HOKKIM DAMF-5 User manual

HOKKIM DIGITAL AUTOMATIC MAINS FAILURE CONTROLLER MANUAL FOR MODEL
DAMF-5.
INTRODUCTION
Thank you for purchasing the Hokkim Digital Automatic Mains Failure Controller model; DAMF-
5. e will do our utmost to provide you with the best service in terms of technical support, stock and
parts replacement. This manual should be read through before attempting to install the unit in order to
avoid damage due to wrong connections. You need to be familiar with this manual in order to fully
understand the functions and features the DAMF-5 can provide for you. A copy should be handed to the
owner’s maintenance team for future reference with a briefing on how to operate it.
The design and development of the Hokkim Digital DAMF-5 Controller comes from many years
of studying the traditional AMF boards hard wired with relays and timers. The heart of the DAMF-5 is
Micro Controller based. It is very flexible, compact, easy to use and comes with many features to suit
most AMF needs. Due to our policy of continuous development, we welcome suggestions for
improvements. Thus, there may be changes after this manual is produced. If in doubt, do not hesitate to
call for our technical support or information on our latest models.
PARTS IDENTIFICATION
e are briefly going through the physical markings of the DAMF-5 so that you can easily locate them
when needed.
1. Front Face Diagram 1. Refer to page 4. It shows the front face of the DAMF-5. There are 6 nos. red
LED to indicate; 1) STARTER. 2) RUN. 3) FUEL SOLENOID. 4) ENERGIZED STOP. 5) 24V.
and 6) 12V. During operation, these LEDs give a quick indications of what the DAMF-5 is doing.
Next is the 3 digit 7-segment display. This display is the most important interface as you will
receive a host of information from it. To help you understand, we have provided the 3 digit
abbreviations at the front face for easy reference. You need to familiarize yourself with the
abbreviations as during operation, the display flashes at half second rate, you have to be quick to
catch what function the DAMF-5 is performing.
2) Terminal Diagram 2 . Refer to page 5. It shows the back terminals from T01 to T24 with the terminal
abbreviations. Note that some of the abbreviations are the same beside different terminal number.
This is the part where you have to be careful during connection. The top row of terminals T01 to
T08 has a mixture of inputs, outputs, and auxiliary supply inputs. Beside T08 is marked 12V or
24V, you can connect an auxiliary supply of 12VDC or 24VDC and the DAMF-5 will
automatically switches to the correct voltage. The front face LED voltage indicator should
correspond with the auxiliary supply connected. The middle row of terminals T09 to T16 is clearly
marked INPUTS. This is where you terminate the inputs from selector switches or alarm contacts.
The bottom row of terminals T17 to T24 is clearly marked OUTPUTS. This is where you
terminate the outputs to relays or lamps. Lastly, at the bottom right is a tiny button marked SET.
This button allows you to change default settings of the DAMF-5.
3) Terminal Abbreviations Diagram 3. Refer to page 7. On one side of the DAMF-5 is the Abbreviations
For Terminals sticker. It shows what you are suppose to connect to each terminal. After
familiarizing yourself with it, it speeds up connection work as you don't need to keep referring to
the Connection Diagram 5.
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4) Default Settings Diagram 4. Refer to page 7. It shows how to change the default factory setting of a
range of parameters. It is advisable to view first the setting to confirm which parameters needs to
be changed. Press the SET button follow by the MFB button to effect the change. This function
can only be performed in the OFF mode.
5) Terminal Connection Diagram 5. Refer to page 7. On the other side of the DAMF-5 is the Terminal
Connection Diagram. Note that the terminals number are not in order, so be careful when
connecting the wires. It is easier to separate out the inputs from the outputs when drawing the
diagram. Always refer to the terminal number together with the abbreviation to avoid mistake.
6) Dimension Diagram 6. Refer to page 12. It shows the physical shape and dimensions of the DAMF-5.
The body is made of heat resistant ABS plastic and the front face and terminal is made of high
impact PC (Poly Carbonate).
FRONT FACE.
Refer to Front Face Diagram 1. The 6 nos. red LEDs indicates to you what the DAMF-5 is doing during
operation. They are as follows;
1. STARTER- hen the STR relay energize, this LED lights, and the starter should be cranking to start
the gen-set.
2. RUN- hen gen-set runs, its output voltage energizes the GRR relay, this LED lights and the starter
should stop cranking.
3. FUEL SOLENOID- To begin starting, the FSR relay energize, this LED lights and fuel solenoid valve
open to feed diesel to the engine.
4. ENERGIZE STOP- To stop the gen-set, the ESR relay energize, this LED lights and fuel is cut from
the engine. Note; gen-sets use either Fuel Solenoid or Energize Stop.
5. 24V - hen auxiliary supply is 20VDC and above, this LED lights. Maximum allowable voltage is
32VDC.
6. 12V - hen auxiliary supply is 15VDC and below, this LED lights. Minimum allowable voltage is
7VDC.
IMPORTANT NOTE : THE AUXILIARY SUPPLY SHOULD NOT BE ALLO ED TO RISE FROM
BELO 15VDC TO BELO 20VDC. BUT, MAY FALL FROM ABOVE 20VDC TO ABOVE
15VDC. If you do not understand this statement, contact our technical personnel. Other wise damage may
occur to the DAMF-5.
You need to study the 3 digit 7-segment display abbreviation and familiarize yourself with it as it is the
most important interactive interface of the DAMF-5. The display tells you what function is being
performed. If there is a count down timer, the display flashes between the count down time and the
abbreviation at half second rate. A total of 20 abbreviations is listed below in alphabetical order;
1. Att Attempts - This display shows the number of set attempts of crank and rest before fail to start
alarm occurs. It can be set from 1 to 9 attempts in 1 attempt increments. Default is 6.
2. Aut Automatic - This display shows the automatic mode being selected. In this mode press the MFB
button to perform lamp test.
3. Crt Crank Starter Timer - This display shows cranking timer has started. The timer can be set from
1 to 20 seconds in 1 second increments. Default is 6 seconds.
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4. EFA External Fault Alarm - This display shows external alarm has occur and gen-set stopped and
cannot be started. After ESt count down, press the MFB once to accept the alarm. After clearing the
fault, press the MFB again to reset the alarm.
5. ESt Energized Stop Timer - This display shows energized stop timer has started. The timer can be set
from 5 to 60 seconds in 5 seconds increments. Default is 10 seconds. Note; when the energized stop
timer is running, the alarm cannot be accept or reset.
6. FtS Fail To Start - This display shows fail to start alarm has occur and gen-set stopped and cannot be
started. After ESt count down, press the MFB once to accept the alarm. After clearing the fault, press
the MFB again to reset the alarm.
7. Hot High ater Temperature - This display shows high water temperature alarm has occur and gen-
set stopped and cannot be started. After ESt count down, press the MFB once to accept the alarm.
After clearing the fault, press the MFB again to reset the alarm.
8. LFL Low Fuel Level - If the Low Fuel Level setting is ‘1’, This display shows low fuel level alarm
has occur and gen-set stopped and cannot be started. After ESt count down, press the MFB once to
accept the alarm. After clearing the fault, press the MFB again to reset the alarm. If the setting is ‘0’,
display does not show, shutdown does not occur and gen-set can be started. Alarm bell sound and
Low Fuel Level fault lamp flashes. Alarm can be accepted.
9. LOP Low Oil Pressure - This display shows low oil pressure alarm has occur and gen-set stopped and
cannot be started. After ESt count down, press the MFB once to accept the alarm. After clearing the
fault, press the MFB again to reset the alarm.
10. LPt Lamp Test - This display shows lamp test is being perform. All alarm fault lamps should be
lighted. To do this, press the MFB button in the Aut mode.
11. OFF This display shows the OFF mode being selected. In this mode press and release the MFB
button to view the parameter settings. Repeat to toggle through all the settings. 10 seconds of
inactivity revert the display back to OFF.
12. OPt Oil Pressure Timer - This display shows oil pressure timer has started. The timer can be set from
1 to 20 seconds in 1 second increments. Default is 10 seconds. After count down, low oil pressure
fault becomes active.
13. OSP Over Speed - This display shows over speed alarm has occur and gen-set stopped and cannot be
started. After ESt count down, press the MFB once to accept the alarm. After clearing the fault, press
the MFB again to reset the alarm.
14. rdy Manual Ready - This display shows the manual mode being selected. In this mode press the MFB
button to start the gen-set. To off the gen-set switch to OFF mode.
15. rSt Rest Starter Timer - This display shows rest starter timer has started. The timer can be set from 1
to 20 seconds in 1 second increments. Default is 10 seconds.
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16. run Generator Run - This display shows the gen-set is running. The moving _. _. _. indicates normal
condition.
17. Sdt Shutdown Timer - This display shows shutdown timer has started. The timer can be set from 30 to
990 seconds in 30 seconds increments. Default is 120 seconds.
18. SEt Set Mode - This display shows set mode is active. To do this, press the SET button at the back in
the OFF mode. To change the default settings, press and release the MFB button to toggle to the
desire parameter. Press and HOLD to change the setting, when the desired value is shown, quickly
release the button. Press and release the MFB button again to toggle to the next parameter. 10 seconds
of inactivity and the new value will be burn into the memory. The - - - display is shown when this is
taking place. In case auxiliary supply failure occurs in this stage, the memory burning may not be
complete and you may have to repeat the process.
19. SFC Supply Fail Contact - If the supply fail contact setting is ‘1’, then the supply fail timer start when
supply fail contacts closes. If the setting is ‘0’. then the supply fail timer start when supply fail
contacts opens. This give you the flexibility to choose either ‘close contacts’ or ‘open contacts’ to start
20. SFt Supply Fail timer - This display shows supply fail timer has started. The timer can be set from 1
to 10 seconds in 1 second increments. Default is 5 seconds.
Front Face
Diagram 1
TERMINALS
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Refer to Terminal Diagram 2. These terminals allows you to wired up the DAMF-5 to external relays,
push buttons, selector switch, bell, fault inputs, lamps, etc. to complete the AMF Control Board. A
detailed description of the terminals is given below;
Terminal
Diagram 2
TERMINALS T0 TO T24
No. Abbrev. Details.
T0 0V Negative of auxiliary supply.
T02 ESR Energized Stop Relay output to relay coil. Type; open collector to negative.
The relay energize to stop the gen-set.
T03 FSR Fuel Solenoid Relay output to relay coil. Type; open collector to negative.
The relay energize to run the gen-set.
T04 SFC Supply Fail Contact input from free contacts to negative. hen mains supply
fail, the contacts close or open to start the gen-set.
T05 GRR Generator Run Relay input from free contacts to negative. hen gen-set has
started, its output voltage energizes this relay to close the contacts and stop
the starter cranking. Other wise also known as AFR, AC Fail Relay.
T06 MFB Multi Function Button input from free contacts to negative.This button is
indeed used for many functions. In fact it is the only button use to perform
most required functions other then the Emergency Stop Button.
T07 ESB Emergency Stop Button input from free contacts to negative. hen this
button is pressed, the auxiliary supply is cut from the Micro Controller. All
outputs ceases to operate except the Energized Stop Relay which energizes
for approximately 45 seconds before releasing.
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No. Abbrev. Details.
T08 +V Positive of auxiliary supply. 12VDC or 24VDC.
T09 AUT Automatic mode input from free contacts to negative.
T 0 MAN Manual mode input from free contacts to negative.
T TES Test mode input from free contacts to negative.
T 2 EFA External Fault Alarm input from free contacts to negative. hen
additional faults are required, an external alarm annunciator is added to
provide the contacts to shutdown the gen-set when external faults occurs.
T 3 LOP Low Oil Pressure alarm input from free contacts to negative.
T 4 HWT High Water Temperature alarm input from free contact to negative.
T 5 OSP Over Speed alarm input from free contacts to negative.
T 6 LFL Low Fuel Level alarm input from free contacts to negative.
T 7 STR Starter Relay output to relay coil. Type; open collector to negative. This
relay energize to crank the gen-set starter.
T 8 BEL Bell output to alarm bell coil. Type; open collector to negative. The bell
sound when fault occurs.
T 9 MAR Master Alarm Relay output to relay coil. Type; open collector to
negative. This relay energizes when any fault occurs. It is use for remote
signaling or BAS Building Automation System.
T20 FTS Fail To Start alarm output to lamp. Type; open collector to negative.
Flashes when Fail To Start fault occurs.
T2 LOP Low Oil Pressure alarm output to lamp. Type; open collector to negative.
Flashes when Low Oil Pressure fault occurs.
T22 HWT High Water Temperature alarm output to lamp. Type; open collector to
negative. Flashes when High ater Temperature fault occurs.
T23 OSP Over Speed alarm output to lamp. Type; open collector to negative.
Flashes when Over Speed fault occurs.
T24 LFL Low Fuel Level alarm output to lamp. Type; open collector to negative.
Flashes when Low Fuel Level fault occurs.
- SET Set button to allow changing of default factory settings of a range of
parameters to suit your requirements. Operates only in OFF mode.
INSTALLATION AND WIRING
The DAMF-5 is 96 x 96 DIN size front panel mounted. After fixing it together with all related items,
commence wiring by referring to diagram 5. If possible, mark the wires according to the terminal
numbers. This allows for easier trouble shooting. Some of the terminations will not be required as the unit
allows for various possibilities. Use a 6A fuse or MCB (Miniature Circuit Breaker) for the DAMF-5
auxiliary supply to protect against accidental shorting. A separate 20A fuse or MCB for fuel solenoid and
starter supply. Note that the GRR relay coil must be 240VAC and the supply taken from incoming side of
main MCCB (Molded Case Circuit Breaker). Only one R relay is use, for either Energized Stop or Fuel
Solenoid. So, connect to either T02 or T03, which ever suit the gen-set.
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Terminal Abbreviations Default Settings
Diagram 3 Diagram 4
Note: Lamp Test can only be performed in the Aut Mode.
Terminal Connection Diagram 5
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TESTING
After completing the wiring, use a continuity tester to check that the wiring are properly done and the unit
is ready for testing. IMPORTANT NOTICE; it is of the assumption that the testing in done in the factory
and not at site where wirings are connected and the gen-set ready to start.
It should be noted that the DAMF-5 is designed for both 12VDC and 24VDC. Do Not feed 240VAC
mains supply into any part of the unit as it will definitely be damaged. All the DAMF-5 outputs are open
collector type, Do Not connect a positive source direct to them, always connect in series relays, bell or
lamps from source before connecting to the output. As the testing process is long, it is broken into steps,
at any time feel free to repeat the steps, as follows:
1) Check Voltage
Check the charger and battery voltage. It should be around 27VDC or 13.5VDC depending on the
battery type used. Both voltage is suitable as an auxiliary power source. Do Not use a power source
that is between 15VDC and 20VDC. It is not healthy for the DAMF-5 and may cause damage. If an
18VDC source is connected, it will select 12VDC power input and that is 150% higher. The
internal relay will overheat and fail after prolong period.
2) Switch On
Select to Off mode and switch on the circuit breaker. Notice that the display shows H H H for one
second before displaying OFF. Confirm that the supply voltage LED correspond with the auxiliary
voltage.
3) Emergency Stop
Press the emergency stop button. The display should goes off and the Energize Stop LED lighted. If
in use, check that the Energize Stop relay energizes. ait for about 45 seconds until the LED goes
off and the relay de-energizes. All other relays or lamps should be off but the supply LED remain
lighted. This confirms the Emergency Stop is functioning. Reset the button to continue.
4) View Default Settings
Remain in the Off mode, press and release the MFB button to view the parameter settings. Repeat
to toggle through the range of parameters. The display flashes between the parameter and its value
at half second interval. 10 seconds of inactivity at any stage reverts the display back to OFF. The
range of parameters and default value should be as follows;
SFC - 1, SFt - 5, Crt - 6, rSt - 10, Att - 6, OPt - 10, Sdt - 120, ESt - 10, LFL - 0 and OFF.
5) Change Default Parameter Settings.
Remain in the Off mode, press and release the SET button. hen the display shows SEt, press and
releases the MFB button and repeat to toggle to the desired parameter. Then press and HOLD the
MFB button, when the desired value is shown, quickly releases the button. Repeat the process to
change the next parameter or wait 10 seconds and the new value will be burn into the memory.
During the burning process display shows - - - . Burning is complete when display shows OFF.
View the parameters again to confirm the new settings.
6) Lamp Test
Select to Automatic mode and the display shows Aut. Press and HOLD the MFB button, the
display should show LPt and all the fault lamps lighted. Release the button and display reverts
back to Aut and all fault lamps off. Repeat if desired. The only time you can perform lamp test is in
the Automatic mode.
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7) Fault Stimulation
Remain in the Automatic mode. Using a short wire with both ends strip of insulation, connect one
end to negative terminal T01. Touch the other end to Low Fuel Level alarm input T16. If the LFL
parameter is set to ‘0’, then the display remain at Aut but alarm bell sounds and Low Fuel Level
fault lamp flashes. If the LFL parameter is set to ‘1’, then the display flashes LFL, alarm bell
sounds and Low Fuel Level fault lamp flashes. Press and release the MFB button once to accept
the alarm. Bell is silenced and Low Fuel Level fault lamp remain lighted.
Next, touch the Over Speed alarm input T15. Notice how the display shows LFL but flashes the
OSP, the same with the fault lamps. Alarm bell sounds again. The DAMF-5 can differentiate a new
fault once the old fault was accepted. Press and release the MFB button once to accept the alarm.
Now, touch the High ater Temperature alarm input T14 follow by External Fault Alarm alarm
input T12. Notice again how the display shows LFL follow by OSP but flashes HWT and EFA,
the same with the fault lamps. HWT and EFA are treated as new faults.
Note; EFA does not have fault indicating lamp. Its fault lamp or lamps is located at the external
alarm annunciator unit which is added when the local fault indication in the DAMF-5 is
insufficient. Press and release the MFB button twice to accept and reset the alarm. The display
reverts back to Aut.
To stimulate Fail To Start, you have to prepare a jumper wire from SFC input T04 to negative.
This jumper connection can be done at the Termination Connectors side. If this test is done at site
where the gen-set is connected and ready to start, remember to switch off the Starter Control MCB.
Assuming that all parameter are set at default, to begin Fail To Start test, connect the jumper wire
to negative. The display shows the SFt count down follow by the Crt count down and rSt count
down. The Crt count down and rSt count down is repeated 6 times before Fail To Start alarm is
triggered. Notice the followings before the alarm is triggered, the Fuel Solenoid LED is lighted,
FSR relay is energized, when Crt count down begins, the Starter LED is lighted and STR relay
energizes, when rSt count down begins, the Starter LED is off and STR relay de-energizes. Once
the alarm is triggered, the display flashes FtS, alarm bell sounds and Fail To Start fault lamp
flashes. Press and release the MFB button twice to accept and reset the alarm The display reverts
back to Aut. At this stage the LOP fault cannot be tested because the gen-set did not start. LOP
fault test is only done after Automatic Run. Do not remove the SFC input T04 jumper wire.
8) Automatic Run
Remain in the Automatic mode. To stimulate Generator Run, you have to prepare another jumper
wire from GRR input T05 to negative. To begin, connect the SFC input T04 jumper to negative.
The display shows the SFt count down follow by the Crt count down. During the Crt count down,
connect the GRR input T05 to negative. The display shows the OPt count down follow by run
with the moving _. _. _. Note, the Fuel Solenoid LED is lighted. At this stage the LOP fault can be
tested. Use the negative T01 wire and touch the LOP alarm input T13. The display shows the ESt
count down, Fuel Solenoid LED off, Energize Stop LED lighted and LOP fault lamp flashes. After
count down, the Energize Stop LED is off and the display flashes LOP. Disconnect the SFC input
T04 and GRR input T05 jumper wires from negative. Press and release the MFB button twice to
accept and reset the alarm. During the ESt count down, the alarm cannot be accept or reset.
9) Automatic Shutdown
Remain in the Automatic mode. Repeat the Automatic Run until the display shows run. To begin,
disconnect the SFC input T04 jumper from negative. The display shows the Sdt count down follow
by the ESt count down. Notice, when ESt count down starts, Fuel Solenoid LED off, Energize
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Stop LED lighted. After ESt count down, the display shows Aut. Shutdown completed. Disconnect
the GRR input T05 jumper from negative.
10)Manual Run
Select to Manual mode and the display shows rdy. To begin, press and release the MFB button.
The FSR relay energizes, the STR relay energizes when button is pressed and de-energize when
button is released. The display shows Crt when button is pressed and rdy when released. Repeat as
you like. Next, press the MFB button and touch the GRR input jumper to negative. The display
begin the OPt count down and when finished, displays run to indicate gen-set has started.
11)Manual Stop
After the manual run is complete and the display shows run, to begin manual stop, you can do one
of the followings;
a. Press the Emergency Stop Button.
b. Select to Off mode.
c. Do a fault stimulation.
d. Select to Automatic mode (SFC input T04 not connected) for automatic shutdown.
12) Test Run
Select to Test mode and the test run begin with the display showing SFt count down. After SFt
count down, the Crt count down and rSt count down is repeated until you touches the GRR input
T05 to negative. If not, the Fail To Start alarm will be triggered. After the GRR input T05 touches
negative, the display shows OPt count down and when finished, displays run to indicate gen-set is
running. Remember to note the usual, when Crt count down begins, the Fuel Solenoid Relay and
Starter Relay energizes, when rSt count down begins Fuel Solenoid Relay remain energized while
Starter Relay de-energizes.
13)Test Stop
The test stop is the same as manual stop, you can do one of the followings; a) Press the Emergency
Stop Button. b) Select to Off mode. c) Do a fault stimulation. d) Select to Automatic mode (SFC
input T04 not connected) for automatic shutdown.
14)Conclusion
After finishing all the steps mentioned above, you have completed testing the DAMF-5. You can
repeat some of the test, if you like, with different and unusual combinations not normally done in
actual operation. For example, you can trigger different faults at different stages of count downs or
change to different modes during count downs. e have already done a comprehensive test to
ensure that the software is robust and can withstand abuse. If you have discover some weird
combinations of unusual test or switching over that causes the DAMF-5 software to freeze, we
would appreciate it if you can inform us so that we can fix it. Thanks.
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