Datakom DKG-307 User manual

DKG-307 User Manual V-37 (01.03.2012)
DKG-307 AUTOMATIC
MAINS FAILURE UNIT
CANBUS AND MPU VERSIONS
The controller is a comprehensive AMF unit for
single genset standby or dual genset mutual standby
operations.
The unit is available with MPU or CANBUS versions.
The CANBUS version connects to ECU controlled
electronic engines providing engine control,
protection and instrumentation without extra senders.
The unit is able to initiate modem calls and send
SMS messages in fault conditions through external
modems.
The unit provides a comprehensive set of digitally
adjustable timers, threshold levels, input and output
configurations, operating sequences and engine
types. 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 allows
remote monitoring and control.
The unit supports MODBUS protocol enabling
communication with PLCs and building management
systems. The MODBUS protocol is also supported
through GSM and PSTN modems.
True RMS measurements
ECU connection through J1939 CAN option
MPU input option
Dual genset mutual standby operation
Event logging with time stamp and
measurements
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
FEATURES
DESCRIPTION

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Section
1. INSTALLATION
1.1. Introduction to the Control Panel
1.2. Mounting the Unit
1.3. Wiring the Unit
2. INPUTS AND OUTPUTS
3. DISPLAYS
3.1. Led Displays
3.2. Digital Displays
4. ALARMS AND WARNINGS
5. MODES OF OPERATION
6. OTHER FEATURES
6.1. Remote start operation
6.2. Sender type selection
6.3. Engine heating operation
6.4. Engine Idle Speed Operation
6.5. Engine Block Heater
6.6. Fuel Pump Control
6.7. Mains Simulation (Disable Start)
6.8. Delayed Mains Simulation, Battery Charging
6.9. Dual Genset Mutual Standby Operation
6.10. Service Request Display
6.11. Engine Hours Meter
6.12. Date-Time Display
6.13. Display of Software Version
6.14. Modem connection
6.15. SMS message sending
6.16. Remote Monitoring and Programming
6.17. Automatic Exerciser
6.18. Resuming to factory set parameters
6.19. Gas engine fuel solenoid control
6.20. Load Shedding / Dummy Load
6.21. Fuel Theft / Fuelling Messages
6.22. Firmware Update
6.23. Changing the Default Engine Speed in Volvo Engines
6.24. Engine Control Mode
6.25. Dual Voltage and Frequency
6.26. Single Phase Operation
7. J1939 ENGINE MONITORING AND CONTROL PORT
8. MODBUS COMMUNICATION
9. WEEKLY OPERATION SCHEDULE
10. EVENT LOGGING
11. STATISTICAL COUNTERS
12. MAINTENANCE
13. PROGRAMMING
14. TROUBLESHOOTING
15. DECLARATION OF CONFORMITY
16. TECHNICAL SPECIFICATIONS
17. CONNECTION 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 neutral
Mains voltage phase L2 to neutral
Mains voltage phase L3 to neutral
Mains voltage phase L1-L2
Mains voltage phase L2-L3
Mains voltage phase L3-L1
Gen voltage phase L1 to neutral
Gen voltage phase L2 to neutral
Gen voltage phase L3 to neutral
Gen voltage phase L1-L2
Gen voltage phase L2-L3
Gen voltage phase L3-L1
Gen current phase L1
Gen current phase L2
Gen current phase L3
Gen frequency
Engine speed (rpm)
Gen total kW
Gen total pf
Battery voltage,
Coolant temperature
Oil pressure
Oil temperature
Fuel level
1.1 Introduction to the Control Panel
1. 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 in
its position bythe 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 byseparate 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- or BAT+.
The charge alternator connection terminal provides also the excitation current, thus it is not
necessaryto use an external charge lamp.
WARNING: ELECTRICITY CAN KILL
ALWAYS disconnect the power BEFORE connecting
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 devices
(e.g. automatic fuses) MUST be provided as part of the installation.
3) The building mains supply MUST incorporate appropriate short-circuit
backup protection (e.g. a fuse or circuit breaker) of High Breaking
Capacity (HBC, at least 1500A).
Use cables of adequate current carrying capacity (at least 0.75mm2)
and temperature range.
WARNING: THE UNIT IS NOT FUSED.
Use external fuses for Mains phases: L1,L2,L3,
Generator phase: L1,L2,L3, Battery positive: BAT(+).
Install the fuses as nearly as possible to the unit in a
place easily accessible for the user.
The fuse rating should be 6 Amps.
Engine body must be grounded for correct operation of
the unit, otherwise incorrect voltage and frequency
measurements 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 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 phase
inputs, 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 will
be de-energized. In order to provide extra
security, the normally closed contact of the
generator contactor should be serially
connected to this output.
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 anykind 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 alternator‟s D+ terminal to
this terminal. This terminal will supply the
excitation current and measure the voltage of
the charge alternator.
17
RELAY-2 (HORN RELAY)
Output 10A/28VDC
This relay has programmable function,
selectable from a list.
18
RELAY-1 (STOP RELAY)
Output 10A/28VDC
This relay has programmable function,
selectable from a list.
19
START RELAY
Output 10A/28VDC
This relaycontrols the engine cranking.
20
FUEL RELAY
Output 10A/28VDC
This relayis 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 PRESSURE
28
RECTIFIER FAIL
29
CURR_1+
Current transformer
inputs, 5A-AC
Connect the generator current transformer
terminals to these inputs. Do not connect the
same current transformer to other instruments
otherwise a unit fault will occur. Connect each
terminal of the transformer to the unit‟s related
terminal. Do not use common terminals. Do
not use grounding. Correct polarity of
connection is vital. If the measured power is
negative, then change the polarity of each 3
current transformers. The rating of the
transformers should be the same for each of
the 3 phases. The secondary winding rating
shall 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 anykind of sender.
CANBUS VERSIONS
36
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 VERSIONS
36
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 bythe
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 alarm
led turns on steadily. If a warning condition occurs,
this led will flash. Alarms work on a first occurring
basis. The occurrence of a fault will disable other
faults of lower or equal priority.
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 Displays
3. DISPLAYS

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The unit has 3 seven segment displays. Theyshow:
-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 current
transformers. 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 DISPLAY: By pressing the MENU key below values may read:
-oil pressure (bar)
-coolant temperature (ºC)
-fuel level
-generator frequency (Hz)
-generator active power (KW)
-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 the
existing alarms will persist and disable the operation of the genset.
Alarms operate in a first occurring basis:
-If an alarm is present, following alarms, load_dumps and warnings will not be accepted,
-If a load_dump is present, following load_dumps and warnings will not be accepted,
-If a warning is present, following warnings will not be accepted.
Alarms may be of LATCHING type following programming. For latching alarms, even if the alarm
condition is removed, the alarms will stay on and disable the operation of the genset. The existing alarms
may be canceled by pressing one of the operating mode buttons (LOAD TEST / TEST / OFF / AUTO).
Most of the alarms have programmable trip levels. See the programming chapter for adjustable
alarm limits.
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 Holdoff
Timer delay after the engine is running. Also if the oil pressure switch is open at the beginning of a start
attempt, then the engine will not be started and 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 is
blow 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 the
electronic 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 Overcurrent
Limit for Overload 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 the
Excess Power limit for Overload Timer. If the power goes below the limit before expiration of the timer
then no alarm will be set.
GENSET LOW VOLTAGE: Set if any of the generator phase voltages goes outside programmed limits
for Overload Timer. This fault will be monitored with holdoff timer delay after the engine is running.
GENSET HIGH VOLTAGE: Set if any of the generator phase voltages goes outside programmed limits
for Overload Timer. This fault will be monitored with holdoff timer delay after the engine is running.
LOW 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 a
warning or alarm following programming.
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: 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 take
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 AUTO led will flash, and the
operation 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 or OFF 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 of REMOTE START mode of operation. The SPARE-2 input may
be assigned as Remote Start Input using the program parameter P_083.
The REMOTE START signal may be a NO or NC contact, switching to either battery positive or
battery negative. These selections are made using programming menu.
It is also necessary to set the ACTION program parameter of the SPARE-2 input to 3in order to
prevent any alarm from this input.
In this mode the mains phases are not monitored. If the REMOTE START signal is present
then the mains will be supposed to fail, inversely if the REMOTE START signal is absent, then mains
voltages will be supposed to be present. The front panels mimic diagram‟s mains LEDs will reflect the
status of the REMOTE START input.
The unit has the ability to adapt to any type of oil pressure and temperature senders. The
commonly used standard sender characteristics are recorded in memory and selectable from a list.
However non standard senders may also be used by entering their characteristics to the table.
Oil Pressure Sender Type Selection:
Selectable sender types are:
0: Sender characteristics are defined in Sender Characteristics table.
1: VDO 0-7 bars (10-180 ohms)
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: VDO
2: 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: VDO
2: DATCON DAH type
3: 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 the
genset should not take the load before reaching a suitable temperature. The unit offers 2 different
ways of engine heating.
1. Timer controlled heating:
This operation mode is selected when the Engine Heating Method parameter is set to 0. In this
mode, the engine will run during parameter Engine Heating Timer, and then the genset will take the
load.
2. Timer and temperature controlled heating:
This operation mode is selected when the Engine Heating Method parameter is set to 1. In this
mode, at first the engine will run during parameter Engine Heating Timer, then it will continue to run
until the measured coolant temperature reaches the limit defined in parameter Engine Heating
Temperature. When the requested temperature is reached, the load will be transferred to the genset.
This operation mode may be used as a backup to the engine body heater. If the engine body is warm
the heating will be skipped.
It may be required that the engine runs at the idle speed for a programmed duration for engine
heating. The idle operation duration is adjusted with the parameter Idle Speed Timer. The idle speed
will be set by the governor control unit of the engine.
Any of the spare relay outputs may be assigned as IDLE output using Relay Definition
program parameters. Also relays on an extension module may be assigned to this function.
The Idle speed operation is performed both in engine start-up and cool-down sequences.
Speed and voltage protections are disabled during idle speed operation.
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 Limit parameter, the fuel pump relay output will
operate. When the fuel level reaches Fuel Pump High Limit parameter, the relay will turn off. Thus
the chassis fuel tank level will be always kept between Fuel Pump Low Limit and Fuel Pump High
Limit parameters.
The fuel pump relay function may be assigned to spare relays using Relay Definition program
parameters. Also relays on an extension module may be assigned to this function.
The unit offers an optional SIMULATE MAINS signal input. The SPARE-2 digital input may be
assigned as Simulate Mains using program parameter P_084.
It is also necessary to set the ACTION program parameter of the related input to 3in order to
prevent any alarms generated from this input.
The SIMULATE MAINS signal maybe a NO or NC contact, switching to either battery positive or
battery negative. These selections are made using the programming menu.
If the Simulate Mains input is defined and the input signal is active, the mains phases are not
monitored and supposed to be inside limits. This will prevent the genset from starting even in case of a
mains failure. If the genset is running when the signal is applied, then usual Mains Waiting and
Cooldown cycles will be performed before engine stop. When the SIMULATE MAINS signal is present,
the front panels mimic diagram‟s mains LEDs will reflect the mains voltages as present.
When the signal is passive, the unit will revert to normal operation and monitor the mains
voltage status.
The REMOTE START operation overrides SIMULATE
MAINS 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 where
batteries are able to supply the load during a certain period. The genset is requested to run only when
battery voltage drops below the critical level. Once the engine runs, the rectifier system starts charging
the batteries and the battery voltage goes up immediately. Thus the engine should continue to run a
programmed period for effective charging. The critical battery voltage level will be detected by an
external unit which provides the digital Simulate Mains signal for the genset control unit.
The unit offers an optional SIMULATE MAINS signal input. The SPARE-2 digital input may be
assigned as Simulate Mains using program parameter P_084.
It is also necessary to set the ACTION program parameter of the related input to 3in order to
prevent any alarms generated from this input.
The SIMULATE MAINS signal maybe a NO or NC contact, switching to either battery positive or
battery negative. These selections are made using the programming menu.
If the Delayed Simulate Mains program parameter (P_085) is set to 1 and the input signal is
active when the genset is not feeding the load, the mains phases are not monitored and supposed to
be inside limits. This will prevent the genset from starting when the simulate mains signal is present
(batteries charged). The genset will start when mains voltages are out of limits and the simulate mains
signal not present.
If the genset is running when the signal is applied, then MAINS SIMULATION will be
prevented during P_086 Flashing Relay Timer program parameter. After this, usual Mains Waiting
and Cooldown cycles will be performed before engine stop. When the SIMULATE MAINS signal is
present, the front panels mimic diagram‟s mains LEDs will reflect the mains voltages as present.
When the signal is passive, the unit will revert to normal operation and monitor the mains
voltage status.
The REMOTE START operation overrides DELAYED
SIMULATE MAINS operation. When both parameters
“Remote Start Operation” and “Delayed Simulate
Mains” are set then REMOTE START operation mode is
performed.
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 Simulation feature. Please review
chapter 6.7 for a detailed explanation of this feature.
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 (for
example 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 will
be no time limit. If the engine hours is also selected as 0 hours this will mean that the SERVICE
REQUEST display will be inoperative.
When the engine hours OR the time limit is over, the SERVICE REQUEST led (red) will start to
flash and the service request relay function will be active.
The service request relay function may be assigned to spare relays using Relay Definition
program parameters. Also relays on an extension module may be assigned to this function.
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 and
LAMP TEST keys for 5 seconds.
The SERVICE REQUEST led has no effect on the
genset 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 memoryand 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 modem
calls made from a remote location. GSM modems and classic cable network (PSTN) modems are
acceptable.
If the modem is connected to the unit, the Modem Enable program parameter should be set
to 1, otherwise faulty operation may occur.
A maximum of 2 telephone numbers can be defined for outgoing modem calls. In case of
alarm, the unit will attempt to reach control centers associated with each number. In case of modem
connection 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 battery
voltage than the unit. Most of other desktop modems with standard AT commands are also usable, but
it is the user‟s responsibility to provide an uninterrupted AC supply source to the modem. The
necessary modem cable will be supplied by DATAKOM.
Modem calls are always terminated by the central RAINBOW software. However the unit does
not allow connection durations exceeding 2 minutes, and hangs up the modem when this period
expires.
The PC program used for remote monitoring and programming is the same RAINBOW
software used for RS-232 connection.
Please note that the modem operation is also compatible with the MODBUS communication.
Thus the unit can iniate and receive calls to/from a MODBUS master station. Please review chapter_8
for more details on MODBUS communication.
If Modem Enable or SMS Enable or MODBUS Address
parameters are different from zero, the local PC
connection 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 6
phone numbers. If modem is enabled, only 4 telephone numbers are available for SMS sending.
The unit is also able to send SMS messages in below conditions, without creating a visible alarm
or warning:
Mains Fail, Mains Restored (enabled via SMS on Mains Change program parameter)
Fuel Theft, Fuelling (enabled by setting the Fuel Consumption / Hour parameter to other than 0)
If both modem and SMS are enabled, the unit will send SMS messages first and attempt modem
connection afterwards.
The maximum number of alarms transmitted in a SMS message is 4. This limitation is due to the
maximum length of an SMS message which is 160 characters.
A sample GSM SMS message is given below:
DKGxxx <SITE-ID>
STOP :LOW OIL PRESSURE SW.
END OF ALARM LIST
The first line of the message carries information about the unit type and the site identity string.
This line is intended for the identification of the genset sending the SMS message.
Each following line will give one fault information. The message will always be terminated by the
“END OF ALARM LIST” string.
When the message is sent, the existing alarms will be masked, causing the audible alarm relayto
release and preventing consecutive GSM SMS messages. Any new upcoming alarm will result in a new
GSM SMS message. The new message will indicate all existing alarms, even masked ones.
The necessary GSM modem cable will be supplied by DATAKOM. This is the same cable as
PSTN (land) modems.
If Modem Enable or SMS Enable or MODBUS Address
parameters are different from zero, the local PC
connection 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 be
downloaded from www.datakom.com.tr internet site with password login.
The modem, SMS and Modbus modes are not compatible with the local PC connection. Modem
Enable, SMS Enable and MODBUS Address program parameters should be set to 0 before
connection.
The RAINBOW software allows the visualization and recording of all measured parameters.
The recorded parameters may then be analyzed graphically and printed. The software also allows the
programming of the unit and the storage of the program parameters to PC or the downloading of
stored parameters from PC to the unit.
For PCs without a serial port, below USB to serial adapters are tested and approved :
DIGITUS USB 2.0 TO RS-232 ADAPTER (PRODUCT CODE: DA70146 REV 1.1)
DIGITUS USB 1.1 TO RS-232 ADAPTER (PRODUCT CODE: DA70145 REV 1.1)
FLEXY USB 1.1 TO SERIAL ADAPTER (PRODUCT CODE BF-810)
CASECOM USB TO SERIAL CONVERTER (MODEL: RS-01)
The necessary PC connection cable will be supplied by DATAKOM. The cable length should
not be over 3 meters.
6.16 Remote Monitoring and Programming