Datakom DKG-325 User manual

DKG-325 User Manual Firmware V-56
DKG-325
GENSET
CONTROL &
ATS PANEL
DKG-325, is a ready-to-use control and transfer panel
for gasoline and diesel gensets rated up to 15kVA. It
supports both 1 and 3 phase gensets.
The unit incorporates all necessary components for
battery charging, genset control and load transfer
between mains and genset.
Gensets may be automatized using the DKG-325,
without the need for any additional equipment. Thanks
to the unit, automatization of small gensets has become
easy and cost effective.
In AUTO position, the unit monitors 3 phases of the
mains, runs and stops the genset automatically and
performs load transfer. When the engine is running, it
monitors internal protections and alarm inputs.
The unit features 2 contactors, battery charging rectifier
and the automatic control circuitry in one enclosure. It is
the equivalent of a complete genset control panel.
Internal contactors are rated for 40Amp switching and
are capable of carrying 25Amp continuously.
Fuel and crank outputs are provided through 40Amp
rated relays and do not require additional relays.
The internal battery charging rectifier is rated 1Amp
@12V-DC. The internal rectifier is sufficient for the float
charging of the engine start battery.
The unit features 3 internal current transformers. It
measures currents and power from both genset and
mains.
Timers, threshold levels, input and output configurations
are digitally programmable. Programs are modified
through front panel pushbuttons and do not require an
additional unit.
• Automatic mains monitoring
• Automatic load transfer
• Automatic starting and stopping
• Automatic stopping in fault condition
• Test mode available
• Emergency backup mode
• Internal current transformers
• Detailed load measurements and
protections
• Internal battery charging rectifier
• 40 Amp rated Fuel and Crank outputs
• Front panel adjustable parameters
• Stop, preheat and choke output capability
• Configurable spare digital input
• Survives cranking voltage dropouts
• Compact dimensions, flush mounted
Mains Voltages: L1-N, L2-N, L3-N
Mains Voltages: L1-L2, L2-L3, L3-L1
Genset Voltages: L1-N, L2-N, L3-N
Genset Voltages: L1-L2, L2-L3, L3-L1
Load Currents: L1, L2, L3
Load phase and total kW, kVA, kVAr, cosΦ
Genset Frequency
Battery Voltage
Oil pressure
Coolant temperature
Engine run Hours
Service Counters
MEASUREMENTS
FEATURES
DESCRIPTION

DKG-325 User Manual Firmware V-56
- 2 -
Any unauthorized use or copying of the contents or any part of this document is prohibited.
This document describes minimum requirements and necessary steps for the successful installation of
the DKG-325 family units.
Follow carefully advices given in the document. These are often good practices for the installation which
reduce future issues.
For all technical queries please contact Datakom at below e-mail address:
[email protected].tr
If additional information to this manual is required, please contact the manufacturer directly at below e-
mail address: [email protected].tr
Please provide following information in order to get answers to any question:
- Device model name (see the back panel of the unit),
- Complete serial number (see the back panel of the unit),
- Firmware version (read from the display screen),
- Measuring-circuit voltage and power supply voltage,
- Precise description of the query.
REVISION
DATE
WRITTEN
DESCRIPTION
01
28.08.2015
MH
First edition
CAUTION: Potential risk of injury or death.
WARNING: Potential risk of malfunction or material damage.
ATTENTION: Useful hints for the understanding of device operation.
TERMINOLOGY
QUERRIES
REVISION HISTORY
ABOUT THIS DOCUMENT
COPYRIGHT NOTICE

DKG-325 User Manual Firmware V-56
- 3 -
DKG325 is available in various options and peripheral features. Please use below information for ordering
the correct version:
DKG325
-G
-T
-00
Screw Type Bracket
Stock Code=J10P01 (1 unit)
Spring Type Bracket
Stock Code=K16P01 (1 unit)
Watertight Gasket, Stock Code= K35P01
SPARE PARTS
ORDER CODES
Product Code
Watertight
Gasket
Conformal
Coating
Coating
Variant
00: standard unit
01...99: customer
specific products

DKG-325 User Manual Firmware V-56
- 4 -
Electrical equipment should be installed only by qualified
specialist. No responsibility is assured by the manufacturer or
any of its subsidiaries for any consequences resulting from the
non-compliance to these instructions.
Check the unit for cracks and damages due to transportation.
Do not install damaged equipment.
Do not open the unit. There are no serviceable parts inside.
Fuses must be connected to the phase voltage inputs, in close
proximity of the unit.
Fuses must be of fast type (FF).
Disconnect all power before working on equipment.
When the unit is connected to the network do not touch
terminals.
Any electrical parameter applied to the device must be in the
range specified in the user manual. Although the unit is
designed with a wide safety margin, over-range parameters
may reduce lifetime, alter operational precision or even
damage the unit.
Do not try to clean the device with solvent or the like. Only
clean with a dump cloth.
Verify correct terminal connections before applying power.
Only for panel base mounting.
WARNING
Use of fuses of higher rating than allowed may
result in serious hazards.
SAFETY NOTICE
Failure to follow below instructions will result in
death or serious injury

DKG-325 User Manual Firmware V-56
- 5 -
1. INSTALLATION INSTRUCTIONS
2. MOUNTING
2.1 DIMENSIONS
2.2 SEALING, GASKET
2.3 ELECTRICAL INSTALLATION
3. TERMINAL DESCRIPTIONS
3.1. BATTERY VOLTAGE INPUT
3.2. AC VOLTAGE INPUTS
3.3. DIGITAL INPUTS
3.4. ANALOG SENDER INPUTS
3.5. CHARGE INPUT TERMINAL
3.6. LOAD OUTPUTS
3.4. DIGITAL OUTPUTS
4. CONNECTION DIAGRAM
5. TERMINAL DESCRIPTION
6. TECHNICAL SPECIFICATIONS
7. DESCRIPTION OF CONTROLS
7.1. FRONT PANEL FUNCTIONALITY
7.2. PUSHBUTTON FUNCTIONS
7.3. DISPLAY SCREEN ORGANIZATION
7.4. MEASURED PARAMETERS
7.5. LED INDICATORS
8. OPERATION OF THE UNIT
8.1. QUICK START GUIDE
8.2. STOP MODE
8.3. MANUAL RUN MODE
8.4. AUTO MODEN
9. PROTECTIONS AND ALARMS
9.1. SERVICE REQUEST ALARM
9.2. ALARMS
10. PROGRAMMING
11. CRANK CUTTING
TABLE OF CONTENTS

DKG-325 User Manual Firmware V-56
- 6 -
12. SOFTWARE FEATURES
12.1. REMOTE START OPERATION
12.2. MAINS SIMULATION
12.3. DELAYED MAINS SIMULATION, BATTERY CHARGING
12.4. SERVICE REQUEST DISPLAY
12.5. ENGINE HOUR METER
12.6. SOFTWARE VERSION DISPLAY
12.7. GAS ENGINE FUEL SOLENOID CONTROL
12.8. SINGLE PHASE OPERATION
13. DECLARATION OF CONFORMITY
14. MAINTENANCE
15. DISPOSAL OF THE UNIT
16. ROHS COMPLIANCE
17. TROUBLESHOOTING
TABLE OF CONTENTS (continued)

DKG-325 User Manual Firmware V-56
- 7 -
Before installation:
Read the user manual carefully, determine the correct connection diagram.
Remove all connectors and mounting brackets from the unit, then pass the unit through the
mounting opening.
Put mounting brackets and tighten. Do not tighten too much, this can brake the enclosure.
Make electrical connections with plugs removed from sockets, then place plugs to their sockets.
Be sure that adequate cooling is provided.
Be sure that the temperature of the environment will not exceed the maximum operating
temperature in any case.
Below conditions may damage the device:
Incorrect connections.
Incorrect battery voltage.
Reverse battery voltage
Voltage at measuring terminals beyond specified range.
Voltage applied to digital inputs over specified range.
Current at measuring terminals beyond specified range.
Overload or short circuit at relay outputs
Connecting or removing data terminals when the unit is powered-up.
High voltage applied to communication ports.
Excessive vibration, direct installation on vibrating parts.
Below conditions may cause abnormal operation:
Battery voltage below minimum acceptable level.
Frequency out of specified limits
Missing earthing
1. INSTALLATION INSTRUCTIONS

DKG-325 User Manual Firmware V-56
- 8 -
Dimensions: 200x148x72mm (7.9”x5.8”x2.9”)
Panel cutout: 176x121mm minimum (7.0”x4.8”)
Weight: 700g (1.5 lb)
Mount the unit on a flat, vertical surface. Before mounting, remove the mounting brackets and connectors
from the unit, then pass the unit through the mounting opening.
Place and tighten mounting brackets.
2.1. DIMENSIONS
2. MOUNTING

DKG-325 User Manual Firmware V-56
- 9 -
The module will come with one of below bracket types:
Screw type bracket
Spring type bracket
Screw type bracket installation
Spring type bracket installation
Do not tighten too much, this may break the unit.

DKG-325 User Manual Firmware V-56
- 10 -
The rubber gasket provides a watertight means of mounting the module to the genset panel. Together
with the gasket, IEC 60529-IP65 protection can be reached from the front panel. A short definition of IP
protection levels is given below.
1st Digit Description of Protection Level
0 Not protected
1 Protected against solid foreign objects of 50 mm diameter and greater
2 Protected against solid foreign objects of 12,5 mm diameter and greater
3 Protected against solid foreign objects of 2,5 mm diameter and greater
4 Protected against solid foreign objects of 1,0 mm diameter and greater
5 Protected from the amount of dust that would interfere with normal operation
6 Dust tight
2nd Digit Description of Protection Level
0 Not protected
1 Protected against vertically falling water drops
2 Protected against vertically falling water drops when enclosure is tilted up to 15 °
3 Protected against water sprayed at an angle up to 60 ° on either side of the vertical
4 Protected against water splashed against the component from any direction
5 Protected against water projected in jets from any direction
6 Protected against water projected in powerful jets from any direction
7 Protected against temporary immersion in water
8 Protected against continuous immersion in water, or as specified by the user
2.2. SEALING, GASKET
Module
Gasket
Panel

DKG-325 User Manual Firmware V-56
- 11 -
Although the unit is protected against electromagnetic disturbance, excessive
disturbance can affect the operation, measurement precision and data communication
quality.
ALWAYS remove plug connectors when inserting wires with a screwdriver.
Fuses must be connected to the battery and phase voltage inputs, in close
proximity of the unit.
Fuses must be of fast type (FF). AC fuses must be max 25A.
Use cables of appropriate temperature range.
Use adequate cable section, at least 0.75mm2 (AWG18).
Follow national rules for electrical installation.
For the correct operation, engine body must be
grounded. Otherwise faulty voltage and frequency
measurements may occur.
Do not install the unit close to high electromagnetic
noise emitting devices like contactors, high current
busbars, switchmode power supplies and the like.
2.3. ELECTRICAL INSTALLATION

DKG-325 User Manual Firmware V-56
- 12 -
Battery terminals are both internal battery charger outputs and battery supply inputs.
When AC mains supply is available, the unit charges the battery. When mains voltages fail, the unit
continues operation through the engine battery.
Charger output voltage:
13.7VDC
Charger output current
1.0 ADC
Operating voltage range:
8 - 16VDC
Cranking dropouts:
Survives 0VDC during 100ms. The voltage before surge should be
9VDC minimum
Max. Operating current:
500mA @ 12VDC. (All features active, outputs open)
Typical operating current:
250mA @ 12VDC. (All features passive, digital outputs open)
Measurement range:
0 - 36VDC
Display resolution:
0.1VDC
Accuracy:
1.0% + 1 digit @ 12VDC
Measurement method:
True RMS
Input voltage range:
14 to 250 VAC (phase-neutral)
Min voltage for frequency
detect:
15 VAC (Ph-N)
Measurement range:
0 to 330VAC ph-N (0 to 570VAC ph-ph)
Input impedance:
4.5M-ohms
Display resolution:
1VDC
Accuracy:
1.0% + 1 digit @ 230VAC ph-N (±2VAC ph-N)
1.0% + 1 digit @ 400VAC ph-ph (±3VAC ph-ph)
Frequency range:
DC to 100 Hz
Frequency display
resolution:
0.1 Hz
Frequency accuracy:
0.2% + 1 digit (±0.2 Hz @ 50Hz)
Be sure that battery connection is not reversed.
Reverse connection will damage the unit.
3.1. BATTERY VOLTAGE INPUT
3. TERMINAL DESCRIPTIONS
3.2. AC VOLTAGE INPUTS

DKG-325 User Manual Firmware V-56
- 13 -
Contact type:
Normally open or normally closed (programmable)
Switching:
Battery negative or battery positive (programmable)
Structure:
47 k-ohms resistor to battery positive, 110k-ohms to battery negative.
Measurement:
Analog voltage measurement.
Open circuit voltage:
70% of battery voltage
Low level threshold:
35% of battery voltage
High level threshold:
85% of battery voltage
Maximum input voltage:
+100VDC with respect to battery negative
Minimum input voltage:
-70VDC with respect to battery negative
Noise filtering:
yes
Structure:
667 ohms resistor polarizing to 3.3VDC
Measurement:
Analog resistor measurement.
Open circuit voltage:
+3.3VDC
Short circuit current:
5mA
Measurement range:
0 to 5000 ohms.
Open circuit threshold:
5000 ohms.
Resolution:
1 ohms @ 300 ohms or lower
Accuracy:
2 %+1 ohm (±7 ohms @300 ohms)
Noise filtering:
yes
3.4. ANALOG SENDER INPUTS
3.3. DIGITAL INPUTS

DKG-325 User Manual Firmware V-56
- 14 -
The Charge terminal is both an input and output.
When the engine is ready to run, this terminal supplies the excitation current to the charge alternator.
The excitation circuit is equivalent to a 2W lamp.
Structure:
battery voltage output through 82 ohm resistor
voltage measurement input
Output current:
130mA @12VDC
Charge Fail Warning
Threshold:
6VDC
Open circuit voltage:
battery positive
Overvoltage protection:
> 500VDC continuous, with respect to battery negative
Reverse voltage
protection:
-30VDC with respect to battery negative
Structure:
Genset or mains voltage through 2 internal relays. Internal current
transformers on the load line.
Max. switching current:
25A @250VAC
Max switching voltage:
440VAC
The unit has 3 digital outputs. One of them may be selected as FUEL or STOP. The auxiliary output
function may be selected from list.
Structure:
Positive switching relay outputs
Max. Continuous current:
Fuel & crank:40A, Auxiliary:10A
Max. Switching current:
16 VDC
3.7. DIGITAL OUTPUTS
3.6. LOAD OUTPUTS
3.5. CHARGE INPUT TERMINAL

DKG-325 User Manual Firmware V-56
- 15 -
4. CONNECTION DIAGRAM

DKG-325 User Manual Firmware V-56
- 16 -
Term
Function
Technical data
Description
1
MAINS NEUTRAL
Input, 0-250V-AC
Neutral terminal for the mains phases.
2
MAINS-L1
Mains phase inputs,
0-250V-AC
Connect the mains phases to these inputs.
The mains voltages upper and lower limits
are programmable.
Mains inputs must be protected by fuses.
Fuse rating must be max 25A
3
MAINS-L2
4
MAINS-L3
5
LOAD L3
AC Load supply
output, 25A-AC max.
Supply the load from these outputs. The
maximum output current rating is 25A per
phase.
6
LOAD L2
7
LOAD L1
8
GENSET-L1
Genset phase inputs,
0-250V-AC
Connect the genset phases to these
inputs. The genset voltages upper and
lower limits are programmable.
9
GENSET-L2
10
GENSET-L3
Term
Function
Technical data
Description
11
OIL PRESSURE SENDER
Resistor measuring
input,
0-5000 ohms
Connect to the oil pressure sender.
Do not connect the sender to other
devices. The input is programmable in
order to use to any sender type.
12
COOLANT TEMP. SENDER
Connect to the coolant temperature
sender. Do not connect the sender to
other devices. The input is programmable
in order to use to anysender type.
13
LOW OIL PRESSURE
SWITCH
Digital Inputs,
0-30Vdc
Connect to the low oil pressure switch to
this terminal.
14
HIGH TEMP SWITCH
Connect to the high temperature switch to
this terminal.
15
SPARE FAULT INPUT
The prioritylevel of this input is adjustable.
16
CHARGE
Input and output
Connect the charge alternator’s D+/WL
terminal to this terminal. This terminal will
supply the excitation current and measure
the voltage of the charge alternator.
17
AUXILIARY RELAY
OUTPUT
10A-DC/16V-DC
This relay has programmable function,
selectable from a list. Factory set as
ALARM output.
18
BATTERY NEGATIVE
O VDC
Power supply negative connection.
Term
Function
Technical data
Description
19
BATTERY POSITIVE
+12 V-DC
The positive terminal of the DC Supply.
20
DIGITAL OUTPUT 1
Relay Outputs
40A/12V-DC
CRANK output, capable of driving the
starter motor directly.
21
DIGITAL OUTPUT 2
FUEL output, capable of driving the FUEL
solenoid directly.
Drawing excessive current from load outputs may
damage the unit.
5. TERMINAL DESCRIPTION

DKG-325 User Manual Firmware V-56
- 17 -
DC Supply Range: 9.0 - 16.0 V-DC.
DC supply current:
250 mA-DC typical @12V-DC
500 mA-DC max. @12V-DC
Alternator Voltage: 0-250 V-AC (Phase-Neutral)
Alternator Frequency: 0-100 Hz.
Mains Voltage: 0-250 V-AC (Phase-Neutral)
Mains Frequency: 0-100 Hz.
Load Current: 3x25A / 230V-AC continuous
Cranking Dropouts: survives 0V for 100ms.
Fuel and Crank Relay Outputs: 40 A / 12V-DC
Auxiliary Output: 10A / 12 V-DC
Charge Excitation: min 2 W.
Battery Charge Current: min 1A / 13.7V-DC (195-250V-AC)
Operating temp.: -40°C (-40°F) to 70°C (158°F).
Storage temp.: -55°C (-67°F) to 80°C (176°F).
Maximum humidity: 95% non-condensing.
Dimensions: 200x 148 x 72 mm (GxYxD)
Panel Cutout: 176 x 121mm minimum.
Weight: 700 g (approx..)
Enclosure: Flame retardant, high temp ABS/PC (UL94-V0)
IP Protection: IP54 (front).
EU Directives
-2006/95/EC (low voltage)
-2004/108/EC (electromagnetic compatibility)
Reference standards for EU Conformity:
-EN 61010 (safety)
-EN 61326 (EMC)
6. TECHNICAL SPECIFICATIONS

DKG-325 User Manual Firmware V-56
- 18 -
BUTTON
FUNCTION
Selects RUN mode. The genset runs off-load.
Selects AUTO mode. The genset runs when necessary and takes the load.
Selects OFF mode. The genset stops.
If held pressed for 10 seconds, resets service counters.
Selects next display parameter. If held pressed, select the LAMP TEST then
PROGRAMMING functions.
When held pressed for 5 seconds, enters a special PROGRAMMING mode where
high level parameters may also be adjusted.
7.2. PUSHBUTTON FUNCTIONS
7.1. FRONT PANEL FUNCTIONALITY
7. DESCRIPTION OF CONTROLS
RUN mode
button
STOP mode
button
AUTO mode
button
Menu
selection
button
Mimic Diagram
(system status)

DKG-325 User Manual Firmware V-56
- 19 -
The unit measures a large number of electrical and engine parameters. The display of the parameters is
organized as a list which can be scanned by pressing the MENU button.
Each depression of the button will cause the display to switch to the next parameter. After the last
parameter the display will switch to the first parameter.
Parameter list:
Mains phase-neutral voltages: L1, L2, L3
Mains phase-phase voltages: L12, L23, L31
Genset phase-neutral voltages: L1, L2, L3
Genset phase-phase voltages: L12, L23, L31
Load currents: L1, L2, L3
Total active power
Total cosØ
Genset frequency
Battery voltage
Oil pressure
Coolant temperature
Engine run hours
Engine run hours to service
Time to service
Firmware version
The unit performs a detailed set of AC measurements.
The list of measured AC parameters is below:
Mains voltage phase L1 to neutral
Mains voltage phase L2 to neutral
Mains voltage phase L3 to neutral
Mains voltage phase L1-L2
Mains voltage phase L2-L3
Mains voltage phase L3-L1
Mains frequency
Mains current phase L1
Mains current phase L2
Mains current phase L3
Mains total kW
Mains total pf
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 frequency
Gen current phase L1
Gen current phase L2
Gen current phase L3
Gen average current
Gen total kW
Gen total pf
Battery voltage
Oil pressure (bar, kPa)
Coolant temperature
7.4. MEASURED PARAMETERS
7.3. DISPLAY SCREEN ORGANIZATION

DKG-325 User Manual Firmware V-56
- 20 -
MODE LEDS: Turns on when related operating mode is selected.
MAINS AND GENSET LEDS:
MAINS: Flashes when all mains phase voltages and the mains frequency are within limits.
Turns on when the load is fed by the mains.
GENSET: Flashes when all genset phase voltages and the genset frequency are within limits.
Turns on when the load is fed by the genset.
If a REMOTE START input is defined, the MAINS led will
reflect the status of the REMOTE START signal.
The led is also affected by MAINS SIMULATION and FORCE
TO START signals.
7.5. LED INDICATORS
RUN mode
indicator
AUTO mode
indicator
Display unit
leds
Mains led.
Flashes when
mains is OK,
turns-on steady
when load is fed
by mains.
Genset led.
Flashes when
genset is
running, turns-on
steady when
load is fed by the
genset.