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Teksan Generator Control Panels

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1. REMOTE DISPLAY PANEL FUNCTIONALITY TERMINAL DESCRIPTION mU TECHNICAL SPECIEICATIGO NS emo end neu eo dean Rena rep saat eeu ne teo de ke aee emend ken adeo Prep dus DESCRIPTION OF CONTROLS EERE FRONT PANEL FUNCTIONAL Y icri timui en tte tn eain eio e ne eo dte n Fra isi eer nae ade HENRI PUSHBUTTON FUNCTIONS tera ate te e entera Re eto Den eue eu ee dera Ea eto enu Lee ee qeu DISPLAY SCREEN ORGANIZATION rete inae eene rennen AUTOMATIC DISPLAY SCROLL eee ka aeo MEASURED PARAMETERS ws seccsicecetesecesnscticecetsteaesnaneeceansceiestaceadeactatedesbacedcecesssssesbacedeneutatsdessaneecteusoesseai 5 225 56 WAVEFORM DISPLAY amp HARMONIC 5 5 DISPLAYING EVENT LOGS K35D01 EN 6 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 STATISTICAL COUNTERS OPERATION OF THE UNIT initia noto re
2. Lh l Starter Motor 4 Connect to the engine body close to the senders 2 Ground from one end only 41 Battery Negative must grounded K35D01 EN V 1 4 PRELIMINARY VERSION TJ 509T User Manual Rev 01 AMF FUNCTIONALITY CTs AT ALTERNATOR SIDE LOAD L1L2L3 N ALTERNATOR N N39 TN39 cro VrN39 O N39 INV Nd 98 9 98 039 98 9 QN 9 QN S QN 413 110 7 A31 713037 10 ON 1 8 MOT Z N MS dW3 L IH 9 MS A311009 S V3HVdS t W907 W9d N 23HVdS Z N dOLS YINI L N 911 Zin dOLS Z LN Wasviv L LN Tana v LN ANVHO E LN Lv 1V o ECU e a o Starter Motor 4 Connect to the engine body close to the senders 2 Ground from one end only 1 CN t o o c 2 5 a D 3 E gt E 2 5 2 5 Hi e LO V 1 4 PRELIMINARY VERSION TJ 509T User Manual Rev 01 ATS FUNCTIONALITY LOAD L1L2 L3 ALTERNATOR L10 INY9 Z 9 Lp ndW V S8v Ot 98 68 98 8 9 8 69 9 GNS ZS S GNS LS 110 7 QNS S Aa 1303 ONS Eb 8 SS3ud 110 GNS PL N3QN3S 0S 7MV
3. L d3aNas 13SN39 lt ded P gt gt gt gt gt sHaiNnoa E TET S o SUIS o SHal3vHvd o 9 SMLVIS SISATVNV SISATVNV SNIZINOHHSS SNIVIN 195 99 SINALI NNJN NIVIN 55 K35D01 EN TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 MEASURED PARAMETERS The unit performs a detailed set of AC measurements Mains currents and power parameters listed in blue color are measured and displayed only if CTs are placed at load side please see connection diagrams section for more details The list of measured AC parameters is below Mains voltage phase L1 to neutral Mains voltage phase L2 to neutral Mains voltage phase L3 to neutral Mains average voltage phase to neutral Mains voltage phase L1 L2 Mains voltage phase L2 L3 Mains voltage phase L3 L1 Mains frequency Mains current phase L1 Mains current phase L2 Mains current phase L3 Mains average current Mains kW phase L1 Mains kW phase L2 Mains kW phase L3 Mains total kW Mains kVA phase L1 Mains kVA phase L2 Mains kVA phase L3 Mains kVAr phase L1 Mains kVAr phase L2 Mains kVAr phase L3 Mains pf phase L1 Mains pf phase L2 Mains pf phase L3 Mains total pf Mains neutral current Below engine parameters are always measur
4. MOTORIZED CIRCUIT BREAKER 11939 CANBUS ENGINE SUPPORT ice en tee etn ei ae ETHERNET GSM CONFIGURATION p DYNAMIC DNS ACCESSING THE EMBEDDED WEB 5 CENTRAL MONITORING OF 5 5 WEB MONITORING AND CONTROL OF 5 5 ETHERNET MODBUS GATEWAY GPRS MODBUS GATEWAY LOAD TRANSFER MODES teen cits Te vacate EE FE ERU ERR TRANSFER WITH INTERRUPTION jn UNINTERRUPTED prupWISeehnibicm DATA RECORDING MEDIA REY EE RON ER DIRECTORY STRUCTURE teen tte nne ee eR Hec Rak nine ne
5. AC VOLTAGE 5 RR AG CURRENT INPUTS DIGITAL INPUTS EET ANALOG SENDER INPUTS AND SENDER GROUND see CHARGE INPUT TERMINAL assente ru tne enun eoa t cup kay exea eere MAGNETIC PICKUP INPUT 2 5 ntn ae onere kx MAINS CONTACTOR OUT RU GENERATOR CONTACTOR OUT PU iet DIGITAL chard cease a a roa neii e aiea INPUT OUTPUT EXTENSION eH X 5 485 501 gem IHeeise Egi e USB DEVICE PORT UEpDAQeMIe Dg DEEP GSM MODEM OPTIONAL K35D01 EN 5 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 SELECTING THE TOPOLOGY e ettet rao reete en nen eet atn nen nane neenon itane ran SERE 3 PHASE 4 WIRE STA
6. 26 not used reserved 27 not used reserved 28 not used reserved 29 not used reserved 30 not used reserved 31 Condition exist K35D01 EN 115 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ETHERNET CONFIGURATION Please see related document GSM CONFIGURATION Please see related document DYNAMIC DNS FEATURE Please see related document ACCESSING THE EMBEDDED WEB SERVER Please see related document CENTRAL MONITORING OF GENSETS Please see related document WEB MONITORING AND CONTROL OF GENSETS Please see related document E MAIL SENDING Please see related document ETHERNET MODBUS GATEWAY OPERATION This feature is not available yet GPRS MODBUS GATEWAY OPERATION This feature is not available yet K35D01 EN 116 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 LOAD TRANSFER MODES The unit offers 2 ways of transferring the load from genset to mains and vice versa transfer with interruption no break transfer with or without synchronization TRANSFER WITH INTERRUPTION This is the most conventional way of transferring the load between the genset and mains There will be a power interruption period during the transfer Note that the program parameters Mains Contactor Timer and Genset Contactor Timer define the power interruption period interlock between the two contactors to prevent an a
7. Max switching current 16A 250VAC Max switching voltage 440VAC Max switching power 4000VA DIGITAL OUTPUTS The unit offers 6 digital outputs with programmable function selectable from list Structure Negative pulling protected semiconductor output One terminal is connected to battery negative Max continuous current 1 0 ADC Max switching voltage 33 VDC Overvoltage protection 40 VDC Short circuit protection gt 1 7 ADC Reverse voltage 500 VDC protection K35D01 EN 23 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 INPUT OUTPUT EXTENSION The module provides resources for 32 additional digital inputs and 32 additional digital outputs Extension Connector Digital inputs can be extended using DKG 188 Digital Input Extension modules each one providing 8 inputs Digital inputs are programmable through the main controller The switching characteristic is not programmable and must be battery negative Any function can be assigned to digital inputs Digital outputs can be extended using DKG 186 Fet Extension modules each one providing 8 outputs Digital outputs have the same electrical characteristics as on board outputs They have programmable functions through the main controller Any function can be assigned to any output Input and output extension modules are connected to the main controller in a cascade structure in any order The connection cable
8. UNDERSTANDING THE CSV RECORDED DATA LIST RECORD PERIOD eeceeeeeeeceeeceeececececaaecsaeceaecaeeeaeeeeeeeeeseneseneseaeeeaeesaaecaeeaaeed organ isid au icq Load Shedding Dummy Load c ccccssscesssecssseeessececscecesecesseeccsaececseecaeecessececaseceeseeesseesenaesesaseseeeees Remote Start Operaatio Mi ott Rete t erem Pes ates dee oe et Disable Auto Start Simulate Battery Charging Operation Delayed Simulate Dual Genset Mutual Standby Operation ccccccccccecessssssneceeeeecessesesaeseeesecesseseaaeseeeeseeesesnaaeeeeseseesees Dual Voltage and Frequency rece Ee X REI AREE Single Phase Operation repe Ee Un EE E Ea ERR External Control of the de tei teet ete n re Enea een i FO E een e ro Automatic WEEKLY OPERATION SCHEDULER asscccscosscecstevseccteeactecasevccnessesaneseaaciccsseacsecounacduceanacdncuaonecacdvencdecsvandeess Engine Heating Engine Idle Speed Operatlon etr tree E Engine Block Heater ict en rtt rore eaten ra
9. 39VL 10A SNIVIN l13SN39 Wot vot 100 100 V11N3HHn9 39VIL 10A SNIVIA l13SN39 wot 001 100 wot wot 100 m Dmm 00 wot 100 00 wot 100 100 19101 13SN39 323IAH3S u3H10 N 1N3HH 12 l13SN39 L 39IAH3S OL SAVG b 39IAH3S OL SHH NOISH3A N E c L N c b l3SN39 13SN39 13SN39 N 2 L N E c b uana N E c L SNIVIN SNIVIA SNIVIA 39VH3AV SNIVIA 6 2 1 SLIOA 6 6 1 SLIOA SLIOA 9 VA 110 S Hd Hd 145 39 145 39 135N39 SNIVIA Lnv1009 v4 d3aNas l13SN39 snivis 9 LINO ALAS Wavy SLIOA SLIOA EcL SLIOA jd 9 Nol Tn na Nol di NYM 0 IX3N 138N39 138N39 138N39 SNIVIA H3OIN3S l13SN39 190 100 100 100 100 100 00 100 100 100 e ST 490 100 100 NOISH3A MS 110 S39DVLIOA di AVMALVD WU38IAfTN INI 6 2 1 SLIOA c SLIOA EcL SLIOA di LN3I19 ss3HQY IX3N Hd Hd SNIVIA Hd Hd SNIVIA SNIVIA 100 100 4100 100 00 100 100 on fees SIN3 LI SH3LNNOS S 13 31 WNOIS 553 00 SNLVLS WS9
10. Each depression of the e button will cause the display to switch to the previous group of parameters After the first group the display will switch to the last group Navigation inside a groups is made with buttons Each depression of the 9 button will cause the display to switch to the next parameter the same group After the last parameter the display will switch to the first parameter Each depression of the button will cause the display to switch to the previous parameter the same group After the first parameter the display will switch to the last parameter Below is a basic list of parameter groups Genset Parameters Genset voltages currents kW kVA kVAr pf etc Engine Parameters Analog sender readings rpm battery voltage engine hours etc J1939 Parameters Opens only if the J1939 port is enabled The unit is able to display a long list of parameters under the condition that the engine sends this information A complete list of available readings is found at chapter J1939 CANBUS ENGINE SUPPORT Mains Parameters Mains voltages currents kW kVA kVAr pf etc Mains currents and power parameters are displayed only when CT Selection is made as LOAD SIDE Otherwise mains current and power related parameters will not be displayed Synchronization Display A graphical synchroscope is displayed The synchroscope display is updated 10 times a second in order to have smooth sweep Scopemeter Display
11. The unit features both MPU and J1939 CANBUS inputs Thus both mechanical and electronic engines are supported It is strongly recommended to wire speed detection through MPU or J1939 CANBUS and enter correct low and high rpm limit values in order to preserve engine speed protection 400HZ OPERATION The standard unit is also 400Hz enabled The nominal frequency setting accepts up to 500Hz Usual low and high limits will apply without any special setting The measurement system of the unit allows frequencies up to 1000Hz to be measured precisely However the display is limited to 650Hz Frequencies over 650Hz will be displayed as 650Hz The bandwidth of the harmonic analyzer is limited to 1800Hz Thus in case of a 400Hz system only the 3 harmonic will be displayed The waveform display of a 400Hz signal will be represented with 10 points It will not be as accurate as 50 60Hz signals For more details please read chapter Waveform Display amp Harmonic Analysis K35D01 EN 39 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 REMOTE DISPLAY UNIT FUNCTIONALITY The unit is able to become the remote display and control panel of another identical module The connection between two modules is done through RS 485 ports For the best results a 120 ohms balanced low capacitance cable should be used The data rate between modules is selectable between 2400 and 115200 bauds A high data rate offers better synchroniz
12. TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 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 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 When a Remote Start input is defined the mains phases are not monitored When the Remote Start signal is present then the mains will be supposed to fail inversely when the Remote Start signal is absent then mains voltages will be supposed to be present The front panels mimic diagram s mains LEDs will always reflect the status of the Remote Start input Disable Auto Start Simulate Mains The unit offers an optional Disable Auto Start signal input Any digital input may be assigned as Disable Auto Start 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 Disable Auto Start 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 Disable Auto Start input is defined and t
13. If the engine rpm goes over this limit High RPM Warning Limit R 100 R 100 R 10 when feeding the load this will generate a GENSET HIGH RPM warning If the engine rpm goes over this limit High RPM Shutdown o o When feeding the load this will generate Limit R 100 R 100 15 GENSET HIGH RPM shutdown alarm and the engine will stop If the engine rpm goes outside of the RPM Fail Timer sec 0 10 3 limits during this timer an engine speed fault will occur If the engine rpm goes over the High RPM Shutdown Limit by this quantity ee bs jon this will generate immediately a GENSET 9 HIGH RPM shutdown alarm and the engine will stop 0 speed signal existency not checked 1 If the speed signal is lost it will Loss of Signal Check 0 1 0 generate a Speed Signal Lost fault condition The action taken upon fault condition is programmable 0 shutdown alarm Loss of Speed Signal 0 2 0 1 loaddump alarm Action 2 warning If the speed signal is lost during this Speed Signal sec 0 240 0 timer a Speed Signal Lost fault will occur If the charge alternator voltage goes Low Charge Voltage V DC 0 40 6 0 under this limit a charge alternator Warning Limit voltage warning will occur If the charge alternator voltage goes Low Charge Voltage 1 under this limit a charge alternator Shutdown Limit 4 40 voltage shutdown will occur and the engine will stop If the charge alternator v
14. TJ 509T User Manual Rev_01 ELECTRICAL PARAMETERS GROUP Parameter Definition Unit Min Max Factory Set Description Current Transformer Primary Amp 5000 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 Voltage Transformer Ratio 5000 1 0 This is the voltage transformer ratio This value will multiply all voltage and power readings If transformers are not used the ratio should be set to 1 0 Nominal Voltage V AC 300 230 The nominal value of genset and mains voltages Voltage limits are defined by reference to this value Nominal Frequency Hz 500 50 The nominal value of genset and mains frequency Frequency limits are defined by reference to this value Nominal Voltage 2 V AC 300 120 When secondary voltage is selected this is the nominal value of genset and mains voltages Voltage limits are defined by reference to this value Nominal Frequency 2 Hz 500 60 When secondary frequency is selected this is nominal value of genset and mains frequency Frequency limits are defined by reference to this value Mains Voltage Low Limit 96 V 100 V 100 V 20 If one of the mains phases goes under this limit it means that the mains are off and starts the transfer to the genset in AUTO mode The value is defined with reference
15. 20120101 csv The unit will record data in a directory named with the first 11 characters of its site id parameter In order to avoid confusion between records it is highly recommended to configure the site id parameter accordingly to the genset installation place Thus the same memory module may be used for recording in different controllers Inside the lt SITE ID gt directory the unit will open a separate directory for each year of recording The directory will be simply named by the year like 2012 2013 etc Inside the year directory the controller will record data in a different file for each day of recording The record file will be named YYYYMMDD like 20120331 representing March 31 2012 Thus alphabetical listing will produce a sorted list by date of recording The recorded file is of CSV comma separated values type This is a text file which can be directly opened with Microsoft Excel program without any loss of information It can be also opened with any text editor like Notepad program Inside the file each record consists of a line including a large set of measured parameters The recorded parameters list is not adjustable The controller records all practically necessary parameters UNDERSTANDING THE CSV FORMAT The csv file is basically a text file format Thanks to this it can be opened by any text editor in any operating system When opened with the Microsoft Excel program the values will appear in tabu
16. ALARM Mute Previous display group STOP mode button AUTO mode button TEST mode button button K35D01 EN 51 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 PUSHBUTTON FUNCTIONS FUNCTION Selects TEST mode The genset runs and takes the load Selects RUN mode The genset runs off load Selects AUTO mode The genset runs when necessary and takes the load Selects OFF mode The genset stops FUNCTION Selects next display screen in the same display group LAMP TEST when held pressed Selects previous display group Selects next display group Selects previous display screen in the same display group Resets the ALARM RELAY Manual MAINS CONTACTOR control in RUN mode w 194 o LJ Manual GENSET control in RUN mode When held pressed for 5 seconds enters PROGRAMMING mode K35D01 EN 52 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 DISPLAY SCREEN ORGANIZATION The unit measures a large number of electrical and engine parameters The display of the parameters is organized as PARAMETER GROUPS and items in a group Navigation between different groups are made with buttons Each depression of the button will cause the display to switch to the next group of parameters After the last group the display will switch to the first group
17. DESCRIPTION decimal SIZE 10504 256bit Shutdown alarm bits Bit definitions are given at the end of the 10519 document 10520 R 256bit Loaddump alarm bits Bit definitions are given at the end of the 10535 document 10536 R 256bit Warning alarm bits Bit definitions are given at the end of the 10551 document 10604 R 16bit Unit operation status 07 genset at rest 1 7 wait before fuel 2 engine preheat 3 wait oil flash off 4 crank rest 5 cranking 6 engine run idle speed 77 engine heating 8 running off load 9 synchronizing to mains 10 2 load transfer to genset 112 gen cb activation 127 genset cb timer 13 2 master genset on load 14 peak lopping 15 power exporting 16 slave genset on load 17 synchronizing back to mains 18 load transfer to mains 19 mains cb activation 20 mains cb timer 21 stop with cooldown 22 cooling down 23 engine stop idle speed 24 immediate stop 25 engine stopping 10605 R 16bit Unit mode 0 STOP mode 1 AUTO mode 2 MANUAL mode 3 TEST mode 10606 R 16bit x1 Genset operation timer In various wait statuses the genset operation status will change at the expiration of this timer 10610 R 16bit Device hardware version information 10611 R 16bit Device software version information 10616 R 32bit x1 Counter number of genset runs 10618 R 32bit x1 Counter number of genset cranks 10620 R 32bit x1 Counter number of genset on load 10622 R 32bit x100 Counter engine hours run 10624 R 32
18. K35D01 EN 129 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 MODBUS COMMUNICATIONS This chapter is a brief description of the Modbus properties of the controller For a complete documentation please use DKG 509T Modbus Application Manual The unit offers the possibility of MODBUS communication through below carriers RS485 serial port with adjustable baud rate between 2400 and 115200 bauds MODBUS TCP IP through Ethernet port 10 100Mb MODBUS TCP IP through GSM GPRS modem 84 42kb The MODBUS properties of the unit are Data transfer mode RTU Serial data selectable baud rate 8 bit data no parity 1 bit stop Modbus TCP IP Ethernet 10 100Mb or GPRS Class 10 Supported functions Function 3 Read multiple registers Function 6 Write single register Function 16 Write multiple registers Each register consists of 2 bytes 16 bits A larger data structure will contain multiple registers The Modbus communications requires a slave address to be assigned to each device in the Modbus network This address ranges between 1 and 240 and allows the addressing of different slave devices in the same network Each device in the same RS 485 serial network must be assigned a different slave address Otherwise the Modbus communications will not be performed Devices using Modbus TCP IP with different IP or port addresses may use any slave address It is advised to set these slave addresses to the default s
19. Structure battery voltage output through 20 ohm e voltage measurement input resolution Output current 160mA 12VDC 80mA 24VDC Voltage measurement 0 1VDC Voltage measurement accuracy 2 0 1V 0 9V 30VDC Alarm Threshold Charge Fail Warning adjustable Threshold Charge Fail Shutdown adjustable Open circuit voltage battery positive Overvoltage protection gt 500VDC continuous with respect to battery negative Reverse voltage protection 30VDC with respect to battery negative MAGNETIC PICKUP INPUT Structure Differential frequency measurement input Input impedance 50 k ohms Input voltage 0 5VAC RMS to 30VAC RMS Max common mode voltage SVDC Frequency range 10Hz to 10 kHz Resolution 1 rpm Accuracy 0 2 1 rpm 21500 rpm Flywheel teeth range 1 to 500 Do not share MPU with other devices K35D01 EN 200 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 MAINS CONTACTOR OUTPUT Structure Relay output normally closed contact One terminal is internally connected to mains phase L1 input Max switching current 12A 250VAC Max switching voltage 440VAC Max switching power 3000VA GENERATOR CONTACTOR OUTPUT Structure Relay output normally open contact One terminal is internally connected to genset phase L1 input
20. TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 MCB modules can be operated by 2 different ways The unit supports both configurations Below is the terminology used M gear motor PF ready to close contact XF close coil MX open coil MN undervoltage trip release AUX auxiliary contacts MCB WITH OPEN CLOSE COILS MCB WITH CLOSE UV COILS CONTROLLER OUTx OUTy CONTROLLER OUTx OUTy BAT BAT In the diagram at left relay function assignments should be as below OUTx Mains or Genset Close Pulse OUTYy Mains Genset Open Pulse In the diagram at right relay function assignments should be as below OUTx Mains or Genset Close Pulse OUTy Mains or Genset Undervoltage Coil K35D01 EN 112 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 J1939 CANBUS ENGINE SUPPORT The unit offers a special 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 an appropriate balanced 120 ohms low capacitance coaxial cable The external conductor should be grounded at one end only 120 ohms termination resistor is installed 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 accord
21. Tans v LNO LNO iva 2 340 92404 9 1ndu eueds yndu p indu duj eueds 9015 eueds eueds To Main Control gt Panel RS 485 port Avec cV AMALIVE 2 Ground from one end only Battery Negative must be grounded 46 K35D01 EN TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 TERMINAL DESCRIPTION Term Function Technical data Description BATTERY POSITIVE 12 or 24VDC The positive terminal of the DC Supply Do not connect this terminal BATTERY NEGATIVE O VDC Power supply negative connection Function Technical data Description DIGITAL OUTPUT 1 DIGITAL OUTPUT 2 DIGITAL OUTPUT 3 DIGITAL OUTPUT 4 DIGITAL OUTPUT 5 DIGITAL OUTPUT 6 Protected Semiconductor Outputs 1A 28VDC This relay has programmable function selectable from a list Factory set as CRANK output This relay has programmable function selectable from a list Factory set as FUEL output This relay has programmable function selectable from a list Factory set as ALARM output This relay has programmable function selectable from a list Factory set as PREHEAT output This relay has programmable function selectable from a list Factory set as STOP output This relay has programmable function selectable from a list
22. This group display waveforms of voltages and currents as an oscilloscope All Ph N and Ph Ph voltages as well as phase currents are available This feature is especially useful to investigate waveform distortions and harmonic loads Graphical Harmonic Analysis Results This group displays harmonic composition of voltages and currents All Ph N and Ph Ph voltages as well as phase currents are available This feature is especially useful to investigate the harmonic caused by complex loads Only harmonics above 2 are represented in the graphics because of the display resolution In order to see all harmonic levels please use the Alphanumerical Harmonic Analysis Results Alphanumerical Harmonic Analysis Results This group displays harmonic composition of voltages and currents with 0 1 resolution All Ph N and Ph Ph voltages as well as phase currents are available This feature is especially useful to investigate the harmonic caused by complex loads Alarm Display This group displays all existing alarms one screen per alarm When there is no more alarm to display it will show END OF ALARM LIST GSM Modem Parameters Signal strength counters communication status IP addresses etc Ethernet Parameters Ethernet connection status counters IP addresses etc Status amp Counters Groups This group includes various parameters like genset status service counters date time firmware version etc K35D01 EN 53 TJ 509T User Manual Re
23. then the ambient fan relay function will become active Ambient Fan Turn Off C 250 80 If the ambient temp is below this limit then the ambient fan relay function will become inactive Service 1 Engine Hours hours 5000 250 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 service 1 engine hours Service 1 Period month 24 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 Service 1 Period Service 1 Alarm Level 0 no action 1 shutdown alarm 2 loaddump alarm 3 warning K35D01 EN 91 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ENGINE PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Set Description Service 2 Engine Hours hours 5000 250 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 service 2 engine hours Service 2 Period month 24 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 R
24. 0 5 The mains MCB open relay will be activated during this period Review chapter Motorized Circuit Breaker Control for more details Mains MCB Undervoltage Coil Timer sec 10 0 5 The mains MCB undervoltage coil is energized during this period before the mains MCB close relay is activated Review chapter Motorized Circuit Breaker Control for more details Mains MCB Fail Timer sec 10 2 0 If a mains MCB feedback input is defined and if the mains MCB fails to change position before the expiration of this timer then a fault condition occurs Mains Phase Order Check Enable 0 mains phase order checking disabled 1 if mains phase order is faulty then a warning is given and mains contactor deenergized Genset Contactor Timer sec 600 0 5 This is the period after the mainscontactor has been deactivated and before the genset contactor has been activated Genset MCB Close Pulse sec 10 0 5 After the genset MCB undervoltage coil is energised and genset MCB undervoltage coil timer is elapsed the genset MCB close relay will be activated during this period Review chapter Motorized Circuit Breaker Control for more details Genset MCB Open Pulse sec 10 0 5 The genset MCB open relay will be activated during this period Review chapter Motorized Circuit Breaker Control for more details Genset MCB Undervoltage Coil Timer sec 10 0 5 The g
25. 1 0 0 6 File Tools Help Scada Configuration Functionality Screen Options Timers Exercise Scheduler Time Module 00 Functionality Miscellaneous Warning Before Start Delayed Simulate Mains Secondary Volt Freq Timers Latch AllWamings Pressure Switch Priority Buzzer Enable Exercise Scheduler Time Event Logs Enable H Generator Mains Periodic Warning Engi E i Anala ires Mode Change Latch All Warnings Entrance Digital Inputs Mains Fail Digital Outputs GENSET LOW HIGH Set if the generator frequency is outside programmed limits These faults will FREQUENCY be monitored with Fault Holdoff Timer delay after the engine is running Low and high limits are separately programmable The detection delay is also programmable Another high frequency shutdown limit which is 12 above the high limit is always monitored and stops the engine immediately GENSET LOW HIGH Set if the generator rpm is outside programmed limits These faults will be RPM monitored with Fault Holdoff Timer delay after the engine is running Low and high limits are separately programmable The detection delay is also programmable The high rpm overshoot limit is always monitored and stops the engine immediately GENSET LOW HIGH Set if any of the generator phase voltages goes outside programmed limits VOLTAGE for Voltage Fail Timer This fault will be monitored with Fault Holdoff Tim
26. 1800 1900MHz module GPRS multi slot class 10 8 GPRS mobile station class B Compliant to GSM phase 2 2 Class 4 2 W 850 900 MHz Class 1 1 W 1800 1900MHz Functionality Embedded TCP IP Web Client SMTP SNMP Modbus over IP SMS e mail 40 C to 85 C Data speed max 85 6 kbps download 42 8 kbps upload SIM card type external SIM 3V 1 8V GPRS enabled Antenna Quad band magnetic with 2m cable K35D01 EN 31 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 Module certificates CE FCC ROHS PTCRB GCF IC ICASA REACH K35D01 EN 32 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 Various topologies selectable through program parameter The topology is independently selectable for both genset and mains sections In following drawings the connections are shown for the alternator Current transformers are supposed connected to the alternator side Similar topologies re available for the mains side as well SELECTING THE TOPOLOGY Rainbow Plus Beta Version 1 0 0 2 File Tools Help Configuration Topology Options Display Timers Voltage Frequency Module Generator Connection Type Mains Engine Generator Phase Order Check Analog Input i ai 3 Phase 4 Wire Star v B Digi 2 Phase 3 Wire 11 12 Digital Outputs Commu
27. 80 web server The unit will answer queries to this port only This is the port number of the internal Modbus over IP terminal The unit will Modbus ower IP Port 7 0 59523 nee answer Modbus requests to this port only This is the port number used for e mail SMTP Port 0 65535 587 sending 0 ethernet port disabled Ethemet Enable 7 i 1 1 ethernet port enabled This parameter controls e mail sending when IP address of GPRS or ethernet connection is changed No warnings E mail on IP Change 0 0 generated 0 no e mail on IP change 1 e mail sent on IP change K35D01 EN 106 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 SYNCHRONIZATION PARAMETERS Parameter Definition Unit Min Max Factory Description Set No Break Transfer _ 0 1 0 0 only interrupted transfer enabled Enable 1 no break transfer enabled If the phase and voltage synchronization is not successful before Synchronization Fail the expiration of this timer then a Timeout 9 ic Synchronization Fail warning is given and the transfer will be performed with interruption Synchronization When synchronization is detected both sec 0 25 0 5 contactors will stay closed during this Contactor Timeout timer This is the maximum difference Max Freq Difference Hz 0 1 2 0 0 5 between mains and genset frequencies to close both contactors This is the maximum difference between the mains phase L1 and the genset phase L1 voltages to cl
28. Enable This parameter controls remote control of the unit through Rainbow Modbus and Modbus IP 0 remote control disabled 1 remote control enabled Annunciator Mode 0 normal operation 1 the unit becomes an annunciator of the remote unit Engine genset control functions are disabled CT Location Gen Load Gen 0 CTs are at the genset side Mains currents are not measured 1 CTs are at load side Both mains and genset currents are monitored following contactor status Reverse CT Direction This parameter is useful to invert all CT polarities at the same time 0 normal CT polarity assumed 1 reverse CT polarity assumed K35D01 EN 80 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 CONTROLLER CONFIGURATION GROUP continued Parameter Definition Unit Min Max Pe Description Internal buzzer control not functional in 509T 0 buzzer disabled 1 buzzer enabled Buzzer Enable 0 1 1 0 AMF functionality The unit controls both engine and load transfer The genset starts based on mains status 1 ATS functionality The unit controls the load transfer and issues genset start signal based on mains status 2 REMOTE START functionality The unit controls engine and alternator The genset starts with external signal 3 RESERVED Not used Unit Functionality 0 3 AMF K35D01 EN 81 PRELIMINARY VERSION V 1 4
29. F voltage V DC 50 350 290 this will generate a HIGH BATTERY arning Limit waming If the battery voltage goes over this High Battery Voltage limit this will generate a HIGH Shutdown Limit 90 BATTERY shutdown alarm and the engine will stop If the battery voltage goes outside of the Voltage Pall 0 10 3 limits during this timer a battery voltage fault will occur If any genset phase voltage differs from the average more than this limit it will Genset Voltage generate a Voltage Unbalance fault Unbalance Limit 0 100 0 0 condition The action taken upon fault condition is programmable If this parameter is set to 0 0 then voltage unbalance is not monitored 0 no action Genset Voltage _ 0 3 0 1 shutdown alarm Unbalance Action 2 loaddump alarm 3 warning If any genset phase current differs from the average more than this limit it will generate a Current Unbalance fault 0 100 0 0 condition The action taken upon fault condition is programmable If this parameter is set to 0 0 then voltage unbalance is not monitored 0 no action Genset Current _ 0 3 0 1 shutdown alarm Unbalance Action 2 loaddump alarm 3 warning K35D01 EN 84 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ELECTRICAL PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Set Description Genset Reverse Power Warning Limit kW 50000 If the genset power is
30. Generic DETROIT DIESEL ENGINE 0 Generic DEUTZ ENGINE 0 Generic 1 EMR2 2 EMR3 JOHN DEERE ENGINE 0 Generic PERKINS ENGINE 0 Generic 1 ADEM3 2 ADEM 1 3 VOLVO ENGINE 0 Generic 1 without CIU unit 2 EDC4 CATERPILLAR ENGINE 0 Generic SCANIA ENGINE 0 Generic 1 Single Speed 2 All Speed IVECO ENGINE 0 Generic MTU MDEC ENGINE 0 MDEC 302 1 MDEC 201 2 MDEC 303 3 MDEC 304 4 MDEC 506 BOSCH INJECTION SYSTEM 0 Generic 1 EDC 731 2 EDC 9 3 K35D01 EN 93 TJ 509T User Manual Rev_01 PRELIMINARY VERSION ENGINE PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Description Set This parameter adjusts the speed of an 0 41939 Speed Adjust 100 100 0 0 ECU controlled engine by 8 High Air Inlet If the air inlet temperature measured 9 5 through ECU is over this limit then Temperature Warning C 0 200 0 high Air inl il Limit igh air inlet temperature warning wi occur If the air inlet temperature measured High Air Inlet C 0 200 0 through ECU is over this limit then a Temperature Alarm Limit high air inlet temperature shutdown loaddump alarm will occur High Air Inlet 0 shutdown alarm Temperature Alarm 0 1 1 loaddump alarm Action Low Coolant Levei If the coolant level measured through 4 us 96 0 100 0 ECU is below this limit then a low Warning Limit coolant level warning will occur If the coolant lev
31. 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 Disable Auto Start 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 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 On 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 Disable Auto Start operation When both Remote Start Operation and Delayed Simulate Mains are enabled then REMOTE START operation mode is performed K35D01 EN 124
32. Point 12 reading Sender Curve 13 ohm ohms 0 5000 Point 13 ohm value Sender Curve 13 value X 0 10000 Point 13 reading Sender Curve 14 ohm ohms 0 5000 Point 14 ohm value Sender Curve 14 value X 0 10000 Point 14 reading Sender Curve 15 ohm ohms 0 5000 Point 15 ohm value Sender Curve 15 value X 0 10000 Point 15 reading Sender Curve 16 ohm ohms 0 5000 Point 16 ohm value Sender Curve 16 value X 0 10000 Point 16 reading If the sender type parameter is set to Sender Nam _ zero not used this string is used as sender name while displaying the sender reading If the sender type parameter is set to Sender Low Fault String _ _ _ zero not used this string is used as sender low value fault in the alarm display If the sender type parameter is set to zero not used this string is used as Sender Tah Paul Sing 7 high Ge fault in the alarm display K35D01 EN 98 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 DIGITAL INPUT CONFIGURATION EHE GI NNI ENH A AB HL v 1 The unit has 8 digital inputs By using external input extension modules up to 40 inputs total are available Only parameters of one input are explained below Other inputs have identical parameter set The input name is freely programmable thus the input can be adapted to any functionality through programming The input name entry is made through RainbowPlus program only Each
33. Power limit for Reverse Power Timer If the power goes below the limit before expiration of the timer then no alarm will be set REVERSE POWER Set if the genset power kW is negative and goes over the Reverse Power limit for Reverse Power Timer If the power goes below the limit before expiration of the timer then no alarm will be set GENSET PHASE ORDER FAIL Set if the fault is enabled and the genset phase order is reverse MAINS CB FAIL TO OPEN Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor Open Close Fail Timer PICKUP SIGNAL LOST Set if the rom measured from the magnetic pickup input falls below the Crank Cut RPM level during Loss of Speed Signal Timer The action of signal loss is programmable SERVICE REQUEST Set if at least one of the service counters has expired In order to reset the service counters please hold pressed both with buttons during 5 seconds The screen will display Completed K35D01 EN 70 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 WARNINGS Digital input and analog sender alarms are fully programmable for the alarm name sampling and action Onlv internal alarms are explained in this section All warnings can be made latching by enabling a single program parameter Controller Configuration gt Latch All Warnings Rainbow Plus Beta Version
34. THE PROGRAMMING MODE To enter the program mode press together Q MENU and MENUP buttons for 5 seconds When the program mode is entered below password entry screen will be displayed PHRSE TAGES Press 2 ASE TAGE buttons for 5 seconds Enter Your Password 3J A 4 digit password must be entered using V and MENU buttons The V A buttons modify the value of the current digit The MENU buttons navigate between digits The unit supports 3 password levels The level 1 is designed for field adjustable parameters The level 2 is designed for factory adjustable parameters The level 3 is reserved It allows recalibration of the unit The password level 1 is factory set to 1234 and the password level 2 is factory set to 9876 Passwords are not front panel adjustable If a wrong password is entered the unit will still allow access to the program parameters but in read only mode If password 0000 is entered only EVENT LOG file will be available K35D01 EN 74 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 NAVIGATING BETWEEN MENUS The program mode is driven with a two level menu system The top menu consists on program groups and each group consists on 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 Select
35. TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 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 On Timer and Flashing Relay Off Timer program parameters 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 On Off Timers Each time the period programmed using Flashing Relay Timer elapses the relay output will change position The flashing relay function may be assigned to any digital output using Output Configuration program parameters The dual genset intermittent operation uses also the Disable Auto Start feature Please review related chapter 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 i
36. Terminal Description set number Relay 01 3 4 Factory set as Crank Relay output Relay 02 1 5 Factory set as Fuel Relay output Relay 03 2 6 Factory set as Horn Relay output Relay 04 8 7 Factory set as Preheat Relay output Relay 05 4 8 Factory set as Stop Relay output Relay 06 7 9 Factory set as Idle Speed Relay output Relay 07 6 72 Factory set as Mains Contactor Relay output Relay 08 5 51 Factory set as Genset Contactor Relay output Relay 09 1 Relay extension module 1 Relay 10 1 Relay extension module 1 Relay 11 1 Relay extension module 1 Relay 12 1 Relay extension module 1 Relay 13 1 Relay extension module 1 Relay 14 1 Relay extension module 1 Relay 15 1 Relay extension module 1 Relay 16 1 Relay extension module 1 Relay 17 1 Relay extension module 2 Relay 18 1 Relay extension module 2 Relay 19 1 Relay extension module 2 Relay 20 1 Relay extension module 2 Relay 21 1 Relay extension module 2 Relay 22 1 Relay extension module 2 Relay 23 1 Relay extension module 2 Relay 24 1 Relay extension module 2 Relay 25 1 Relay extension module 3 Relay 26 1 Relay extension module 3 Relay 27 1 Relay extension module 3 Relay 28 1 Relay extension module 3 Relay 29 1 Relay extension module 3 Relay 30 1 Relay extension module 3 Relay 31 1 Relay extension module 3 Relay 32 1 Relay extension module 3 Relay 33 1 Relay extension module 4 Relay 34 1 Relay extension
37. When the scheduler prevents genset operation in AUTO mode the AUTO led will flash The scheduler consists of 144 programmable parameters one for each hour in a week Thus every hour of the week may be independently selected as ON or OFF times These programmable parameters allow the genset to operate automatically only in allowed time limits 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 K35D01 EN 127 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 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 tem
38. configuration is used in cases where the engine is required to run until destruction This may be the case under critical conditions like fire fighting or other emergency cases This input should be configured as a Warning Thus when protections are disabled a warning message will immediately appear on the screen When protections are disabled all shutdown alarms and loaddumps will become warnings They will appear on the screen but will not affect genset operation The input may be constantly activated or preferably it may be activated by an external key activated switch in order to prevent unauthorized activation Disabling protections will allow the genset run until destruction Place written warnings about this situation in the genset room SERVICE REQUEST ALARM The SERVICE REQUEST 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 unit offers 3 independent service counter sets in order to enable different service periods with different priorities The fault level created upon expiration of service timers may be set as Warning Loaddump or Shutdown Thus different levels of fault conditions may be generated at different overrun levels Each service counte
39. cut 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 K35D01 EN 135 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 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 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 15 volts The unit removes starting with the generator frequency and needs at least 15 volts to measure the frequency The unit is also able to cut cranking from charge alternator voltage and oil pressure input Pl
40. faults will FREQUENCY be monitored with Fault Holdoff Timer delay after the engine is running Low and high limits are separately programmable The detection delay is also programmable Another high frequency shutdown limit which is 12 above the high limit is always monitored and stops the engine immediately GENSET LOW HIGH Set if the generator rpm is outside programmed limits These faults will be RPM monitored with Fault Holdoff Timer delay after the engine is running Low and high limits are separately programmable The detection delay is also programmable The high rpm overshoot limit is always monitored and stops the engine immediately GENSET LOW HIGH Set if any of the generator phase voltages goes outside programmed limits VOLTAGE for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running LOW HIGH BATTERY VOLTAGE Set if the genset battery voltage is outside programmed limits Low and high limits are separately programmable The detection delay is also programmable FAIL TO START Set if the engine is not running after programmed number of start attempts LOW CHARGE VOLTAGE Set if the charge alternator voltage is below the programmed limit This fault will be monitored with Fault Holdoff Timer delay after the engine is running J1939 ECU FAIL Set if no information has been received during 3 seconds from the ECU of the electronic engine This fault co
41. gasket SPARE PARTS Screw type bracket Self Retaining type bracket Stock Code J10P01 per unit Stock Code K16P01 per unit Sealing Gasket Stock Code K35P01 K35D01 EN 3 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 SAFETY NOTICE Failure to follow below instructions will result in death or serious injury e Electrical equipment should be installed only by qualified specialist No responsibility is assured by the manufacturer or any of its subsidiaries for any consequences resulting from the non compliance to these instructions Check the unit for cracks and damages due to transportation Do not install damaged equipment Do not open the unit There are no serviceable parts inside e Fuses must be connected to the power supply and phase voltage inputs in close proximity of the unit e Fuses must be of fast type FF with a maximum rating of 6A e Disconnect all power before working on equipment e When the unit is connected to the network do not touch terminals e Short circuit terminals of unused current transformers e Any electrical parameter applied to the device must be in the range specified in the user manual Although the unit is designed with a wide safety margin over range parameters may reduce lifetime alter operational precision or even damage the unit Do not try to clean the device with solvent or the like Only clean with a dump cloth e Verify correct termin
42. in the same event button will display the same information of the previous event e button will display the same information of the next event K35D01 EN 61 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 STATISTICAL COUNTERS The unit provides a set of non resettable incremental counters for statistical purposes The counters consist on total genset kWh total genset kVArh inductive total genset kVArh capacitive total engine hours total engine starts engine hours to service 1 time to service 1 engine hours to service 2 time to service 2 engine hours to service 3 time to service 3 These counters are kept in a non volatile memory and are not affected from power failures K35D01 EN 62 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 OPERATION OF THE UNIT QUICK START GUIDE STOPPING THE ENGINE Press STOP STARTING THE ENGINE Press RUN MANUAL LOAD TRANSFER Use MAINS and ene buttons LOAD TEST Press TEST genset will run and take the load AUTOMATIC OPERATION Press AUTO Check that AUTO READY led is illuminated Mode can be changed anytime without negative effect Changing the operation mode while the genset is running will result into a behavior suitable for the new operating mode STOP MODE The STOP mode is entered by pressing the button In this mode the genset will be in a rest state When STOP mode is selected if the genset is running
43. is provided with each extension module TO OTHER INPUT OUTPUT W TEKSAN TJ 509 T EXTENSION MODULES AN DKG 188 INPUT DKG 186 OUTPUT EXTENSION MODULE EXTENSION MODULE K35D01 EN 24 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 RS 485 PORT Structure RS 485 non isolated Connection 3 wires A B GND Half duplex Baud rate 2400 115200 bauds selectable Data type 8 bit data no parity 1 bit stop Termination External 120 ohms required Common mode voltage 0 5 VDC to 7VDC internally clamped by transient suppressors Max distance 1200m 9600 bauds with 120 ohms balanced cable 200m 115200 bauds with 120 ohms balanced cable The RS 485 port features MODBUS RTU protocol Multiple modules up to 128 can be paralleled on the same RS 485 bus for data transfer to automation or building management systems The Modbus register list is available at Datakom technical support The RS 485 port provides also a good solution for distant PC connection where RainbowPlus program will enable programming control and monitoring For more details about programming control and monitoring through RS 485 port please refer to RainbowPlus user manual J1939 CANBUS PORT Structure CANBUS non isolated Connection 3 wires CANH CANL GND Data rate 250 kbps Termination Internal 120 ohms provided Common mode voltage 0 5 VDC to 15 VD
44. long string may be entered ENGINE SERIAL NUMBER The engine serial number string is designed to identify the current controller Ths string is added to GSM SMS messages e mails web page headers etc MODEM1 2 SMS1 2 3 4 TELEPHONE NUMBERS These telephone number buffers accept up to 16 digits including the wait character in order to enable dialing through a pabx If Modem Selection External PSTN Modem First 2 numbers are used for modem calls Other selections all numbers are used for SMS sending Enter numbers starting from first character Do leave blank characters at the beginning K35D01 EN 103 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 GSM MODEM PARAMETERS Parameter Definition Description APN User Name The APN access point name username may be required by the GSM operator However some GSM operators may allow access without username The exact information should be obtained from the GSM operator Please search the GSM operator s website with APN string APN Password If the APN access point name username is required by the GSM operator most probably the APN password will also be required However some GSM operators may allow access without password The exact information should be obtained from the GSM operator Please search the GSM operator s website with APN string APN Name The APN access point name is always required by the
45. module 4 Relay 35 1 Relay extension module 4 Relay 36 1 Relay extension module 4 Relay 37 1 Relay extension module 4 Relay 38 1 Relay extension module 4 Relay 39 1 Relay extension module 4 Relay 40 1 Relay extension module 4 K35D01 EN 101 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 Below is a short list for reference purposes Please use the RainbowPlus program for complete selection list A OUTPUT FUNCTION LIST No Description No Description No Description 1 Fuel 41 Genset Ph Order Fail 81 2 Horn 42 Auto Ready 82 3 Crank 43 Weekly Schedule On 83 4 Stop Solenoid 44 Exerciser On 84 5 Genset Contactor 45 Mains Fail 85 6 Mains Contactor 46 Pgm Mode Active 86 7 Idle Speed 47 Engine Running 87 8 Preheat 48 Genset Voltage Ok 88 9 Alternate Crank 49 Alarm Check Enable 89 10 Fuel Main Winding 50 Oil Pressure Ok 90 11 Genset Close Pulse 51 Shutdown Alarm 91 12 Genset Open Pulse 52 Loaddump Alarm 92 13 Genset UV Coil 53 Warning Alarm 93 14 Mains Close Pulse 54 Shutdown or Loaddump 94 15 Mains Open Pulse 55 Secondary Volt amp Freq 95 16 Mains UV Coil 56 Test Mode 96 17 Flashing Relay 57 Auto Mode 97 18 Gas Solenoid 5
46. negative and goes above this limit then a REVERSE POWER warning will be generated If this parameter is set to 0 then reverse power fault is not monitored Genset Reverse Power Loaddumpg Limit kW 50000 If the genset power is negative and goes above this limit then a REVERSE POWER loaddump will be generated Genset Reverse Power Fail Timer sec 120 If the genset power is negative and over limits during this timer a reverse power fault will occur Genset Overcurrent Limit Amp 50000 If one of the genset phase currents goes over this limit when feeding the load this will generate a genset overcurrent fault condition The action taken upon fault condition is programmable If this parameter is set to 0 then overcurrent fault is not monitored Genset Overcurrent Limit 2 Amp 50000 When secondary voltage is selected if one of the genset phase currents goes over this limit when feeding the load this will generate a genset overcurrent fault condition The action taken upon fault condition is programmable If this parameter is set to 0 then overcurrent fault is not monitored Genset Overcurrent Action 0 shutdown alarm 1 loaddump alarm Overcurrent Time Multiplier 64 16 This parameter defines the reaction speed of the overcurrent detector A higher number means higher sensitivity Detailed explanation is given at chapter Overcurrent Protection Genset Overloa
47. performed with interruption Synchronization When synchronization is detected both contactors will stay closed during this Contactor Timeout timer This is the maximum difference between mains and genset frequencies to Max Freq Difference close both contactors This is the maximum difference between the mains phase L1 and the genset Max Volt Difference phase L1 voltages to close both contactors If voltage transformer is used this quantity is multiplied with voltage transformer ratio This is the maximum phase angle between the mains phase L1 and the Dillerence genset phase L1 voltages to close both contactors K35D01 EN 118 TJ 509T User Manual Rev_01 PRELIMINARY VERSION _ V 1 4 DATA RECORDING DATA RECORDING MEDIA Data can be recorded in USB flash memory As soon as a USB flash memory is inserted the unit will start data recording and continue until the memory is removed USB HOST USB FLASH MEMORY A The USB Host port is available with COMM option A If USB Device is plugged then USB Host port will not function K35D01 EN 119 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 DIRECTORY STRUCTURE The unit will record data in either an USB Flash memory The record structure is the same in both cases GENSET 01 2012 ames 20121231 csv 20121230 s Last day of the year 20120101 csv 20111231 q First day of the year
48. phase electrical network it is advised to select the topology as Single Phase 2 Wires When the topology is set to Single Phase 2 Wires 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 External Control of the Unit The unit offers total external control through programmable digital inputs Any digital input may be programmed for below functions Force STOP mode Force AUTO mode Force 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 pushbuttons 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 K35D01 EN 126 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 Automatic Exerciser The unit offers 7 independent automatic exercisers The exercise operation may be done on a 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 paramete
49. sender has below programmable parameters Parameter Definition Unit Min Max Factory Description Set Selects between predefined input functions Selected input name is Input Function 0 99 displayed in the line below If this parameter is set to 0 then the input name string can be freely entered shutdown alarm loaddump alarm warning no fault condition from this input always on engine running after hold off timer reserved non latching The fault disappears when cause is removed Latching 0 1 1 latching The fault persists even if the cause is removed Requires manual reset 0 Normally open 1 Normally closed 0 Battery negative 1 Battery positive 0 No delay 1 2 Action 0 3 Sampling 0 3 Oo N Contact type 0 1 Switching 0 1 _ Delayed 15 Response delay 0 3 Delayed 5sec 3 Delayed 10sec K35D01 EN 99 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 INPUT FUNCTION LIST No Description No Description No Description 1 User Defined Function 41 Over Resonance 81 reserved for future use 2 Low Oil Press Switch 42 Short Circuit Alarm 82 reserved for future use 3 High Temp Switch 43 Reset Service 1 Alm 83 reserved for future use 4 Coo
50. sender to other devices 21 ANALOG SENDER 2 Connect to the coolant temperature COOLANT TEMP SENDER sender Do not connect the sender to other devices 22 ANALOG SENDER 3 Connect to the fuel level sender FUEL LEVEL SENDER Do not connect the sender to other devices 23 ANALOG SENDER 4 Connect to the oil temperature sender OIL TEMP SENDER Do not connect the sender to other devices Term Function Technical data Description 24 PROTECTION GROUND Output OVdc Connect the protective shield of the RS 485 cable to this terminal from one end only 25 RS 485 Digital communication Connect the A B data lines of the RS 485 26 RS 485A port link to these terminals 27 MPU Analog input 0 5 to Connect the MPU unit to these inputs 28 MPU 30V AC Use a twisted cable pair or coaxial cable for best results 29 PROTECTION GROUND Output OVdc Connect the protective shield of the MPU and CANBUS J1939 cables to this terminal from one end only 30 CANBUS H Digital communication Connect the J1939 port of an electronic 31 CANBUS L port 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 K35D01 EN 48 TJ 509T User Manual Rev_01 PRELIMINARY VERSION 1 4 Term Function Technical data Description 51
51. to Nominal Voltage Mains Voltage High Limit V 100 V 100 V 20 If one of the mains phases goes over this limit it means that the mains are off and starts the transfer to the genset in AUTO mode The value is defined with reference to Nominal Voltage Mains Voltage Fail Timer sec 10 If at least one of the mains phase voltages goes outside of the limits during this timer it means that the mains are off and it starts the transfer to the genset in AUTO mode Instant Mains Dropout 96 50 If the mains phase voltages are outside limits but not more than this parameter with reference to nominal voltage then the genset will run without releasing the mains contactor When the genset is ready to take the load the load will be transferred If this parameter is set to zero then the mains contactor is immediately released at mains failure K35D01 EN 82 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ELECTRICAL PARAMETERS GROUP continued Parameter Definition Unit Min Factory Description Set If the mains frequency goes under this Mains Frequency Low limit it means that the mains are off and Limit F 100 F 100 F 10 starts the transfer to the genset in AUTO mode The value is defined with reference to Nominal Frequency If the mains frequency goes over this Mains Frequency Hi
52. under load then it will be immediately unloaded The engine will continue to run during Cooldown Timer and will stop afterwards If the STOP button is pressed again then the engine will immediately stop If the engine fails to stop after the expiration of Stop Timer then a Fail to Stop warning will occur In this mode the mains contactor will be energized only if mains phase voltages and frequency are within the programmed limits If enabled the mains phase order is also checked If a Remote Start or Force to Start signal arrives in STOP mode the genset will not start until AUTO mode is selected K35D01 EN 63 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 AUTO MODE The AUTO mode is entered by pressing the e button The AUTO mode is used for the automatic transfer between genset and mains The controller will constantly monitor the mains availability It will run the engine and transfer the load when a mains failure occurs If a panel lock input is defined and signal is applied then mode change will not occur However display navigation buttons are still enabled and parameters may be visualized The mains availability evaluation sequence is below e If at least one of the mains phase voltages or the mains frequency is outside limits the mains will be supposed failing Otherwise mains is available e Ifa Simulate Mains signal is present then mains are made available e Force to Start signal is present t
53. 01 PRELIMINARY VERSION V 1 4 LOADDUMP ALARMS Digital input and analog sender alarms are fully programmable for the alarm name sampling and action Onlv internal alarms are explained in this section VOLTAGE UNBALANCE Set if any of the generator phase voltages differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running CURRENT UNBALANCE Set if any of the generator phase currents differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running The action taken at fault condition is programmable OVERCURRENT Set if at least one of the genset phase currents goes over the Overcurrent Limit for the period allowed by the IDMT curve setting The allowed timer is dependent of the overcurrent level If currents go below the limit before expiration of the timer then no alarm will be set Please check chapter Overcurrent Protection IDMT for more details The action taken at fault condition is programmable OVERLOAD Set if the genset power kW supplied to the load goes over the Overload Load Dump limit for Overload Timer If the power goes below the limit before expiration of the timer then no alarm will be set REVERSE POWER Set if the genset power kW is negative and goes over the Reverse
54. 31033k8 80 110 MOT NI ZZ MS dW3L IH 9 1 92 67 5 NI SZ V3sVdS t NI vc 349001 9 NI EZ 22 9018 83W3 L LZ 39SuVHO 9L 91 5 2 1no sc 40158 2 1 8 WAV 1V L 1 ZL 73na v 1410102 LNO 6L Iva bb o BMS 2 440 92104 9 sleds 0015 AoueDJjeul3 ynduj eds AvC CV AH3 LIVS 2 Ground from one end only Battery Negative must be grounded 43 K35D01 EN V 1 4 PRELIMINARY VERSION TJ 509T User Manual Rev 01 REMOTE START FUNCTIONALITY LOAD ALTERNATOR L10 L2 L20 L3 L30 INVO HNVO GN9d 8 987 987 9 ANS 9 ANS S QNS dii3L QNS A31 1303 ANS QNS 710 ANS H3QN3S WV4A LO3Y 8 MOT Z NI MS dW3 LL IH 9 NI MS A3171009F S NI V3sHVdS t NI M9071 WOd NI NI 4018 3W3 L NI 9 LNO Zino 4018 2 LNO Wuv ilv L LNO Tana v LNO ANVHO E LNO 2 6 To ECU o 2 BMS Jepueg Starter Motor 4 Connect to the engine body close to the senders 2 Ground from one end o
55. 4 CONTROLLER CONFIGURATION GROUP continued Parameter Definition Unit Min Max Factory Set Description SMS on Mains Change This parameter controls SMS sending when mains voltages status is changed No warnings generated 0 no SMS on mains failed or restored 1 SMS sent on mains failed or restored SMS on IP Change This parameter controls SMS sending when IP address of GPRS connection is changed No warnings generated 0 no SMS on IP change 1 SMS sent on IP change E mail on IP Change This parameter controls e mail sending when IP address of GPRS or ethernet connection is changed No warnings generated 0 no e mail on IP change 1 e mail sent on IP change Fuel Pump Low Limit 100 20 If the fuel level measured from the sender input falls below this level then the FUEL PUMP function will become active Fuel Pump High Limit 96 100 80 If the fuel level measured from the sender input goes above this level then the FUEL PUMP function will become passive Warning Before Start This parameter controls the activation of the ALARM output during Engine Start Delay timer before engine run 0 no warning before start 1 warning before start Latch all Warnings 0 warnings are latching non latching on parameter control 1 all warnings are latched Even if the fault source is removed warnings will persist until manually reset Remote Control
56. 4 Battery Potential Switched The J1939 measurements are also available for Modbus operation Please check chapter Modbus Communications 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 warnings 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 in text within the alarm list table together with their SPN FMI codes The complete list of fault codes is given in the engine manufacturer s user manual K35D01 EN 113 TJ 509T User Manual Rev_01 Below is a basic list of fault conditions x denotes any PRELIMINARY VERSION SPN DESCRIPTION 94 x Fuel filter restriction Fuel pressure sensor fail 98 X Low oil level High oil level Oil level sensor fail 100 X Low oil pressure Oil pressure sensor fail 102 X High boost pressure Turbo outlet pressure sensor fail 105 X Intake manifold temp high Intake manifold temp sensor fail 107 X Air filter restriction Air filter sensor fail 108 X Athmospheric pressure sensor fail 110 x High coolant temperature Coolant temperature sen
57. 7 service time to service total engine cranks total engine runs 3 level password protection Adjustable setting parameters 4 Remote monitoring On RS 232 port through software o Remote start operation with dry contact RS 232 serial port 4 PA RS 485 serial port MODBUS communications 4 4 Electronic engine control and monitoring through J1939 CAN 4 4 Alarm Warning indicator 4 4 Periodic maintenance service request indicator 4 4 Graphic LCD display 4 4 4 Standard 1 TJ9MS5N TJ10MS5N TJ11MS5N TJ15MS5N TJ20M 5N O Optional 2 Analogue fuel level gauge exists on the base frame fuel tank X Not applicable NA 3 The load shedding feature consists on the disconnection of the least crucial loads in a single step when the generator set power approaches to its programmed limits An additional breaker is needed in the ATS panel for the disconnection www teksangenerator com 18 01 2012 TEKSAN GENERATOR lt Multiple language support Mimic diagram indicating the current status of the mains and generator set x voltages and contactors Configurable analogue inputs Configurable digital inputs qa lt 4 lt lt Configurable digital outputs N N Relay output expansion capability up Dual generator set mutual standby operation Lockable control panel door Spring clamp type terminals Alarm h
58. 8 Manual Mode 98 19 Fuel Pump Control 59 Off Mode 99 20 Choke 60 Not In Auto 100 21 Block Heater 61 Genset At Rest 101 22 Coolant Cooler 62 Waiting Before Fuel 102 23 Coolant Heater 63 Preheating 103 24 Fan Control 64 Waiting Oil Flash Off 104 25 Air Flap Control 65 Engine Heating 105 26 Canopy Fan Control 66 Synchronizing 106 27 Ambient Fan Control 67 Cooling Down 107 28 Remote Start Output 68 Stopping 108 29 Genset Ready 69 Protections Disabled 109 30 Bus Bar Contactor 70 Remote Start Input 110 31 Bus Bar Close Pulse 71 Disable Auto Start 111 32 Bus Bar Open Pulse 72 Force to Start 112 33 Bus Bar UV Coil 73 Auto Restore Inhibited 113 34 Load Shedding 74 Gen Loading Inhibited 114 35 Load Add 75 Inp Expansion1Mounted 115 36 Load Substract 76 Inp Expansion2Mounted 116 37 Service 1 Request 77 Out Expansion1 Mounted 117 38 Service 2 Request 78 Out Expansion2Mounted 118 39 Service 3 Request 79 Master Unit 119 40 Mains Ph Order Fail 80 120 K35D01 EN 102 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 SITE ID STRING The site identity string is designed to identify the current controller This is the site Id string sent at the beginning of SMS messages e mails and web page headers for the identification of the genset sending the message Any 20 character
59. C internally clamped by transient suppressors Max distance 200m with 120 ohm balanced cable K35D01 EN 25 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ETHERNET PORT SS 5500 0889 ole gt m Ethernet 2 Connector 2 Data Flow led Link Established led Description IEEE802 3 compliant 10 100 Base TX RJ45 ethernet port with indicating leds Data rate 10 100 Mbits s auto detecting Connector RJ45 Cable type CAT5 or CAT6 Isolation 1500 VAC 1 minute Max distance 30m Functionality Embedded TCP IP Web Server Web Client SMTP e mail SNMP Modbus over IP LED FUNCTIONS GREEN This led turns on when the ethernet link is established connector inserted YELLOW This led blinks when data transfer occurs inwards or outwards Periodic blinking will witness data flow STANDARD ETHERNET CABLE K35D01 EN 26 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 USB DEVICE PORT Lodi USB Device USB Device Connector Description USB 2 0 not isolated HID mode Data rate Full Speed 1 5 12 Mbits s auto detecting Connector USB B printer connector Cable length Max 6m Functionality Modbus FAT32 for firmware upgrade boot loader mode only The USB Device port is designed to connect the module to a PC Using the RainbowPlus software programmin
60. CAL PARAMETERS GROUP rerit retten tio ENGINE PARAMETERS GROUP iter ertet e a ADJUST DATE AND gue WEEKLY OPERATION SCHEDULE eiie trit entendre tnnt ener RH HER indeed dendedeeenetnaenadbacieess EXERCISER SCHEDULE Et SENDER CONFIGURAT ION 1 cate rhe eo eee opea di tui ee yeso Se DIGITAL INPUT CONFIGURATION ette nh pir emu nra Id ee eo t n Fnit n eerta hai OUTPUT CONEIGURATION 2 3 d cue iere Ren pde eae ep ea xv SITEIDSTRING E E ENGINE SERIAL NUMBER erii MODEM1 2 SMS1 2 3 4 TELEPHONE GSM MODEM PARAMIETERS 5 arret tote thue rite hun ehe rena ea eR ea ETHERNET PARAMIETERS rerit eterne etate anre arbe ek SYNCHRONIZATION PARAMETERS ccccccticeseactececttsersenescteceeatcerseursetedevaecessvansdesorvenseesnensedesevsatananaetcereets K35D01 EN 7 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 CRANK CUTTING i OVERCURRENT PROTECTION
61. E 2 WIRE ALTERNATOR L1 K35D01 EN 97 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 uk JP 5 En n E a single lu WI fulfill various duties minimizing stock cost CT LOCATION SELECTION CTs may be placed at alternator or load busbars The CT location selection is configured with Controller Configuration CT Location parameter When CTs are located at the alternator side them mains current and power parameters will not be displayed When CTs are located at load side then both mains and genset currents and power parameters will be displayed based on contactor positions Please review AMF functionality connection diagrams for CT connection details AMF FUNCTIONALITY When AMF functionality is selected the unit will monitor mains voltages provide mains and genset contactor control run the engine and provide engine and alternator instrumentation and fault monitoring The unit features both MPU and J1939 CANBUS inputs Thus both mechanical and electronic engines are supported The unit provides control outputs for both contactors and motorized circuit breakers ATS FUNCTIONALITY When ATS functionality is selected the unit will monitor mains voltages provide mains and genset contactor control and issue a Remote Start signal to the engine controller It will provide alternator instrumentation and fault monitoring Engine instrumentation and protection will be insured by the engi
62. EQUEST will be indicated depending on Service 2 Period Service 2 Alarm Level 0 no action 1 shutdown alarm 2 loaddump alarm 3 warning Service 3 Engine Hours hours 5000 250 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 service 3 engine hours Service 3 Period month 24 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 Service 3 Period Service 3 Alarm Level 0 no action 1 shutdown alarm 2 loaddump alarm 3 warning K35D01 EN 92 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ENGINE PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Set Description 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 J1939 Engine Brand 15 GENERIC CUMMINS DETROIT DIESEL DEUTZ JOHN DEERE PERKINS VOLVO CATERPILLAR SCANIA VECO 10 MTU MDEC 11 BOSCH Other values Reserved Do not use J1939 ECU Type GENERIC ENGINE BRAND 0 Generic CUMMINS ENGINE 0
63. Factory set as IDLE SPEED output 10 CHARGE Input and output Connect the charge alternators D terminal to this terminal This terminal will supply the excitation current and measure the voltage of the charge alternator 11 DIGITAL INPUT 1 12 DIGITAL INPUT 2 Digital Inputs 0 30Vdc The input has programmable function Factory set as LOW OIL PRESSURE SWITCH The input has programmable function Factory set as HIGH TEMP SWITCH K35D01 EN 47 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 Term Function Technical data Description 13 DIGITAL INPUT 3 The input has programmable function Factory set as EMERGENCY STOP 14 DIGITAL INPUT 4 The input has programmable function Factory set as LOW COOLANT LEVEL SWITCH 15 DIGITAL INPUT 5 The input has programmable function Factory set as SPARE INPUT 1 16 DIGITAL INPUT 6 The input has programmable function Factory set as SPARE INPUT 2 17 DIGITAL INPUT 7 The input has programmable function Factory set as SPARE INPUT 3 18 DIGITAL INPUT 8 The input has programmable function Factory set as FORCE OFF MODE 19 SENDER GROUND Ground potential for analog senders Connect to the engine body close to senders 20 ANALOG SENDER 1 Connect to the oil pressure sender OIL PRESSURE SENDER Do not connect the
64. GENERATOR CONTACTOR Relay output 16A AC This output provides energy to the generator contactor If the generator phases do not have acceptable voltage or frequency values the generator contactor will be de energized In order to provide extra security the normally closed contact of the mains contactor should be serially connected to this output 52 GEN L1 Generator phase Connect the generator phases to these 54 GEN L2 inputs 0 300V AC inputs The generator phase voltages 56 GEN L3 upper and lower limits are programmable 58 GENERATOR NEUTRAL Input 0 300V AC Neutral terminal for the generator phases Term Function Technical data Description 59 CURR_1 Current transformer Connect the generator current transformer inputs 5A AC terminals to these inputs 60 CURR 1 Do not connect the same current transformer to other instruments otherwise a unit fault will occur 91 SURP 2 Connect each terminal of the transformer to the unit s related terminal 62 CURR_2 Do not use common terminals Do not use grounding 63 CURR_3 Correct polarity of connection is vital The rating of the transformers should be 64 CURR_3 identical for each of the 3 phases The secondary winding rating shall be 5 Amperes ex 200 5 Amps Term Function Technical data Description 65 MAINS NEUTRAL Input 0 300V AC Neutral terminal for the mains phases 67 MAINS L3 Mains phase inputs Connect the mains phases to these inputs 0 300V AC The mains
65. GSM Datakom modem 3 external GSM generic modem 4 external PSTN land modem External Modem Baud bps 2400 115200 115200 This is the data rate for accessing the Rate external modem If the GSM SIM card uses pin number enter the pin number here If incorrect GSM Sim Card Pin 7 0000 9999 0 pin number is entered then the SIM card will not operate 0 SMS messages disabled 2 j 1 SMS eoa enabled GPRS Connection _ 0 1 0 0 GPRS disabled Enable 1 GPRS enabled Web Programming _ 0 1 0 0 Web programming disabled Enable 1 Web programming enabled 0 Web control disabled Web Control Enable 0 1 0 1 Web control enabled Web Refresh Rate et 0 240 5 The unit will refresh the web page with this interval Ping Period ae 30 900 120 The unit will check the availability of the internet connection with this interval Ping Period min 0 240 0 The unit will check the availability of the internet connection with this interval Rainbow Refresh Rate sec 0 65535 5 The uni update the distant monitoring terminal with this rate Rainbow Address A Port _ 0 65535 0 This is the port number of the first monitoring terminal address Rainbow Address 2 Port _ 0 65535 0 This is the port number of the second monitoring terminal address This is the port number of the internal Web Server Port 0 65535 80 web server The unit will answer queries to this port only Internal Modbus TCP IP server s port Modbus TCP IP Port 0 65535 502 numb
66. GSM operator The exact information should be obtained from the GSM operator Please search the GSM operator s website with APN string SMS Service Center Number The SMS service center number may be required by the GSM operator However some GSM operators may allow SMS sending without SMS service center number The exact information should be obtained from the GSM operator Please search the GSM operator s website with sms service center string Below GSM modem related parameters are found in the Controller Configuration group Parameter Definition Unit Min Max ic DOSEH pon If the GSM SIM card uses pin number enter the pin number here If incorrect 0000 7289A p pin number is entered then the SIM card will not operate 0 SMS messages disabled SMS Enable B 1 8 1 SMS messages enabled GPRS Connection _ 0 1 0 0 GPRS disabled Enable 1 GPRS enabled This parameter controls SMS sending when mains voltages status is changed No warnings generated SMS on Mains Change 0 1 0 0 no SMS on mains failed or restored 1 SMS sent on mains failed or restored This parameter controls SMS sending when IP address of GPRS _ connection is changed No warnings SMS on IP Change 0 1 0 generated 0 no SMS on IP change 1 SMS sent on IP change K35D01 EN 104 TJ 509T User Manual Rev_01 ETHERNET PARAMETERS PRELIMINARY VERSION V 1 4 P
67. INARY VERSION V 1 4 RS 232 PORT Description RS 232 non isolated Functionality External GSM modem external PSTN modem Connector DB 9 9 pins male Connection 5 wires Rx Tx DTR CxD GND Full duplex Baud rate 2400 115200 bauds selectable Data type 8 bit data no parity 1 bit stop Max distance 15m Cable type Standard modem cable Terminal description 1 CxD input 6 NC 4 234 5 2 Rx input 3 Tx output 8 NC 4 DTR output 9 NC 5 GND K35D01 EN 29 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 GSM MODEM OPTIONAL The optional internal GSM modem offers the advantage of being internally powered and is fully compatible with the unit It does not require any special setup The 1800 1900 MHz magnetic antenna together with its 2 meter cable is supplied with the internal modem option The antenna is intended to be placed outside of the genset panel for the best signal reception Antenna connector Magnetic antenna The module requires a GPRS enabled SIM card for full functionality Voice only type SIM cards will usually not function properly Please refer to GSM Modem Configuration Guide for more details K35D01 EN 30 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 Push the extraction tab SIM CARD EXTRACTION SIM CARD EXTRACTION INSERTION SIM CARD PLACEMENT Description Quad band GSM GPRS 850 900
68. 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 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
69. LIMINARY VERSION V 1 4 240 250 260 270 280 290 300 ing delay in function of the percent load level with TMS 36 18s 16s 14s 12s 11s 10s 9s ing delay curve in function of the load level with TMS 36 100000 overload level times x setpoint 1 T T T T T T 111213 14 15 16 17 18 19 2 2 1 2 2 2 3 2 4 2 5 2 6 27 28 2 9 3 K35D01 EN 110 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 MOTORIZED CIRCUIT BREAKER CONTROL The unit offers full control for any brand and model of motorized circuit breakers MCB The MCB control is performed through 3 digital output functions namely Open Close and Undervoltage coil controls Only 2 of these outputs are used in a single application Any digital output can be assigned to MCB control signals through programming menu MCB CLOSE MCB OPEN SEQUENCE SEQUENCE The MCB CLOSE sequence is below Activate UV output wait for undervoltage coil timer tuv Activate CLOSE output wait for close pulse timer ta Deactivate CLOSE output The MCB OPEN sequence is below Deactivate UV output Activate OPEN output wait for open pulse timer top Deactivate OPEN output Open Pulse Close Pulse and Undervoltage Coil timers are adjusted through programming menu If MCB feedback input is defined and the MCB fails to change position after the expiration of MCB Fail timer then a fault condition will occur K35D01 EN 111
70. N state duration timer Flashing Relay OFF Timer min 1200 Dual Genset Systems flashing relay OFF state duration Real Time Clock Adjust 255 117 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 Hysteresis Voltage V AC 30 This parameter provides the mains and genset voltage limits with a hysteresis feature in order to prevent faulty decisions For example when the mains are present the mains 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 Engine Control Only 0 Genset control 1 Engine control no alternator Alternator Pole Pairs This parameter is used for frquency to rpm conversion For a 1500 1800 rpm engine select 2 For a 3000 3600 rpm engine select 1 RPM from genset frequency 0 read rpm from the MPU input 1 convert frequency to rpm using Alternator Pole Pairs Crank Teeth Count 244 30 This is the number of pulses generated by the magnetic pickup sensing unit in one turn of the flywheel Secondary Volt Freq 0 Use primary volt frequency limits 1 Use secondary volt frequency limits K35D01 EN 79 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1
71. R RR 3 WIRE DELTA initi oet td dun dU eee based cette PHASE 4 WIRE tien enitn eae 3 PHASE WIRE DELTA 2 12 3 PHASE WIRE DELTA 2 CT 2 PHASE WIRE DELTA 2 CTS L1 L2 iicet eerte 2 PHASE WIRE DELTA 2 CTs 11 13 1 PHASE 2 WIRE riter net tune e Ee CR NE eaa asleep PB ace CT LOCATION SELECTION mE EE ATS FUNCTIONALITY cR REMOTE START FUNCTIONALITY eene thanh pano ENGINE CONTROLLER pue rasrdd gen REMOTE DISPLAY UNIT CONNECTION DIAGRAMS c aeii apii a AMF FUNCTIONALITY CTs AT LOAD SIDE AMF FUNCTIONALITY CTs AT ALTERNATOR 50 ATS FUNCTIONALITY eddies ERR REMOTE START FUNCTIONALITY 5 2 2 itp timen aio ruat n taa nnda ana ruat a pna eain nre hann inni ENGINE CON TROL FUNCTIONALITY
72. RPM level during Loss of Speed Signal Timer The action of signal loss is programmable SERVICE REQUEST Set if at least one of the service counters has expired In order to reset the service counters please hold pressed both with buttons during 5 seconds The screen will display Completed K35D01 EN 72 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 PROGRAMMING RESETTING TO FACTORY DEFAULTS 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 Hold pressed OFF LAMP TEST and ALARM MUTE RETURN TO FACTORY SET ds MUTE keg Hold pressed ALARM MUTE K35D01 EN 73 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 The program mode is used to adjust timers operational limits and the configuration of the unit Although a free PC program is provided for programming every parameter may be modified through the front panel regardless of the operating mode When modified program parameters are automatically recorded into a non erasable memory and take effect immediately The program mode will not affect the operation of the unit Thus programs may be modified anytime even while the genset is running ENTERING
73. RSION V 1 4 DISPLAYING EVENT LOGS The unit features more than 400 event logs with date time stamp and full snapshot of measured values at the moment that the event has occurred Stored values in an event record are listed below event number event type fault definition see below for various event sources date and time operation mode operation status on load on mains cranking etc mains phase voltages L1 L2 L3 mains frequency genset phase voltages L1 L2 L3 genset phase currents L1 L2 L3 genset frequency genset total active power kW genset total power factor oil pressure engine temperature fuel level oil temperature canopy temperature ambient temperature engine rpm battery voltage charge voltage Possible event sources are various Every source can be individually enabled or disabled Rainbow Plus Beta Version 1 0 0 6 File Tools Help Configuration Scada Module Functionality Miscellaneous Warming Before Start v Delayed Simulate Mains Secondary Volt Freq C Timers Latch All Wamings Oil Pressure Switch Priority 7 Buzzer Enable Exercise Scheduler Time Event Logs Enable E i t bl Periodic v Mains Restore Warning v Mode Change Shut Down v PGM Entrance v Se oe lon a Mains Fail Load Dump v Periodic event recorded every 30 minutes when the engine is running and every 60 minutes any
74. TEKSAN GENERATOR All measured and statistical parameters operating modes warnings and alarms and the current status of the mains and generator set can be viewed from the generator set control panel The control panels are manufactured with following features and dimensions Structure The control panels are made of A1 quality steel sheet and painted with electrostatics powder against corrosion Control Panel Mounting The control panels are mounted on the base frame until 825 kVA generator sets The control panels are mounted on the alternator isolated from the vibration for bigger sized generator sets Control Panel Dimensions Width 220 mm Length 600 mm Height 400 mm Please contact with Teksan for project based special panel and control systems 1 TJ9MS5N TJ10MS5N TJ1 1MS5N TJT5MS5N TJ20M S 5N TJ10PE5N 14 Automatic control panel provided with emergency generator sets starts and stops generator set automatically in case of a mains failure with complete control and protection functions These functions are realized with micro processor based control module The modes of operation are selected by pushing the front panel bottons It is designed to be used when mains power is not available or when it is aimed to start stop the generator set manually Control and protection functions are realized with micro processor based control module The modes of operation are selected by pushing the front panel bot
75. agents DISPOSAL OF THE UNIT Following DIRECTIVE 2002 96 EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 27 January 2003 on waste electrical and electronic equipment WEEE this unit should be stored and disposed separately from the usual waste ROHS COMPLIANCE The european ROHS directive restricts and prohibits the use of some chemical materials in electronic devices Following the DIRECTIVE 2011 65 EU OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 8 June 2011 on the restriction of the use of certain hazardous substances in electrical and electronic equipment this product is listed in annex I under category Monitoring and control instruments including industrial monitoring and control instruments and exempted from ROHS directive However Datakom is not using any ROHS uncompliant electronic components in the production Only the solder contains lead The switching to unleaded solderin is in progress K35D01 EN 134 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 TROUBLESHOOTING GUIDE Below is a basic list of most often encountered troubles More detailed investigation may be required in some cases 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 voltage readings on the screen Upper and lower limits of the mains voltages may be to
76. al connections before applying power e Only for front panel mounting Current Transformers must be used for current measurement No direct connection allowed K35D01 EN 4 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 TABLE OF CONTENTS COPYRIGHT eg Pied ang iupeeihuid peces RELATED DOCUMBEN S eerie ett se en AE Ea E REVISION HISTORY isa re sneadstioaaveasdenseansdiiaaveatebsbeadideeaiead outeatezite TERMINOLOGY d cuocere SPARE PARTS ECRIRE RUE E DUE rel KE aaae iea sea gg MH INSTALEATION INSTRUCTIO NS conis rante teen ihren a o een De ek a e eet a On 4 DIMENSIONS SEALING GASKET ELECTRICAL INSTAELATIQN 5 oca taie oett aea TERMINAL DESCRIPTIONS iiscetteccervetesiscarteccessagesaaartedeesvesiessdasend cossedesdsdertediedbegestadesteeceastudedeeted nauaguasadeens BATTERY VOLTAGE INPULT eire ifie ren ibn
77. arameter Definition Factory Set Description Network IP Address 0 0 0 0 This is the IPv4 internet protocol version 4 address that the unit will require from the DHCP dynamic host control protocol server If this parameter is set to 0 0 0 0 then the unit will require any IPv4 address from the DHCP server If you are not an IP professional please leave this address as 0 0 0 0 Gateway IP Address 0 0 0 0 This is the router IPv4 address If the Network IP address and Gateway IP Address are set to 0 0 0 0 then the unit will get the gateway address automatically If you are not an IP professional please leave this address as 0 0 0 0 Subnet Mask 255 255 255 0 Reserved for IP professionals If you are not an IP professional please leave this address as 255 255 255 0 User IP Mask 1 2 3 255 255 255 255 0 0 0 0 0 0 0 0 These 3 registers control the IPv4 access to the unit The remote IPv4 address is logical AND ed with these IP addresses If the result gives the remote IP address then access is enabled Thus access may be limited to the same LAN members x x x 255 or strictly to predefined IPv4 addresses Domain Name d500 dyndns ip com This string is used in Dynamic DNS feature The unit will register itself to the dynamic DNS server under this name For more detailed information please review chapter on Dynamic DNS Feature and the document Dynam
78. arning Level X 0 10000 If defined defines the high warning K35D01 EN 97 TJ 509T User Manual Rev_01 PRELIMINARY VERSION 1 4 Parameter Definition Unit Min Max Sender Curve 1 ohm ohms 0 5000 Point 1 ohm value Sender Curve 1 value X 0 10000 Point 1 reading Sender Curve 2 ohm ohms 0 5000 Point 2 ohm value Sender Curve 2 value X 0 10000 Point 2 reading Sender Curve 3 ohm ohms 0 5000 Point 3 ohm value Sender Curve 3 value X 0 10000 Point 3 reading Sender Curve 4 ohm ohms 0 5000 Point 4 ohm value Sender Curve 4 value X 0 10000 Point 4 reading Sender Curve 5 ohm ohms 0 5000 Point 5 ohm value Sender Curve 5 value X 0 10000 Point 5 reading Sender Curve 6 ohm ohms 0 5000 Point 6 ohm value Sender Curve 6 value X 0 10000 Point 6 reading Sender Curve 7 ohm ohms 0 5000 Point 7 ohm value Sender Curve 7 value X 0 10000 Point 7 reading Sender Curve 8 ohm ohms 0 5000 Point 8 ohm value Sender Curve 8 value X 0 10000 Point 8 reading Sender Curve 9 ohm ohms 0 5000 Point 9 ohm value Sender Curve 9 value X 0 10000 Point 9 reading Sender Curve 10 ohm ohms 0 5000 Point 10 ohm value Sender Curve 10 value X 0 10000 Point 10 reading Sender Curve 11 ohm ohms 0 5000 Point 11 ohm value Sender Curve 11 value X 0 10000 Point 11 reading Sender Curve 12 ohm ohms 0 5000 Point 12 ohm value Sender Curve 12 value X 0 10000
79. ation between modules but the distance will be limited Typically at 115200 bauds and with adequate cable the distance will be 200m maximum At 9600 bauds and adequate cable the distance can go up to 1200m Below settings are necessary PARAMETER MAIN UNIT REMOTE DISPLAY UNIT Annunciator Mode 0 1 RS 485 Enable 1 1 RS 485 Baud Rate any same as main unit Modbus Slave Address any same as main unit The remote display panel should be powered up with an isolated voltage source like a wall adapter Otherwise damages due to ground potential differences may occur K35D01 EN 40 V 1 4 PRELIMINARY VERSION TJ 509T User Manual Rev 01 N lt lt 2 O O 2 2 o a lt o EF O gt lt Q Z 2 LL LL lt e lt 2 e No o L1 o 12 o L3 o N MAINS E A CACI ALTERNATOR L10 INVO HNVO QN9d v s8t 68 9 ANS 9 ANS S QNS 110 7 QNS 1305 ANS QNS 110 ANS 7IIV310338 NI 110 MOT Z NI MS dW3 L IH79 NI 000 8 NI V33VdS t NI W9dF NI NI 018 H3W3 L NI ASYVHO 9 LNO Zino 4015 02 LNO LNO 7Tani v LNO MNVYO E LNO 179 Jo ECU
80. bit x100 Counter engine hours since last service 10626 R 32bit x100 Counter engine days since last service 10628 R 32bit x10 Counter genset total active energy KWh 10630 R 32bit x10 Counter genset total inductive reactive energy kVArh ind 10632 R 32bit x10 Counter genset total capacitive reactive energy kVArh cap 10634 R 32bit x100 Counter remaining engine hours to service 1 10636 R 32bit x100 Counter remaining engine days to service 1 10638 R 32bit x100 Counter remaining engine hours to service 2 10640 R 32bit x100 Counter remaining engine days to service 2 10642 R 32bit x100 Counter remaining engine hours to service 3 10644 R 32bit x100 Counter remaining engine days to service 3 K35D01 EN 133 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 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 UL CSA Conformity certification teting in progress UL 508 Edition 17 UL 2200 1st Edition UL 840 Edition 3 CSA C22 2 NO 14 Edition 10 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
81. ccidental phase to phase short circuit A If this transfer method is used it is advised to make an electrical Transfer from genset to mains The generator contactor releases The unit waits for Mains Contactor Timer The mains contactor is energized Transfer from mains to genset The mains contactor releases The unit waits for Generator Contactor Timer The generator contactor is energized K35D01 EN 117 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 UNINTERRUPTED TRANSFER In this mode the transfer will be made without power interruption This implies that both of the mains and generator contactors will be active during transfer The maximum duration that both contactors will be active is programmable However this process may be quicker with the use of one auxiliary feedback contact from each contactor Thus the changeover will be quite instantaneous preventing any excess or reverse power condition To prevent a phase to phase short circuit below criteria must be met The mains and generator voltages must be equal The mains and generator voltages must have the same phase The mains and generator voltages must have the same phase sequence order The unit will allow an Uninterrupted Transfer only if all of the below conditions are fulfilled Mains phase voltages within the programmed limits Mains frequency within the programmed limits Genset phase voltages within the programmed limits Gense
82. d If automatic operation is disabled by weekly exerciser the AUTO led will flash K35D01 EN 95 TJ 509T User Manual Rev_01 EXERCISER SCHEDULE BEER PROGRHIMMING WEEKLY SCHEDULE PEXERCISER SCHEDULE SENDER CONFIGURATION PRELIMINARY VERSION PROGRAMING bhExerciser Schedule 1 Exerciser Schedule Z Exerciser Schedule 3 V 1 4 sm 1 Exerciser Schedule 1 HEEK m DAY Mo Es as o Bein The unit provides 7 independent automatic exerciser programs Automatic exercise may be done weekly or monthly basis If monthly exercise is selected the week day and hour is adjustable for each exercise item If weekly exercise is selected the day and hour is adjustable for each exercise item Exercise can be done with or without load Thus the genset can be instructed to run automatically in given days and times of a week and take the load K35D01 EN 96 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 SENDER CONFIGURATION The unit has 4 analog sender inputs Only parameters of one sender are explained below Other senders have identical parameter set Each sender has 16 step programmable curves The sender name and reading unit is freely programmable thus the sender can be adapted to any type through programming Each sender has below programmable parameters Parameter Definition Unit Min Max Factory Description Set Selects be
83. d Limit kW 50000 If the total genset active power goes over this limit when feeding the load this will generate a genset overload loaddump alarm If this parameter is set to 0 then overload fault is not monitored Genset Overload Fail Timer sec 120 If the genset active power is over the limit during this timer an overload fault will occur Load Shedding Low Limit kW 50000 If the genset power goes below this limit then the load shedding relay will be deactivated Review chapter Load Shedding for more details Load Shedding High Limit kW 50000 If the genset power goes above this limit then the load shedding relay will be activated Review chapter Load Shedding for more details K35D01 EN 85 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ELECTRICAL PARAMETERS GROUP continued Parameter Definition Unit Min Factory Description Set This is the minimum delay between 2 Load Add Delay sec 0 240 0 load_add pulses Review chapter Load Shedding for more details This is the minimum delay required for a load_add pulse after a load_substract Load Subtract Add Delay 120 pulse Review chapter Load Shedding for more details This is the time between the mains Mains Waiting Timer 0 50000 30 voltages and frequency entered within the limits and the generator contactor is deactivated Th
84. d to flow for unlimited time Currents above the limit will cause the IDMT protection to trigger with a delay depending on the strength of the overcurrent Higher the current faster the protection will trip When a non tripping overcurrent condition occurs the unit will keep trace of it In case of a consecutive overcurrent the controller will take into account the residual heat caused by the previous overcurrent and will trip faster than usual The IDMT multiplier adjusts the sensitivity of the IDMT detector When the multiplier is low then tripping will be faster for the same current The unit provides separate Overcurrent limits for primary and secondary volt speed amp settings Switching from primary volt freq amps to secondary values will also switch the IDMT detector to the secondary setting The action of the tripping may be selected as a Loaddump stop after cooldown or shutdown alarm immediate stop Current Limit Over Current 1 J 100 3 Over Current 2 J ao g Over Current IDMT Multiplier J 3 Over Current Action Load Dump Screenshot from RainbowPlus configuration program Generator gt Current section K35D01 EN 109 TJ 509T User Manual Rev_01 Below is a table showing the tri 100 110 120 130 140 150 160 Below is the tri tripping de unlimited 3600s 900s 400s 225s 144s 100s lay in seconds 170 180 190 200 210 220 230 73s 56s 44s 36s 30s 25s 21s PRE
85. dded web server and low cost design Web monitoring The unit complies and mostly exceeds world s Web programming tightest safety EMC vibration and environmental GSM SMS optinal standards for the industrial category e mail Modbus RS 485 Software features are complete with easy firmware Modbus over IP upgrade process through USB port SNMP The Windows based PC software allows monitoring USB Host and programming through USB RS 485 Ethernet USB Device and GPRS RS 485 RS 232 J1939 CANBUS FUNCTIONALITIES TOPOLOGIES AMF unit with uninterrupted transfer ATS unit with uninterrupted transfer 2 phases 3 wires L1 L2 Remote start controller 2 phases 3 wires L1 L3 Manual start controller 3 phases 3 wires 3 CTs Engine controller 3 phases 3 wires 2 CTs L1 L2 Remote display amp control unit 3 phases 3 wires 2 CTs L1 L3 Waveform display of V amp 1 3 phases 4 wires star Harmonic analysis of V amp 3 phases 4 wires delta CTs at genset or load side 1 phase 2 wires TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 COPYRIGHT NOTICE Any unauthorized use or copying of the contents or any part of this document is prohibited This applies in particular to trademarks model denominations part numbers and drawings ABOUT THIS DOCUMENT This document describes minimum requirements and necessary steps for the successful installation of the 509T family units Follow carefully advices given in the docu
86. e L3 100 0 0 0 100 1 00 Total 300 0 0 0 300 1 00 K35D01 EN 19 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 EFFECT OF POLARITY REVERSAL MAINS or ALTERNATOR CONTROLLER The generator is still loaded with 100 kW On each phase The load Power Factor PF is 1 PF in phase L2 will show 1 00 due to reverse CT polarity The result is that total generator power displayed by the controller is 100 kW Measured values are as follows kW kVAr kVA pf Phase L1 100 0 0 0 100 1 00 Phase L2 100 0 0 0 100 1 00 Phase L3 100 0 0 0 100 1 00 Total 100 0 0 0 300 0 33 EFFECT OF PHASE SWAPPING MAINS or ALTERNATOR CONTROLLER The generator is still loaded with 100 kW on each phase The load Power Factor PF is 1 PF in phases L2 and L3 will show 0 50 due to phase shift between voltages and currents which is caused by CT swapping The result is that total generator power displayed by controller is 0 kW Measured values are as follows kW kVAr kVA pf Phase L1 100 0 0 0 100 1 00 Phase L2 50 0 86 6 100 0 50 Phase L3 50 0 86 6 100 0 50 Total 0 0 0 0 300 0 0 K35D01 EN 20 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 DIGITAL INPUTS Number of inputs 8 inputs all configurable Function selection from list Contact type Normally open or normally closed programmable Switching Battery negat
87. e energized the stop solenoid will be energized for Stop Solenoid timer and the diesel will stop e The unit will be ready for the next mains failure If the operation of the genset is disabled by the weekly schedule then the AUTO led will flash and the operation of the genset will be as in the OFF mode K35D01 EN 64 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 RUN MODE MANUAL CONTROL The RUN mode is entered by pressing the button When the RUN mode is selected the engine will be started regardless of the mains availability The starting sequence is as described below e The unit turns on the fuel and preheat glow plugs if any and waits for preheat timer e The engine will be cranked for programmed times during crank timer When the engine fires the crank relay will be immediately deactivated See section Crank Cutting for more details e The engine will run at idle speed during Idle Speed Timer e The engine will run unloaded until another mode is selected The RUN mode allows also manual contactor control through MC and GC buttons When a contactor button is pressed the related contactor will change position Thus if it was on then it will turn off If it was off then it will turn on If the other contactor was on then it will turn off the controller will wait for the related contactor timer and the contactor will turn on This will prevent manual closure of both contactors If unint
88. ease read chapter CRANK CUTTING The unit is inoperative Measure the DC supply voltage between terminals BAT and BAT at the rear of the unit If OK turn all 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 are skipped These parameters are reserved for factory setting and cannot be modified 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 The genset runs but does not take the load Check that the genset Yellow led is on steadily Adjust genset voltage and frequency limits if necessary Check that the digital output 8 is configured as Genset Contactor Check Genset Contactor Timer program parameter Check that a Genset Loading Inhibit input signal is not active Check input functions If an input is configured as Genset Loading Inhibit then check the signal is not present at this input K35D01 EN 136
89. ed Fault Holdoff Timer sec 120 12 This parameter defines the delay after the engine runs and before the fault monitoring is enabled Alarm Relay Timer sec 120 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 Intermittent Alarm Relay 0 continuous 1 intermittent turns on and off every second Emergency Backup Operation 0 In RUN mode the load will not be transferred to the genset even if the mains fails 1 In RUN mode the load will be transferred to the genset if the mains fails Exerciser Enable 0 automatic exerciser disabled 1 automatic exerciser enabled Exercise Period 0 exercise once per week 1 exercise once per month The exact exerciser day and time is adjusted within the EXERCISE SCHEDULE section Exercise Off On Load 0 Exercise at RUN mode 1 Exercise at TEST mode K35D01 EN 277 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 CONTROLLER CONFIGURATION GROUP continued K35D01 EN 276 Parameter Definition Unit Min Max _ Factory Description Set Delayed Simulate Mains _ 0 1 0 Pi delayed simulate mains disabled delayed simulate mains enabled 0 not used 1 Internal GSM modem Modem Selection 0 4 0 2 external
90. ed Engine speed rpm Battery voltage Gen voltage phase L1 to neutral Gen voltage phase L2 to neutral Gen voltage phase L3 to neutral Gen average voltage phase to neutral Gen voltage phase L1 L2 Gen voltage phase L2 L3 Gen voltage phase L3 L1 Gen frequency Gen current phase L1 Gen current phase L2 Gen current phase L3 Gen average current 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 Gen pf phase L1 Gen pf phase L2 Gen pf phase L3 Gen total pf Gen Neutral current The unit features 4 analog senders fully configurable for the name and function Below is a typical list of analog senders capable of changing following configuration Coolant temperature Oil pressure bar kPa Fuel level 96 It Oil temperature C F K35D01 EN 56 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 LED LAMPS AUTO READY m Mains indicator available led alarm indicator I Warning Genset indicator Contactor on led Service request Genset indicator available led TEST mode TE AUTO mode STOP mode indicator indicator indicator indicator STATUS LEDS AUTO READY Turns on when the AUTO mode is selected and there is no condition preventing engine start ALARM Turns on when a shutdown alarm or loaddump condition exists WARNING Turns on when a warning conditio
91. ed 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 STATUS PROGRAMMING 9 Ifinside the 8 DISPLAY EVENT LOGG group then _ P COHTROLLER CONFIG exit to main ELECTRICAL PARAMS Enter inside the group Next group Previous group 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 MENU P button is pressed next parameter will be displayed If lt MENU button is pressed then the list of parameters in this group will be displayed Edit parameter Return to the main menu Next parameter inside the same group Previous parameter inside the same group K35D01 EN T9 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 MODIFYING PARAMETER VALUE ee Pee READY CONTROLLER COHFIG LED Contrast Decrease parameter value Increase parameter value Pre
92. eds Engine Heating Temperature K35D01 EN 128 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 Fuel Pump Control The unit is able to provide a digital output function 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 level falls below Fuel Pump Low Limit parameter the fuel pump output function will become active When the fuel level reaches Fuel Pump High Limit parameter the output function will become passive 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 any digital output using Relay Definition program parameters 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 any digital output using Relay Definition program parameters
93. el 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 Place and tighten mounting brackets 121mm 176 Panel Cutout WALL min 60mm 40mm Required Panel Depth K35D01 EN 12 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 Two different types of brackets are provided Screw type bracket Self retaining type bracket Installation of screw type bracket Installation of self retaining type bracket Do not tighten too much this may break the unit K35D01 EN 13 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 SEALING GASKET The rubber gasket provides a watertight means of mounting the module to the genset panel Together with the gasket IEC 60529 IP65 protection can be reached from the front panel A short definition of IP protection levels is given below 1st Digit 0 Not protected 1 Protected against solid foreign objects of 50 mm diameter and greater 2 Protected against solid foreign objects of 12 5 mm diameter and greater 3 Protected against solid foreign objects of 2 5 mm diameter and greater 4 Protected against solid foreign objects of 1 0 mm diameter and greater 5 Protected from the amount of dust that would interfere with normal operation 6 Dust tight 2nd Digit 0 Not protected 1 Protected against vertically falling water drops 2 Protected aga
94. el measured through Low Coolant Level Alarm 6 ECU is below this limit then a low nud 0 100 0 Limit coolant level shutdown loaddump alarm will occur Low Coolant Level Alarm 0 shutdown alarm 0 1 0 Action 1 loaddump alarm K35D01 EN 94 V 1 4 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ADJUST DATE AND TIME PROGRAMMING 9 PROGRAMI Adjust Date ADJUST DATE Adiust Mon Adrust Date Adjust These parameters allow adjusting the battery backup real time clock of the module Once set the clock will continue to run even if DC power is removed from the unit Parameter Definition Unit Min Max Description 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 WEEKLY OPERATION SCHEDULE 51005121 1 2 b HONDA WEEKLY SCHEDULE TUESDAY MONDAY HEDNESDR In AUTO mode it is possible to define the periods where automatic operation is desired It may be required that the genset does not start at night or weekends Weekly schedule programs allow an hourly setting of automatic operation of the unit during one week There are 7days x 24hours 144 parameters Each hour of the week can be independently defined as AUTO or OFF perio
95. enset MCB undervoltage coil is energised during this period before the genset MCB close relay is activated Review chapter Motorized Circuit Breaker Control for more details Genset MCB Fail Timer sec 10 2 0 If a genset MCB feedback input is defined and if the genset MCB fails to change position before the expiration of this timer then a fault condition occurs Genset Phase Order Check Enable 0 genset phase order checking disabled 1 if genset phase order is faulty then a genset phase order fail loaddump alarm is given K35D01 EN 87 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ENGINE PARAMETERS GROUP Parameter Definition Unit Min Max Factory Description Set The nominal value of engine rpm Low Nominal RPM rpm 0 50000 1500 rpm limits are defined by reference to this value When secondary frequency is selected this is the nominal value of engine rpm Momina REMA IPOD Low high rpm limits are defined by reference to this value If the engine rpm goes under this limit Low RPM Warning Limit R 100 R 100 R 10 when feeding the load this will generate a GENSET LOW RPM warning If the engine rpm goes under this limit Low RPM Shutdown When feeding the load this will generate Limit R 100 R 100 R 15 GENSET LOW RPM shutdown alarm and the engine will stop
96. er delay after the engine is running LOW HIGH BATTERY VOLTAGE Set if the genset battery voltage is outside programmed limits Low and high limits are separately programmable The detection delay is also programmable FAIL TO STOP Set if the engine has not stopped before the expiration of the Stop Timer LOW CHARGE VOLTAGE Set if the charge alternator voltage is below the programmed limit This fault will be monitored with Fault Holdoff Timer delay after the engine is running K35D01 EN 71 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 J1939 ECU FAIL Set when an engine fault code is received from the ECU of the electronic engine This fault will not cause an engine stop If necessary the engine will be stopped by the ECU VOLTAGE UNBALANCE Set if any of the generator phase voltages differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running CURRENT UNBALANCE Set if any of the generator phase currents differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running The action taken at fault condition is programmable OVERCURRENT Set if at least one of the genset phase currents goes over the Overcurrent Limit for the period allowed by the IDMT c
97. er The unit answers Modbus requests to this port only SMTP Port _ 0 65535 587 This is the port number used for e mail sending 0 ethernet modbus gateway function disabled Ethernet to RS 485 0 1 0 1 ethernet modbus gateway function Modbus Gateway Enable enabled The unit will redirect Modbus requests from ethernet to the RS 485 port 0 gprs modbus gateway function disabled GPRS to RS 485 _ 0 1 0 1 gprs modbus gateway function Modbus Gateway Enable enabled The unit will redirect Modbus requests from GPRS to the RS 485 port TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 CONTROLLER CONFIGURATION GROUP continued Parameter Definition Unit Min Max Factory Set Description RS 485 Enable 1 1 0 RS 485 port disabled 1 RS 485 port enabled Modbus Address 255 1 This is the modbus controller identity used in Modbus communication RS 485 Baud Rate bps 2400 115200 9600 This is the data rate of the RS 485 Modbus port Ethernet Enable 1 0 ethernet port disabled 1 ethernet port enabled Oil Pressure Switch Priority 0 crank cut is performed through oil pressure switch and oil pressure sender reading 1 crank cut is performed only through oil pressure switch Flashing Relay ON Timer min 1200 Delayed Simulate Mains Operation max genset running time after Simulate Mains signal disappears Dual Genset Systems flashing relay O
98. ernator Excitation 160mA 12VDC 80mA 24VDC Ethernet Port 10 100 Mbits USB Device USB 2 0 Full speed USB Host USB 2 0 Full speed RS 485 Port selectable baud rate RS 232 Port selectable baud rate Operating temperature 20 C to 70 C 4 to 158 F Storage temperature 40 C to 80 C 40 to 176 F Maximum humidity 95 non condensing IP Protection IP54 from front panel IP30 from the rear Dimensions 200 x 148 x 46mm WxHxD Panel Cut out Dimensions 176 x 121 mm minimum Weight 450 g approx Case Material High Temperature non flammable ROHS compliant ABS PC Mounting Flush mounted with rear retaining plastic brackets EU Directives Conformity 2006 95 EC low voltage 2004 108 EC electro magnetic compatibility Norms of reference EN 61010 safety requirements EN 61326 EMC requirements UL Compatibility UL 508 Industrial Control Equipment CSA Compatibility CAN CSA C22 2 No 14 2005 Industrial Control Equipment K35D01 EN 50 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 DESCRIPTION OF CONTROLS FRONT PANEL FUNCTIONALITY Graphic LCD screen Mimic Diagram sysem status Mains Contactor control in RUN mode AUTO READY indicator Next display group Fault condition indicators Genset Contactor control in RUN mode Next screen in the same group LAMP TEST if held pressed Previous screen in the same group
99. errupted transfers are allowed then the unit will check the synchronization If synchronization is complete then it will make an uninterrupted transfer where both contactors will be on for a short while If Emergency Backup mode is enabled and if the mains are off then the mains contactor will be deactivated and the generator contactor will be activated When the mains are on again a reverse changeover to the mains will be performed but the engine will be kept running unless another mode is selected In order to stop the engine press button or select another mode of operation K35D01 EN 65 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 TEST MODE The TEST mode is entered by pressing the button The TEST mode is used in order to test the genset under load Once this mode is selected the engine will run as described in the AUTO mode regardless of the mains availability and the load will be transferred to the genset The genset will feed the load indefinitely unless another mode is selected K35D01 EN 66 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 PROTECTIONS AND ALARMS The unit provides 3 different protection levels being warnings loaddumps and shutdown alarms 1 SHUTDOWN ALARMS These are the most important fault conditions and cause The ALARM led to turn on steadily The genset contactor to be released immediately The engine to be stopped immediately Alarm digital
100. etting which is 1 K35D01 EN 130 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 Parameters required for RS 485 Modbus operation Modbus Slave Address may be set between 1 and 240 RS 485 Enable must be set to 1 or checkbox enabled RS 485 Baud Rate selectable between 2400 and 115200 bauds All devices in the same network must use the same Baud Rate The complete RS 485 port specifications are found in the D 500 700 User Manual Selecting a higher baud rate will allow faster communication but will reduce the communication distance Selecting a lower baud rate will increase the communication distance but will cause slower response times Typically 9600 bauds will allow 1200m distance with special balanced 120 ohms cable Parameters required for Modbus TCP IP through Ethernet port Modbus Slave Address may be set between 1 and 240 If only one unit is available in the same IP address it is advised to keep the default address 1 Ethernet Enable This parameter should be set to 1 or checked in order to enable the ethernet port Modbus TCP IP Port The usual setting is 502 However the unit is able to work on any port address User IP Mask There are 3 mask registers available The use of the registers are emphasized in the D 500 700 User Manual Please set the first mask as 255 255 255 0 for the proper operation Ethernet Network IP May be left as 0 0 0 0 for automatic address claim or set to a value in order to cla
101. eutral Gen voltage phase L3 to neutral Gen average voltage phase 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 average current 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 Gen pf phase L1 Gen pf phase L2 Gen pf phase L3 Gen total pf Neutral current Oil pressure bar amp psi Coolant temperature C amp F Fuel level Oil temperature C amp F Canopy temperature C amp F Engine speed rpm Battery voltage Engine hours 121 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 SOFTWARE FEATURES 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 digital output 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 u
102. from tab Account Name of the e mail recipient datakom d500 gmail com 9500 1234 This is the e mail password of above e mail account Password Mail Server Address smtp mail yahoo com This is the Outgoing Mail Server Address of the above e mail account ex smtp gmail com E mail Address 1 E mail Address 2 E mail Address 3 These are e mail recipient addresses where the unit is intended to send e mail messages Up to 3 e mails can be sent at once A Below ETHERNET related parameters are found in the Controller Configuration group Parameter Definition Unit Min Max i Web Programming _ 0 0 0 Web programming disabled Enable 1 Web programming enabled 0 Web control disabled VOD 0 i 1 Web control enabled The unit will refresh the web page with Web Refresh Rate sec 0 240 5 this interval The unit will check the availability of the Period m 0 220 internet connection with this interval The unit will update the distant eae B 95898 9 monitoring terminal with this rate This is the port number of the first Rainbow Address 1 Port 0 65535 0 monitoring terminal address This is the port number of the second Rainbow Address 2 Port 0 65535 0 monitoring terminal address This is the port number of the internal Web Server Port 0 65535
103. g control of the genset and monitoring of measured parameters are achieved The RainbowPlus software can be downloaded from www datakom com tr website The connector on the module is of USB B type Thus A to B type USB cable should be used This is the same cable used for USB printers For more details about programming control and monitoring please refer to RainbowPlus user manual A The battery voltage must be connected If USB Device is plugged then USB Host port will not function K35D01 EN 27 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 USB HOST PORT USB FLASH MEMORY USB HOS Port A The USB Host port is available in units with COMM option Description USB 2 0 not isolated Power Supply 5V 300mA max Output Data rate Full Speed 1 5 12 Mbits s auto detecting Connector USB A PC type connector Cable length Max 1 5m Functionality USB memory FAT32 data recording Memory capacity all USB flash memories The USB Host port is designed for detailed data recording The period of recording is adjustable through program parameter As soon as a USB flash memory is inserted the unit will start data recording and continue until the memory is removed For more details about data recording please review chapter Data Recording A If USB Device is plugged then USB Host port will not function K35D01 EN 28 TJ 509T User Manual Rev_01 PRELIM
104. gh limit it means that the mains are off and Limit F 100 F 100 F 10 starts the transfer to the genset in AUTO mode The value is defined with reference to Nominal Frequency If the mains frequency goes outside of Mains Frequency Fail 0 10 1 the limits during this timer it means that Timer the mains are off and starts the transfer to the genset in AUTO mode If one of the genset phase voltages goes Genset Low Voltage o under this limit when feeding the load Warning Limit VES generate a GENSET LOW VOLTAGE warning If one of the genset phase voltages goes Genset Low Voltage under this limit when feeding the load Shutdown Limit V 100 V 100 V 20 this will generate a GENSET LOW VOLTAGE shutdown alarm and the engine will stop If one of the genset phase voltages goes Genset High Voltage over this limit when feeding the load this Warning Limit M SR LL will generate a GENSET HIGH VOLTAGE warning If one of the genset phase voltages goes Genset High Voltage over this limit when feeding the load this Shutdown Limit V 100 V 100 V 20 will generate a GENSET HIGH VOLTAGE shutdown alarm and the engine will stop If at least one of the genset phase Genset Voltage Fail voltages goes outside of the limits Timer SRE 1o 1 during this timer a genset voltage fault g this gens ge fau will occur If the genset frequency goes under this Genset Low Fre
105. hase L2 L3 voltage 10262 R 32bit x10 Genset phase L3 L1 voltage 10264 R 32bit x10 Mains phase L1 current 10266 R 32bit x10 Mains phase L2 current 10268 R 32bit x10 Mains phase L3 current 10270 R 32bit x10 Genset phase L1 current 10272 R 32bit x10 Genset phase L2 current 10274 R 32bit x10 Genset phase L3 current 10276 R 32bit x10 Mains neutral current 10278 R 32bit x10 Genset neutral current 10292 R 32bit x10 Mains total active power 10294 R 32bit x10 Genset total active power 10308 R 32bit x10 Mains total reactive power 10310 R 32bit x10 Genset total reactive power 10324 R 32bit x10 Mains total apparent power 10326 R 32bit x10 Genset total apparent power 10334 R 16bit x10 Mains total power factor 10335 R 16bit x10 Genset total power factor 10338 R 16bit x100 Mains frequency 10339 R 16bit x100 Genset frequency 10341 R 16bit x100 Battery voltage 10361 R 16bit x10 Oil pressure in bars multiply by 14 50 to for psi 10362 R 16bit x10 Engine temp in C multiply by 1 8 then add 32 for F 10363 R 16bit x10 Fuel level in 96 10364 R 16bit x10 Oil temp in C multiply by 1 8 then add 32 for F 10365 R 16bit x10 Canopy temp in C multiply by 1 8 then add 32 for F 10366 R 16bit x10 Ambient temp in C multiply by 1 8 then add 32 for F 10376 R 16bit x1 Engine rpm K35D01 EN 132 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ADDRESS R W DATA COEFF
106. he 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 Disable Auto Start 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 DISABLE AUTO START and FORCE TO START operations K35D01 EN 123 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 Battery Charging Operation Delayed Simulate Mains 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 Disable Auto Start signal for the genset control unit The unit offers an optional Disable Auto Start signal input Any digital input may be assigned as Simulate
107. hen mains are unavailable Remote Start input is defined then this signal decides of mains availability When mains are evaluated as unavailable then an engine start sequence begins The unit waits during Engine Start Delay for skipping short mains failures If the mains is restored before the end of this timer the genset will not start e The unit turns on the fuel and preheat glow plugs if any and waits for preheat timer e The engine will be cranked for programmed times during crank timer When the engine fires the crank relay will be immediately deactivated See section Crank Cutting for more details e The engine will run at idle speed during Idle Speed Timer The engine will run unloaded during engine heating timer e If alternator phase voltages frequency and phase order are correct the unit will wait for the generator contactor period and the generator contactor will be energized When mains are evaluated as available again then an engine stop sequence begins e The engine will continue to run for the mains waiting period to allow mains voltages to stabilize e Then the generator contactor is deactivated and the mains contactor will be energized after mains contactor timer e lfacooldown period is given the generator will continue to run during the cooldown period e Before the end of cooldown the unit will reduce the engine speed to idle speed e At the end of cooldown the fuel solenoid will be d
108. ic DNS Account Setting Membership Address members dyndns org This string is used in Dynamic DNS feature This is the address used in registering to the dynamic DNS server For more detailed information please review chapter on Dynamic DNS Feature and the document Dynamic DNS Account Setting These strings are used in Dynamic DNS feature while registering to the dynamic DNS server Username Password For more detailed information please review chapter on Dynamic DNS Feature and the document Dynamic DNS Account Setting This internet address is regularly accessed in order to Pi check the availability of internet access ing Address www google com The access period is defined in parameter Controller Configuration Ping Period IP Confirmation Address checkip dyndns org This internet address is regularly accessed in order to read the IPv4 address of the unit Rainbow Address 1 Rainbow Address 2 These parameters accept both internet addresses like http datakom com tr and IPv4 addresses like 78 192 238 116 Information for remote monitoring is sent to these addresses The port information of these addresses are found in Controller Configuration group K35D01 EN 105 TJ 509T User Manual Rev_01 PRELIMINARY VERSION _ V 1 4 ETHERNET PARAMETERS continued Parameter Definition Factory Set Description This is the account name appearing in the
109. id of the gas engine if assigned by Relay Definitions will be opened after this delay during cranking Crank Cut Voltage V AC 65000 100 The crank relay output is deenergized when the genset phase L1 voltage reaches this limit Crank Cut Frequency Hz 100 10 The crank relay output is deenergized when the genset frequency reaches this limit Crank Cut RPM rpm 65000 500 The crank relay output is deenergized when the engine rpm reaches this limit Crank Cut Charge Voltage V DC 40 6 The crank relay output is deenergized when the charge alternator voltage reaches this limit Crank Cut with Oil Pressure 0 no crank cut with oil pressure 1 cranking is cut when oil pressure switch is open or the oil pressure measured is above shutdown limit Crank Cut with Oil Pressure Delay sec 30 2 If crank cutting with oil pressure is enabled cranking is cut after this delay when oil pressure switch is open or the oil pressure measured is above shutdown limit Charge Input Connected 0 Crank cutting with charge input disabled 1 Crank cutting with charge input enabled Fuel Tank Capacity Lt 65000 0 The full capacity of the fuel tank If this parameter is zero the fuel quantity in the tank is not displayed Fuel Consumption per Hour 100 0 0 This parameter is the threshold for sending FUEL THEFT and FUELLING sms messages If th
110. im a defined address Ethernet Gateway IP Should be set in accordance with your local switch configuration Ethernet Subnet Mask Should be set in accordance with your local switch configuration The complete Ethernet port specifications are found in the D 500 700 User Manual Please rewiev the document Ethernet Configuration Guide for D 500 700 for more details about the ethernet port setup Parameters required for Modbus TCP IP through GSM GPRS Modem Modbus Slave Address may be set between 1 and 240 If only one unit is available in the same IP address it is advised to keep the default address 1 Modem Selection Internal or external following your configuration Modem Baud Rate Selectable only for external modem 115200 bauds advised Selecting a lower baud rate will slow down communication between the controller and the modem GPRS Connection Enable This parameter should be set to 1 or checked Modbus TCP IP Port Set this value to 80 User IP Mask There are 3 mask registers available The use of the registers are emphasized in the D 500 700 User Manual Please set the first mask as 255 255 255 0 for the proper operation Data Formats 16bit variables These variables are stored in a single register Bit O denotes the LSB and bit 15 denotes the MSB 32 bit variables These variables are stored in 2 consecutive registers The high order 16 bits are in the first register and the low order 16 bits are in the second register B
111. increase the cable section proportionally Current Transformers must be used for current measurement No direct connection allowed The engine body must be grounded Otherwise faulty voltage and frequency measurements may occur For the correct operation of the exerciser and weekly schedule programs adjust the real time clock of the unit through programming menu K35D01 EN 15 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 TERMINAL DESCRIPTIONS BATTERY VOLTAGE INPUT Supply voltage 9 to 33VDC Cranking dropouts Survives OVDC during 100ms The voltage before surge should be 9VDC minimum Overvoltage protection Withstands 150VDC continuously Reverse voltage 33VDC continuous Maximum operating current 500mA 12VDC All options included digital outputs open 250mA 24VDC All options included digital outputs open Typical operating current 250mA 0 12VDC all options passive digital outputs open 125mA 24VDC all options passive digital outputs open Measurement range 0 to 36VDC Display resolution 0 1VDC Accuracy 0 5 1 digit 24VDC K35D01 EN 16 TJ 509T User Manual Rev_01 PRELIMINARY VERSION AC VOLTAGE INPUTS V 1 4 Measurement method True RMS Sampling rate 8000 Hz Harmonic analysis up to 31th harmonic Input voltage range 14 to 300 VAC Minimum voltage for fre
112. ingly 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 If connected the MPU unit and related analog senders are discarded The controller is able to read and display all below parameters under condition that the engine sends these information Most engines send only some of them If the engine does not send a parameter the unit will simply skip it Thus only available information are displayed The complete list of J1939 display parameters is below 1 Engine Brand ECU Type J1939 SW version 2 Engine Coolant Level 3 Engine Oil Level 4 Engine Coolant Pressure 5 Engine Fuel Delivery Pressure 6 Barometric Pressure 7 Engine Crankcase Pressure 8 Engine Turbocharger Boost Pressure 9 Engine Air Inlet Pressure 10 Engine Air Filter1 Differential Pressure 11 Engine Fuel Temperature 12 Ambient Air Temperature 13 Engine Air Inlet Temperature 14 Engine Intake Manifold1 Temperature 15 Engine Exhaust Gas Temperature 16 Engine Fuel Rate 17 Engine Instantaneous Fuel Economy 18 Engine Average Fuel Economy 19 Engine Total Fuel Used 20 Engine Total Hours 21 Engine Percent Load at Current Speed 22 Actual Engine Percentage Torque 23 Drivers Demand Engine Percentage Torque 24 Accelerator Pedal Position 2
113. ins exa e aree eu et er Eee vx cr ae esters Fuel P mp CODtro titt ierit eese mise K35D01 EN 8 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 Gas Engine Fuel Solenoid Control cccccessscccececessesssaecececseeesesueaeeeesceseeseaaeaeeeesceseeaeaeeeesessessesnaeaeeess MODBUS COMMUNICATIONS 2 12 Ret peer ERR Ten HERREN RR RE M RR EY eR X eL vaaxees DECLARATION OF CONFORMITY etra me Mene DRY ERE e ee Ert Een geo vendo widrn cme DISPOSAL OF THE UNIT 5 EUER TROUBLESHOOTING ccs einn seine ide pa a eaa K35D01 EN 9 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 INSTALLATION INSTRUCTIONS Before installation Read the user manual carefully determine the correct connection diagram e Remove all connectors and mounting brackets from the unit then pass the unit through the mounting opening Put mounting brackets and tighten Do tighten too much this can brakmicroe the enclosure Make electrical connections with plugs removed from sockets then place plugs to their sockets sure that adequate cooling is provided Be sure that the temperature of the environment will not exceed the maximum operating temperature in a
114. inst vertically falling water drops when enclosure is tilted up to 15 3 Protected against water sprayed at an angle up to 60 on either side of the vertical 4 Protected against water splashed against the component from any direction Protected against water projected in j 6 Protected against water projected in powerful jets from any direction 7 Protected against temporary immersion in water 8 Protected against continuous immersion in water or as specified by the user K35D01 EN 14 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ELECTRICAL INSTALLATION Do not install the unit close to high electromagnetic noise emitting devices like contactors high current busbars switchmode power supplies and the like disturbance can affect the operation measurement precision and data communication quality ALWAYS remove plug connectors when inserting wires with a screwdriver Fuses must be connected to the power supply and phase voltage inputs in close proximity of the unit Fuses must be of fast type FF with maximum rating of 6A Use cables of appropriate temperature range Use adequate cable section at least 0 75mm AWG18 Follow national rules for electrical installation Current transformers must have 5A output For current transformer inputs use at least 1 5mm section AWG15 cable e The current transformer cable length should not exceed 1 5 meters If longer cable is used
115. is is the connection topology of mains voltages and CTs Detailed explanations are given in the chapter TOPOLOGIES 2 phase 3 wire L1 L2 2 phase 3 wire L1 L3 3 phase 3 wire 3 phase 3 wire 2CTs L1 L2 3 phase 3 wire 2CTs L1 L3 3 phase 4 wire star 3 phase 4 wire delta single phase 2 wire Mains Connection Topology NOohoND O This is the connection topology of genset voltages and CTs Detailed explanations are given in the chapter TOPOLOGIES 2 phase 3 wire L1 L2 2 phase 3 wire L1 L3 3 phase 3 wire Genset Connection 2 3 3 phase 3 wire 2CTs L1 L2 4 5 6 Topology 3 phase 3 wire 2CTs L1 L3 3 phase 4 wire star 3 phase 4 wire delta 7 single phase 2 wire This is the period after the generator contactor has been deactivated and before the mains contactor has been activated Mains Contactor Timer sec 0 600 0 5 K35D01 EN 86 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ELECTRICAL PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Set Description Mains MCB Close Pulse sec 10 0 5 After the mains MCB_undervoltage coil is energized and mains MCB_undervoltage coil timer is elapsed the mains MCB close relay will be activated during this period Review chapter Motorized Circuit Breaker Control for more details Mains MCB Open Pulse sec 10
116. is 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 K35D01 EN 90 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ENGINE PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Set Description Coolant Cooler On C 250 90 If the coolant temp is above this limit then the cooler relay function will become active Coolant Cooler Off C 250 80 If the coolant temp is below this limit then the cooler relay function will become inactive Coolant Heater On C 250 50 If the coolant temp is below this limit then the heater relay function will become active Coolant Heater Off C 250 60 If the coolant temp is above this limit then the heater relay function will become inactive Fan Overrun Timer sec 240 The cooler relay will stay active during this timer after the coolant temp is below Coolant Cooler Off limit Canopy Fan Turn On C 250 90 If the canopy temp is above this limit then the canopy fan relay function will become active Canopy Fan Turn Off C 250 80 If the canopy temp is below this limit then the canopy fan relay function will become inactive Ambient Fan Turn On C 250 90 If the ambient temp is above this limit
117. it arrays Arrays larger than 16 bits are stored in multiple registers The LSB of the first register is bit 0 The MSB of the first register is bit 15 The LSB of the second register is bit 16 The MSB of the second register is bit 31 and so on K35D01 EN 131 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 Below is a shortlist of available Modbus registers For complete register map please refer to D 500 700 Modbus Application Manual ADDRESS R W DATA COEFF DESCRIPTION decimal SIZE 8193 W 16bit x10 Pushbutton simulation BIT 0 Simulate Stop button BIT 1 Simulate Manual button BIT 2 Simulate Auto button BIT 3 Simulate Test button BIT 4 Simulate Run button BIT 5 Simulate GCB button 7 Simulate Menu button BIT 8 Simulate Menu button BIT 9 Simulate Up button BIT10 Simulate Down button BIT14 Button Long pressed BIT15 Button Very Long Pressed 10240 R 32bit x10 Mains phase L1 voltage 10242 R 32bit x10 Mains phase L2 voltage 10244 R 32bit x10 Mains phase L3voltage 10246 R 32bit x10 Genset phase L1 voltage 10248 R 32bit x10 Genset phase L2 voltage 10250 R 32bit x10 Genset phase L3 voltage 10252 R 32bit x10 Mains phase L1 L2 voltage 10254 R 32bit x10 Mains phase L2 L3 voltage 10256 R 32bit x10 Mains phase L3 L1voltage 10258 R 32bit x10 Genset phase 1 L2 voltage 10260 R 32bit x10 Genset p
118. ive or battery positive programmable Structure 47 k ohms resistor to battery positive 110k ohms to battery negative Measurement Analog voltage measurement Open circuit voltage 7096 of battery voltage Low level threshold 35 of battery voltage High level threshold 85 of battery voltage Maximum input voltage 100VDC with respect to battery negative Minimum input voltage 70VDC with respect to battery negative Noise filtering yes ANALOG SENDER INPUTS AND SENDER GROUND Number of inputs 4 inputs all configurable additional sender ground input Function selection from list Structure 667 ohms resistor polarizing to 3 3VDC Measurement Analog resistor measurement Open circuit voltage 3 3VDC Short circuit current 5mA Measurement range 0 to 5000 ohms Open circuit threshold 5000 ohms Resolution 1 ohms 300 ohms or lower Accuracy 2 1 ohm 7 ohms 0300 ohms Common mode voltage 3VDC range Noise filtering yes K35D01 EN 21 PRELIMINARY VERSION V 1 4 TJ 509T User Manual Rev_01 CHARGE INPUT TERMINAL The Charge terminal is both an input and output When the engine is ready to run this terminal supplies the excitation current to the charge alternator The excitation circuit is equivalent to a 2W lamp The threshold voltages for warning and shutdown alarm are adjustable through program parameter
119. l the coolant temperature reaches the Engine Heating Temperature and at least during the Engine Heating Timer Cooldown Timer sec 600 120 This is the period that the generator runs for cooling purpose after the load is transferred to mains Stop Solenoid Timer sec 90 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 Number of Starts Number of Starts Choke Timer sec 240 5 This is the control delay of CHOKE output The choke output is activated together with the crank output It is released after this delay or when engine runs whichever occurs first K35D01 EN 89 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ENGINE PARAMETERS GROUP continued Parameter Definition Unit Min Factory Set Description Idle Speed Timer sec 240 0 When the engine runs the Idle output relay function will be active during this timer While the IDLE output is active low voltage low frequency and low rpm checks are disabled Idle Holdoff Timer sec 30 10 While the IDLE periode is over low voltage low frequency and low speed checks are enabled after the expiration of this timer Gas Solenoid Delay sec 240 5 The gas soleno
120. lant Level Switch 44 Reset Service 2 Alm 84 reserved for future use 5 Rectifier Fail Switch 45 Reset Service 3 Alm 85 reserved for future use 6 Emergency Stop 46 reserved for future use 86 reserved for future use 7 Alternator High Temp 47 reserved for future use 87 reserved for future use 8 Excitation Loss Sw 48 reserved for future use 88 reserved for future use 9 Low Fuel Switch 49 reserved for future use 89 reserved for future use 10 Earthquake Detector 50 reserved for future use 90 reserved for future use 11 Gen Cont Auxiliary 51 reserved for future use 91 reserved for future use 12 Mains Cont Auxiliary 52 reserved for future use 92 reserved for future use 13 Force AUTO Mode 53 reserved for future use 93 reserved for future use 14 Force OFF Mode 54 reserved for future use 94 reserved for future use 15 Force TEST Mode 55 reserved for future use 95 reserved for future use 16 Over Load Switch 56 reserved for future use 96 reserved for future use 17 Manual Fuel Fill 57 reserved for future use 97 reserved for future use 18 Priority 58 reserved for future use 98 reserved for future use 19 Remote Start 59 reserved for future use 99 reserved for future use 20 Disable Auto Start 60 reserved for future use 100 reserved for future use 21 Force to Start 61 reserved for future use 22 Fault Reset 62 reserved for future use 23 Alarm Mute 63 reserved for futu
121. lated form enabling application of formulas graphs and other features of Excel program K35D01 EN 120 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 RECORDED DATA LIST RECORD PERIOD The recording period is adjustable between 2 seconds and 18 hours by program parameter A short period will give better resolution but it will generate more data in the memory card One data record is typically 250 bytes long thus with a minimum period of 2 seconds the unit will store 10 8 MB of data per day 250x30x60x24 A typical memory of 4GB will store data during 370 days more than 1 year With a recording period of 1 minute 4GB memory card will store data during 30 years Below parameters are recorded Date and time of recording Operating mode Mains voltage phase 11 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 Mains current phase L1 Mains current phase L2 Mains current phase L3 Mains average current Mains frequency Mains kW phase L1 Mains kW phase L2 Mains kW phase L3 Mains total kW Mains kVA phase L1 Mains kVA phase L2 Mains kVA phase L3 Mains kVAr phase L1 Mains kVAr phase L2 Mains kVAr phase L3 Mains pf phase L1 Mains pf phase L2 Mains pf phase L3 Mains total pf Mains neutral current K35D01 EN Gen voltage phase L1 to neutral Gen voltage phase L2 to n
122. ment These are often good practices for the installation of genset control units which reduce future issues For all technical queries please contact Datakom at below e mail address datakom datakom com tr RELATED DOCUMENTS FILENAME DESCRIPTION 509T Rainbow Installation Rainbow Plus 509T Installation Guide 509TRainbow Usage Rainbow Plus 509T Usage Guide RainbowPlus_USER RainbowPlus User Manual 509TDYNdns account setting pdf Dynamic DNS Account Setting for 509T 509TEthernet Configuration Ethernet Configuration Guide for 509T 509TGSM Configuration GSM Configuration Guide for 509T 509TFirmware Update Firmware Update Guide for 509T 509T MODBUS Modbus Application Manual for 509T REVISION HISTORY REVISION DATE AUTHOR DESCRIPTION 01 29 09 2011 MH First issue firmware version 1 06 TERMINOLOGY A CAUTION Potential risk of injury or death A WARNING Potential risk of malfunction or material damage A ATTENTION Useful hints for the understanding of device operation K35D01 EN 2 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ORDERING CODES The 509T family units are available in various options and peripheral features Please use below information for ordering the correct version 509 G T 00 Variant 00 standard unit 01 99 customer specific products Family Code With Conformal Coating With Sealing
123. mer Phase 40 shift in a CT will cause erroneous power and power factor readings although amp 35 readings are correct Datakom advises CT rating to be selected following this table for the best measurement accuracy 1mm 1 5mm 2 5mm 50 LL EU LLLA LL a N EE tt ARG RRR 15 20 25 30 35 40 45 50 CABLE LENGHT TO CT m 2x CT RATING VA SELECTING THE ACCURACY CLASS The CT accuracy class should be selected in accordance with the required measurement precision The accuracy class of the Datakom controller is 0 5 Thus 0 5 class CTs are advised for the best result K35D01 EN 18 TJ 509T User Manual Rev_01 CONNECTING CTs PRELIMINARY VERSION V 1 4 Be sure of connecting each CT to the related phase input with the correct polarity Mixing CTs between phases will cause faulty power and pf readings Many combinations of incorrect CTs connections are possible so check both order of CTs and their polarity Reactive power measurement is affected by incorrect CTs connection in similar way as active power measurement CORRECT CT CONNECTIONS MAINS or ALTERNATOR CONTROLLER Let s suppose that the genset is loaded with 100 kW on each phase The load Power Factor PF is 1 Measured values are as follows kW kVAr kVA pf Phase L1 100 0 0 0 100 1 00 Phase L2 100 0 0 0 100 1 00 Phas
124. n exists SERVICE REQUEST Turns on when at least one of the service counters has expired MODE LEDS Each led turns on when the related mode is selected either locally or remotely MIMIC DIAGRAM LEDS MAINS AVAILABLE This led turns on when all mains phase voltages and the mains frequency are within limits If enabled the mains phase rotation order must be also right When any digital input is defined as Remote Start this led will reflect the status of the input When a Simulate Mains signal is present then mains status will become available When a Force to Start signal is present then the mains status will become not available MAINS CONTACTOR ON Turns on when the mains contactor is activated GENSET CONTACTOR ON Turns on when the genset contactor is activated GENSET AVAILABLE This led turns on when all genset phase voltages and the genset frequency are within limits If enabled the genset phase rotation order must be also right If a Remote Start input is defined then the Mains led will reflect the input status Simulate Mains and Force to Start signals will also affect this led K35D01 EN 57 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 WAVEFORM DISPLAY amp HARMONIC ANALYSIS The unit features waveform display together with a precision harmonic analyzer for both mains and genset voltages and currents Both phase to neutral and phase to phase voltages are available for analysis thus 18 channels in t
125. na toe Rt eadzensutadaneetecedcnsatacaeesteaeseqsatadaaeetsdetensaracdeeebaaevens QUICK START GUIDE c STOP MODE ELE AUTO MODE H RUN MODE MANUAL CONTROL terreni ether eee ne sio ae pu er TEST MODE EE PROTECTIONS AND DISABLING ALL PROTECT Q ra SERVICE REQUEST ALARM SHUTDOWN ALARMS RRm LOADDUMP ALARMS EE WARNINGS T ER RESETTING FACTORY DEFAULTS acre ee huh tah eai ENTERING THE PROGRAMMING nen enne en enn nnne en nennen ene NAVIGATING BETWEEN MENJS rrr treten teh pa eno p ane eh pen gerer Re MODIFYING PARAMETER ortu nno ennt nn teneant n nean reina PROGRAMMING 2 pa eene PROGRAM PARAMETER LIST rn ke Pens CONTROLLER CONFIGURATION ELECTRI
126. ndition is only controlled when fuel is on VOLTAGE UNBALANCE Set if any of the generator phase voltages differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running CURRENT UNBALANCE Set if any of the generator phase currents differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running The action taken at fault condition is programmable OVERCURRENT Set if at least one of the genset phase currents goes over the Overcurrent Limit for the period allowed by the IDMT curve setting The allowed timer is dependent of the overcurrent level If currents go below the limit before expiration of the timer then no alarm will be set Please check chapter Overcurrent Protection IDMT for more details The action taken at fault condition is programmable PICKUP SIGNAL LOST Set if the rom measured from the magnetic pickup input falls below the Crank Cut RPM level during Loss of Speed Signal Timer The action of signal loss is programmable SERVICE REQUEST K35D01 EN Set if at least one of the service counters has expired In order to reset the service counters please hold pressed both with and buttons during 5 seconds The screen will display Completed 69 TJ 509T User Manual Rev_
127. ne controller REMOTE START FUNCTIONALITY When the Remote Start functionality is selected the unit will wait for a Remote Start signal from external controller Upon reception of this signal it will run the engine and provide engine and alternator instrumentation and fault monitoring The genset contactor MCB control functionality will be available The unit features both MPU and J1939 CANBUS inputs Thus both mechanical and electronic engines are supported K35D01 EN 38 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ENGINE CONTROLLER FUNCTIONALITY When the Engine Controller functionality is selected genset electrical measurements and protections will be disabled The unit is supposed to control an engine without alternator 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 Note that the engine controller functionality is compatible with both AMF and Remote Start modes When AMF and Engine controller modes are selected the unit will monitor the mains and will run the engine upon mains failure This functionality is useful for the backup electric motor driven systems during mains failures like fire pump or irrigation systems When Remote Start and Engine controller modes are selected the unit will start and stop the engine with external signal only
128. nication 3 Phase 3 Wire 3 Phase 3 Wire L1 L2 CT 3 Phase 3 Wire L1 L3 CT 3 Phase 4 Wire Star 3 Phase 4 Wire Delta Single Phase 2 Wire Topology Selection L2 Rainbow Plus Beta Version 1 0 0 2 Fie Tools Help Configuration Topology Timers Voltage Frequency Module Generator Connection Type T i Phase Order Check Engine Mains dde id Parameters 3 Phase 4 Wire Star v Da ua le Communication 3Ph 3 Wire 3 Phase 3 Wire L1 L2 CT 3 Phase 3 Wire L1 L3 CT 3 Phase 4 Wire Star 3 Phase 4 Wire Delta Single Phase 2 Wire Topology Selection K35D01 EN 33 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 3 PHASE 4 WIRE STAR ALTERNATOR L1 TO LOAD 3P 4W STAR 3 PHASE 3 WIRE DELTA ALTERNATOR L1 K35D01 EN 34 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 3 PHASE 4 WIRE DELTA ALTERNATOR L1 3 PHASE 3 WIRE DELTA 2 CT L1 L2 ALTERNATOR L1 2 z z K35D01 EN 35 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 3 PHASE 3 WIRE DELTA 2 CT L1 L3 ALTERNATOR L1 2 PHASE 3 WIRE DELTA 2 CTs L1 L2 ALTERNATOR 11 K35D01 EN 36 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 2 PHASE 3 WIRE DELTA 2 CTs L1 L3 ALTERNATOR L1 1 PHAS
129. nly Battery Negative must be grounded 44 K35D01 EN V 1 4 PRELIMINARY VERSION TJ 509T User Manual Rev 01 ENGINE CONTROL FUNCTIONALITY INYO HNVO V S8V 98 8 9 QNS 9 QNS S QNS dWAL 10 7 QNS A3171303 ANS W3QN3S QNS SS33d 110 QNS 71V31033F8 NI MOT Z NI MS diW3 L IH 9 NI MS 311009F7S NI V38VdS t NI 3901 W9d NI 23H VdS c NI 4018 H3W3 L NI 9 LNO 4110 4018 LNO LNO Tand v LNO LNO 1V8 Jepueg dwol bx Jepues apo 440 92104 1ndu eueds jndu ejeds ejeds piss WoT Ng LS CN Jopueg sseJg Starter Motor 4 Connect to the engine body close to the senders 2 Ground from one end only Battery Negative must be grounded 45 K35D01 EN V 1 4 PRELIMINARY VERSION TJ 509T User Manual Rev 01 REMOTE DISPLAY PANEL FUNCTIONALITY INYO HNVO V S8v 9 88 QN9 S8t 9 QNS 9 QNS S QNS diN3 L 110 7 QNS 1 ANS QNS 110 1 ANS lt 1 8 NI NI MS dW3 L IH 9 MS 31710059 8 NI V38VdS t NI 3201 WOd NI 233VdS NI 4018 H3lIA3 L NI 9 LNO 4 1 0 4018 LNO 1
130. nput 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 complete application manual K35D01 EN 125 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 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 useful 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 Secondary 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 om Volt Freq Select using INPUT FUNCTION SELECT program group Below parameters are available for second voltage frequency selection Nominal Voltage Nominal Frequency Nominal RPM Genset Overcurrent Limit Single Phase Operation If the unit is used in a single
131. ny case Below conditions may damage the device Incorrect connections e Incorrect power supply voltage Voltage at measuring terminals beyond specified range e Voltage applied to digital inputs over specified range Current at measuring terminals beyond specified range Overload or short circuit at relay outputs e Connecting or removing data terminals when the unit is powered up High voltage applied to communication ports Ground potential differences at non isolated communication ports Excessive vibration direct installation on vibrating parts Current Transformers must be used for current measurement No direct connection allowed Below conditions may cause abnormal operation Power supply voltage below minimum acceptable level Power supply frequency out of specified limits e Phase order of voltage inputs not correct Current transformers not matching related phases Current transformer polarity incorrect Missing grounding K35D01 EN 10 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 Dimensions 200x148x47mm 7 9 x5 8 x1 9 Panel Cutout 176x121mm minimum 7 0 x4 8 Weight 450g 1 Ib TEKSAN TJ 509 7 148mm 200mm ae HEHBBBIHHHH H5 K35D01 EN 11 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 The unit is designed for panel mounting The user should not be able to access parts of the unit other than the front pan
132. o tight Check the parameters Mains Voltage Low Limit and Mains Voltage High Limit Standard values are 170 270 volts 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 2 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 Please review chapter AC CURRENT INPUTS A Short circuit 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 Oil pressure switch not connected Oil pressure switch connection wire
133. oltage goes mi Voltage Fail sec 0 120 1 under limits during this timer a charge imer alternator voltage fault will occur K35D01 EN 88 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ENGINE PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Set Description Engine Heating Temperature C 80 0 If it is requested that the engine runs without load until reaching a certain temperature this parameter defines the temperature Engine Start Delay sec 240 1 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 30 0 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 Crank Timer sec 15 6 This is the maximum start period Starting will be automatically cancelled if the genset fires before the timer Wait Between Starts sec 240 10 This is the waiting period between two start attempts Engine Heating Timer sec 240 4 This is the period used for engine heating before load transfer 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 unti
134. orn Space heater Lighting inside control panel Lighting outside control panel 0000440 lt 0 04 0 Analogue measurement gauges 4 Standard O Optional x Not applicable NA 3 www teksangenerator com 18 01 2012 TEKSAN GENERATOR Generator set low high speed High coolant temperature Low coolant temperature Low oil pressure High oil temperature Mains phase order fail Battery charger rectifier failure Charge alternator or broken belt failure Low battery voltage High battery voltage Low fuel level Stop fail Reverse power SO 0 04440 lt 4 4 4 lt 4 lt 0 OAK KO AAA AKAM Service request Generator set low high speed High coolant temperature Low oil pressure High oil temperature High battery voltage Low fuel level Start fail Overload Excess power Genset low high voltage Low coolant level above 275 kVA Reverse power OS 4 44 lt lt OS 4 44 lt lt V Standard O Optional X Not applicable NA www teksangenerator com 18 01 2012 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 DATAKOM TJ 509 T GENSET CONTROLLER TP TEKSAN TJ 509 1 DESCRIPTION COMMUNICATIONS The 509T is a next generation genset control unit Ethernet combining multi functionality and wide GSM GPRS optional communication possibilities together with a reliable Embe
135. ose both Max Volt Difference VAC 0 20 5 contactors If voltage transformer is used this quantity is multiplied with voltage transformer ratio This is the maximum phase angle Phase Difference deg 0 20 10 between the mains phase L1 and the genset phase L1 voltages to close both contactors K35D01 EN 107 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 CRANK CUTTING In order to insure fast and reliable crank cutting the unit uses various resources for engine running condition detection Cranking is stopped when at least one of below conditions is met Crank timer expired The crank timer is adjusted through Engine Parameters gt Crank Timer The maximum allowed timer is 15 seconds Genset AC voltage over threshold If the genset phase L1 AC voltage reaches Engine Parameters gt Crank Cut Voltage then cranking is immediately stopped Genset frequency over threshold If the genset phase L1 frequency reaches Engine Parameters gt Crank Cut Frequency then cranking is immediately stopped Genset rpm over threshold If the genset rpm reaches Engine Parameters gt Crank Cut RPM then cranking is immediately stopped Charge alternator voltage over threshold Following setting is necessary Engine Parameters gt Charge Input Connected 1 If the charge alternator voltage reaches Engine Parameters gt Crank Cut Charge Voltage then cranking is immediately sto
136. otal are possible A In order to enable display and analysis of mains currents current transformers must be placed at load side Available channels are Mains volts V1 V2 V3 U12 U23 U31 Mains currents 11 12 I3 Genset volts V1 V2 V3 U12 U23 U31 Genset currents 11 12 I3 MATHS Wi SCOPEMETER Scopemeter Display The waveform display memory is of 100 samples length and 13 bit resolution with a sampling rate of 4096 s s Thus one cycle of a a 50Hz signal is represented with 82 points The vertical scale is automatically adjusted in order to avoid clipping of the signal The waveform is displayed on the device screen and with more resolution on PC screen through the RainbowPlus program The display memory is also available in the Modbus register area for third party applications For more details please check chapter MODBUS Communications The waveform display is updated twice a second All channels may be scrolled using e buttons K35D01 EN 58 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 The harmonic analyzer consists on a Fast Fourier Transform FFT algorithm which is run twice a second on the selected channel The sample memory is 1024 samples length and 13 bits resolution with a sampling rate of 4096 s s The theory says that a periodic signal may have only odd multiples of the main frequency Thus in a 50Hz network harmonics will be found only at 150 250 350 450 Hz etc The
137. output to operate 2 LOAD DUMPS These fault conditions come from electrical trips and cause ALARM led to turn on steadily The genset contactor to be released immediately The engine to be stopped after Cooldown period The Alarm digital output to operate 3 WARNINGS These conditions cause The WARNING led to turn on steadily The Alarm digital output to operate If a fault condition occurs the display will automatically switch to the ALARM LIST page Alarms operate in a first occurring basis If a shutdown alarm is present following shutdown alarms loaddumps and warnings will not be accepted If a loaddump is present following loaddumps and warnings will not be accepted If a warning is present following warnings will not be accepted If the ALARM MUTE button is pressed the Alarm output will be deactivated however the existing alarms will persist and disable the operation of the For latching alarms even if the alarm condition is removed the alarms will stay on and disable the operation of the genset Existing alarms may be canceled by pressing one of the operating mode buttons 006 Most of the alarms have programmable trip levels See the programming chapter for adjustable alarm limits K35D01 EN 67 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 DISABLING ALL PROTECTIONS The unit allows any digital input to be configured as Disable Protections This input
138. perature 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 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 digital output may be assigned as IDLE output using Relay Definition program parameters The Idle speed operation is performed both in engine start up and cool down sequences Low speed and low voltage protections are disabled during idle speed operation Engine Block Heater The unit is able to provide a digital output in order to drive the block heater resistor The temperature reference is the coolant temperature measured from the analog sender input The block heater output function may be assigned to any digital output using Relay Definition program parameters 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 exce
139. pped Oil pressure above threshold Following setting is necessary Engine Parameters gt Crank Cut with Oil Pressure 1 The crank cutting with oil pressure offers a programmable delay through Engine Parameters gt Crank Cut with Oil Pressure Delay The parameter is factory set to 2 seconds Both low oil pressure switch and oil pressure sender readings may be used for crank cutting The oil pressure switch is always used The sender may be disabled through Controller Configuration gt Oil Pressure Switch Priority parameter If enabled when oil pressure is detected cranking is stopped after adjustable timer delay K35D01 EN 108 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 OVERCURRENT PROTECTION IDMT The unit offers a programmable IDMT protection function in order to protect the alternator against excessive currents The IDMT Inverse Definite Minimum Time protection function has such tripping characteristics that the tripping time varies inversely with the value of current Beyond a certain current limit the tripping time becomes constant definite and causes tripping in minimum time The tripping formula is defined as below TMS 2 T 7 TMS is the IDMT time multiplier setting This is also the tripping time at 100 overload lis the current of the most loaded phase is the programmed overcurrent limit tis the tripping time in seconds Currents below the overcurrent limit are allowe
140. quency o limit when feeding the load this will Warning Limit generate GENSET LOW FREQUENCY warning If the genset frequency goes under this Genset Low Frequency limit when feeding the load this will Shutdown Limit F 100 F 100 F 20 generate a GENSET LOW FREQUENCY shutdown alarm and the engine will stop K35D01 EN 83 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 ELECTRICAL PARAMETERS GROUP continued Parameter Definition Unit Min Factory Description Set If the genset frequency goes over this Genset High Frequency limit when feeding the load this will Warning Limit generate GENSET HIGH FREQUENCY warning If the genset frequency goes over this Genset High Frequency limit when feeding the load this will Shutdown Limit F 100 F 100 F 20 generate a GENSET HIGH FREQUENCY shutdown alarm and the engine will stop If the genset frequency goes outside of ibis fequens Fall sec 0 10 1 the limits during this timer a genset frequency fault will occur Low Battery Voltage If the battery voltage falls below this Warning Limit V DC 50 35 0 12 0 limit this will generate a LOW BATTERY warning If the battery voltage falls below this Low Battery Voltage limit this will generate a LOW Shutdown Limit 990 0 BATTERY shutdown alarm and the engine will stop f the battery voltage goes over this limit
141. quency detection 15 VAC Ph N Supported topologies 3 ph 4 wires star 3 ph 3 wires delta 3ph 4 wires delta 2ph 3 wires L1 L2 2ph 3 wires L1 L3 1 ph 2 wires Measurement range 0 to 330VAC ph N 0 to 570VAC ph ph Common mode offset max 100V between neutral and BAT Input impedance 4 5M ohms Display resolution 1VDC Accuracy 0 5 1 digit 230VAC ph N 2VAC ph N 0 5 1 digit 400VAC ph ph 3VAC ph ph Frequency range DC to 500Hz Frequency display resolution 0 1 Hz Frequency accuracy 0 2 1 digit 0 1 Hz 50Hz K35D01 EN 17 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 AC CURRENT INPUTS Measurement method True RMS Sampling rate 8000 Hz Harmonic analysis up to 31th harmonic Supported topologies 3 ph 3 CTs 3 ph 2 CTs L1 L2 3 ph 2 CTs L1 L3 2 ph 2 CTs L1 L2 2 ph 2 CTs L1 L3 1 ph 1 CT CT secondary rating 5A Measurement range 5 5 to 5000 5A minimum Input impedance 15 mili ohms Burden 0 375W Maximum continuous 6A current Measurement range 0 1 to 7 5A Common mode offset Max 5VAC between BAT and any CT terminal Display resolution 1A Accuracy 0 5 1 digit 4 5A 5 500A full range SELECTING THE CT RATING AND CABLE SECTION The load on a CT should be kept minimum in order to minimize phase shift effect of the current transfor
142. r set has both programmable engine hours and maintenance time limit 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 this service counter set is not operative When the engine hours OR the time limit is over the SERVICE REQUEST led red will start to flash and the service request output function will be active The service request can also create a fault condition of any level following parameter setting The service request output function may be assigned to any digital output 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 keys f 5 seconds not affected from power supply failures The time and engine hours to service are displayed in the GENSET STATUS menu group K35D01 EN 68 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 SHUTDOWN ALARMS Digital input and analog sender alarms are fully programmable for the alarm name sampling and action Onlv internal alarms are explained in this section GENSET LOW HIGH Set if the generator frequency is outside programmed limits These
143. re use 24 Panel Lock 64 reserved for future use 25 Fuel Pump Switch 65 reserved for future use 26 Secondary Volt amp Freq 66 reserved for future use 27 Disable Protections 67 reserved for future use 28 Auto Restore Inhibit 68 reserved for future use 29 GensetLoadinglnhibit 69 reserved for future use 30 Air Flap Fault 70 reserved for future use 31 Canopy Door Open 71 reserved for future use 32 Station Door Open 72 reserved for future use 33 Station Over Heat Sw 73 reserved for future use 34 Weather Cloudy 74 reserved for future use 35 Weather Rainy 75 reserved for future use 36 Lightning 76 reserved for future use 37 Cooler Fan Fault 77 reserved for future use 38 Heater Fan Fault 78 reserved for future use 39 Canopy Fan Fault 79 reserved for future use 40 Station Fan Fault 80 reserved for future use K35D01 EN 100 TJ 509T User Manual Rev_01 OUTPUT CONFIGURATION PRELIMINARY VERSION V 1 4 The parameters below define the functions of relay outputs The unit has 8 relay outputs All relays have programmable functions selected from a list Relays may be extended up to 40 using Relay Extension Modules Other relays are in the optional Extension Modules Parameter Definition Factory
144. rs related to the exerciser are Exercise start day and hour Exercise duration Exercise off_load on_load Please refer to the programming section for a more detailed description of the above parameters When the start day and hour of exercise has come the unit will automatically switch to either RUN or TEST mode The engine will run 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 immediately terminated Using the weekly exercise mode and with suitable parameter setting the unit may feed the load from the genset during predefined hours of each day This operation may be used in high tariff periods of the day WEEKLY OPERATION SCHEDULER 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 scheduler is active only in AUTO mode When the scheduler prevents genset operation in AUTO mode the AUTO led will flash
145. sed for both purposes It is also possible to control more complex external systems with multiple steps using LOAD_ADD and LOAD_SUBSTRACT output functions Any digital output may be assigned to these signals When the load is below the Load Shedding Low Limit the controller will activate the Load Add output The external system will increase the load until it goes over the low limit where the Load Add output will become inactive When the load is above the Load Shedding High Limit the controller will activate the Load Substract output The external system will decrease the load until it goes below the high limit where the Load Substract output will become inactive There are protection delays between two pulses The parameters used in Load Shedding feature are in the Electrical Parameters Group Factory Parameter Definition Unit Min Max Set Description If the genset power goes below this Load Shedding Low Limit kW 0 5097100 0 limit then the load shedding relay will be deactivated If the genset power goes above this Shedding Migh kw o 509T00 o limit then the load shedding relay will be activated This is the minimum delay between 2 load_add pulses Eon nad Peay sec ene 9 This is also the minimum delay between 2 load substract pulses Load Subtract Add Delay min 0 120 0 This is the minimum delay beween load_add and load_substract pulses K35D01 EN 122
146. sor 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 X High inlet air temperature High inlet manifold air temperature Inlet manifold air temperature sensor fail 174 X High fuel temperature Fuel temperature sensor fail 175 X High oil temperature Oil temperature sensor fail 190 X Overspeed Speed sensor loss of signal Speed sensor mechanical failure 228 X Timing calibration required 234 X Incorrect ecm software 620 X ECU internal 5V fail 629 X ECU hardware fail 651 X Injector cylinder 1 fault 652 X 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 X ECU internal power supply fail 723 X Secondary engine speed sensor fail 1108 X Critical override enabled 1111 X Check configuration parameters 2000 X ECU failure K35D01 EN 4414 V 1 4 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 Below is a basic list of FMI codes Please be aware that these codes may differ slightly depending on the engine brand and model DESCRIPTION 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
147. t frequency within the programmed limits Mains phase order correct or phase order check must be disabled Genset phase order correct or phase order check must be disabled The difference between mains and genset frequencies not more than programmed limit The voltage difference mains L1 and genset L1 not more than programmed limit The phase angle between mains L1 and genset L1 not more than programmed limit When an uninterrupted transfer cycle is started the unit will wait until the expiration of the Synchronization Fail Timer to find a matching frequency phase and voltage Usually with frequencies matching at 2Hz and voltages matching at 10 volts an Uninterrupted Transfer is expected to successful If matching is found before the expiration of the Synchronization Fail Timer then both contactors will be activated If contactor auxiliary contacts are used the other contactor will release immediately If contactor auxiliary contacts are not used the other contactor will release after contactor timeout The unit offers below parameters for the setup of the Uninterrupted transfer feature Parameter Definition Description No Break Transfer 0 only interrupted transfer enabled Enable 1 no break transfer enabled If the phase and voltage synchronization is not successful before the ey nehrenization Fal expiration of this timer then a Synchronization Fail warning is given and the SIGUE transfer will be
148. tons www teksangenerator com 18 01 2012 TEKSAN GENERATOR Manual operation 4 4 Automatic operation 4 Control module type TJ519 TJ509 Emergency stop button 4 4 Phase Neutral generator set voltage measurement V 4 4 Phase Phase generator set voltage measurement V 4 4 3 phase generator set current measurement A 4 4 Generator set frequency measurement Hz 4 4 Phase Neutral mains voltage measurement V x 4 Phase Phase mains voltage measurement V x 4 Mains frequency measurement Hz x 4 Battery DC voltage measurement VDC V 4 3 phase generator set active power measurement kW 4 4 Generator set total active power measurement kW 4 4 3 phase generator set power factor measurement 4 4 Generator set total power factor measurement Vv Engine oil pressure measurement bar 4 4 Engine oil temperature measurement C Engine coolant temperature measurement C 4 4 Engine speed measurement rpm 4 4 Fuel level measurement 96 12 24 VDC operation V 4 Earth leakage protection Battery charger rectifier 4 Automatic exerciser operation daily weekly monthly Load shedding Dummy load Event logging with date time stamp number 200 200 Event logging with date time stamp and complete measurements number 18 18 Statistical counters engine hours run generator set total active power kWh engine hours to
149. tween predefined sender functions If this parameter is set to 13 14 15 then the sender name string can be freely entered 0 shutdown alarm 1 loaddump alarm 0 always 1 2 Sender Type 0 15 Alarm Level 0 1 on engine running after hold off timer reserved If sender resistor is above 5000 ohms a fault case is generated This parameter defines the action taken upon fault case 0 no alarm 1 shutdown alarm 2 loaddump alarm 3 warning The low alarm may be selected as shutdown or loaddump with alarm Low Alarm Check Enable 0 0 1 level parameter 0 low value alarm disabled 1 low value alarm enabled Low Warning Check 0 low value warning disabled Enable 1 low value warning enabled The high alarm may be selected as shutdown or loaddump with alarm 0 0 1 level parameter 0 high value alarm disabled 1 high value alarm enabled High Warning Check 0 high value warning disabled Enable 1 high value warning enabled If enabled defines the low alarm limit The low alarm may be selected as shutdown or loaddump with alarm level parameter Low Warning Level X 0 10000 If defined defines the low warning If enabled defines the high alarm limit The high alarm may be selected as Alarm Handling 0 3 C Sender Open Alarm 0 3 High Alarm Check Enable Low Alarm Level 0 10000 Level 4 Ls shutdown or loaddump with alarm level parameter High W
150. unit is able to analyze up to 1800Hz and up to 31th harmonic whichever is smaller Thus in a 50Hz system all 31 harmonics will be displayed but in a 60Hz system only 29 harmonics will come to the Screen In case of a 400Hz system only the 3 harmonic will be displayed T mes qa 3 m eel ow MAINS Wi HARMONICS e ael u a TANT ee Tae PROUD AOE ae Thee he T m Graphical Harmonic Table Alphanumeric Harmonics Table Harmonic are represented by 2 different ways on the device display The first one is a graphical representation allowing one sight perception of the harmonic structure Because of the display resolution only harmonics above 2 are displayed The second display is alphanumeric thus all harmonics are displayed with 0 1 resolution in order to provide more detailed information On RainbowPlus program harmonics and waveform are displayed on a single screen with more resolution Mains Generators Engine Digital Inputs Digital Outputs Analog Inputs Harmonics Alarms Counters Event Log User Page Harmonics THD 3 4 Scopemeter 2202 V gt WS 1 millisecond Harmonic Channel Selection Mains Voltage L1 N RainbowPlus Scada section Harmonic Analysis and Waveform Display K35D01 EN 59 TJ 509T User Manual Rev_01 PRELIMINARY VE
151. urve setting The allowed timer is dependent of the overcurrent level If currents go below the limit before expiration of the timer then no alarm will be set Please check chapter Overcurrent Protection IDMT for more details The action taken at fault condition is programmable OVERCURRENT Set if at least one of the genset phase currents goes over the Overcurrent Limit REVERSE POWER Set if the genset power kW is negative and goes over the Reverse Power limit for Reverse Power Timer If the power goes below the limit before expiration of the timer then no alarm will be set MAINS PHASE ORDER FAIL 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 GENSET CB FAIL TO CLOSE OPEN Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor Open Close Fail Timer MAINS CB FAIL TO CLOSE Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor Open Close Fail Timer SYNCHRONIZATION FAIL Set if the uninterrupted transfer is enabled and voltage frequency and phase matching is not found before the expiration of the Synchronization Fail Timer PICKUP SIGNAL LOST Set if the rom measured from the magnetic pickup input falls below the Crank Cut
152. v_01 PRELIMINARY VERSION V 1 4 AUTOMATIC DISPLAY SCROLL The unit will automatically scroll all Mains Genset and Engine measurements with programmable interval The scroll period setting can be performed using the RainbowPlus program through Module gt Screen options Rainbow Plus Beta Version 1 0 0 6 File Tools Help Scada Configuration Functionality Screen Options Timers Exercise Scheduler Time Module Functionality Screen Screen Options LCD Contrast 39 v Timers Exercise Scheduler Time Screen Generator Genset De MUR Status Prompts Enable Screen Scroll Timer lt J Engine Analog Inputs Language v Digital Inputs Digital Outputs Eventually the same parameter can be modified through the front panel programming menu The related parameter is Controller Configuration Screen Scroll Timer If the Screen Scroll Timer is set to zero then scrolling will be disabled When a front panel button is pressed the scrolling is suspended during 2 minutes If a fault condition occurs the display will automatically switch to the ALARM LIST page K35D01 EN 54 V 1 4 PRELIMINARY VERSION TJ 509T User Manual Rev 01 490 100 49004 4904 100 100 4904 8 490 100 4904 3unss3ud 18V1S 9 SNIVIA ogan SHH 135 39 00 wot 100 100
153. vious parameter Long Press Return to the upper menu Next parameter PROGRAMMING MODE EXIT To exit the program mode press one of the mode selection keys If no button is pressed during 2 minutes the program mode will be cancelled automatically STATUS a 3 DISPLAY EVENT LOGG CONTROLLEF WARNING ELECTRI ELEM TA LLHL FARAHS SERVICE HRHITS REQUEST Press any mode button K35D01 EN 76 PRELIMINARY VERSION PROGRAM PARAMETER LIST TJ 509T User Manual Rev_01 V 1 4 CONTROLLER CONFIGURATION GROUP Parameter Definition Unit Min Max Factory Set Description LCD Contrast 30 50 39 This parameter is used to set LCD contrast Adjust for the best viewing angle Screen Scroll Timer sec 250 The screen will scroll between different measurements with this interval If set to zero the screen scroll will be disabled Language 0 English language selected 1 Local language selected This language may depend on the country where the unit is intended to be used Genset Default Display This parameter selects the screen which is displayed during genset on load operation genset voltages table genset currents and freq table genset kW and pf table genset kVA and kVAr table genset average measurements Status Prompt Window Enable Status prompts disabled Status prompts enabl
154. voltages upper and lower limits are programmable 69 5 1 2 71 MAINS L1 72 MAINS CONTACTOR Relay output 16A AC This output provides energy to the mains contactor If the mains phases do not have acceptable voltages the mains contactor will be de energized In order to provide extra security the normally closed contact of the generator contactor should be serially connected to this output K35D01 EN 49 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 TECHNICAL SPECIFICATIONS DC Supply Range 9 0 to 33 0 V DC DC power consumption 250 mA DC typical 12V DC 125 mA DC typical 24V DC 500 mA DC max 12V DC 250 mA DC max 24V DC Alternator voltage 0 to 330 V AC Ph N 0 to 570V Ph Ph Alternator frequency 0 500 Hz Mains voltage 0 to 330 V AC Ph N 0 to 570V Ph Ph Mains frequency 0 500 Hz Current Inputs from current transformers 5A CT Range 5 5A to 5000 5A VT Range 0 1 1 to 6500 1 kW Range 0 1kW to 65000 kW Accuracy Voltage 0 5 1 digit Current 0 5 1 digit Frequency 0 5 1 digit Power kW kVAr 1 0 2digit Power factor 0 5 1digit Digital inputs input voltage 0 to 36 V DC Analog input range 0 5000 ohms Mains and genset contactor outputs 16Amps 250V DC Outputs Protected mosfet semiconductor outputs rated 1Amp 28V DC Cranking dropouts survives OV for 100ms Magnetic pickup voltage 0 5 to 30V RMS Magnetic pickup frequency 10 to 10000 Hz Charge Alt
155. way Mode change event recorded when the operation mode is changed Mains fail event recorded when mains status is changed to fail Mains restore event recorded when mains is restored Shutdown alarm event recorded when a shutdown alarm occurs Loaddump alarm event recorded when a loaddump alarm occurs Warning event recorded when a warning occurs Program mode entrance event recorded when program mode is entered The password level is also saved K35D01 EN 60 TJ 509T User Manual Rev_01 PRELIMINARY VERSION V 1 4 Event logs are displayed within the program mode menu This is designed in order to reduce the interference of event logs with other measurement screens To enter the event display press together 9 ana buttons for 5 seconds When the program mode is entered below password entry screen will be displayed Press 2 PRU buttons 7 for 5 Enter Your Password seconds T H r 1I x1Ix Skip the password entry screen by pressing the button 4 times The screen below left will come Press again the button The last stored event will open as in the below right picture The first page will display the event number event type fault type and date time information POISPLAY EVENT LOGG ENGINE SHUTDOWN Fail To Start 12 03 2012 18 55 14 When displaying event logs button will display the next information in the same event button will display the previous information

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