Senz Awas Mondioal

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DKG-507 User Manual V-37 (01.03.2012)

DKG-507 AUTOMATIC

MAINS FAILURE UNIT

CANBUS AND MPU VERSIONS

The controller is a comprehensive AMF unit forsingle genset standby or dual genset mutual standby

operations.

The unit is available with MPU or CANBUS versions.The CANBUS version connects to ECU controlledelectronic engines providing engine control,protection and instrumentation without extra senders.

The unit is able to initiate modem calls and sendSMS messages in fault conditions through externalmodems.

The unit provides a comprehensive set of digitallyadjustable timers, threshold levels, input and outputconfigurations, operating sequences and enginetypes. All programs may be modified via front panelpushbuttons, and do not require an external unit.

Last 100 faults are stored in the event log file. The

event log includes not only the date-time information,

but also a comprehensive list of measured genset

parameters at the time that the fault has occurred.

The WINDOWS based RAINBOW program allowsremote monitoring and control.

The unit supports MODBUS protocol enablingcommunication with PLCs and building managementsystems. The MODBUS protocol is also supportedthrough GSM and PSTN modems.

True RMS measurements

ECU connection through J1939 CAN option

MPU input option

Internal GSM modem option

Dual genset mutual standby operation

Event logging with time stamp andmeasurements

Battery backed-up real time clock

Built in daily / weekly / monthly exerciser

Weekly operation schedule programs

Field adjustable parameters

RS-232 serial port

Free MS-Windows Remote monitoring SW

GSM and PSTN modem support

GSM SMS message sending on fault

MODBUS communications

Customer logo display capability

10ADC relay outputs

Configurable analogue inputs: 4

Configurable digital inputs: 7

Configurable relay outputs: 2

Total relay outputs: 6

I/O expansion capability

Plug-in connection system

FEATURESDESCRIPTION


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Section1. INSTALLATION

1.1. Introduction to the Control Panel1.2. Mounting the Unit1.3. Wiring the Unit

2. INPUTS AND OUTPUTS3. DISPLAYS

3.1. Led Displays3.2. Digital Displays

4. ALARMS AND WARNINGS5. MODES OF OPERATION6. OTHER FEATURES

6.1. Remote start operation6.2. Sender type selection

6.3. Engine heating operation6.4. Engine Idle Speed Operation6.5. Engine Block Heater6.6. Fuel Pump Control6.7. Mains Simulation (Disable Start)6.8. Delayed Mains Simulation, Battery Charging6.9. Dual Genset Mutual Standby Operation6.10. Service Request Display6.11. Engine Hours Meter6.12. Date-Time Display6.13. Display of Software Version6.14. Modem connection6.15. SMS message sending6.16. Remote Monitoring and Programming6.17. Automatic Exerciser6.18. Resuming to factory set parameters6.19. Gas engine fuel solenoid control6.20. Load Shedding / Dummy Load6.21. Fuel Theft / Fuelling Messages6.22. Firmware Update6.23. Changing the Default Engine Speed in Volvo Engines6.24. Engine Control Mode6.25. Dual Voltage and Frequency

6.26. Single Phase Operation7. J1939 ENGINE MONITORING AND CONTROL PORT8. MODBUS COMMUNICATION9. WEEKLY OPERATION SCHEDULE10. EVENT LOGGING11. STATISTICAL COUNTERS12. MAINTENANCE13. PROGRAMMING14. TROUBLESHOOTING15. DECLARATION OF CONFORMITY16. TECHNICAL SPECIFICATIONS17. CONNECTION DIAGRAMS

TABLE OF CONTENTS


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The unit is a control and protection panel used in gensets. It shows the measured values on its

displays. The unit is designed to provide user friendliness for both the installer and the user.Programming is usually unnecessary, as the factory settings have been carefully selected to fit most

applications. However programmable parameters allow the complete control over the generating set.

Programmed parameters are stored in a Non Volatile Memory and thus all information is retained even

in the event of complete loss of power.

The measured parameters are:

Mains voltage phase L1 to neutralMains voltage phase L2 to neutralMains voltage phase L3 to neutralMains voltage phase L1-L2Mains voltage phase L2-L3Mains voltage phase L3-L1Gen voltage phase L1 to neutralGen voltage phase L2 to neutralGen voltage phase L3 to neutralGen voltage phase L1-L2Gen voltage phase L2-L3Gen voltage phase L3-L1Gen current phase L1Gen current phase L2Gen current phase L3Gen frequencyEngine speed (rpm)

Gen total kWGen total pfBattery voltage,Coolant temperatureOil pressureOil temperature

Fuel level

1.1 Introduction to the Control Panel1. INSTALLATION


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The unit is designed for panel mounting. The user should not be able to access parts of the

unit other than the front panel.

Mount the unit on a flat, vertical surface. Before mounting, remove the mounting brackets and

connectors from the unit, then pass the unit through the mounting opening. The unit will be maintained inits position by the mounting brackets spring.

The output of the current transformers shall be 5 Amperes. The input current rating of the current

transformers may be selected as needed (between 10/5 and 9000/5 amps). Current transformer outputs

shall be connected by separate cable pairs from each transformer, to related inputs. Never use common

terminals or grounding. The power rating of the transformer should be at least 5 VA. It is recommended to

use 1% precision transformers.

If analogue senders (e.g. temperature, oil pressure or fuel level) are connected to the unit, it is not

possible to use auxiliary displays, otherwise the unit may be damaged. If temperature or oil pressure or

fuel level displays are already present on the generator control panel, do not connect the senders to the

unit. The unit is factory programmed for VDO type senders. However different types of senders are

selectable via programming menu. Please check the programming section.

The programmable digital inputs are compatible with both normally open and normally

closed contacts, switching either to BAT- orBAT+.

The charge alternator connection terminal provides also the excitation current, thus it is not

necessary to use an external charge lamp.

WARNING: ELECTRICITY CAN KILLALWAYS disconnect the power BEFORE connectin

the unit.The fuse rating should be 6 Amps.1) ALWAYS remove the plug connectors when inserting wires with a

screwdriver.2) An appropriate and readily accessible set of disconnection device

(e.g. automatic fuses) MUST be provided as part of the installation3) The building mains supply MUST incorporate appropriate short-ci

backup protection (e.g. a fuse or circuit breaker) of High BreakingCapacity (HBC, at least 1500A).

WARNING: THE UNIT IS NOT FUSED.Use external fuses for Mains phases: L1,L2,L3,Generator phase: L1,L2,L3, Battery positive: BAT(+).Install the fuses as nearly as possible to the unit in a

lace easil accessible for the user.

Engine body must be grounded for correct operationthe unit, otherwise incorrect voltage and frequencymeasurements may occur.

1.3 Wiring the Unit

1.2 Mounting the Unit


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RS-232 SERIAL PORT: This connector provides serial data input and output for various purposes like

remote monitoring and remote programming.

EXTENSION CONNECTOR: This connector is intended for the connection to output extension modules.The optional relay extension module provides 8 programmable 16A relay outputs. The unit allows the use

of up to 2 I/O extension modules.

Term Function Technical data Description

1 GENERATOR CONTACTOR Relay output, 16A-AC This output provides energy to the generatorcontactor. 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.

2 GEN-L1 Generator phaseinputs, 0-300V-AC

Connect the generator phases to these inputs.The generator phase voltages upper and

lower limits are programmable.3 GEN-L2

4 GEN-L3

5 GENERATOR NEUTRAL Input, 0-300V-AC Neutral terminal for the generator phases.

6 MAINS NEUTRAL Input, 0-300V-AC Neutral terminal for the mains phases.

7 MAINS-L3 Mains phase inputs,0-300V-AC

Connect the mains phases to these inputs.

The mains voltages upper and lower limits are

programmable.

8 MAINS-L2

9 MAINS-L1

10 MAINS CONTACTOR Relay output, 16A-AC This output provides energy to the mainscontactor. If the mains phases do not have

acceptable voltages, the mains contactor willbe de-energized. In order to provide extra

security, the normally closed contact of the

generator contactor should be serially

connected to this output.

11 GROUND O VDC Power supply negative connection.

12 BATTERY POSITIVE +12 or 24VDC The positive terminal of the DC Supply shallbe connected to this terminal. The unit

operates on both 12V and 24V battery

systems.

13 FUEL LEVEL SENDER Input, 0-5000 ohms Analogue fuel level sender connection. Do notconnect the sender to other devices. The input

has programmable ohms for VDO senders.14 OIL PRESSURE SENDER Input, 0-5000 ohms Analogue oil pressure sender connection. Donot connect the sender to other devices. The

input has programmable characteristics and

connects to any kind of sender.

15 COOLANT TEMP. SENDER Input, 0-5000 ohms Analogue high temperature senderconnection. Do not connect the sender to

other devices. The input has programmable

characteristics and connects to any kind of

sender.

2. INPUTS AND OUTPUTS


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Term Function Technical data Description

16 CHARGE Input and output Connect the charge alternators D+ terminal tothis terminal. This terminal will supply the

excitation current and measure the voltage of

the charge alternator.

17 RELAY-2 (HORN RELAY) Output 10A/28VDC This relay has programmable function,selectable from a list.

18 RELAY-1 (STOP RELAY) Output 10A/28VDC This relay has programmable function,selectable from a list.

19 START RELAY Output 10A/28VDC This relay controls the engine cranking.

20 FUEL RELAY Output 10A/28VDC This relay is used for fuel solenoid control.

21 EMERGENCY STOP Digital inputs These inputs have programmablecharacteristics selected via the program

menu. Each input may be driven by a

normally closed or normally open contact,

switching either battery+ or battery-. The effect

of the switch is also selectable from a list. See

PROGRAMMING section for more details.

22 SPARE-2

23 PROGRAM LOCK

24 SPARE-1

25 COOLANT LEVEL

26 HIGH TEMP

27 LOW OIL PRESSURE28 RECTIFIER FAIL

29 CURR_1+ Current transformerinputs, 5A-AC

Connect the generator current transformerterminals to these inputs. Do not connect thesame current transformer to other instrumentsotherwise a unit fault will occur. Connect eachterminal of the transformer to the units relatedterminal. Do not use common terminals. Donot use grounding. Correct polarity ofconnection is vital. If the measured power isnegative, then change the polarity of each 3current transformers. The rating of thetransformers should be the same for each of

the 3 phases. The secondary winding ratingshall be 5 Amperes. (For ex. 200/5 Amps).

30 CURR_1-

31 CURR_2+

32 CURR_2-

33 CURR_3+

34 CURR_3-

35 OIL TEMP. SENDER Input, 0-5000 ohms Analogue oil temperature sender connection.Do not connect the sender to other devices.

The input has programmable characteristics

and connects to any kind of sender.

CANBUS VERSIONS36 CANBUS-L Digital communication

port

Connect the J1939 port of an electronic

engine to these terminals.

The 120 ohm terminating resistors are inside

the unit. Please do not connect external

resistors.

Use a twisted cable pair or coaxial cable for

best results.

37 CANBUS-H

MPU INPUT VERSIONS36 MPU - Analog input, 0.5 to

30V-AC

Connect the MPU unit to these inputs

Use a twisted cable pair or coaxial cable for

best results.

37 MPU +


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The unit has 12 LEDs, divided in 3 groups:-Group_1: Operating mode: This group indicates the genset function.-Group_2: Mimic diagram: This group indicates the current status of the mains and genset

voltages and contactors.

-Group_3: Warnings and alarms: This group indicates the existence of abnormal conditions

encountered during operation.

Function Color Description

MAINS ON Green The LED will turn on when all 3 mains phase voltagesare within the limits.

MAINS OFF Red The LED will turn on when at least one of the mainsphase voltages is outside limits.

LOAD MAINS Green It turns on when the mains contactor is activated.LOAD GENERATOR Yellow It turns on when the generator contactor is activated.

GENERATOR Yellow The LED will flash when the engine is running. It willturn on steadily when all 3 generator phase voltages

are within the programmed limits.

TEST Yellow It turns on when the related operation mode isselected. One of these LEDs is always on and

indicates which operation mode is selected.

If the operation of the genset is disabled by the

weekly operation schedule, then the AUTO led will

flash.

RUN Yellow

STOP Yellow

AUTO Green

WARNINGS & ALARMS Red If a fault condition resulting to the engine shutdown or

loaddump condition has occurred, the related alarmled turns on steadily. If a warning condition occurs,

this led will flash. Alarms work on a first occurring

basis. The occurrence of a fault will disable other

faults of lower or equal priority.

SERVICE REQUEST Red Engine periodic maintenance request indicator. Itturns on when the preset engine hours or time

duration after previous service has elapsed.

3.1 Led Displays3. DISPLAYS


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The unit has 3 seven segment displays. They show:-Measured parameters,

-Service counters,-Statistical counters,-Program parameters.

The navigation between different screens in a group is made with the MENU button.Holding the MENU button pressed for 1 second makes the display to switch to the next group.

VOLTAGE DISPLAY: This display shows:

-phase R voltage if the load is on mains

-Phase U voltage if the load is on the genset

By pressing the MENU key, below values may be displayed:

-(L1-L2-L3) mains phase to neutral voltages

-(L1-L2-L3) generator phase to neutral voltages

-(L12-L23-L31) mains phase to phase voltages

-(L12-L23-L31) generator phase to phase voltages

If the service counters group is displayed, then this display will show the counter name.

In programming mode it displays (PGM).

CURRENT DISPLAY: This display will show the current values measured using the currenttransformers. Using the programming menu, current transformers within the range of 10/5A to 9000/5A

may be programmed.

In programming mode it displays the program number.

MULTIFUNCTION DISPLAYS: By pressing the MENU key below values may read:

-generator frequency (Hz)

-generator active power (KW)

-engine rpm

-fuel level

-oil temperature

-battery voltage (V-DC),

In programming mode it displays the program value.

3.2 Digital Displays


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Alarms indicate an abnormal situation in the generating set are divided into 3 priority levels:

1- ALARMS: These are the most important fault conditions and cause:

-Therelated ALARM led to be on steadily,

- The genset contactor to be released immediately,

- The engine to be stopped immediately,

- The Horn, Alarm, Alarm+Load_dump and Alarm+Load_dump+Warning digital

outputs to operate, (if selected via programming menu)

2- LOAD_DUMPS: These fault conditions cause:

- Therelated ALARM led to be on steadily,

- The genset contactor to be released immediately,

- The engine to be stopped after Cooldown period,

- The Horn, Alarm+Load_dump and Alarm+Load_dump+Warning digital outputs to

operate, (if selected via programming menu)

3- WARNINGS: These conditions cause:

- Therelated ALARM led to flash,- The Horn and Alarm+Load_dump+Warning digital outputs to operate, (if selected

via programming menu)

If the ALARM MUTE button is pressed, the Horn output will be deactivated; however theexisting alarms will persist and disable the operation of the genset.

Alarms operate in a first occurring basis:

-If an alarm is present, following alarms, load_dumps and warnings will not be accepted,

-If a load_dump is present, following load_dumps and warnings will not be accepted,

-If a warning is present, following warnings will not be accepted.

Alarms may be of LATCHING type following programming. For latching alarms, even if the alarm

condition is removed, the alarms will stay on and disable the operation of the genset. The existing alarmsmay be canceled by pressing one of the operating mode buttons (LOAD TEST / TEST / OFF / AUTO).

Most of the alarms have programmable trip levels. See the programming chapter for adjustable

alarm limits.

4. ALARMS AND WARNINGS


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LOW OIL PRESSURE: Set if a signal is detected at the Low Oil Pressure Switch input or the oil

pressure value measured from the sender is below the programmed limit. Warning and alarm limits are

separately programmable for the oil pressure sender input. This fault will be monitored with HoldoffTimer delay after the engine is running. Also if the oil pressure switch is open at the beginning of a start

attempt, then the engine will not be started and the oil pressure alarm led will flash. When the oil

pressure switch closes, normal operation will be resumed.

HIGH TEMPERATURE: Set if a signal is detected at the High Temperature Switch input or the coolant

temperature value measured from the sender is above the programmed limit. Warning and alarm limits

are separately programmable for the temperature sender input.LOW TEMPERATURE (warning) : Set if the coolant temperature value measured from the sender isblow the Engine Heating Temperature limit.

LOW SPEED / HIGH SPEED: Set if the generator frequency or rpm is outside programmed limits.These faults will be monitored with Holdoff Timer delay after the engine is running. Low and high limits

for warning and alarm are separately programmable. Another high shutdown limit which is 12% above

the high limit is always monitored and stops the engine immediately.

START FAIL (alarm): Set if the engine is not running after programmed number of start attempts.STOP FAIL (warning): Set if the engine has not stopped before the expiration of the Stop Timer.

ECU FAIL (warning): 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.ECU FAIL (alarm): Set if no information has been received during 3 seconds from the ECU of theelectronic engine. This fault condition is only controlled if fuel is on.

OVERLOAD (load_dump): Set if at least one of the genset phase currents goes over the OvercurrentLimit forOverload Timer. If currents go below the limit before expiration of the timer then no alarm will

be set.

EXCESS POWER (load_dump): Set if the genset power (KW) supplied to the load goes over theExcess Power limit forOverload Timer. If the power goes below the limit before expiration of the timer

then no alarm will be set.

GENSET LOW VOLTAGE: Set if any of the generator phase voltages goes outside programmed limitsforOverload Timer. This fault will be monitored with holdoff timer delay after the engine is running.GENSET HIGH VOLTAGE: Set if any of the generator phase voltages goes outside programmed limitsforOverload Timer. This fault will be monitored with holdoff timer delay after the engine is running.

LOW COOLANT LEVEL: Set if a signal is detected at the low coolant level input.

HIGH BATTERY VOLTAGE: Set if the battery voltage goes above programmed limits. Both warning and

alarm levels for high battery voltage are programmable.

LOW BATTERY VOLTAGE (warning): Set if the battery voltage goes below the programmed limit.

During engine cranking this fault is not monitored.

CHARGE: Set if a charge alternator failure (or broken belt) occurs. This fault condition may result to awarning oralarm following programming.

RECTIFIER FAIL: Set if a signal is detected at the rectifier fail input. This input is only monitored whenmains voltages are present.

EMERGENCY STOP: Set if a signal is detected at the emergency stop input.

SPARE: Set if a signal is detected from the related spare fault input.


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The modes of operation are selected by pushing the front panel keys. Changing the operation

mode while the genset is running will result into a behavior suitable for the new operating mode. For

example, if the TEST mode is selected when genset is running at RUN mode, then the genset will takethe load.

STOP: In this mode, the mains contactor will be energized if mains phase voltages are within the

programmed limits. The engine will be stopped.

AUTO: It is used for genset and mains automatic transfer. If at least one of the mains phase voltages is

outside limits, the mains contactor will be deactivated.

The diesel will be started for programmed times after the preheat timer. When the engine runs, the crank

relay will be immediately deactivated. The engine will run without load during engine heating period. After

this, if alternator phase voltages and frequency are within limits, then the unit will wait for the generator

contactor period and the generator contactor will be energized.

When all the mains phase voltages are within the limits, the engine will continue to run for the mains

waiting period. At the end of this period the generator contactor is deactivated and the mains contactor will

be energized. If a cooldown period is given, the generator will continue to run during cooldown period. At

the end of the period, the fuel solenoid will be de-energized and the diesel will stop. The unit will be ready

for the next mains failure.

If the operation of the genset is disabled by the weekly schedule, then the AUTO led will flash, and theoperation of the genset will be as in the OFF mode.

RUN: It is used to test the generator when the mains are on, or keep the generator running in the

emergency backup mode. The operation of the generator is similar to the AUTO mode, but the mains

contactor will not be deactivated if the mains are not off. If the mains are off, mains contactor will be

deactivated and the generator contactor will be activated. When the mains are on again, a changeover to

the mains will be made, but the engine will be kept running unless another mode is selected. To stop the

engine, select AUTO orOFF mode.

TEST: It is used to test the genset under load. Once this mode is selected, the engine will run and the

load will be transferred to the genset. The genset will feed the load indefinitely unless another mode is

selected.

5. MODES OF OPERATION


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The unit offers the possibility ofREMOTE START mode of operation. The SPARE-2 input maybe assigned as Remote Start Input using the program parameterP_083.

The REMOTE START signal may be a NO or NC contact, switching to either battery positive orbattery negative. These selections are made using programming menu.

It is also necessary to set the ACTION program parameter of the SPARE-2 input to 3 in order toprevent any alarm from this input.

In this mode the mains phases are not monitored. If the REMOTE START signal is presentthen the mains will be supposed to fail, inversely if the REMOTE START signal is absent, then mainsvoltages will be supposed to be present. The front panels mimic diagrams mains LEDs will reflect the

status of the REMOTE START input.

The unit has the ability to adapt to any type of oil pressure and temperature senders. Thecommonly used standard sender characteristics are recorded in memory and selectable from a list.However non standard senders may also be used by entering their characteristics to the table.

Oil Pressure Sender Type Selection:Selectable sender types are:0: Sender characteristics are defined in Sender Characteristics table.

1: VDO 0-7 bars (10-180 ohms)2: VDO 0-10 bars (10-180 ohms)3: DATCON 0-7 bars (240-33 ohms)4: DATCON 0-10 bars (240-33 ohms)5: DATCON 0-7 bars (0-90 ohms)6: DATCON 0-10 bars (0-90 ohms)7: DATCON 0-7 bars (75-10 ohms)

Temperature Sender Selection:Selectable sender types are:0: Sender characteristics are defined in Sender Characteristics table.1: VDO2: DATCON DAH type

3: DATCON DAL type

Fuel Level Sender Selection:The Fuel Level Sender characteristic is programmable through table.

Oil Temperature Sender Selection:Selectable sender types are:0: Sender characteristics are defined in Sender Characteristics table.1: VDO2: DATCON DAH type3: DATCON DAL type

6.2 Sender type Selection

6.1 Remote Start Operation

6. OTHER FEATURES


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Especially on engines without a body heater, or with a failing one, it may be desired that thegenset 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 thismode, the engine will run during parameterEngine Heating Timer, and then the genset will take theload.

2. Timer and temperature controlled heating:This operation mode is selected when the Engine Heating Method parameter is set to 1. In thismode, at first the engine will run during parameterEngine Heating Timer, then it will continue to rununtil the measured coolant temperature reaches the limit defined in parameterEngine HeatingTemperature. 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.

It may be required that the engine runs at the idle speed for a programmed duration for engineheating. The idle operation duration is adjusted with the parameterIdle Speed Timer. The idle speedwill be set by the governor control unit of the engine.

Any of the spare relay outputs may be assigned as IDLE output using Relay Definitionprogram parameters. Also relays on an extension module may be assigned to this function.

The Idle speed operation is performed both in engine start-up and cool-down sequences.

Speed and voltage protections are disabled during idle speed operation.

The unit is able to provide a relay output in order to drive the block heater resistor. The

temperature reference is the coolant temperature measured from the the analog sender input.

The block heater relay function may be assigned to spare relays using Relay Definition

program parameters. Also relays on an extension module may be assigned to this function.

The engine body temperature limit is adjusted using the parameterEngine Heating

Temperature. The same parameter is used for engine heating operation.

The relay will become active if the body temperature falls to 4 degrees below the limit set by

Engine Heating Temperature. It turns off when the body temperature exceeds Engine HeatingTemperature.

6.5 Engine Block Heater

6.4 Engine Idle Speed Operation

6.3 Engine Heating Operation


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The unit is able to provide a relay output in order to drive the fuel pump motor. The fuel pump

is used in order to transfer fuel from the large capacity main tank (if exists) to the genset daily tank

which is generally integrated in the chassis and has a limited capacity.

The fuel level reference is measured through the analog fuel level sender. When the

measured fuel level falls below Fuel Pump Low Limit parameter, the fuel pump relay output willoperate. When the fuel level reaches Fuel Pump High Limit parameter, the relay will turn off. Thusthe chassis fuel tank level will be always kept between Fuel Pump Low Limit and Fuel Pump HighLimit parameters.

The fuel pump relay function may be assigned to spare relays using Relay Definition programparameters. Also relays on an extension module may be assigned to this function.

The unit offers an optional SIMULATE MAINS signal input. The SPARE-2 digital input may beassigned as Simulate Mains using program parameterP_084.

It is also necessary to set the ACTION program parameter of the related input to 3 in order toprevent any alarms generated from this input.

The SIMULATE MAINS signal may be a NO or NC contact, switching to either battery positive orbattery negative. These selections are made using the programming menu.

If the Simulate Mains input is defined and the input signal is active, the mains phases are notmonitored 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 andCooldown cycles will be performed before engine stop. When the SIMULATE MAINS signal is present,the front panels mimic diagrams mains LEDs will reflect the mains voltages as present.

When the signal is passive, the unit will revert to normal operation and monitor the mainsvoltage status.

The REMOTE START operation overrides SIMULATEMAINS and FORCE TO START operations.

6.7 Mains Simulation (Disable Start)

6.6 Fuel Pump Control


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The Delayed Mains Simulation feature is used in battery backed up telecom systems wherebatteries 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 chargingthe batteries and the battery voltage goes up immediately. Thus the engine should continue to run aprogrammed period for effective charging. The critical battery voltage level will be detected by anexternal unit which provides the digital Simulate Mains signal for the genset control unit.

The unit offers an optional SIMULATE MAINS signal input. The SPARE-2 digital input may beassigned as Simulate Mains using program parameterP_084.

It is also necessary to set the ACTION program parameter of the related input to 3 in order toprevent any alarms generated from this input.

The SIMULATE MAINS signal may be a NO or NC contact, switching to either battery positive orbattery negative. These selections are made using the programming menu.

If the Delayed Simulate Mains program parameter (P_085) is set to 1 and the input signal isactive when the genset is not feeding the load, the mains phases are not monitored and supposed tobe 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 mainssignal not present.

If the genset is running when the signal is applied, then MAINS SIMULATION will beprevented during P_086Flashing Relay Timer program parameter. After this, usual Mains Waitingand Cooldown cycles will be performed before engine stop. When the SIMULATE MAINS signal ispresent, the front panels mimic diagrams 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 DELAYEDSIMULATE MAINS operation. When both parametersRemote Start Operation and Delayed SimulateMains are set then REMOTE START operation modeperformed.

6.8 Delayed Mains Simulation, Battery Charging


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Dual genset intermittent operation consists of regular switching of the load between 2 gensets.

The use of 2 gensets instead of one is due either to safety purposes in case of a genset failure or to a

continuous operation requesting service stops.The running period for each genset is adjustable using Flashing Relay Timer program

parameter. If the time is adjusted as 0 hours, it will be actually set to 2 minutes for faster testing

purposes.

A flashing relay output function is provided, based on the parameterFlashing Relay Timer.Each time the period programmed using Flashing Relay Timer elapses, the relay output will changeposition.

The flashing relay function may be assigned to spare relays using Relay Definition programparameters. Also relays on an extension module may be assigned to this function.

The dual genset intermittent operation uses also the Mains Simulation feature. Please reviewchapter6.7 for a detailed explanation of this feature.

Please contact DATAKOM for a complete applicationmanual.

6.9 Dual Genset Mutual Standby Operation


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This led is designed to help the periodic maintenance of the genset to be made consistently.

The periodic maintenance is basically carried out after a given engine hours (for example 200

hours), but even if this amount of engine hours is not fulfilled, it is performed after a given time limit (forexample 12 months).

The unit has both programmable engine hours and maintenance time limit. The engine hours is

programmable with 50-hour steps, the time limit is programmable with 1 month steps. If any of the

programmed values is zero, this means that the parameter will not be used. For example a maintenance

period of 0 months indicates that the unit will request maintenance only based on engine hours, there willbe no time limit. If the engine hours is also selected as 0 hours this will mean that the SERVICE

REQUEST display will be inoperative.

When the engine hours OR the time limit is over, the SERVICE REQUEST led (red) will start to

flash and the service request relay function will be active.

The service request relay function may be assigned to spare relays using Relay Definitionprogram parameters. Also relays on an extension module may be assigned to this function.

The remaining engine hours and the remaining time limit are kept stored in a non-volatile memory

and are not affected from power supply failures.

The time and engine hours to service are displayed in the STATISTICAL COUNTERS menu.

To turn off the SERVICE REQUEST led, and reset the

service period, press together the ALARM MUTE andLAMP TEST keys for 5 seconds.

The SERVICE REQUEST led has no effect on thegenset operation.

6.10 Service Request Display


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The unit features a non-erasable incremental engine hour meter. The hour meter information is

kept in a non-volatile memory and is not affected from power supply failures.

The engine hours may be displayed STATISTICAL COUNTERS menu.

The date & time display is provided for verification.

Some additional features are installed within consecutive software releases. In order to be

sure of the validity of the status of the unit, the software version needs to be known.The software version of the unit is displayed together with the data time information.

The software version consists of 2 numbers. The first number represent the operating software

version of the unit.

The unit is capable of making modem calls in case of alarm, as well as answering modemcalls made from a remote location. GSM modems and classic cable network (PSTN) modems areacceptable.

If the modem is connected to the unit, the Modem Enable program parameter should be set

to 1, otherwise faulty operation may occur.A maximum of 2 telephone numbers can be defined for outgoing modem calls. In case ofalarm, the unit will attempt to reach control centers associated with each number. In case of modemconnection failure, the call will be repeated up to 30 times with 2 minute intervals.

Advised modems are DATAKOM types which are powered up from the same DC batteryvoltage than the unit. Most of other desktop modems with standard AT commands are also usable, butit is the users responsibility to provide an uninterrupted AC supply source to the modem. Thenecessary modem cable will be supplied by DATAKOM.

Modem calls are always terminated by the central RAINBOW software. However the unit doesnot allow connection durations exceeding 2 minutes, and hangs up the modem when this periodexpires.

The PC program used for remote monitoring and programming is the same RAINBOWsoftware used for RS-232 connection.

Please note that the modem operation is also compatible with the MODBUS communication.

Thus the unit can iniate and receive calls to/from a MODBUS master station. Please review chapter_8for more details on MODBUS communication.

IfModem Enable orSMS Enable orMODBUS Addressparameters are different from zero, the local PCconnection will not work.

6.14 Modem Connection

6.13 Software Version Display

6.12 Date & Time Display

6.11 Engine Hour Meter


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The GSM SMS sending is activated by setting the SMS Enable program parameter to 1.

When a fault condition occurs, the unit will compose an SMS message and will send it to up to 6phone numbers. If modem is enabled, only 4 telephone numbers are available for SMS sending.

The unit is also able to send SMS messages in below conditions, without creating a visible alarmor warning:

Mains Fail, Mains Restored (enabled via SMS on Mains Change program parameter)Fuel Theft, Fuelling (enabled by setting the Fuel Consumption / Hour parameter to other than 0)

If both modem and SMS are enabled, the unit will send SMS messages first and attempt modemconnection afterwards.

The maximum number of alarms transmitted in a SMS message is 4. This limitation is due to themaximum length of an SMS message which is 160 characters.

A sample GSM SMS message is given below:

DKGxxx STOP :LOW OIL PRESSURE SW.

END OF ALARM LIST

The first line of the message carries information about the unit type and the site identity string.This line is intended for the identification of the genset sending the SMS message.

Each following line will give one fault information. The message will always be terminated by theEND OF ALARM LIST string.

When the message is sent, the existing alarms will be masked, causing the audible alarm relay torelease and preventing consecutive GSM SMS messages. Any new upcoming alarm will result in a newGSM SMS message. The new message will indicate all existing alarms, even masked ones.

The necessary GSM modem cable will be supplied by DATAKOM. This is the same cable asPSTN (land) modems.

IfModem Enable orSMS Enable orMODBUS Addressparameters are different from zero, the local PCconnection will not work.

6.15 SMS Message Sending


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Thanks to its standard serial RS-232 port, the unit offers the remote monitoring and

programming feature.

The remote monitoring and programming PC software is called RAINBOW and may bedownloaded from www.datakom.com.tr internet site with password login.

The modem, SMS and Modbus modes are not compatible with the local PC connection. ModemEnable, SMS Enable and MODBUS Address program parameters should be set to 0 beforeconnection.

The RAINBOW software allows the visualization and recording of all measured parameters.

The recorded parameters may then be analyzed graphically and printed. The software also allows the

programming of the unit and the storage of the program parameters to PC or the downloading of

stored parameters from PC to the unit.

For PCs without a serial port, below USB to serial adapters are tested and approved :

DIGITUS USB 2.0 TO RS-232 ADAPTER (PRODUCT CODE: DA70146 REV 1.1)DIGITUS USB 1.1 TO RS-232 ADAPTER (PRODUCT CODE: DA70145 REV 1.1)FLEXY USB 1.1 TO SERIAL ADAPTER (PRODUCT CODE BF-810)CASECOM USB TO SERIAL CONVERTER (MODEL: RS-01)

The necessary PC connection cable will be supplied by DATAKOM. The cable length shouldnot be over 3 meters.

6.16 Remote Monitoring and Programming


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The unit offers automatic exerciser operation. The exercise operation may be done on a daily,weekly or monthly basis.

The start day and time of the exercise is programmable as well as its duration. The exercisemay be done with or without load following programming.

Program parameters related to the exerciser are:Exercise start day and hourExercise durationExercise off_load/on_loadExerciser Period (Daily / Weekly / Monthly)

Please refer to the programming section for a more detailed description of the aboveparameters.

When the start day and hour of exercise has come, the unit will automatically switch to eitherOFF_LOAD TEST orLOAD TEST mode. The engine will run and if the on_load exercise is selectedthen 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 thegenset unless the Emergency Backup Operation is allowed by setting the related programparameter 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 beterminated.

Using the daily exercise mode, the unit may feed the load from the genset during predefinedhours of the day. This operation may be used in high tariff periods of the day.

In order to resume to the factory set parameter values:

-hold pressed the OFF, LAMP TEST and ALARM MUTE buttons for 5 seconds,-FACT RSET 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 and FACT RSET DONEwill be displayed during 5 seconds.

It is not possible to restore user parameters.

6.18. Resuming to factory set parameters

6.17 Exerciser


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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 afterthe cranking has been started and should be closed between crank cycles. The delay between thecrank start and solenoid opening is adjusted using the Gas Solenoid Delay program parameter.

The gas engine fuel solenoid relay function may be assigned to spare relays using RelayDefinition program parameters. Also relays on an extension module may be assigned to this function.

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 fallsbelow the programmed limit. The internal Load Shedding function is always active. Any of the auxiliaryrelays may be used as the load shedding output.

The dummy load function consists on the connection of a dummy load if the total genset loadis 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 beused for both purposes.

The parameters used in Load Shedding feature are in the Electrical Parameters Group:Load Shedding Low Limit: If the genset active power output goes below this limit, then the LoadShedding relay will be deactivated.Load Shedding High Limit: If the genset active power output goes above this limit, then the LoadShedding relay will be activated.

The unit is able to send SMS messages in fuel theft or fuelling conditions.

These SMS messages are sent without creating visible fault condition.

These features are enabled by setting the program parameterEngine Parameters > FuelConsumption / Hour to a value other than 0%.

The Fuel Consumption / Hour parameter should be set to a value clearly greater than the

maximum fuel consumption of the engine.

If the fuel level measured from the sender input is decreased more than this parameter in 1hour period, then a FUEL THEFT sms message is sent to programmed telephone numbers.

If the fuel level measured from the sender input is increased more than this parameter in 1hour period, then a FUELLING sms message is sent to programmed telephone numbers.

6.21. Fuel Theft / Fuelling Messages

6.20. Load Shedding / Dummy Load

6.19. Gas Engine Fuel Solenoid Control


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The unit offers possibility of updating the firmware in the field. The firmware is updated throughthe RS-232 serial port using Rainbow or a special DOS program.

The unit will go to firmware download mode with a special command from the PC program. Indownload mode, the display of the unit will show DL V1.00

During firmware update process, the progress is visible through a percentage counter on thescreen.

The firmware update operation will take around 3 minutes.

After completion of the update a special command will set back the unit to normal operationmode.

Volvo engines equipped with EMS-II engine control unit have the engine speed selectablethrough the J1939 CANBUS. The unit offers the possibility to the user to switch between the primaryand secondary speed using the programming menu.

If the program parameterVolvo Speed Toggle is increased, the unit will freeze for a fewseconds and switch the engine to 1800 rpm, which is generally the secondary speed. When theparameter is decreased, the speed is set to the primary speed, which is generally 1500 rpm.

Please note also that a fine adjustment of the engine speed in the 8 % range may be doneusing the program parameterJ1939 Speed Adjust.

In engine control mode, the unit is supposed to control an engine without alternator.

The engine control mode is activated by a program parameter in the Controller

Configuration group.

When the Engine Control Mode is activated:

-the unit will not display genset AC parameters (volts, amps, kW and pf).-genset voltage and frequency protections are disabled. However engine rpm protections willbe active.

It is strongly recommended to enter correct low andhigh rpm limit values in order to enable engine speedprotection.

The unit must be in OFF mode, otherwise the speed

switching will not be performed.

6.24. Engine Control Mode

6.23. Changing the Default Engine Speed in Volvo Engines

6.22. Firmware Update


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The unit offers 2 sets of voltage and frequency protection limit values. The user is allowed toswitch between these 2 sets anytime.

This feature is especially usefull in dual voltage or frequency gensets for easy switchingbetween 2 operating conditions.

The switching to the second set of limit values is performed by applying signal to the SPARE-1digital input.

In order to assign this functionality to the SPARE-1 input, the program parameterP_092Secondary Volt/Freq should be set to 1.

Below parameters are available for second voltage-frequency selection:

Mains Low Voltage Limit

Mains High Voltage LimitMains Low Frequency LimitMains High Frequency Limit

Genset Low Voltage Shutdown Limit

Genset Low Voltage Warning LimitGenset High Voltage Warning LimitGenset High Voltage Shutdown LimitGenset Low Frequency Shutdown LimitGenset Low Frequency Warning LimitGenset High Frequency Warning LimitGenset High Frequency Shutdown LimitGenset Low RPM Shutdown LimitGenset Low RPM Warning LimitGenset High RPM Warning LimitGenset High RPM Shutdown Limit

If the unit is used in a single phase electrical network, it is advised t set the Single PhaseEnable program parameter in CONTROLLER CONFIGURATION group to 1.

When Single Phase Enable is set to 1, then the unit will measure electrical parameters onlyon 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.

6.26. Single Phase Operation

6.25. Dual Voltage and Frequency


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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 connectionbetween the unit and the engine should be made with either a twisted cable pair or a coaxial cable. If acoaxial cable is used, the external conductor should be grounded at one end only.

The 120 ohms termination resistor is included inside the unit. Please do not connect externalresistor.

The J1939 port is activated by setting the program parameterJ1939 Enable to 1. The J1939Engine Type parameter should be set accordingly. The list of available engines is given at theprogramming 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 rpminformation are picked up from the ECU unit. Other available measurements have no effect on engineoperation. In total, the unit is capable of receiving 21 parameters from the J1939.

The J1939 measurements are also available for Modbus operation. Please check chapter 8 formore details.

When the fuel output is active, if no information is received from the ECU during last 3seconds, then the unit will give a ECU FAIL alarm and stop the engine. This feature preventsuncontrolled engine operation.

The fault conditions of an electronic engine are considered by the unit as warnings and donot cause engine stop. The engine is supposed protected by the ECU which will stop it when

necessary.

The electronic engine fault codes are displayed within the alarm list table in text, togetherwith theirSPN-FMI codes. A maximum of 8 fault codes can be displayed.

The complete list of fault codes is given in the engine manufacturers user manual.

7. J1939 ENGINE MONITORING AND CONTROL PORT(ONLY CANBUS VERSIONS)


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Below is a basic list of fault conditions (x denotes any FMI)

SPN FMI DESCRIPTION

94 x Fuel filter restrictionFuel pressure sensor fail

98 x Low oil level

High oil levelOil level sensor fail

100 x Low oil pressureOil pressure sensor fail

102 x High boost pressureTurbo outlet pressure sensor fail

105 x Intake manifold temp highIntake manifold temp sensor fail

107 x Air filter restrictionAir filter sensor fail

108 x Athmospheric pressure sensor fail

110 x High coolant temperature

Coolant temperature sensor fail111 x Low coolant levelCoolant level sensor fail

164 x High injector activation pressureInjector activation pressure sensor fail

168 x Battery voltage failure

172 x High inlet air temperatureHigh inlet manifold air temperatureInlet manifold air temperature sensor fail

174 x High fuel temperatureFuel temperature sensor fail

175 x High oil temperatureOil temperature sensor fail

190 x OverspeedSpeed sensor loss of signalSpeed 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








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


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Below is a basic list of FMI codes.

Please be aware that these codes may differ slightly depending on the engine brand andmodel.

FMI DESCRIPTION

0 Value too high Valid data, but above the normal working range1 Value too low Valid data, but below the normal working range

2 Faulty data Intermittent or faulty data orShort circuit to battery voltage, injector high voltage side

3 Electrical fault Abnormally high voltage or short circuit to batt eryvoltage, injector low voltage side

4 Electrical fault Abnormally low voltage or short circuit to batterynegative, 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 batterynegative

7 Mechanical fault Faulty response from mechanical system

8 Mechanical or electrical fault Abnormal frequency9 Communication fault Abnormal updating rate orOpen 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)









31 Condition exist


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The unit offers the possibility of MODBUS communication via its RS232 serial port.The connection to the MODBUS master may be done in 3 ways:

1) RS232 connection using directly the RS232 port provided.2) RS422/485 connection using external RS422/485 converter.3) Modem connection using external modem.

The MODBUS mode is activated by assigning a controller address to the unit using MODBUSAddress program parameter. The possible address range is 1 to 144. Setting the address to 0 willdisable the MODBUS mode and allow communication under RAINBOW protocol.

The MODBUS properties of the unit are:-Data transfer mode: RTU-Serial data: 9600 bps, 8 bit data, no parity, 1 bit stop-Supported functions:

-Function 3 (Read multiple registers)-Function 6 (Write single register)

Detailed description about the MODBUS protocol is found in the document Modicon ModbusProtocol Reference Guide.The web address is: www.modbus.org/docs/PI_MBUS_300.pdf

Below is a limited shortlist of readable registers. For the detailed Modbus ApplicationManual and a complete list of registers please contact DATAKOM.

ADDRESS(hex)

R /W

DATASIZE

COEFFICIENT DESCRIPTION

0000 R 16bit x1 Mains Phase L1 voltage



0003 R 16bit x1 Genset Phase L1 voltage



0006 R 16bit x1 Genset Phase L1 current



000C R 16bit x1 Mains Phase L12 voltage000D R 16bit x1 Mains Phase L23 voltage

000E R 16bit x1 Mains Phase L31 voltage

000F R 16bit x1 Genset Phase L12 voltage



0012 R 16bit x10 Mains frequency

0013 R 16bit x10 Genset frequency

0016-0017 R 32bit x256 Genset active power: this 24 bit signed register holdsthe genset active power multiplied by 256. Leastsignificant 16 bits are in the register 0016h. Mostsignificant 8 bits are in the LSB of the register 0017h.

0018 R 8bit x100 Power factor multiplied by 100 (signed byte). Negativevalues indicate a capacitive power factor.

002A R 16bit x1 Engine speed (rpm)

002B R 16bit x10 Oil pressure in bars.

002C R 16bit x1 Coolant temperature in degrees C.

002D R 16bit x1 Fuel level as %

002F R 16bit x10 Battery voltage

003D R 8bit - Operating modebit_3: manual modebit_4: auto modebit_5: off modebit_6: test modebit_7: load test mode

8. MODBUS COMMUNICATION
http://c/Documents%20and%20Settings/DATAKOM/Application%20Data/Microsoft/Word/www.modbus.org/docs/PI_MBUS_300.pdfhttp://c/Documents%20and%20Settings/DATAKOM/Application%20Data/Microsoft/Word/www.modbus.org/docs/PI_MBUS_300.pdfhttp://c/Documents%20and%20Settings/DATAKOM/Application%20Data/Microsoft/Word/www.modbus.org/docs/PI_MBUS_300.pdf


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In most applications, the genset is requested to operate only in working hours. Thanks to theweekly program feature unwanted operation of the genset may be prohibited.

The unit has one programmable turn-on/turn-off time pairs for each day of week. Theseprogrammable parameters allow the genset to operate automatically only in allowed time limits.

The weekly operation schedule is only active in AUTO mode. In other modes it will not affectthe genset operation.

In AUTO mode, if the operation of the genset is disabled by the weekly schedule, then theAUTO led will flash (instead of a steady on state).

Each turn-on/turn-off time is defined in 10 minute steps.

Unused programs should be set to 24:00.

An example setup may be as follows:

Monday Turn_on 07:00

Monday Turn_off 18:00Tuesday Turn_on 07:00Tuesday Turn_off 18:00Wednesday Turn_on 07:00Wednesday Turn_off 18:00

Thursday Turn_on 07:00Thursday Turn_off 18:00

Friday Turn_on 07:00Friday Turn_off 18:00

Saturday Turn_on 07:00Saturday Turn_off 13:00

Sunday Turn_on 24:00 (Sunday no turn on time, last operation mode continues)

Sunday Turn_off 24:00 (Sunday no turn off time, last operation mode continues)

If the same time is used for turn on and turn off, then it will be considered as a turn-on time.

The unit has a battery backed-up precision real time clock circuit. The real time clock circuitwill continue its operation even in power failures. The real time clock is precisely trimmed using theReal Time Clock Adjust program parameter. For more details check the programming section.

9. WEEKLY OPERATION SCHEDULE


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The unit keeps record of the last 100 events in order to supply information for the service personal.

The genset status information and a comprehensive set of measured values are stored within the

event memory. The events are recorded with a time stamp which comes from the internal real timeclock circuit of the unit.

The events are stored in a circular memory. This means that a new coming event will erase the oldestrecorded event.

Events are kept in a non-volatile memory and are not affected from power failures.

Events are not visible on the device display. They can be downloaded to the computer and saved in

an Excel file.

Event sources are:-Shutdown alarms, Load dump alarms, Warnings

-Engine crank starts-Periodic records.

Event record contents are:Event type (alarms, mode change, periodic, etc)Date and timeGenset operating mode (AUTO, MANUAL,OFF,TEST, LOAD TEST)Genset operation status (mains ok, running, cooldown etc)Genset phase voltages L1-L2-L3Genset phase currents L1-L2-L3Genset frequencyGenset active power (KW)Genset power factor

Engine rpmOil pressureCoolant temperatureFuel levelBattery voltageMains phase voltages L1-L2-L3Mains frequencyDigital input statusesCharge input statusJ1939 VAlues (if applicable)

The unit provides a set of non resettable incremental counters for statistical purposes.

The counters consist on:-total engine hours-total genset KWh-engine hours to service-time to service-total engine cranks-total genset runs

These counters are kept in a non-volatile memory and are not affected from power failures.

11. STATISTICAL COUNTERS

10. EVENT LOGGING


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Wipe the unit, if necessary with a soft damp cloth. Do not use chemical agents

DO NOT OPEN THE UNIT !

There are NO serviceable parts inside the unit.

12. MAINTENANCE


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The program mode is used to program timers, operational limits and the configuration of the unit.

To enter the program mode, hold pressed the MENUbutton for 5 seconds.When the program mode is entered, the upper display will show PRGM and the mid display

will indicate the program parameter number. The lower display will show the parameter value.

If the PROGRAM LOCK input is tied to GROUND, the program value modification will be

disabled to prevent unauthorized intervention.

It is advised to keep the PROGRAM LOCK input tied to GROUND.

The program mode will not affect the operation of the unit. Thus programs may be modified

anytime, even while the genset is running.

Navigation between program parameters is performed via the MENUbutton. Holding thebutton pressed will cause the program parameter number to increase faster.

Parameter value may be increased and decreased with andbuttons. If these keys areheld pressed, the program value will be increased/decreased faster.

When a program parameter is modified, it is automatically saved in memory.

IfMENUbutton is pressed, next parameter will be displayed.

Program parameters are kept in a non-volatile memory and are not affected from powerfailures.

To exit the program mode press one of the mode selection keys. If no button is pressed during 1minute the program mode will be cancelled automatically.

Program parameters are organized in 2 groups as low and high levels. Entering the program

mode by pressing the MENUbutton will allow access to only low level parameters.

In order to access all parameters please hold OFF and MENUbuttons pressed.

13. PROGRAMMING


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PGM Parameter Definition Unit Fact.Set Description

P_000Current TransformerRatio

A 500This is the rated value of current transformers.

All transformers must have the same rating.The secondary of the transformer will be 5 Amps.

P_001 Overcurrent Limit A 0

If the current goes above this limit, during theperiod defined in Overload Timeout then a

Overcurrent Load Dump alarm will be generated.If this parameter is 0 then Overcurrent check isdisabled.

P_002 Excess Power Limit KW 0

If the active power goes above this limit, during theperiod defined in Overload Timeout then anExcess Power Load Dump alarm will begenerated.If this parameter is 0 then Excess Power check isdisabled.

P_003Mains Voltage LowLimit

V 170If one of the mains phases goes under this limit, itmeans that the mains are off and it starts thetransfer to the genset in AUTO mode.

P_004 Mains Voltage HighLimit

V 270If one of the mains phases goes over this limit, itmeans that the mains are off and it starts thetransfer to the genset in AUTO mode.

P_005Mains Frequency LowLimit

Hz 45If the mains frequency goes under this limit, itmeans that the mains are off and it starts thetransfer to the genset in AUTO mode.

P_006Mains FrequencyHigh Limit

Hz 55If the mains frequency goes above this limit, itmeans that the mains are off and it starts thetransfer to the genset in AUTO mode.

P_007Genset Low VoltageShutdown Limit

V 190

If one of the generator phase voltages goes underthis limit when feeding the load, this will generate aGENSET LOW VOLTAGE shutdown alarmandthe engine will stop.

P_008 Genset Low VoltageWarning Limit

V 200 If one of the generator phase voltages goes underthis limit when feeding the load, this will generate aGENSET LOW VOLTAGE warning.

P_009Genset High VoltageWarning Limit

V 250If one of the generator phase voltages goes abovethis limit when feeding the load, this will generate aGENSET HIGH VOLTAGE warning.

P_010Genset High VoltageShutdown Limit

V 260

If one of the generator phase voltages goes overthis limit when feeding the load, this will generate aGENSET HIGH VOLTAGE alarm and the enginewill stop.

P_011Low FrequencyShutdown

Hz 30If the genset frequency goes under this limit, aGENSET LOW SPEED alarm is generated and theengine stops.

P_012 Low FrequencyWarning

Hz 35 If the genset frequency goes under this limit, aGENSET LOW SPEED warning is generated.

P_013High FrequencyWarning

Hz 54If the genset frequency goes over this limit, aGENSET HIGH SPEED warning is generated.

P_014High FrequencyShutdown

Hz 55If the genset frequency goes over this limit, aGENSET HIGH SPEED alarm is generated and theengine stops.

P_015Low Battery VoltageWarning

V 9.0If the battery voltage falls below this limit, this willgenerate a LOW BATTERY warning.

P_016High Battery VoltageWarning

V 31.0If the battery voltage goes over this limit, this willgenerate a HIGH BATTERY warning.

P_017High Battery Voltage

Shutdown

V 33.0If the battery voltage goes over this limit, this willgenerate a HIGH BATTERY shutdownalarm and

the engine will stop.


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P_018Low Oil PressureWarning

bar 1.4If the oil pressure measured from the analog inputfalls below this limit, this will generate a LOW OILPRESSURE SENDER warning.

P_019

Low Oil Pressure

Shutdown bar 1.0

If the oil pressure measured from the analog inputfalls below this limit, this will generate a LOW OIL

PRESSURE SENDER alarm is generated and theengine stops.

P_020High TemperatureWarning

C 95If the coolant temperature measured from theanalog input goes over this limit, this will generatea HIGH TEMPERATURE SENDER warning.

P_021High TemperatureShutdown

C 98

f the coolant temperature measured from theanalog input goes over this limit, this will generatea HIGH TEMPERATURE SENDER alarm and theengine will stop.

P_022 Low Fuel Warning % 20If the fuel level measured from the analog inputfalls below this limit, a LOW FUEL LEVELSENDER warning is generated.

P_023 Low Fuel Shutdown % 10the fuel level measured from the analog input fallsbelow this limit, a LOW FUEL LEVEL SENDERshutdown alarm is generated and the engine stops.

P_024High Oil TemperatureWarning

C 100If the oil temperature measured from the analoginput goes over this limit, this will generate a HIGHOILTEMPERATURE SENDER warning.

P_025High Oil TemperatureShutdown

C 120

f the oil temperature measured from the analoginput goes over this limit, this will generate a HIGHOIL TEMPERATURE SENDER alarm and theengine will stop.

P_026Oil Pressure Sendertype

- 1

This parameter selects the oil pressure sendertype.0: Non standard sender. The sender

characteristics are defined in SenderCharacteristics table.1: VDO 0-7 bars (10-180 ohms)2: VDO 0-10 bars (10-180 ohms)3: DATCON 0-7 bars (240-33 ohms)4: DATCON 0-10 bars (240-33 ohms)5: DATCON 0-7 bars (0-90 ohms)6: DATCON 0-10 bars (0-90 ohms)7: DATCON 0-7 bars (75-10 ohms)

P_027Coolant Temp.Sender Type

- 1

This parameter selects the temperature sendertype:0: The sender characteristics are defined inSender Characteristics table.

1: VDO2: DATCON DAH type3: DATCON DAL type

P_028Oil Temp. SenderType

- 1

This parameter selects the temperature sendertype:0: The sender characteristics are defined inSender Characteristics table.1: VDO2: DATCON DAH type3: DATCON DAL type


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P_029 Hysteresis Voltage V 8

This parameter provides the mains and gensetvoltage limits with a hysteresis feature in order toprevent faulty decisions.For example, when the mains are present, themains voltage low limit will be used as the

programmed low limit. When the mains fail, thelow limit will be incremented by this value. It isadvised to set this value to 8 volts.

P_030Engine HeatingTemperature

C 0

If it is requested that the engine runs without loaduntil reaching a certain temperature, thisparameter defines the temperature.If the coolant temperature falls below thisparameter, an Engine Low Temperature warningwill occur.

P_031 Fault Holdoff Timer sec 12This parameter defines the delay after the engineruns and before the fault monitoring is enabled.

P_032 Overload Timeout sec 5

This is the period between the current or activepower go over the limits and OVERCURRENT orEXCESS POWER Load Dump alarms occur.This is also the period between the frequency goesout of the limits and OVERSPEED orUNDERSPEED alarms occur.This is also the period between the genset voltagegoes out of the limits and HIGH VOLTAGE orLOWVOLTAGE alarms occur.

P_033 Engine Start Delay sec 0

This is the time between the mains fails and thefuel solenoid turns on before starting the genset. Itprevents unwanted genset operation in batterybacked-up loads.

P_034 Preheat Timer sec 1

This is the time after the fuel solenoid is energizedand before the genset is started. During thisperiod the PREHEAT relay output is energized (ifassigned by Relay Definitions)

P_035 Choke Timer sec 5

This is the control delay of CHOKE output.The choke output is activated together with thecrank output. It is released after this delay or whenengine runs (whichever occurs first).

P_036 Gas Solenoid Delay sec 5The gas solenoid of the gas engine will be openedafter this delay during cranking.

P_037 Crank Timer sec 10This is the maximum start period. Starting will beautomatically cancelled if the genset fires beforethe timer.

P_038 Wait Between Starts sec 10This is the waiting period between two start

attempts.P_039 Idle Speed Timer sec 0

When the engine runs, the Idle output relayfunction will be active during this timer.

P_040 Engine Heating Timer sec 4This is the period used for engine heatingfollowing the program parameter.

P_041 Mains Waiting Timer min 0.5This is the time between the mains voltagesentered within the limits and the generatorcontactor is deactivated.

P_042 Cooldown Timer min 1.0This is the period that the generator runs for coolingpurpose after the load is transferred to mains.


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P_043Genset ContactorTimer

sec 1This is the period after the mains contactor hasbeen deactivated and before the generatorcontactor has been activated.

P_044Mains Contactor

Timer

sec 1This is the period after the generator contactor hasbeen deactivated and before the mains contactor

has been activated.

P_045 Stop Solenoid Timer sec 10

This is the maximum time duration for the engineto stop. During this period the STOP relay outputis energized (if assigned by Relay Definitions). Ifthe genset has not stopped after this period, aFAIL TO STOP warning occurs.

P_046 Number of Starts - 3 This is the maximum number of start attempts.

P_047Mains Phase OrderEnable

- 00: mains phase order checking disabled1: if mains phase order is faulty, then a warning isgiven and mains contactor deenergized.

P_048Genset Phase OrderLoaddump

- 00: genset phase order checking disabled1: if genset phase order is faulty, then a loaddumpis generated and the genset stops after cooldown.

P_049RPM from gensetfrequency

- 1

This parameter is used in the conversion of thegenset frequency to engine rpm.0: read rpm from the optional MPU input1: convert frequency to rpm (using crank teethcount)

P_050 Crank Teeth Count - 30

This is the number of pulses generated by themagnetic pickup sensing unit in one turn of theflywheel.This parameter is also used in the conversion ofthe genset frequency to engine rpm. Thefrequency in Hz is multiplied with this parameterduring conversion to rpm.

P_051 Low rpm Shutdown rpm 0 If the engine speed goes under this limit, a GENSETLOW SPEED alarm is generated and the enginestops.

P_052 Low rpm Warning rpm 0If the engine speed goes under this limit, a GENSETLOW SPEED warning is generated.

P_053 High rpm Warning rpm 0If the engine speed goes over this limit, a GENSETHIGH SPEED warning is generated.

P_054 High rpm Shutdown rpm 0If the engine speed goes over this limit, a GENSETHIGH SPEED alarm is generated and the enginestops.

P_055 Alarm Relay Timer sec 60This is the period during which the ALARM relayis active. If the period is set to 0, this will meanthat the period is unlimited.

P_056 Intermittent AlarmRelay

- 0 0: continuous1: intermittent (turns on and off every second)

P_057 Service Engine Hours hour 50

The SERVICE REQUEST led indicator will turn onafter this quantity of engine hours from the lastservice. If the period is set to 0 no SERVICEREQUEST will be generated depending on enginehours.

P_058 Service Period month 6

The SERVICE REQUEST led indicator will turn onafter this amount of time from the last service. Ifthe period is set to 0 no SERVICE REQUEST willbe indicated depending on time.


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P_059Reverse powerwarning limit

KW 0If the genset power is negative and goes abovethis limit then a REVERSE POWER warning willbe generated.

P_060Reverse powerloaddumpg limit

KW 0If the genset power is negative and goes abovethis limit then a REVERSE POWER loaddump willbe generated.

P_061Load Shedding LowLimit

KW 0If the genset power goes below this limit then theload shedding relay will be deactivated.

P_062

Load Shedding High

Limit KW 0

If the genset power goes above this limit then the

load shedding relay will be activated.

P_063 Fuel Pump Low Limit % 20If the fuel level measured from the sender inputfalls below this level, then the FUEL PUMPfunction will become active.

P_064 Fuel Pump High Limit % 80If the fuel level measured from the sender inputgoes above this level, then the FUEL PUMPfunction will become passive.

P_065 Fan turn-on temp C 90If the coolant temp is above this limit then the fanrelay function will become active.

P_066 Fan turn-off temp C 80If the coolant temp is below this limit then the fanrelay function will become inactive.

P_067Engine HeatingMethod

- 0

This parameter defines the engine heatingmethod. The genset will not take the load beforeengine heating is completed.0: engine is heated during Engine Heating Timer.1: engine is heated until the coolant temperaturereaches the Engine Heating Temperature and atleast during the Engine Heating Timer.

P_068 Crank Cut Frequency Hz 10.0When the genset frequency reaches this limit, theengine is supposed running and the crank outputwill release.

P_069Crank Stop with OilPressure

- 0

0: no crank stop with oil pressure1: cranking is stopped when oil presure switch isopen or the oil pressure measured is aboveshutdown limit.

P_070 Crank Stop withCharge

- 0 0: no crank stop with charge input1: cranking is stopped when the charge alternatorvoltage is established.

P_071Charge AlternatorShutdown

- 0

0: The charge input generates CHARGE FAILwarning, and does not stop the engine.1: The charge input generates CHARGE FAILalarm, and stops the engine.

P_072 Line-to-Line Voltages - 00: Display Line to Neutral voltages as default1: Display Line to Line voltages as default

P_073 Oil Pressure in psi - 00: oil pressure display in bars1: oil pressure display in psi

P_074 Temperature in F - 00: temperature display in degrees C1: temperature display in degrees F

Following parameters are in high priority group.


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P_075 Single phase Enable - 00: 3-phase system1: Single phase system

P_076Emergency BackupOperation

- 0

0: In TEST mode, the load will not be transferredto the genset even if the mains fail.1: In TEST mode, the load will be transferred to

the genset if the mains fail.

P_077 Modem Enable - 00: No modem connection, the serial port isconnected to PC1: Modem connected.

P_078 SMS Enable - 00: SMS not enabled1: SMS enabled

P_079 MODBUS Address - 00: RAINBOW communication protocol.1-144: MODBUS communication. This parameteris also the MODBUS controller address of the unit.

P_080SMS on MainsChange

- 0

This parameter controls SMS sending when mainsvoltages status is changed. No warning isgenerated.0: no SMS when mains failed or restored1: SMS sent when mains failed or restored

P_081Fuel Consumption perHour

% 0

This parameter is the threshold for sending FUELTHEFT and FUELLING sms messages.If this parameter is set to 0, then no Fuel Theft andFuelling sms messages will be sent.If SMS is required, set this parameter to a valueabove the hourly fuel consumption of the genset.

P_082Real Time Clock

Adjust- 117

This parameter trims precisely the real time clockcircuit.Values from 0 to 63 speed up the clock with0.25sec/day steps.Values from 127 to 64 slow down the clock with

0.25sec/day steps.P_083 Remote Start Enable - 0

0: no Remote Start signal1: SPARE-2 input is Remote Start signal

P_084Simulate MainsEnable

- 00: no Simulate Mains signal1: SPARE-2 input is Simulate Mains signal

P_085Delayed SimulateMains

- 0

0: The SPARE-2 input has normal function1: The SPARE-2 input has delayed simulatemains function. See chapter 6.8 for more info.

P_086 Flashing Relay Timer hours 0

Delayed Simulate Mains Operation: maxgenset running time after Simulate Mains signaldisappears.Dual Genset Systems: flashing relay toggletimer. Please contact DATAKOM for dual genset

mutual stanby operation.


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P_087Exercise Day andTime

- 168

This parameter defines the start day and hour ofthe exerciser.Values higher or equal to 168 mean that theexerciser is off.The exercise may be selected to start at the

beginning of the any hour of the week. Theparameter value is the hour count of the start time.Examples:

0 = exercise starts at Monday 00:008 = exercise starts at Monday 08:00

24 = exercise starts at Tuesday 00:00167 = exercise starts at Sunday 23:00168 = exerciser offIf a daily exercise is selected, then the dayinformation is dont care and the exercise will beperformed every day regardless of the dayselection.If the monthly exerciser is selected, then the

exercise will be performed during the first 7 daysof each month at the programmed day and hour.

P_088 Exercise Duration min 10This parameter defines the exercise duration andprogrammed in 10 minute steps up to 24 hours.

P_089 Exercise Off/On Load - 00: Exercise at TEST mode1: Exercise at LOAD TEST mode

P_090 Exercise Period - 1

0: exercise every day (the exercise will beperformed every day regardless of the dayselection of Exercise Dat and Time parameter).1: exercise once per week2: exercise once per month (the exercise will beperformed during the first 7 days of each month atthe programmed day and hour).

P_091 Language Selection - 0

This is the language used in SMS messages.0: english1: turkish2: french3: russian

P_092 Secondary Volt/Freq - 00: Use primary voltage/frequency limits1: When signal is applied to the SPARE-1 input,use secondary voltage/frequency limits

P_093 Engine Control Only - 00: Genset control1: Engine control (no alternator


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P_094 J1939 Enable - 0

0: The J1939 port is inoperative.1: The analog measurements (oil, temp, rpm) arepicked_up from the ECU. If the ECU communicationis lost, then the engine will be stopped.

P_095 J1939 Engine Type - 0

00: GENERIC ENGINE TYPE16: CUMMINS CM85032: DETROIT DIESEL48: DEUTZ Generic49: DEUTZ EMR250: DEUTZ EMR364: JOHN DEERE80: PERKINS81: PERKINS ADEM 382: PERKINS ADEM 1.396: VOLVO (with CIU unit)97: VOLVO EMS298: VOLVO EDC4112: CATERPILLAR ADEM II/III128: SCANIA S6129: SCANIA Single Speed130: SCANIA All Speed144: IVECO160: MTU MDEC 302161: MTU MDEC 201162: MTU MDEC 303163: MTU MDEC 304164: MTU MDEC 505176: BOSCH Generic177: BOSCH EDC 731178: BOSCH EDC 9.3Other values: Reserved. Do not use.

P_096 J1939 Speed Adjust % 50This parameter adjusts the speed of an ECUcontrolled engine by +/- 8%.

P_097VOLVO SpeedToggle

- -

This program parameter is not stored, but only used

in order to activate the primary or secondary speedselection operation of a Volvo EMS-II engine controlunit.0: Initiate the primary speed select operation1: Initiate the secondary speed select operation

Below parameters are applicable to J1939 enabledversions only.


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P_098 2nd

Overcurrent Limit A 0

When secondary volt/freq limits are active:If the current goes above this limit, during theperiod defined in Overload Timeout then aOvercurrent Load Dump alarm will be generated.If this parameter is 0 then Overcurrent check is

disabled.

P_0992

ndMains Voltage

Low LimitV 84

When secondary volt/freq limits are active:If one of the mains phases goes under this limit, itmeans that the mains are off and it starts thetransfer to the genset in AUTO mode.

P_1002

ndMains Voltage

High LimitV 136

When secondary volt/freq limits are active:If one of the mains phases goes over this limit, itmeans that the mains are off and it starts thetransfer to the genset in AUTO mode.

P_1012

ndMains Frequency

Low LimitHz 55

When secondary volt/freq limits are active:If the mains frequency goes under this limit, itmeans that the mains are off and it starts thetransfer to the genset in AUTO mode.

P_1022

ndMains Frequency

High LimitHz 65

When secondary volt/freq limits are active:If the mains frequency goes above this limit, itmeans that the mains are off and it starts thetransfer to the genset in AUTO mode.

P_1032

ndGenset Low

Voltage ShutdownLimit

V 90

When secondary volt/freq limits are active:If one of the generator phase voltages goes underthis limit when feeding the load, this will generate aGENSET LOW VOLTAGE shutdown alarmandthe engine will stop.

P_1042

ndGenset Low

Voltage Warning LimitV 94

When secondary volt/freq limits are active:If one of the generator phase voltages goes underthis limit when feeding the load, this will generate a

GENSET LOW VOLTAGE warning.

P_1052

ndGenset High

Voltage Warning LimitV 130

When secondary volt/freq limits are active:If one of the generator phase voltages goes abovethis limit when feeding the load, this will generate aGENSET HIGH VOLTAGE warning.

P_1062

ndGenset High

Voltage ShutdownLimit

V 136

When secondary volt/freq limits are active:If one of the generator phase voltages goes overthis limit when feeding the load, this will generate aGENSET HIGH VOLTAGE alarm and the enginewill stop.

P_1072

ndLow Frequency

ShutdownHz 40

When secondary volt/freq limits are active:If the genset frequency goes under this limit, aGENSET LOW SPEED alarm is generated and the

engine stops.

P_1082

ndLow Frequency

WarningHz 45

When secondary volt/freq limits are active:If the genset frequency goes under this limit, aGENSET LOW SPEED warning is generated.

P_1092

ndHigh Frequency

WarningHz 65

When secondary volt/freq limits are active:If the genset frequency goes over this limit, aGENSET HIGH SPEED warning is generated.

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