phase voltages L1 L2 L3 Mains frequency Digital input voltages Charge input voltage ce KG 545 User Manual Program Group Controller Configuration Parameter Definition Unit Factory Set Description LCD Contrast 35 This parameter is used to set LCD contrast Adjust for the best viewing angle Alarm Relay Timer sec 60 This is the period during which the ALARM relay is active If the period is set to 0 this will mean that the period is unlimited 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 every 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 Exerc
3. Oil pressure switch not connected Oil pressure switch connection wire cut Oil pressure switch faulty Oil pressure switch closes too lately If oil pressure switch closes the unit will start Optionally oil pressure switch may be replaced The engine does not run after the first start attempt then the unit does not start again and OIL PRESSURE 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 33 RE KG 545 User Manual KIRLOSKAR POWER IDEAS 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 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
4. phase voltages is outside limits LOAD MAINS Green lt turns on when the mains contactor is activated LOAD GENERATOR Yellow lt 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 STOP Yellow selected One of these LEDs is always on and indicates which operation mode is selected AUTO Green If the operation of the genset is disabled by the MANUAL Yellow N operation schedule then the AUTO led will ALARM Red If a fault condition resulting to the engine shutdown has occurred the alarm led turns on steadily If a warning 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 LOW OIL PRESSURE Red Turns on when a low oil pressure condition is detected either from the sender or switch input HIGH ENGINE TEMP Red Turns on when a high coolant temperature condition is detected either from the sender or switch input BATTERY VOLTAGE Red Turns on when a low or high battery voltage condition is detected UNDER OVER SPEED Red Turns on when a low or high speed condition is detected LOW FUEL LEVEL Red Turns on when a low fuel level condition is detected either from the sender or switch input OVERLOAD Red Turns on when overcurrent o
5. Number Parameter Definition Factory Set Description Modem 2 SMS 2 telephone number 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 Program Group SMS 3 Telephone Number Parameter Definition Factory Set Description SMS 3 telephone number This SMS telephone number accepts up to 16 digits Program Group SMS 4 Telephone Number Parameter Definition Factory Set Description SMS 3 telephone number This SMS telephone number accepts up to 16 digits Program Group SMS 5 Telephone Number Parameter Definition Factory Set Description SMS 3 telephone number This SMS telephone number accepts up to 16 digits Program Group SMS 6 Telephone Number Parameter Definition Factory Set Description SMS 3 telephone number This SMS telephone number accepts up to 16 digits 32 RE KG 545 User Manual KIRLOSKAR POWER IDEAS 9 TROUBLESHOOTING The genset operates while AC mains are OK or continues to operate after AC mains are OK Check engine body grounding AC mains voltages may be outside programmed limits measure the phase voltages Check the AC vo
6. User Manual KIRLOSKAR POWER IDEAS Program Group Engine Parameters continued Parameter Definition Unit Factory Set Description Crank Timer sec 10 This is the maximum start period Starting will be automatically cancelled if the genset fires before the timer Wait Between Starts sec 10 This is the waiting period between two start attempts Cooldown Timer min 1 0 This is the period that the generator runs for cooling purpose after the load is transferred to mains Idle Speed Timer sec 10 When the engine runs the Idle output relay function will be active during this timer 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 Low Fuel Shutdown Yo 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 Fuel Consumption per Hour Yo This parameter is used to calculate the fuel quantity in the fuel tank in engine hours This is also 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 Check chapter 6 19 for details of fuel theft SMS messages Fuel Tank Capacity Lis This parameter is used to calculate the fuel quantity in the fuel tank If this paramet
7. any of the mode selection keys are pressed during exercise then the exercise will be terminated Using the daily exercise mode the unit may feed the load from the genset during predefined hours of the day This operation may be used in high tariff periods of the day 6 16 Gas Engine Fuel Solenoid Control The unit provides a special function for the fuel solenoid control of a gas engine The fuel solenoid of a gas engine is different from a diesel engine It should be opened after the cranking has been started and should be closed between crank cycles The delay between the crank start and solenoid opening is adjusted using the Gas Solenoid Delay program parameter 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 17 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 in
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9. 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 ACK RESET and V buttons A gt character will appear at the first column of the selected group In order to enter inside a group please press button In order to exit from the group to the main list please press 0 STOP button Navigation inside a group is made also with Wand ACK RESET buttons A list of available parameters will be displayed Selected parameter is shown with a character at the first column In order to display change the value of this parameter please press button Parameter value may be increased and decreased with Wand ACK RESET 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 P button is pressed next parameter will be displayed If O STOP 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 If no button is pressed during 1 minute the program mode will be cancelled automatically 22 RE KG 545 User Manual KI
10. unit is designed for panel mounting The user should not be able to access paris 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 A Do not tighten brackets excessively This may brake the unit Engine body must be grounded for correct operation of the unit otherwise incorrect 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 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 progr
11. 22 IN 3 AUTO START normally closed or normally open contact 23 IN 4 FUEL LEVEL switching either to battery or battery The 4 IN 5 SPARE 1 effect of the switch is also selectable from a 25 IN 6 SPARE 2 list See PROGRAMMING section for more 26 IN 7 SPARE 3 details 27 MAGNETIC PICKUP 28 MAGNETIC PICKUP Term Function Technical data Description 29 MR MAINS R PHASE Mains phase inputs Connect the mains phases to these inputs 30 MY MAINS Y PHASE 0 300V AC The mains voltages upper and lower limits are 31 MB MAINS B PHASE programmable 32 MN MAINS NEUTRAL Input 0 300V AC Neutral terminal for the mains phases Term Function Technical data Description 33 Earth Current transformer Connect the earth current transformer inputs 5A AC terminals to these inputs 34 Earth 35 BS 2 Current transformer Connect the load current transformer inputs SA AC terminals to these inputs Do not connect the 36 BS 1 same current transformer to other instruments otherwise a unit fault will occur Connect each 37 YS2 terminal of the transformer to the unit s related terminal Do not use common terminals Do not use grounding Correct polarity of ee Yai connection is vital If the measured power is negative then change the polarity of each 3 39 RS2 current transformers The rating of the transformers should be the same for ea
12. 28 RE KG 545 User Manual KIRLOSKAR GREEN Program Group Input Configuration 06 Spare 1 Input Parameter Definition Unit Fac Set Description Action 0 0 Shutdown the engine stops immediately Sampling 0 0 Always Latching 1 1 Latching 0 Normally open Contact type 9 1 Normally closed Switching 0 0 Battery negative Note Alaways Set to Zero Response dela 0 0 No delay y 1 Delayed 4sec Program Group Input Configuration 07 Spare 2 Input Parameter Definition Unit Fac Set Description Action 0 0 Shutdown the engine stops immediately Sampling 0 0 Always Latching 1 1 Latching 0 Normally open Contact type I 1 Normally closed Switching 0 0 Battery negative Note Alaways Set to Zero 0 No delay Response delay 0 1 Delayed 4sec Program Group Input Configuration 08 Low Coolant Level Switch Parameter Definition Unit Fac Set Description Action 0 0 Shutdown the engine stops immediately Sampling 0 0 Always Latching 1 1 Latching Contact type 1 1 Normally closed Switching 0 0 Battery negative Note Alaways Set to Zero Response delay 0 0 No delay The below parameters defines the functions of digital outputs The unit has 7 digital outputs All outputs have programmable functions selected from a list The relays may be extended up to 23 using Relay Extension Modules Pro
13. 89 Temp sender warn 10 Shutdown or 43 High speed alarm 90 Low speed warning load_dump or warning 44 Low voltage alarm 91 High speed warning 11 Automatic ready 45 High voltagealarm 92 12 Week on time 46 Fail to start alarm 93 Low Temp snd warn 13 Exerciser on 47 Low fuel sender alarm 94 Fail to stop warning 14 Load_dump alarm 48 Oil Temp sender alarm 95 Low fuel sender 15 49 Canopy Temp sender warn 16 Mains Fail alarm 96 Service request 17 Block Heater 50 warn 18 Service Request 51 High battery voltage 97 Mains Phase Order 19 alarm Fail warning 20 Load Shedding Relay 52 Charge fail alarm 98 Low battery warning 21 Flashing Relay 53 99 High battery warning 22 Gas Solenoid 54 Coolant Level AC switch 100 Charge fail warning 23 Fuel Pump alarm 101 24 Mains Phase Order 55 102 Fail 56 Temp sw load_dump 103 High Earth Current 25 Genset Phase Order 57 Oil switch load_dump warning Fail 58 Emerg Stop load_dump 104 Gen Low voltge 26 Idle Speed 59 warn 27 Cooler Fan 60 Low Fuel Level switch 105 Gen High voltge 28 load_dump warn 29 61 Spare 1 load_dump 106 Reverse Power warn 30 62 Spare 2 load_dump 107 High oil temp warn 31 63 Spare 3 load_dump 108 High canopy temp 64 Oil sender fail Idd warning 65 Temp sender fail Idd 109 66 Fuel Lev sender fail Idd 110 Low coolant level AC 67 Oil Temp snd fail Idd switch w
14. AR POWER IDEAS Program Group Controller Configuration continued Parameter Definition Unit Factory Description Set This parameter controls SMS sending when mains l voltages status is changed No warnings generated eo Mane ananga ai 0 no SMS when mains failed or restored 1 SMS sent when mains failed or restored 0 Fuel level sender not connected biel even en enable l L 1 Low fuel level warning and alarm enabled Canopy Temp Sender l 0 0 Canopy temp sender not connected Enable 1 High canopy temp warning and alarm enabled Program Group Electrical Parameters Parameter Definition Unit Factory Description Set This is the rated value of current transformers Current Transformer Ratio A 500 All transformers must have the same rating The secondary of the transformer will be 5 Amps Earth Fault Current A 500 This is the rated value of earth current transformer Transformer Ratio The secondary of the transformer will be 5 Amps If the current goes above this limit during the period defined in Overload Timeout then a Overcurrent Overcurrent Limit A 700 Load Dump alarm will be generated If this parameter is 0 then Overcurrent check is disabled If the active power goes above this limit during the period defined in Overload Timeout then an Excess Excess Power Limit KW 440 Power Load Dump alarm will be generated If this parameter is 0 th
15. KG 545 User Manual a KIRLOSKAR eo REE N POWER IDEAS KG 545 AUTOMATIC MAINS FAILURE UNIT 2 1 KIRLOSKAR an ALARM ACKIRESET LOW OIL _HIGH ENGINE BATTERY UND PRESSURE TEMPERATURE VOLTAGE ER OVER LOW FUEL OVER PEED LEVEL LOAD FEATURES Automatic mains failure Engine control Generator protection Built in alarms and warning Manual control enabled Magnetic pickup input Dual genset mutual standby operation Load shedding dummy load Gas engine support Engine idle speed control 3 phase mains voltage inputs 3 phase genset voltage inputs 3 phase genset CT inputs Engine oil pressure measurement Engine coolant temperature measurement Fuel level measurement Oil temperature measurement Canopy temperature measurement Genset active power measurement Genset power factor measurement Engine rpm display Periodic maintenance request indicator Engine hours counter Event logging with date time stamp and complete measurement values Stores last 100 events Statistical counters Battery backed up real time clock password protection Programmable parameters RS 232 RS 485 selectable serial port Firmware downloadable from serial port MS Windows Remote monitoring SW local and GSM connection monitoring GSM and PSTN modem support GSM SMS sending on fault Modem calls on fault MODBUS communication 128x64 graphic LCD display KOEL logo display Analogue inputs 5 Digital inputs 9 Digi
16. RLOSKAR POWER IDEAS Program Group EVENT LOGGING The unit keeps record of the last 100 events in order to supply information for the service personal The date time 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 keptin a non volatile memory and are not affected from power failures The event record is reached through programming menu Switching to the previous event is made with button A To exit event record pages press 0 STOP button 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 W button 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 Genset operation status mains ok running cooldown etc Genset phase voltages L1 L2 L3
17. S phase to neutral and phase to phase 2 Genset Phase Currents Presented as a table and Genset frequency 3 Genset Phase kW and Presented as a table power factor 4 Genset Phase kVA and Presented as a table kVAr values 5 Genset average current Presented as a table and voltage genset frequency total kW and PF 6 Genset R Current Genset Phase R Current large characters 7 Genset Y Current Genset Phase Y Current large characters 8 Genset B Current Genset Phase B Current large characters 9 Genset Frequency with large size characters 10 Genset Active Power with large size characters 11 Genset Average Voltage with large size characters 12 Genset kW hours 8 digit counter 13 Earth Leakage Current in Amps and of CT ratio large characters KG 545 User Manual a es KIRLOSKAR GREEN POWER IDEAS Group Screen Contents Description ENGINE 1 Oil Pressure Displayed in bars and kPa large characters PARAMETERS If PSI display is enabled by program parameter then displayed in bars and psi 2 Engine Temperature Displayed in degrees C and degrees F large characters 3 Fuel Status Displayed in of full tank capacity If Fuel Consumption Hour parameter is not zero then also displayed in engine hrs If Fuel Tank Capacity parameter is not zero then also displaed in liters 4 Engine Speed Displayed in RPMs 5 Battery Voltage Display
18. SKAR POWER IDEAS Program Group Electrical Parameters continued Parameter Definition Unit gon Description Low Battery Voltage V 19 0 If the battery voltage falls below this limit this will Warning i generate a LOW BATTERY warning High Battery Voltage yV 29 0 If the battery voltage goes over this limit this will Warning generate a HIGH BATTERY warning This is the time between the mains voltages entered Mains Waiting Timer min 0 5 within the limits and the generator contactor is deactivated 0 mains phase order checking disabled Mains Phase Order Enable 0 1 if mains phase order is faulty then a warning is given and mains contactor deenergized If the genset power is negative and goes above this Reverse power warning limit KW 0 limit then a REVERSE POWER warning will be generated Reverse power loaddumpg If the genset power is negative and goes above this limit KW 0 limit then a REVERSE POWER loaddump will be generated 0 genset phase order checking disabled eae one 0 1 if genset phase order is faulty then a loaddump is generated and the genset stops after cooldown Earth Fault Current Warning If the earth current goes above this limit for overload Limit Yo 0 timeout then a warning will be generated The value is defined as a percentage of genset CT rating If the earth current goes above this limit for overload Earth Fault Current o 0 timeout then a loaddump alarm will be generated Loaddum
19. 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 Engine Parameters Engine speed rpm Battery voltage Coolant temperature Oil pressure Fuel level Oil temperature Canopy temperature Engine run hours Genset Parameters 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 current phase L1 Gen current phase L2 Gen current phase L3 Gen frequency Gen KW phase L1 Gen KW phase L2 Gen KW phase L3 Gen total KW Gen KVA phase L1 Gen KVA phase L2 Gen KVA phase L3 Gen KVAr phase L1 Gen KVAr phase L2 Gen KVAr phase L3 Earth Fault Current Gen pf phase L1 Gen pf phase L2 Gen pf phase L3 Gen total pf Mains Parameters Mains voltage phase L1 to neutral Mains voltage phase L2 to neutral Mains voltage phase L3 to neutral Mains voltage phase L1 L2 Mains voltage phase L2 L3 Mains voltage phase L3 L1 Mains frequency RE KG 545 User Manual KIRLOSKAR POWER IDEAS 1 2 Mounting the Unit The
20. ammable 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 R Y B Generator phase R Y B 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 An appropriate 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 Use cables of adequate current carrying capacity at least 0 75mm2 and temperature range RE KG 545 User Manual KIRLOSKAR POWER IDEAS 2 CONNECTOR DETAILS 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 input output extension modules Each opti
21. arm 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 19 RE KG 545 User Manual KIRLOSKAR POWER IDEAS 6 15 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 Exerciser Period Daily Weekly Monthly Exerciser can only be enabled through PC It cannot be programmed from front panel When the start day and hour of exercise has come the unit will automatically switch TEST mode and the engine will run If a mains failure occurs during 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 the exerciser At the end of the exercise duration the unit will switch back to the initial mode of operation If
22. arning 68 Canopy Temp snd fail 111 Idd 112 Oil sender fail warn 69 Spare 1 sender fail Idd 113 Temp sender fail 70 Spare 2 sender fail Idd warn 71 l 114 Fuel sender fail warn 72 Overcurrent load_dump 115 Oil temp snd fail 73 Excess power Idd warn 74 Reverse power Idd 116 Canopy temp snd fail 75 High Earth current Idd warning 76 l 117 Spare 1 sender fail 77 warning 78 118 Spare 2 sender fail 79 Genset Phase Order Fail warning Loaddump 119 a es KIRLOSKAR GREEN POWER IDEAS 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 30 KG 545 User Manual Program Group Input Function Select Parameter Definition Ag Description Input 01 Function Select 1 High Temp Switch Input 02 Function Select 0 Oil Pressure Switch Input 03 Function Select 4 Emergency Stop Input 04 Function Select 18 Remote Start Input Input 05 Function Select 7 Low Fuel Level Switch Input 06 Function Select 11 Spare 1 Input Input 07 Function Select 10 Spare 2 Input Input 08 Function Select 2 Low Coolant Level switch Input Func
23. ating temperature range 20 C to 70 C 4 F to 158 F Maximum humidity 95 non condensing Dimensions 202x148x48mm WxHxD Panel Cut out dimensions 183 x 134mm minimum Weight 400 g approx Case material High temperature self extinguishing ABS PC UL94 V0 IP protection IP65 from front panel IP30 from the rear 34 KIRLOSKAR KG 545 User Manual 12 CONNECTION DIAGRAM AlUO pu uo wou punog bx papunou6 q 1snw sAnB6baN Alaneg JOJOIN Jeue s a g i W w jo gt li EBBE E O Q A a m 2i lols jaim ig izio i i jf iB it eg ja E x o S jo 13 la S Jo 2 j ja ts 12 Ip 15 f D L dj jo n e Ig lola l 5 K r ig fs gt N lo n 15 E 2 2 j gt Is Ja 2 12 lo a 2 v 3 Ir o le 3 o jg T 2 r I2 le 5 Ilo D i D ka 5 3 naw o l lt 9 lt 5 Fi o F D a D lt a 0 18 o a ja 5 5 8 Q g ej gE Z EREB r Pf Le D gt jo O 2 5 8 jo w gt 5 ZL 9 si eL cb Mw 90 80 87 LZ 9 SZ He EZ TZ bZ OZ GL BL vl uoISUa XF bx ndino 1nduj lv GvS OMG je 7 188r sa ZEZ SY HS8rsy VY ce LE OF 62 z T NI Jojoejuo9 sule 4129 A s10 0ejU0J USeMI9q l yo0Leui eouPEje asN OV6E BELZE YESE PEELE OL veo ty ob Lv Jojoeyuo9 Vi jesuag ea L sng a Ni asng a 39 asny asny O O Le a 81 110 l O17 YOLVNYSLIV N
24. 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 f N will appear at the upper right corner of the screen li If Modem Enable or SMS Enable or MODBUS Address or RS 485 Enable parameters are different from zero the local PC connection will not work Advised modems are KOEL types which are powered up from the same DC battery voltage than the unit Most of other desktop modems with standard AT commanas 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 KOEL Modem calls are always terminated by the central PC 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 PC 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 master station Please review chapter_8 for more details on MODBUS communication 17 RE KG 545 User Manual KIRLOSKAR POWER IDEAS 6 11 SMS Message Sending The GSM SMS sending is activated by setting the SMS Enable program parameter to 1 di If Modem Enable or SMS Enable or MODBUS Address or RS 485 Enable parameters are differ
25. ch of 40 RS 1 the 3 phases The secondary winding rating shall be 5 Amperes For ex 200 5 Amps Term Function Technical data Description 41 GN GENERATOR NEUTRAL Input 0 300V AC Neutral terminal for the generator phases 42 GR GEN R PHASE Generator phase Connect the generator phases to these inputs 43 GY GEN Y PHASE inputs 0 300V AC The generator phase voltages upper and 44 GB GEN B PHASE lower limits are programmable Term Function Technical data Description 45 RS 485 H Input output This is terminal of the RS 485 port 45 RS 485 L Input output This is terminal of the RS 485 port 45 RS 485 GND Output This terminal is internally connected to battery negative Connect the shield of the RS 485 cable to this terminal from one end only RE KG 545 User Manual KIRLOSKAR POWER IDEAS 3 DISPLAYS 3 1 LED Displays The unit has16 LEDS divided in 3 groups Group 1 Operating mode This group indicates the genset function Group 2 Mimic diagram This group indicates the current status of the mains and genset voltages and contactors Group_3 Warnings and alarms This group indicates the existence of abnormal conditions encountered during operation 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
26. d if the mains are not off If the mains are off mains contactor will be deactivated and the generator contactor will be activated When the mains are on again a changeover to the mains will be made but the engine will be kept running unless another mode is selected To stop the engine select AUTO or OFF mode MANUAL It is used to run and stop then engine and operate contactors manually Separate pushbuttons for each operation are provided 12 RE KG 545 User Manual KIRLOSKAR POWER IDEAS 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 AMF REMOTE Dev parameter should be set to 1 in Controller Configuration The REMOTE START signal should be set to NO contact switching to battery negative These selections are made using programming menu 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 Note For AMF Application AMF REMOTE Dev parameter should be set to
27. ed in Volts DC The Minimum Minimum battery voltage Battery Voltage is reset before each engine crank cycle Thus the displayed value reflects the most recent status 6 Oil Temperature Displayed in degrees C and degrees F This screen is displayed only if the Oil Temp analog input is enabled 7 Canopy Temperature Displayed in degrees C and degrees F This screen is displayed only if the Canopy Temp analog input is enabled 8 Engine Hours The engine hours is displayed up to Total Starts 999 999 9 hours Total start count is displayed up to 9999 Group Screen Contents Description MAINS 1 Mains Phase voltages Presented as a table PARAMETERS phase to neutral and phase to phase Mains Phase Currents Presented as a table Mains Frequency and Frequency in Hertz Average Voltage The voltage is the average of both phase voltages Group Screen Description ALARM LIST 1 If no alarm exists then END OF ALARM LIST is displayed Otherwise the first alarm is displayed Each depression of the W button will cause the screen to switch to the next alarm Group Screen Description COMMUNICATION 1 This screen shows the modem parameters STATUS It is displayed only if the modem is enabled Group Screen Contents Description GENSET 1 Genset Status Ascii explanation of the current status STATUS 2 Logo Company logo Kirloskar Green Power Ideas 3 Date amp time Current date and time displayed in large character
28. en Excess Power check is disabled If one of the mains phases goes under this limit it Mains Voltage Low Limit V 180 means that the mains are off and it starts the transfer to the genset in AUTO mode If one of the mains phases goes over this limit it Mains Voltage High Limit V 260 means thatthe mains are off and it starts the transfer to the genset in AUTO mode If the mains frequency goes under this limit it means Mains Frequency Low Limit Hz 45 that the mains are off and it starts the transfer to the genset in AUTO mode If the mains frequency goes above this limit it means Mains Frequency High Limit Hz 55 that the mains are off and it starts the transfer to the genset in AUTO mode If one of the generator phase voltages goes under this Genset Low Voltage V 190 limit when feeding the load this will generate a Shutdown Limit GENSET LOW VOLTAGE shutdown alarm and the engine will stop If one of the generator phase voltages goes under this va V 200 limit when feeding the load this will generate a GENSET LOW VOLTAGE warning If one of the generator phase voltages goes above this ana V 250 limit when feeding the load this will generate a GENSET HIGH VOLTAGE warning If one of the generator phase voltages goes over this Genset High Voltage yV 260 limit when feeding the load this will generate a Shutdown Limit GENSET HIGH VOLTAGE alarm and the engine will stop 25 RE KG 545 User Manual KIRLO
29. ent 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 KOEL 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 be masked causing the audible alarm relay to release and preventing consecutive GSM SMS
30. er is set to zero then the fuel quantity in liters will not be displayed High Canopy Temperature Warning 80 If the canopy temperature measured from the analog input goes over this limit this will generate a HIGH CANOPYTEMPERATURE SENDER warning High Canopy Temperature Shutdown 90 f the oil temperature measured from the analog input goes over this limit this will generate a HIGH OIL TEMPERATURE SENDER alarm and the engine will stop 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 00 99 Last two digits of the current year Hours 00 23 Current hour of the day Minutes 00 59 Current minute of the hour Seconds 00 59 Current second of the minute 27 RE KIRLOSKAR KG 545 User Manual GREEN POWER IDEAS Program Group Input Configuration 01 High Temperature Switch Parameter Definition Unit Fac Set Description Action 0 0 Shutdown the engine stops immediately Sampling 1 1 After holdoff timer Latching 1 1 Latching Contact type 0 0 Normally open Switching 0 0 Battery negative Note Alaways Set to Zero Response delay 0 0 No delay Program Group Input Configuration 02 Low Oil Pressure Switch Parameter Definition U
31. erature 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 below 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 HIGH OIL TEMPERATURE Set if the oil temperature value measured from the sender is above the programmed limit Warning and alarm limits are separately programmable for the temperature sender input HIGH CANOPY TEMPERATURE Set if the canopy temperature value measured from the sender is above the programmed limit Warning and alarm limits are separately programmable for the temperature sender input LOW COOLANT LEVEL Set if a signal is detected at the low coolant level input EMERGENCY STOP Set if a signal is detected at the emergency stop input SPARE 1 SPARE 2 SPARE 3 Set if a signal is detected from the related spare fault input LOW SPEED HIGH SPEED Set if the generator frequency is outside programmed limits 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
32. genset A second press on ACK RESET button will clear existing alarms Alarms operate in a first occurring basis If a shutdown 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 lf 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 cancelled by pressing one of the operating mode buttons TEST OFF AUTO MANUAL Most of the alarms have programmable trip levels See the programming chapter for adjustable alarm limits 10 KG 545 User Manual LOW OIL PRESSURE Set if a signal is detected at the Low Oil Pressure Switch input or the oil pressure value measured from the sender is below the programmed limit Warning and alarm limits are separately programmable for the oil pressure sender input This fault will be monitored with Holdoff Timer delay after the engine is running 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 temp
33. gram Group Relay Definitions Parameter Def Factory Set Description Relay 01 02 CRANK _ RELAY 1 function selected from list Relay 02 00 FUEL RELAY 2 function selected from list Relay 03 26 IDLE RELAY 3 function selected from list Relay 04 03 STOP RELAY 4 function selected from list Relay 05 01 ALARM _ RELAY 5 function selected from list Relay 06 05 MAINS C RELAY 6 function selected from list Relay 07 04 GEN C RELAY 7 function selected from list The function of a programmable relay output may be selected from the below list 00 Fuel 32 Temp switch alarm 80 Temp switch warning 01 Alarm 33 Oil switch alarm 81 Oil switch warn 02 Start 34 Emerg Stop alarm 82 Emerg Stop warning 03 Stop 35 83 l 04 Gen Contactor 36 Fuel Level switch alarm 84 Low Fuel Level 05 Mains Contactor 37 Spare 1 Alarm switch warning 29 KG 545 User Manual 06 Choke 38 Spare 2 Alarm 85 Spare 1 warning 07 Preheat 39 Spare 3 Alarm 86 Spare 2 warning 08 Shutdown alarm 40 Oil sender alarm 87 Spare 3 warning 09 Shutdown or 41 Temp sender alarm 88 Oil sender warning load_dump alarm 42 Low speed alarm
34. he RS 232 serial port using PC software or a special DOS program 7 MODBUS COMMUNICATION The unit offers the possibility of MODBUS communication via its RS232 serial port The connection to the MODBUS master may be done in 3 ways 1 RS232 connection using directly the RS232 port provided 2 RS422 485 connection using external RS422 485 converter 3 Modem connection using external modem The MODBUS mode is activated by assigning a controller address to the unit using MODBUS Address program parameter The possible address range is 1 to 144 Setting the address to 0 will disable the MODBUS mode and allow communication under PC software protocol 21 KG 545 User Manual a es KIRLOSKAR GREEN POWER IDEAS 8 PROGRAMMING The program mode is used to program timers operational limits and the configuration of the unit To enter the program mode press together and Wbuttons together for 5 seconds When the program mode is entered below password entry screen will be displayed ENTER PASSWORD HM 8 8 8 a A 4 digit password must be entered using ACK RESET V and buttons The unit stores 2 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 1 is factory set to 1234 The program mode will not affect the operation of the unit Thus programs
35. he 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 GENSET PHASE ORDER FAIL load dump Set if the genset phase order checking is enabled genset phases are present and genset phase order is reversed 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 Set 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 SERVICE REQUEST warning Set if either time to service or engine hours to service timer is expired 11 a es KIRLOSKAR GREEN POWER IDEAS RE KG 545 User Manual KIRLOSKAR POWER IDEAS 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
36. high limit is always monitored and stops the engine immediately If engine rpm limits are programmed these faults will be equally set using engine rpm limits 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 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 REVERSE POWER load dump Set if the genset power KW supplied to the load is negative and goes over the Reverse Power limit for Overload Timer If the power goes below the limit before expiration of the timer then no alarm will be set HIGH EARTH CURRENT Set if the earth current goes over the Earth Current Warning or Loaddump Limit for Overload Timer If the current goes below the limit before expiration of the timer then no alarm will be set Separate loaddump and warning limits are available through program menu 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 t
37. ing 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 13 RE KG 545 User Manual KIRLOSKAR POWER IDEAS 6 4 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 6 5 Fuel Pump Control The unit is able to provide a relay output in order to drive the fuel pump motor The fuel pump is used in order to transfer fuel from the large capacity main tank if exists to the genset daily tank which is generally integrated in the chassis and has a limited capacity The fuel level reference is measured through the analog fuel level sender When the measured fuel leve
38. is running at TEST mode and mains phases are present then the genset will stop after cooldown OFF In this mode the mains contactor will be energized if mains phase voltages are within the programmed limits The engine will be stopped AUTO It is used for genset and mains automatic transfer If at least one of the mains phase voltages is outside limits the mains contactor will be deactivated The diesel 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 When all the mains phase voltages are within the limits the engine will continue to run for the mains waiting period At the end of this period the generator contactor is deactivated and the mains contactor will be energized 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 mains failure TEST It is used to test the generator when the mains are on or keep the generator running in the emergency backup mode The operation of the generator is similar to the AUTO mode but the mains contactor will not be deactivate
39. ise Duration min 10 This parameter defines the exercise duration and programmed in 10 minute steps up to 24 hours Exercise Off On Load 0 Exercise at TEST mode 1 Exercise at LOAD TEST mode 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 AMF Remote Start Device 0 AMF unit Note For this function set IN 04 to any input other than remote start input 1 Remote Start Unit Note Set IN 04 to Remote start input and set it s Action O3 Modem Enable The serial port is connected to PC Modem connected SMS Enable SMS not enabled SMS enabled GPRS Call Enable standard modem calls GPRS modem calls RS 485 Enable RS 232 comm port enabled RS 485 comm port enabled MODBUS Address O o o o o PC software communication protocol 1 144 MODBUS communication This parameter is also the MODBUS controller address of the unit Real Time Clock Adjust 117 This parameter trims precisely the real time clock circuit Values from 0 to 63 speed up the clock with 0 25sec day steps Values from 127 to 64 slow down the clock with 0 25sec day steps 24 RE KG 545 User Manual KIRLOSK
40. l 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 Note Settable only through PC software 6 6 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 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 TO START operations A The REMOTE START o
41. ll be de energized 11 COOLANT TEMP SENDER Input 0 5000 ohms Analogue temperature sender connection Do not connect the sender to other devices The input has programmable characteristics 12 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 13 FUEL LEVEL SENDER Input 0 5000 ohms Analogue fuel level sender connection Do not connect the sender to other devices The input has programmable ohm value 14 CANOPY TEMPERATURE _ Input 0 5000 ohms Analogue canopy temperature sender SENDER connection Do not connect the sender to other devices 15 OIL TEMPERATURE Input 0 5000 ohms Analogue oil temperature sender connection SENDER Do not connect the sender to other devices The input has programmable characteristics 16 SPARE ANALOG INPUT 1 Input 0 5000 ohms This input is reserved for future use 17 SPARE ANALOG INPUT 2 Input 0 5000 ohms This input is reserved for future use RE KG 545 User Manual away Term Function Technical data Description 18 COOLANT LEVEL Digital input This terminal drives the coolant level sensor with AC signal and senses the coolant liquid level 19 IN O HIGH TEMP Digital inputs These inputs have programmable 20 IN 1 LOW OIL PRESSURE characteristics selected via the program 21 IN 2 EMERGENCY STOP menu Each input may be driven by a
42. ltage readings on the screen Upper and lower limits of the mains voltages may be too tight Check the parameters Mains Voltage Low Limit and Mains Voltage High Limit Standard values are 170 270 volts Check AC mains frequency The hysteresis voltage may be given to excessive The standard value is 8 volts AC voltages or frequency displayed on the unit 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 A Short circuit the outputs of unused Current Transformers When the AC mains fails 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
43. mains signal is present batteries charged The genset will start when mains voltages are out of limits and the simulate mains signal not present 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 15 RE KG 545 User Manual KIRLOSKAR POWER IDEAS 6 8 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 actually set to 2 minutes for faster testing purposes A flashing relay output function is provided based on the parameter Flashing Relay Time
44. 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 KOEL This is the same cable as PSTN land modems 18 RE KG 545 User Manual KIRLOSKAR POWER IDEAS 6 12 Remote Monitoring Thanks to its standard serial RS 232 port the unit offers the remote monitoring 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 PC software allows the visualization and recording of all measured parameters The recorded parameters may then be analyzed graphically and printed 6 13 RS 485 Port The unit offers an RS 485 port as a standard feature Together with the MODBUS communication protocol this offers a convenient way to connect the unit to external automation and management systems The RS 485 port is not isolated it references to the battery negative connection of the unit li The external MODBUS device communicating with the unit should use the same potential as ground reference 6 14 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 Disable Auto Start Force to Start Fault Reset Al
45. mple 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 warning 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 warning will occur In such case contct KOEL engineer to service the engine 16 RE KG 545 User Manual KIRLOSKAR POWER IDEAS 6 10 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 defined for outgoing modem calls In case of alarm the unit will attempt to reach control centers associated with each number In
46. nit Fac Set Description Action 1 0 Shutdown the engine stops immediately 1 Load Dump the engine stops after cooldown Sampling 1 1 After holdoff timer Latching 1 1 Latching Contact type 0 0 Normally open Switching 0 0 Battery negative Note Alaways Set to Zero Response delay 1 1 Delayed 4sec Program Group Input Configuration O3 Emergency Stop Parameter Definition Unit Fac Set Description Action 0 0 Shutdown the engine stops immediately Sampling 0 0 Always Latching 0 0 Non latching Contact type 0 0 Normally open Switching 0 0 Battery negative Note Alaways Set to Zero Response delay 0 0 No delay Program Group Input Configuration 04 Remote Start Input Parameter Definition Unit Fac Set Description Action 3 3 No alarm warning Sampling 0 0 Always Latching 0 0 Non latching 0 Normally open Contact type Q 1 Normally closed Switching 0 0 Battery negative Note Alaways Set to Zero Response delay 1 1 Delayed 4sec Program Group Input Configuration 05 Low Fuel Switch Input Parameter Definition Unit Fac Set Description Action 0 0 Shutdown the engine stops immediately Sampling 0 0 Always Latching 1 1 Latching 0 Normally open Contact type 9 1 Normally closed Switching 0 0 Battery negative Note Alaways Set to Zero 0 No delay Response delay 1 1 Delayed 4sec
47. onal extension module provides 8 programmable inputs or outputs The unit allows the use of up to 2 input and 2 output extension modules Term Function Technical data Description 01 BATTERY NEGATIVE oVDC Power supply negative connection 02 BATTERY POSITIVE 12 or 24VDC The positive DC Supply terminal for both 12V and 24V battery systems Term Function Technical data Description 03 RL 01 CRANK OUTPUT Output 1A 28VDC This output controls the engine cranking 04 RL 02 FUEL OUTPUT Output 1A 28VDC Fuel solenoid output 05 CHARGER WL 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 06 RL O3 IDLE OUTPUT Output 1A 28VDC This output controls the idle speed operation 07 RL O4 STOP OUTPUT Output 1A 28VDC This output controls the engine stop solenoid 08 RL O5 ALARM OUTPUT Output 1A 28VDC This output controls the audible alarm hooter Term Function Technical data Description 09 RL 06 MAINS CONTACTOR Output 1A 28VDC This output controls the mains contactor If the mains phase voltages and frequency are not within limits the mains contactor will be de energized 10 RL 07 GENSET Output 1A 28VDC This output controls the mains contactor If the CONTACTOR mains phase voltages and frequency are not within limits the mains contactor wi
48. p Limit The value is defined as a percentage of genset CT rating Program Group Engine Parameters Parameter Definition Unit Factory Set Description Low Frequency Shutdown Hz 47 If the genset frequency goes under this limit a GENSET LOW SPEED alarm is generated and the engine stops Low Frequency Warning Hz 48 If the genset frequency goes under this limit a GENSET LOW SPEED warning is generated High Frequency Warning Hz 54 If the genset frequency goes over this limit a GENSET HIGH SPEED warning is generated High Frequency Shutdown Hz 55 If the genset frequency goes over this limit a GENSET HIGH SPEED alarm is generated and the engine stops Engine Heating Temperature C If it is requested that the engine runs without load until reaching a certain temperature this parameter defines the temperature If the coolant temperature falls below this parameter an Engine Low Temperature warning will occur Engine Start Delay sec This is the time between the mains fails and the fuel solenoid turns on before starting the genset It prevents unwanted genset operation in battery backed up loads Preheat Timer sec This is the time after the fuel solenoid is energized and before the genset is started During this period the PREHEAT relay output is energized if assigned by Relay Definitions 26 RE KG 545
49. peration overrides SIMULATE MAINS and FORCE 14 RE KG 545 User Manual KIRLOSKAR POWER IDEAS 6 7 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 program parameter is set to 1 and the input signal is active when the genset is not feeding the load the mains phases are not monitored and supposed to be inside limits This will prevent the genset from starting when the simulate
50. r 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 A Please contact KOEL for a complete application manual 6 9 Service Request Warning The periodic maintenance is basically carried out after a given engine hours for exa
51. r excess load condition is detected RE KG 545 User Manual KIRLOSKAR POWER IDEAS 3 2 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 screen groups is done with the button Each depression of the button switches the display to the next screen group Navigation within a group is done with with the W button Each depression of the W button switches the display to the next screen in the same group During operation the unit will scroll automatically between different screens displaying always the most important parameters for the current operating status A AUTO SCROLL may be stopped by long pressing the gt button If an alarm or warning occurs during operation in other then programming mode the display will automatically switch to ALARM LIST position The W or buttons will not function To enable display navigation and mute the internal buzzer press ACK RESET 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 Group Screen Contents Description GENSET 1 Genset Phase voltages Presented as a table PARAMETER
52. s 4 Site Id The generator site id string displayed in large characters 5 Serial Number The generator serial number string displayed in large characters 6 Software Version The unit firmware version number displayed in large characters 7 Maintenance Time to maintenance days and engine hours to Counters maintenance RE KG 545 User Manual KIRLOSKAR POWER IDEAS 4 ALARMS AND WARNINGS Alarms indicate an abnormal situation in the generating set are divided into 3 priority levels 1 SHUTDOWN 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 menu 2 LOAD_DUMPS These fault conditions cause The ALARM led to be on steadily 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 ALARM led to flash The Horn and Alarm Load_dump Warning digital outputs to operate if selected via programming menu If the ACK RESET button is pressed the Horn output will be deactivated however the existing alarms will persist and disable the operation of the
53. tal outputs 7 Input output expansion capability Remote Start operation available Survives cranking dropouts Sealed front panel Plug in connection system for easy replacement RE KIRLOSKAR KG 545 User Manual L E POWER IDEAS TABLE OF CONTENTS Section 1 INSTALLATION 1 1 Introduction to the Control Panel 1 2 Mounting the Unit 1 3 Wiring the Unit 2 CONNECTOR DETAILS 3 DISPLAYS 3 1 Led Displays 3 2 Digital Displays 4 ALARMS AND WARNINGS 5 MODES OF OPERATION 6 OTHER FEATURES 6 1 Remote start operation 6 2 Engine heating operation 6 3 Engine Idle Speed Operation 6 4 Engine Block Heater 6 5 Fuel Pump Control 6 6 Mains Simulation Disable Start 6 7 Delayed Mains Simulation Battery Charging 6 8 Dual Genset Mutual Standby Operation 6 9 Service Request Display 6 10 Modem connection 6 11 SMS message sending 6 12 Remote Monitoring 6 13 RS 485 port 6 14 External Control of the Unit 6 15 Automatic Exerciser 6 16 Gas engine fuel solenoid control 6 17 Load Shedding Dummy Load 6 18 Fuel Theft Fuelling Messages 6 19 Firmware Update 7 MODBUS COMMUNICATION 8 PROGRAMMING 9 TROUBLESHOOTING 10 DECLARATION OF CONFORMITY 11 TECHNICAL SPECIFICATIONS 12 CONNECTION DIAGRAM RE KG 545 User Manual KIRLOSKAR POWER IDEAS 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
54. 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 voltage between terminals 19 and 22 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 AUTO led flashes and the genset does not run when mains fail The unit is in Weekly Schedule OFF time Please check date and time setting of the unit Please check also Weekly Schedule program parameters 10 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 11 TECHNICAL SPECIFICATIONS Alternator voltage 0 to 300 V AC Phase to Neutral 0 to 520 V AC Phase to Phase Alternator frequency 0 100 Hz Mains voltage 0 to 300 V AC Phase to Neutral 0 to 520 V AC Phase to Phase Mains frequency 0 100 Hz DC Supply range 8 0 VDC to 36 0 VDC Communication port RS 232 RS 485 9600 bauds no parity 1 stop bit Oper
55. tion Select List a es KIRLOSKAR GREEN POWER IDEAS 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 Overload Input 16 By pass I P input 17 Priority Input 18 Remote Start Input 19 Disable Auto Start 20 Force to Start 21 Fault Reset 22 Alarm Mute 23 Panel Lock Program Group Site Id Parameter Definition Factory Set Description Site ld String 4 string may be entered This is the site Id string sent at the beginning of an SMS message for the identification of the genset sending the SMS message Any 20 character long o RE KG 545 User Manual KIRLOSKAR POWER IDEAS Program Group Modem 1 SMS 1 Telephone Number Parameter Definition Factory Set Description Modem 1 SMS 1 telephone number 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 first SMS telephone number Program Group Modem 2 SMS 2 Telephone
56. verse 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 Note Settable only through PC software 20 RE KG 545 User Manual KIRLOSKAR POWER IDEAS 6 18 Fuel Theft Fuelling Messages The unit is able to send SMS messages in fuel theft or fuelling conditions These SMS messages are sent without creating visible fault condition These features are enabled by setting the program parameter Engine Parameters Fuel Consumption Hour to a value other than 0 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 twice 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 19 Firmware Update The unit offers possibility of updating the firmware in the field The firmware is updated through t
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