DataKom 309J_USER

8/12/2019 DataKom 309J_USER

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DKG-309 User Manual V-29 (12.09.2011)

DKG-309 AUTOMATIC

MAINS FAILURE UNIT

CANBUS AND MPU VERSIONS

AUTO

AUTO STOP

T

TEST RUN

DKG 309

LOAD

MAINS

GENSET

WARNING

SERVICEREQUEST

PGM

STATUS

ALARM

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

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 ECU alarms are displayed in text.

The unit has an optional internal GSM modemmodule and is able to initiate modem calls and sendSMS messages in fault conditions through eitherinternal or external modems.

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 panel

pushbuttons, 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.

The unit offers multiple language support.

True RMS measurements

ECU connect ion through J 1939 CAN opt ion

J1939 ECU warning s disp layed as text

MPU input opt ion

Internal GSM mod em opt ionDual genset mutual standby o perat ion

Event logging with t ime stamp and

measurements

Bat tery b acked-up real t ime clock

Bui l t in d ai ly / weekly / month ly exerciser

Weekly operat ion schedule programs

Field adjus table parameters

RS-232 serial po rt

Option al RS-485 serial port

Free MS-Window s Remote mo nitor ing SW

GSM and PSTN modem sup port

GSM SMS message sending on faul tMODBUS communic at ions

Mult ip le language supp ort

Customer logo dis play capabi li ty

1A protected semiconduc tor outputs

Conf igurable analogue inpu ts: 4

Conf igurable dig i ta l inputs: 7

Conf igurable relay outpu ts: 2

Total relay outpu ts: 6

I/O expans ion capabil i ty

Plug- in connect ion sys tem

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. Language Selection3.3. Digital Displays

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

6.1. Remote start operation

6.2. Sender type selection6.3. 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. External Control of the Unit6.18. Automatic Exerciser6.19. Resuming to factory set parameters6.20. Gas engine fuel solenoid control6.21. Load Shedding / Dummy Load6.22. Fuel Theft / Fuelling Messages6.23. Firmware Update6.24. Changing the Default Engine Speed in Volvo Engines

6.25. Engine Control Mode6.26. Dual Voltage and Frequency6.27. Single Phase Operation

7. J1939 ENGINE MONITORING AND CONTROL PORT8. MODBUS COMMUNICATION9. WEEKLY OPERATION SCHEDULE10. EVENT LOGGING11. STATISTICAL COUNTERS12. MAINTENANCE13. PROGRAMMING14. TROUBLESHOOTING15. DECLARATION OF CONFORMITY

16. TECHNICAL SPECIFICATIONS17. CONNECTION DIAGRAM

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-L1Mains frequencyGen 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 frequency

Engine speed (rpm)Gen KW phase L1Gen KW phase L2Gen KW phase L3Gen total KWGen pf phase L1Gen pf phase L2Gen pf phase L3Gen 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.

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

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

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

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

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

closedcontacts, switching either to BAT-or BAT+.

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

necessary to use an external charge lamp.

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 aplace easily accessible for the user.The fuse rating should be 6 Amps.

WARNING: ELECTRICITY CAN KILLALWAYS disconnect the power BEFORE connecting the

unit.1) ALWAYS remove the plug connectors when inser t ing wires with a

screwdriver.

2) An appropr iate and readi ly accessib le set of discon nect ion devices

(e.g. autom atic fuses) MUST be pro vided as part of th e instal lat ion.

3) The bui ld ing mains supply MUST incorporate appropr iate shor t -c i rcui t

backup protec tion (e.g. a fuse or circu it breaker) of High B reaking

Capacit y (HBC, at least 1500A).

4) Use cables of adequate current carrying capacity (at least 0.75mm2) an d

temperature range.

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 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.

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 mains

contactor. 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 shall

be 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 not

connect 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. Do

not connect the sender to other devices. The

input has programmable characteristics and

connects to any kind of sender.

15 COOLANT TEMP. SENDER Input, 0-5000 ohms Analogue high temperature sender

connection. Do not connect the sender to

other 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 to

this terminal. This terminal will supply the

excitation current and measure the voltage of

the charge alternator.

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

18 RELAY-1 (STOP RELAY) Output 10A/28VDC This relay has programmable function,

selectable from a list.

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

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

21 EMERGENCY STOP Digital inputs These inputs have programmable

characteristics selected via the program

menu. Each input may be driven by a

normally closed or normally open contact,

switching either battery+ or battery-. The effect

of the switch is also selectable from 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 transformer

inputs, 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 voltages

are within the limits.

MAINS OFF Red The LED will turn on when at least one of the mains

phase voltages is outside limits.

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

GENERATOR Yellow The LED will flash when the engine is running. It will

turn on steadily when all 3 generator phase voltages

are within the programmed limits.

TEST Yellow It turns on when the related operation mode is

selected. One of these LEDs is always on and

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

ALARM Red If a fault condition resulting to the engine shutdown

has occurred, the alarm led turns on steadily. If aloaddump condition occurs, this led will flash. Alarms

work on a first occurring basis. The occurrence of a

fault will disable other faults of lower or equal priority.

WARNING Red If a warning condition has occurred, this led turns on

steadily. The warnings work on a first occurring basis.

The occurrence of a warning will disable other

warnings, however shutdown and loaddump alarms

are still allowed.

SERVICE REQUEST Red Engine periodic maintenance request indicator. It

turns 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 is able to display information in 3 or 4 languages, following versions. Language selection

is made through program parameter CONTROLLER CONFIGURATION > LANGUAGE SELECTION.Below selections are available in the standard version:

0: English language

1: Turkish language

2: Chinese language

3: ask selection at power-up

If language is set to 3, below screen will come at power on:

Left / Up / Down arrow pushbuttons will select the screen language. The language will be asked

everytime power is turned on.

With selections of 0,1,2 this screen will not appear and the selected language is enabled.

The unit has a graphical 128x64 pixel LCD display. It shows:-Measured parameters,-The company logo,-The alarm list-Software version and date-time information,-Statistical counters,-Event records,-Program parameters.

Navigation between different screens s made with the MENU andMENUbuttons. Eachdepression of the MENU button switches the display to the next screen. Each depression of theMENUbutton switches the display to the previous screen.

During operation, the unit will switch automatically between different screens, displayingalways the most important parameters for the current operating status.

If an alarm or warning occurs during operation, in other then programming mode, the displaywill automatically switch to ALARM LISTposition. The MENU or MENUbuttons will not function.To enable display navigation and mute the internal buzzer, press ALARM MUTEbutton first. If there ismore than one alarm, the next alarm is displayed by pressing the button. Thus all existing alarmscan be scanned. END OF ALARM LIST will be displayed when there is no more alarm to display.

The display has a backlight illumination feature. The backlightturns on with the depressionof any button or when the genset runs. It turns off after 4 hours to allow power economy.

3.3 Digital Display

3.2 Language Selection


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Screen Description Contents

1 Mains parameters(phase to neutral)

Genset statusMains Volts L1, Mains FrequencyMains Volts L2 , Battery VoltageMains Volts L3, Coolant Temperature

2 Mains parameters

(phase to phase)

Genset status

Mains Volts L1-L2, Mains FrequencyMains Volts L2-L3, Battery VoltageMains Volts L3-L1, Coolant Temperature

3 Genset parameters(phase to neutral)

Genset statusGenset Current L1, Genset FrequencyGenset Current L2, Genset Active Power (KW)Genset Current L3, Genset Volts L1

4 Genset parameters(phase to phase)

Genset statusGenset Current L1, Genset FrequencyGenset Current L2, Genset Active Power (KW)Genset Current L3, Genset Volts L1-L2

5 Engine parameters Genset statusOil Pressure, Engine rpmCoolant Temperature, Battery VoltageFuel Level,

6 Complete Gensetparameters(phase to neutral)

Genset statusGenset Volts L1, Genset Volts L2, Genset Volts L3Genset Current L1, Genset Current L2, Genset Current L3,Genset Frequency, Oil PressureGenset Active Power (KW), Coolant TemperatureGenset power factor, Fuel LevelEngine rpm, Battery Voltage

7 Complete Gensetparameters(phase to phase)

Genset statusGenset Volts L1-L2, Genset Volts L2-L3, Genset Volts L3-L1Genset Current L1, Genset Current L2, Genset Current L3

Genset Frequency, Oil PressureGenset Active Power (KW), Coolant TemperatureGenset power factor, Fuel LevelEngine rpm, Battery Voltage

8 Graphical Gensetparameters(phase to neutral)

Genset statusGenset Current L1Genset Volts L1

Genset Active Power (%), Genset FrequencyOil PressureCoolant TemperatureFuel Level

9 Graphical Gensetparameters

(phase to phase)

Genset statusGenset Current L1

Genset Volts L1-L2Genset Active Power (%), Genset FrequencyOil PressureCoolant TemperatureFuel Level

10 Genset Phase Powerparameters

Genset statusGenset Phase L1 : Active Power(KW) / Power FactorGenset Phase L2 : Active Power(KW) / Power FactorGenset Phase L3 : Active Power(KW) / Power Factor


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Screen Description Contents

11 CANBUS Measurements1 / 6

Percent TorquePercent LoadFuel Pressure


Fuel RateAverage Fuel Economy

Total Engine Hours13 CANBUS Measurements

3 / 6Air PressureAmbient Air TemperatureOil Temperature


Intake Manifold 1 TemperatureExhaust Gas TemperatureFuel Temperature


Boost PressureAir Filter Differential PressureCrank Case Pressure


Coolant LevelOil LevelCoolant Pressure

17 Company Logo

18 Alarm List If no alarm exists, END OF ALARM LIST will be displayed.Existing alarms, load_dumps, warnings and J1939 ECUwarnings will be displayed as one screen for each entry.

Switching to the next entry will be made with the button.19 Date-Time,

Software VersionDate and time.Operating software version.J1939 software version.

20 Statistical Counters 1 / 3 Engine Hours RunTotal Genset Active Power (KW-h)

21 Statistical Counters 2/ 3 Engine Hours to ServiceTime to Service

22 Statistical Counters 3 / 3 Total Engine CranksTotal Engine Runs


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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:

- The ALARMled to be on steadily,

- The genset contactor to be released immediately,

- The engine to be stopped immediately,

- The Horn, Alarm,Alarm+Load_dumpand Alarm+Load_dump+Warningdigital

outputs to operate, (if selected via programming menu)

2- LOAD_DUMPS:These fault conditions cause:

- The ALARM led to flash,

- The genset contactor to be released immediately,

- The engine to be stopped after Cooldown period,

- The Horn, Alarm+Load_dumpand Alarm+Load_dump+Warningdigital outputs to

operate, (if selected via programming menu)

3- WARNINGS: These conditions cause:

- The WARNING led to be on steadily,

- The Hornand Alarm+Load_dump+Warningdigital outputs to operate, (if selected

via programming menu)

If the ALARM MUTE button is pressed, the Horn output will be deactivated; however the

existing alarms will persist and disable the operation of the genset.

Alarms operate in a first occurring basis:

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

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

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

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

condition is removed, the alarms will stay on and disable the operation of the genset. The existing alarms

may be canceledby pressing one of the operating mode buttons (LOAD TEST / TEST / OFF / AUTO).

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

alarm limits.

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

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

separately programmable for the oil pressure sender input. This fault will be monitored with Holdoff

Timerdelay after the engine is running. Also if the oil pressure switch is open at the beginning of a start

attempt, then the engine will not be started and Oil Pressure Exists! information is displayed. When

the oil pressure switch closes, normal operation will be resumed.HIGH TEMPERATURE:Set if a signal is detected at the High Temperature Switch input or the coolant

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

are separately programmable for the temperature sender input.

LOW TEMPERATURE (warning) :Set if the coolant temperature value measured from the sender is

blow the Engine Heating Temperaturelimit.

LOW FUEL:Set if a signal is detected at the low fuel level input or the the fuel level measured from the

sender is below the programmed limit. Warning and alarm limits are separately programmable for the

fuel level sender input.

RECTIFIER FAIL:Set if a signal is detected at the rectifier fail input. This input is only monitored when

mains voltages are present.

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

SPARE-1 / SPARE-2:Set if a signal is detected from the related spare fault input.

4. ALARMS AND WARNINGS


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LOW SPEED / HIGH SPEED: Set if the generator frequency is outside programmed limits. These faults

will be monitored with Holdoff Timerdelay after the engine is running. Low and high limits for warning

and alarm are separately programmable. Another high frequency shutdown limit which is 12% above the

high limit is always monitored and stops the engine immediately.

START FAIL (alarm):Set if the engine is not running after programmed number of start attempts.

STOP FAIL (warning):Set if the engine has not stopped before the expiration of the Stop Timer.

OVERLOAD (load_dump):Set if at least one of the genset phase currents goes over the Overcurrent

Limit for Overload Timer. If currents goes below the limit before expiration of the timer then no alarm will

be set.

EXCESS POWER (load_dump): Set if the genset power (KW) supplied to the load goes over the

Excess Powerlimit for Overload Timer. If the power goes below the limit before expiration of the timer

then no alarm will be set.

GENSET LOW VOLTAGE:Set if any of the generator phase voltages goes outside programmed limits

for Overload Timer. This fault will be monitored with holdoff timerdelay after the engine is running.

GENSET HIGH VOLTAGE:Set if any of the generator phase voltages goes outside programmed limits

for Overload Timer. This fault will be monitored with holdoff timerdelay after the engine is running.

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

During engine cranking this fault is not monitored.

HIGH BATTERY VOLTAGE:Set if the battery voltage goes above programmed limits. Both warning andalarm levels for high battery voltage are programmable.

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

warningor alarmfollowing programming.MAINS PHASE ORDER FAIL (warning):Set if the mains phase order checking is enabled, mainsphases are present and mains phase order is reversed. This fault prevents the Mains Contactor to close.


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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 LOAD TEST mode is selected when genset is running at TEST mode, then the genset willtake the 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 AUTOled will flash, and the

operation of the genset will be as in the OFFmode.

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 AUTOor OFFmode.

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 of REMOTE STARTmode of operation. Any digital input may beassigned as Remote Start Inputusing Input Function Selectprogram parameters.

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 ACTIONprogram parameter of the related input to 3in 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 Characteristicstable.

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 Characteristicstable.1: VDO2:DATCON DAH type

3:DATCON DAL type

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

Oil Temperature Sender Selection:Selectable sender types are:0:Sender characteristics are defined in Sender Characteristicstable.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 Methodparameter is set to 0. In thismode, the engine will run during parameter Engine Heating Timer, and then the genset will take theload.

2. Timer and temperature controlled heating:This operation mode is selected when the Engine Heating Methodparameter is set to1. In thismode, at first the engine will run during parameter Engine Heating Timer, then it will continue to rununtil the measured coolant temperature reaches the limit defined in parameter Engine 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 parameter Idle 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 outputusing 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 parameter Engine Heating

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

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

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

Temperature.

6.5 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 Limitparameter, the fuel pump relay output will

operate. When the fuel level reaches Fuel Pump High Limitparameter, the relay will turn off. Thus

the chassis fuel tank level will be always kept between Fuel Pump Low LimitandFuel Pump High

Limitparameters.

The fuel pump 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 unit offers an optional SIMULATE MAINSsignal input. Any digital input may be assignedas Simulate Mainsusing Input Function Selectprogram parameters.

It is also necessary to set the ACTIONprogram parameter of the related input to 3in order to

prevent any alarms generated from this input.

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

If the Simulate Mainsinput 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 SIMULATE MAINS andFORCE 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 MAINSsignal input. Any digital input may be assignedas Simulate Mainsusing Input Function Selectprogram parameters.

It is also necessary to set the ACTIONprogram parameter of the related input to 3in 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 is set to 1 and the input signal is activewhen the genset is not feeding the load, the mains phases are not monitored and supposed to beinside 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 Flashing Relay Timer program parameter. After this, 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 mains

voltage status.

The REMOTE START operation overrides DELAYED SIMULATEMAINS operation. When both parameters Remote StartOperation and Delayed Simulate Mains are set then REMOTESTART operation mode is performed.

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 parameter Flashing Relay Timer.

Each time the period programmed using Flashing Relay Timer elapses, the relay output will change

position.

The flashing relay function may be assigned to spare relays using Relay Definition program

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

The dual genset intermittent operation uses also the Mains Simulationfeature. Please review

chapter 6.7for 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 Priorityusing Input Function Selectprogramparameters.

It is also necessary to set the ACTIONprogram parameter of the related input to 3in order to

prevent any alarms generated from this input.

The Prioritysignal 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 Priorityinput is defined, then the system will work in priority mode. If the priority signal isapplied, the unit will become master after each mains failure. If the priority signal is not applied, thenthe unit will become the slave one and the other genset will start.

Please contact DATAKOM for a complete application manual.

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 SERVICE REQUEST led has no effect on the gensetoperation.

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

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

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

period of 0 months indicates that the unit will request maintenance only based on engine hours, there will

be no time limit. If the engine hours is also selected as 0 hours this will mean that the SERVICE

REQUEST display will be inoperative.

When the engine hours ORthe time limit is over, the SERVICE REQUESTled (red) will start to

flash and the service request relay function will be active.

The service request relay function may be assigned to spare relays using Relay Definition

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

To turn off the SERVICE REQUEST led, and reset theservice period, press together the ALARM MUTE andLAMP TEST keys for 5 seconds.

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

and are not affected from power supply failures.

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

6.10 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 datatime 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. GSMmodems and classic cable network (PSTN) modems areacceptable.

If the modem is connected to the unit, the Modem Enableprogram 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.

When the modem call is in progress, a telephone icon ( ) will appear at the upper rightcorner of the screen.

If Modem Enableor SMS Enableor MODBUS Addressparameters aredifferent from zero, the local PC connection will not work.

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, but

it 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.

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 Enableprogram parameter to 1.

If Modem Enableor SMS Enableor MODBUS Addressparameters aredifferent from zero, the local PC connection will not work.

When a fault condition occurs, the unit will compose an SMS message and will send it to up to 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 Changeprogram parameter)Fuel Theft, Fuelling(enabled by setting the Fuel Consumption / Hourparameter to other than 0)

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

When SMS sending is in progress, an (SMS) icon will appear at the upper right corner of thescreen.

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.

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.trinternet site with password login.

The modem, SMS and Modbus modes are not compatible with the local PC connection. ModemEnable, SMS Enableand MODBUS Addressprogram 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.

The unit offers total external control through programmable digital inputs. Each digital input may

be programmed for below functions:- Force STOP mode

- Force AUTO mode

- Force RUN 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 keys. However if the external mode

select signal is removed, the unit will revert to the last selected mode via pushbuttons.

It is also possible to lock the front panel completely for remote command.

6.17 External Control of the Unit

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 TESTor LOAD 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 Operationis 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 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.

6.18 Exerciser


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In order to resume to the factory set parameter values:

-hold pressed the OFF, LAMP TEST and ALARM MUTEbuttons for 5 seconds,

-RETURN TO FACTORY SET will be displayed-immediately press and hold pressed the ALARM MUTEbutton for 5 seconds-factory set values will be reprogrammed to the parameter memory.

It is not possible to restore user parameters.

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 Delayprogram parameter.

The gas engine fuel solenoid 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 load shedding feature consists on the disconnection of the least crucial loads when thegenset 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 Load

Shedding relay will be deactivated.Load Shedding High Limit:If the genset active power output goes above this limit, then the Load

Shedding relay will be activated.

6.21. Load Shedding / Dummy Load

6.20. Gas Engine Fuel Solenoid Control

6.19. Resuming to factory set parameters


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

These SMS messages are sent without creating visible fault condition.

These features are enabled by setting the program parameter Engine Parameters > FuelConsumption / Hourto a value other than 0%.

The Fuel Consumption / Hour parameter should be set to a value clearly greater than themaximum 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 1

hour period, then a FUELLING sms message is sent to programmed telephone numbers.

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 completion bar 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-IIengine control unit have the engine speed selectablethrough the J1939CANBUS. The unit offers the possibility to the user to switch between the primary

and secondary speed using the programming menu.

If the program parameter Volvo Speed Toggleis 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.

The unit mustbe in OFF mode when speed is switched, otherwise theswitching will not be performed.

Please note also that a fine adjustment of the engine speed in the 8 % range may be doneusing the program parameter J1939 Speed Adjust.

6.24. Changing the Default Engine Speed in Volvo Engines

6.23. Firmware Update

6.22. Fuel Theft / Fuelling Messages


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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 ControllerConfigurationgroup.

When the Engine Control Modeis 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 and high rpm limit valuesin order to enable engine speed protection.

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 can be done in 2 ways:

-by setting the program parameter Secondary Volt/Freqto 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 2nd

Volt-Freq Selectusing INPUT FUNCTION SELECT program group.

Below parameters are available for second voltage-frequency selection:

Mains Low Voltage LimitMains High Voltage LimitMains Low Frequency Limit

Mains High Frequency Limit

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

Genset 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

6.26. Dual Voltage and Frequency

6.25. Engine Control Mode


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If the unit is used in a single phase electrical network, it is advised t set the Single PhaseEnableprogram parameter in CONTROLLER CONFIGURATIONgroup to 1.

When Single Phase Enableis set to 1, then the unit will measure electrical parameters onlyon phases L1of genset and mains.

Voltage and overcurrent checks will be performed on phases L1only.

Phases L2 and L3parameters, as well as phase-to-phase voltages are removed from display

screens.

6.27. Single Phase Operation


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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 connection

between 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 ohmstermination resistor is included inside the unit. Please do not connect external

resistor.

The J1939 port is activated by setting the program parameter J1939 Enableto 1. The J1939Engine Typeparameter 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 temperatureand the engine rpminformation are picked up from the ECUunit. Other available measurements are displayed forinformation, but they have no effect on engine operation. In total, the unit is capable of displaying 21parameters 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 FAILalarm and stop the engine. This feature prevents

uncontrolled engine operation.

The fault conditions of an electronic engineare considered by the unit as warningsand do

not cause engine stop. The engine is supposed protected by the ECU which will stop it whennecessary.

The electronic engine fault codesare displayed within the alarm list table in text, togetherwith their SPN-FMIcodes. 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 batteryvoltage, 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 MODBUSAddressprogram parameter. The possible address range is 1 to 144. Setting the address to 0 willdisablethe 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 ApplicationManualand 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://www.modbus.org/docs/PI_MBUS_300.pdfhttp://www.modbus.org/docs/PI_MBUS_300.pdfhttp://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 AUTOmode. In other modes it will not affectthe genset operation.

In AUTOmode, 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 18:00Friday 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 Adjustprogram 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. The events are always displayed starting from the most recent one.

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

Switching from one menu screen to another is made with the MENU andMENUbuttons.

Events are visible inside the Programming menu. Correct password must be entered in order to

display events.

When the EVENT RECORD screen is displayed, each depression on the MENU button makes thedisplay switch to the previous event and MENUbutton makes the display switch to the next event.

To exit event record pages please press MENUbutton until EVENTRECORD is displayed.

Each event is displayed in 4 pages. Event and page numbers are shown at the top right corner of the

display. Events are numbered starting from 1, number 1 being the latest one. Pages are listed from A

to D. Navigation between different pages of the same event is done with andbuttons.

Event sources are:

-Shutdown alarms, Load dump alarms, Warnings-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)

10. EVENT LOGGING


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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.

DO NOT OPEN THE UNIT

There are NO serviceable parts inside the unit.Wipe the unit, if necessary with a soft damp cloth. Do not use chemical agents

12. MAINTENANCE

11. STATISTICAL COUNTERS


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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, press together MENU and MENUbuttons for 1 second.The program mode is only allowed if the PROGRAM LOCK input is left open. If this input is tied to

GROUND, the program value modification will be disabled to prevent unauthorized intervention. It is

advised to keep the PROGRAM LOCKinput tied to GROUND.

When the program mode is entered, below password entry screen will be displayed.

A 4 digit password must be entered using , , MENUandMENU buttons.

The unit stores 3 different passwords. Each password allows access to a different level of

program parameters.

The password level-1 allows access to field adjusted parameters. The level-2 allows access to

factory setup. The password level-3 is reserved to Datakom and allows access to calibration

parameters.

The password level-1 is factory set to 1234 and the password level-2 is factory set to 9876.Passwords can only be modified through Rainbow program.

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

anytime, even while the genset is running.

The program mode is driven with a two level menu system. The top menu consists on program

groups and each group consists of various program parameters.

When program mode is entered, a list of available groups will be displayed. Navigation

between different groups are made with andbuttons. Selected group is shown in reverse video(blue on white). In order to enter inside a group, please press MENUbutton. In order to exit from thegroup to the main list please press MENU button.

Navigation inside a group is made also with andbuttons. 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 MENUbutton. Parameter value may beincreased and decreased with andbuttons. If these keys are hold pressed, the program value willbe increased/decreased by steps of 10. When a program parameter is modified, it is automatically

saved in memory. If MENUbutton is pressed, next parameter will be displayed. If MENU button ispressed, then the list of parameters in this group will be displayed.

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

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

13. PROGRAMMING


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Program Group: Controller Configuration

Parameter Definition,(Password Level)

Unit FactorySet

Description

(1)LCD Contrast - 22This parameter is used to set LCD contrast. Adjust forthe best viewing angle.

(2)Language - 0

0:English language selected.1: Turkish language selected. This language maydepend on the country where the unit is intended tobe used.2:Chinese language selected3:The unit will ask for manual language selection atpower-on.

(2)Secondary Volt/Freq - 00:Use primary voltage/frequency limits1:Use secondary voltage/frequency limits

(2)Single phase Enable - 00:3-phase system1:Single phase system

(2)Line-to-Line Voltages - 00:Display Line to Neutral voltages as default1:Display Line to Line voltages as default

(1)Genset Default Display - 0

This parameter selects the screen which is displayedduring genset on load operation.0:screen 3 (or 4) electrical, large characters1:screen 5 engine parameters, large characters2:screen 6 (or 7) maximum information, small

characters3: screen 8 (or 9)Details of each screen are explained in chapter 3.2

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

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

(1)Alarm Relay Timer sec 60This is the period during which the ALARMrelay isactive. If the period is set to 0, this will mean that theperiod is unlimited.

(1)Intermittent Alarm Relay - 00:continuous1:intermittent (turns on and off every second)

(2)Charge AlternatorShutdown

- 0

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

(1)Emergency BackupOperation

- 0

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


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Program Group: Controller Configuration (continued)Parameter Definition,

(Password Level)Unit Factory

SetDescription

(1)Exercise Day and Time - 168

This parameter defines the start day and hour of theexerciser.

Values higher or equal to 168 mean that theexerciser is off.The exercise may be selected to start at thebeginning 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 be

performed every day regardless of the day selection.If the monthly exerciser is selected, then the exercisewill be performed during the first 7 days of eachmonth at the programmed day and hour.

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

(1)Exercise Off/On Load - 00:Exercise at TESTmode1:Exercise at LOAD TESTmode

(1)Exercise Period - 1

0:exercise every day (the exercise will be performedevery day regardless of the day selection of ExerciseDat 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).

(2)Delayed Simulate Mains - 0

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

(2)Modem Enable - 00: No modem connection, the serial port is connectedto PC1: Modem connected.

(2)SMS Enable - 00:SMS not enabled1:SMS enabled

(2)MODBUS Address - 00:RAINBOW communication protocol.1-144:MODBUS communication. This parameter is

also the MODBUS controller address of the unit.(1)Oil Pressure in psi - 0

0: oil pressure display in bars1: oil pressure display in psi

(1)Temperature in F - 00: temperature display in degrees C1: temperature display in degrees F

(2)Flashing Relay Timer hours 0

Delayed Simulate Mains Operation: max gensetrunning time after Simulate Mains signal disappears.Dual Genset Systems:flashing relay toggle timer.Please contact DATAKOM for dual genset mutualstanby operation.


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Program Group: Controller Configuration (continued)Parameter Definition,

(Password Level)Unit Factory

SetDescription

(1)Real 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 with0.25sec/day steps.

(2)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, the mainsvoltage low limit will be used as the programmed lowlimit. When the mains fail, the low limit will beincremented by this value. It is advised to set thisvalue to 8 volts.

(2)RPM from gensetfrequency

- 1

This parameter is used in the conversion of the

genset frequency to engine rpm.0: read rpm from the optional MPU input1: convert frequency to rpm (using crank teeth count)

(2)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 of thegenset frequency to engine rpm. The frequency in Hzis multiplied with this parameter during conversion torpm.

(2) SMS on Mains Change - 0

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

(2) Fuel Pump Low Limit % 20If the fuel level measured from the sender input fallsbelow this level, then the FUEL PUMP function willbecome active.

(2) Fuel Pump High Limit % 80If the fuel level measured from the sender input goesabove this level, then the FUEL PUMP function willbecome passive.

(2)Oil pressure sender fault

effect- 0

0: no effect1:warning2:loaddump

(2)Coolant temp sender faulteffect

- 00: no effect1:warning

2:loaddump(2)Fuel level sender faulteffect

- 00: no effect1:warning2:loaddump

(2)Oil temp sender faulteffect

- 00: no effect1:warning2:loaddump

(2)RS-485 Enable - 00: RS-232 communication1:RS-485 communication


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Program Group: Electrical ParametersParameter Definition,

(Password Level)Unit Facto

ry SetDescription

(2)Current Transformer

Ratio

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.

(2)Overcurrent Limit A 0

If the current goes above this limit, during the perioddefined in Overload Timeoutthen a Overcurrent LoadDumpalarm will be generated.If this parameter is 0 then Overcurrent check is disabled.

(2)Excess Power Limit KW 0

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

(2)Overload Timeout sec 5

This is the period between the current or active power goover the limits and OVERCURRENT orEXCESSPOWERLoad Dump alarms occur.

This is also the period between the frequency goes outof the limits and OVERSPEED orUNDERSPEED alarmsoccur.This is also the period between the genset voltage goesout of the limits and HIGH VOLTAGE orLOWVOLTAGE alarms occur.

(1)Mains Voltage Low Limit V 170If one of the mains phases goes under this limit, itmeans that the mains are off and it starts the transferto the genset in AUTOmode.

(1)Mains Voltage High Limit V 270If one of the mains phases goes over this limit, itmeans that the mains are off and it starts the transferto the genset in AUTOmode.

(2)Mains Frequency LowLimit

Hz 45 If the mains frequency goes under this limit, it meansthat the mains are off and it starts the transfer to thegenset in AUTOmode.

(2)Mains Frequency HighLimit

Hz 55If the mains frequency goes above this limit, it meansthat the mains are off and it starts the transfer to thegenset in AUTOmode.

(2)Genset Low VoltageShutdown Limit

V 190

If one of the generator phase voltages goes under thislimit when feeding the load, this will generate a GENSETLOW VOLTAGEshutdown alarmand the engine willstop.

(2)Genset Low VoltageWarning Limit

V 200If one of the generator phase voltages goes under thislimit when feeding the load, this will generate a GENSETLOW VOLTAGEwarning.

(2)Genset High VoltageWarning Limit

V 250If one of the generator phase voltages goes above thislimit when feeding the load, this will generate a GENSETHIGH VOLTAGEwarning.

(2)Genset High VoltageShutdown Limit

V 260If one of the generator phase voltages goes over thislimit when feeding the load, this will generate a GENSETHIGH VOLTAGE alarm and the engine will stop.


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Program Group: Electrical Parameters (continued)Parameter Definition,(Password Level)

UnitFactory Set

Description

(2)Low Battery VoltageWarning

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

(2)High Battery VoltageWarning

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

(2)High Battery VoltageShutdown

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

(1)Mains Waiting Timer min 0.5This is the time between the mains voltages enteredwithin the limits and the generator contactor isdeactivated.

(2)Genset Contactor Timer sec 1This is the period after the mains contactor has beendeactivated and before the generator contactor hasbeen activated.

(2)Mains Contactor Timer sec 1This is the period after the generator contactor hasbeen deactivated and before the mains contactor hasbeen activated.

(2)Mains Phase OrderEnable

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

(2)Reverse power warninglimit

KW 0If the genset power is negative and goes above thislimit then a REVERSE POWERwarning will begenerated.

(2)Reverse powerloaddumpg limit

KW 0If the genset power is negative and goes above thislimit then a REVERSE POWERloaddump will begenerated.

(2)Load Shedding Low Limit KW 0If the genset power goes below this limit then theload shedding relay will be deactivated.

(2)Load Shedding HighLimit KW 0 If the genset power goes above this limit then theload shedding relay will be activated.

(2)Genset Phase OrderLoaddump

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


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Program Group: Electrical Parameters (continued)Parameter Definition,(Password Level)

UnitFactorySet

Description

(2)2nd

Overcurrent Limit A 0

When secondary volt/freq limits are active:If the current goes above this limit, during the period

defined in Overload Timeoutthen a OvercurrentLoad Dumpalarm will be generated.If this parameter is 0 then Overcurrent check isdisabled.

(1)2nd

Mains Voltage LowLimit

V 170

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 AUTOmode.

(1)2nd

Mains Voltage HighLimit

V 270

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 AUTOmode.

(2)2ndMains Frequency LowLimit

Hz 45

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 AUTOmode.

(2)2nd

Mains FrequencyHigh Limit

Hz 55

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 AUTOmode.

(2)2nd

Genset Low VoltageShutdown Limit

V 190

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 VOLTAGEshutdown alarmand the

engine will stop.

(2)2ndGenset Low VoltageWarning Limit

V 200When 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 VOLTAGEwarning.

(2)2nd

Genset High VoltageWarning Limit

V 250

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 VOLTAGEwarning.

(2)2nd

Genset High VoltageShutdown Limit

V 260

When secondary volt/freq limits are active:If one of the generator phase voltages goes over thislimit when feeding the load, this will

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