205 User
205 User
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TABLE OF CONTENTS
Section
1. PROGRAMMING SUMMARY
2. INSTALLATION
2.1. Introduction to the Control Panel
2.2. Mounting the Unit
2.3. Wiring the Unit
2.4. Inputs and Outputs
2.5. Digital display
2.6. Led displays
2.7. Periodic maintenance request display
2.8. Alarms
2.9. Modes of Operation
3. MAINTENANCE
4. TROUBLESHOOTING
5. PROGRAMMING
6. CALIBRATION
7. TECHNICAL SPECIFICATIONS
8. DECLARATION OF CONFORMITY
9. DISPOSAL OF THE UNIT
10. ROHS COMPLIANCE
11. CONNECTION DIAGRAM
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1. PROGRAMMING SUMMARY
To enter the program mode, press the PGM button. The display shows (Pr) when program
mode is selected.
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2. INSTALLATION
The control panel 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 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. The unit fits into a standard panel meter opening of
140x68 millimeters. Before mounting, remove the steel spring from the unit, and then pass
the unit through the mounting opening. The unit will be maintained in its position by the
steel spring.
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1.3. Wiring the Unit
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2.4. Inputs and Outputs
SERIAL DATA CONNECTION: This connection is used to transfer data to the PC via the
serial adapter.
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15/16- BAT(+) / BAT(-): The positive (+) and negative (-) terminals of the DC Supply shall
be connected to these terminals. Be careful for the polarization, in case of polarity error the
unit will not operate. The unit operates on both 12V and 24V battery systems.
17- PROGRAM LOCK INPUT: This input is used to prevent unwanted modification to
programmed values. If this input is left open, program values can be modified via the front
panel buttons, but if this input is connected to DC Supply (-) it will not possible to change
the program values.
18- LOW COOLANT LEVEL SWITCH: Connect the cooling radiator liquid level switch to
this input. This switch shall be negative closing in case of low liquid level. This input has
delayed sampling feature to prevent false detection.
19- SPARE-3 ALARM INPUT: Connect the spare alarm switch to this input. The switch
shall be negative closing type.
20- SPARE-2 ALARM INPUT: Connect the spare alarm switch to this input. The switch
shall be negative closing type.
21- SPARE-1 ALARM INPUT: Connect the spare alarm switch to this input. The switch
shall be negative closing type.
22- HIGH TEMPERATURE SWITCH: Connect the high temperature switch to this input.
This switch shall be negative closing switch type.
23- LOW OIL PRESSURE SWITCH: Connect the low oil pressure switch to this input. The
switch should be negative closing in case of loss of oil pressure. This input must be
properly connected for the correct operation of the unit. If oil pressure is provided, the
generator will not start and the oil pressure alarm indicator will flash. However, if the oil
pressure is removed, the unit will resume normal operation.
24- EMERGENCY STOP INPUT: Emergency stop button is connected to this input. The
connection shall be made in order to give DC Supply (-) to the input when the button is
pushed. Pushing the STOP button on the unit's front panel makes the same effect as the
EMERGENCY STOP input. The generator will not operate when the emergency stop signal
is present. When the signal is removed, the unit will resume normal operation. This input
can also be used to prevent externally the automatic operation of the generator. (for ex. by
time watch).
25- OVERLOAD SWITCH: Connect the overload relay output to this input. The relay will be
of negative closing type in case of overload. This alarm will cause the generator to release
the load, but the engine runs until the end of the cooling period.
26- ALTERNATOR HIGH TEMPERATURE SWITCH: Connect the high temperature
switch placed between windings of the alternator to this input. WARNING: This switch shall
be normally closed, and open in case of excess of heat. If this input is not used, connect it
to DC Supply negative terminal, else an alarm will be given continuously. This alarm will
cause the generator to release the load, but the engine runs until the end of the cooling
period.
27- OIL HIGH TEMPERATURE SWITCH: Connect the oil high temperature switch to this
input. This switch shall be negative closing switch type.
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2.5. Digital Display
Below values can be read in sequence by pushing the MENU key in AUTO or TEST
modes:
- (R) phase voltage
- (S) phase voltage
- (T) phase voltage
- (L1) generator phase voltage
- (L2) generator phase voltage
- (L3) generator phase voltage
- (L1) generator phase frequency (engine RPM)
- DC Supply voltage.
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2.7. Periodic Maintenance Request Display
This led is designed to help the periodic maintenance of the generator 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 DKG-205 has both programmable engine hours and maintenance time limit. The
engine hours is programmable between 0 and 750 hours at 50-hour steps, the time limit is
programmable between 0 and 15 months. If any of the programmed value is zero, this
means that the parameter will not be used. For example P19=200 and P20=0 means that
DKG-205 will request maintenance every 200 engine hours, but there will be no time limit.
The remaining engine hours and the remaining time limit are kept stored in a non-volatile
memory and are not modified by power supply failures.
When the engine hours or the time limit is over, the Periodic Maintenance Request led (red)
will start to flash. To turn off the led, the STOP key should be held pressed for 10 seconds.
In this case the digital display will show ‘SER’.
2.8. Alarms
Alarms indicate an abnormal situation in the generating set and most of them cause the
engine to stop immediately.
If an alarm occurs, the related LED will turn on and if the alarm relay option is selected, the
alarm relay will be activated. If the ALARM MUTE key is pressed, the alarm relay will be
deactivated.
Except the emergency stop, alarm LEDs will stay on and disable the operation of the
generating set even if the alarm source is removed. In order to reset the alarm condition,
first choose OFF mode then resume to the previous mode of operation.
CHARGE ALARM: It turns on in case of a charging alternator failure. This alarm will not
cause the engine to stop.
OVERLOAD ALARM: It turns on if a signal comes from the overload relay output. This
alarm will cause the generator to release the load, but the engine runs until the end of the
cooling period.
ALTERNATOR HIGH TEMPERATURE ALARM: It turns on if a signal comes from the high
temperature switch of the alternator. WARNING: This switch shall be normally closed, and
open in case of excess of heat. If this input is not used, connect it to DC Supply negative
terminal, else an alarm will be given continuously. This alarm will cause the generator to
release the load, but the engine runs until the end of the cooling period.
HIGH TEMPERATURE ALARM: It is on when a signal comes from the high temperature
input.
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OIL ALARM: It is on when a signal comes from the oil pressure input. This alarm will be
controlled 4 seconds after the engine is running. If oil pressure is provided when the unit
attempts to start the engine, the oil alarm indicator will flash and the unit will wait until oil
pressure disappears.
LOW COOLANT LEVEL ALARM: It is on when a signal comes from the cooling radiator
water level switch. This input has delayed sampling feature to prevent false detection.
OIL HIGH TEMPERATURE ALARM: It is on when a signal comes from the oil high
temperature switch.
FREQUENCY ALARM: It is on when the alternator frequency is out of the programmed
limits for a longer period than the programmed timer. Alternator frequency will be controlled
4 seconds after the generator contactor is on.
VOLTAGE ALARM: It is on when at least one of the alternator phase voltages is out of the
programmed limits. Alternator voltage will be controlled 4 seconds after the generator
contactor is on.
FAIL TO START: It is on if the engine cannot start to run after the programmed number of
start attempts. This alarm will be erased when the mains are on in order to keep the engine
ready for the next mains failure.
EMERGENCY STOP ALARM: It arises if emergency stop button (or front panel STOP key)
has been pushed. This alarm is not latched. The alarm condition disappears when the
signal is removed. This input is also used externally to prevent the operation of the
generator (for ex. by a timer).
DC SUPPLY ALARM: It is on when DC Supply voltage is above the programmed limit. It
arises at the end of 2 seconds delay period. It does not occur if DC Supply voltage goes
back below the limit before the end of the delay period. This protection is particularly
designed against charge alternator failures.
SPARE-1 ALARM: It turns on when a signal comes from the spare-1 alarm input.
SPARE-2 ALARM: It turns on when a signal comes from the spare-2 alarm input
SPARE-3 ALARM: It turns on when a signal comes from the spare-3 alarm input. This
alarm will not stop the engine.
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2.9. Modes of Operation
The modes of operation are selected by pushing the front panel keys. If the mode is
changed while the engine is running, it will be stopped. Do not change the operation mode
while the generator is in operation.
OFF: In this mode, the mains contactor will be energized if mains phase voltages are within
the programmed limits. The engine will be stopped.
MANUAL: It is used to start and stop the generator manually. If the manual mode is
selected, the fuel relay will be activated and the generator will be ready to be started.
START: It is used to manually start the generator unlimited times. In order to start, it
is needed not to have the oil pressure. When the generator phase voltages are
present or the generator frequency goes over 10 Hz, starting will be automatically
disabled even if the button is pressed.
STOP: It is used to manually deactivate the fuel solenoid as long as desired. When
the stop button is pushed, the generator contactor will also be deactivated.
MAINS/GENERATOR: It is used to manually activate the mains and the generator
contactor. If it is pressed once, the generator contactor will be activated, if it is
pressed once the mains contactor will be activated.
AUTO: It is used for generator 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 wait period. When the engine
runs, the crank relay will be immediately deactivated. After the alternator phase voltages
are within limits, 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 cooling period is given, the generator will
continue to run during cooling 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.
TEST: It is used to test the generator when the mains are on, or keep the generator waiting
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 is
kept running. In order to stop the engine, push the OFF button.
PROGRAM: It is used to program the timers, operational limits and the configuration.
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3. MAINTENANCE
Wipe the unit, if necessary with a soft damp cloth. Do not use chemical agents.
4. TROUBLESHOOTING
When the AC mains fails the unit energizes the fuel solenoid, but does not start,
also OIL PRESSURE ALARM led flashes:
The unit is not supplied with battery (-) voltage at the oil pressure input.
-Oil pressure switch not connected.
-Oil pressure switch connection wire cut.
-Oil pressure switch faulty.
-Oil pressure switch closes too lately. If oil pressure falls, the unit will start. Optionally oil
pressure switch may be replaced.
The engine does not run after the first start attempt, then the unit does not start
again and the OIL PRESSURE ALARM led flashes:
-The oil pressure switch closes very lately. As the unit senses an oil pressure, it does
not start. When oil pressure falls the unit will start. Optionally the oil pressure switch may
be replaced.
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When the AC mains fails, the engine starts to run but the unit gives FAIL TO
START alarm and then the engine stops:
-The generator phase voltage is not connected to the unit. Measure the AC voltage
between terminals (L1) and (Generator Neutral) at the rear of the unit while engine is
running. The fuse protecting the generator phase may be failed. A misconnection may
be occurred. If everything is OK, turn all the fuses off, and then turn all the fuses on,
starting from the DC supply fuse. Then test the unit again.
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5. PROGRAMMING
The programming mode is used to program the timers, operational limits and the
configuration of the unit.
To enter the program mode, press the PGM button. The display shows (Pr) when program
mode is selected. When the MENU key is pressed the program number will be displayed,
when it is released the program value will be shown. In this way all program parameters are
accessed and the values can be increased or decreased by using () and () keys.
Programmed values are stored in a Non Volatile Memory, which is not affected by energy
failures. To exit programming, press the OFF button.
P01=MAINS VOLTAGE LOWER LIMIT: If one of the mains phases goes under this limit, it
means that the mains are off and it starts the transfer to the generator in automatic and test
modes.
P02=MAINS VOLTAGE UPPER LIMIT: If one of the mains phases goes over this limit, it
means that the mains are off and it starts the transfer to the generator in automatic and test
modes.
P03=GENERATOR VOLTAGE LOWER LIMIT: If the generator phase voltage goes under
this limit when feeding the load, this will mean a generator voltage failure and the engine
will stop.
P04=GENERATOR VOLTAGE UPPER LIMIT: If the generator phase voltage goes over
this limit when feeding the load, this will mean a generator voltage failure and the engine
will stop.
P05=FREQUENCY LOWER LIMIT: If the generator frequency goes under this value, it
causes an alarm after the frequency delay timer.
P06=FREQUENCY UPPER LIMIT: If the generator frequency goes over this value, it
causes an alarm after the frequency delay timer.
P07=FREQUENCY DELAY: This is the period between the frequency goes out of the limits
and an alarm occurs
P08=DC SUPPLY UPPER LIMIT: If DC Supply voltage exceeds this limit, it will cause DC
Supply alarm after the 2 second delay and the diesel will stop. This alarm is particularly
designed to prevent failure of the unit in case of charge alternator failure.
P09=NUMBER OF STARTS: Maximum number of start attempts.
P10=WAIT BEFORE START TIMER: Waiting period between the fuel on and start
command.
P11=WAIT TIMER BETWEEN STARTS: Waiting period between two start attempts.
P12=START TIMER: Start period. Start will be automatically deactivated if the generator
starts running before the timer.
P13=STOP TIMER: Stop solenoid activation timer. Enter 0 for an ‘activate to start’ type of
engine.
P14=MAINS WAITING TIMER: This is the time between the mains voltages entered within
the limits and the generator contactor is deactivated.
P15=COOLING TIMER: This is the period that the generator runs for cooling purpose after
the load is transferred to mains.
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P16=MAINS CONTACTOR TIMER: This is the period after the generator contactor has
been deactivated and before the mains contactor has been activated.
P17=GENERATOR CONTACTOR TIMER: This is the period after the generator phases
are within the limits and before the generator contactor has been activated.
P18=RELAY CONFIGURATION: FUEL and AUXILIARY relay configuration:
6. CALIBRATION
To enter the calibration mode, hold pressed the OFF button, then press PGM button. The
rightmost decimal point of the voltage display will turn on. For following operations it is
necessary to display the proper parameter by pressing the MENU key, and modify it by
pressing using () and () keys. For more detailed explanation please refer to programming
chapter of the user's manual.
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7 . TECHNICAL SPECIFICATIONS
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8. DECLARATION OF CONFORMITY
The CE mark indicates that this product complies with the European requirements for
safety, health environmental and customer protection.
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11. CONNECTION DIAGRAM
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