DKG-307 User Manual V-01.13
(08.04.2008)
e-mail : mercuris@mail.ru
http: www.mercuris.ru
DKG-307 AUTOMATIC MAINS FAILURE AND
REMOTE START UNIT
FEATURES
Automatic mains failure,
Engine control,
Generator protection,
Built in alarms and warnings,
3 phase mains voltage inputs
3 phase genset voltage inputs
3 phase genset CT inputs
Engine oil pressure measurement
Engine coolant temperature measurement
Genset active power mea surement
Genset power factor measurement
Periodic maintenance request indicator
Daily / weekly / monthly exerciser
Engine hours counter
Event logging
Statistical counters
Battery backed-up real time clock
Weekly operation schedule programs
Field adjustable parameters
RS-232 serial port
Free MS-Windows Remote monitoring SW:
-local, LAN, IP and modem connection
-monitoring, download of parameters
LED displays
Configurable analogue inputs: 2
Configurable digital inputs: 7
Configurable relay outputs: 2
Total relay outputs: 6
I/O expansion capability
Remote Start operation available
Simulate Mains operation available
Survives cranking dropouts
Sealed front panel
Plug-in connection system for easy replacement
Small dimensions (165x125x48mm)
Low cost
DKG-307 User Manual V-01.13
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TABLE OF CONTENTS
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 Display
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. Service Request Display
6.5. Engine Hour Meter
6.6. Modem connection
6.7. Remote Monitoring and Programming
6.8. Exerciser
6.9. Simulate Mains
7. WEEKLY OPERATION SCHEDULE
8. EVENT LOGGING
9. STATISTICAL COUNTERS
10. MAINTENANCE
11. PROGRAMMING
12. TROUBLESHOOTING
13. DECLARATION OF CONFORMITY
14. TECHNICAL SPECIFICATIONS
15. CONNECTION DIAGRAM
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1. INSTALLATION
1.1 Introduction to the Control Panel
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 R to neutral
Mains voltage phase S to neutral
Mains voltage phase T to neutral
Mains voltage phase R-S
Mains voltage phase S-T
Mains voltage phase T-R
Gen voltage phase U to neutral
Gen voltage phase V to neutral
Gen voltage phase W to neutral
Gen voltage phase U-V
Gen voltage phase V-W
Gen voltage phase W-U
Gen current phase U
Gen current phase V
Gen current phase W
Gen frequency
Gen total KW
Gen total cosΦ
Battery voltage,
Coolant temperature
Oil pressure
Gen frequency
1.2 Mounting the Unit
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 151x111
millimeters. Before mounting, remove the retaining steel spring and connectors from the unit, then pass the
unit through the mounting opening. The unit will be maintained in its position by the steel spring.
Engine body must be grounded for correct operation of
the unit, otherwise incorrect voltage and frequency
measurements may occur.
The output of the current transformers shall be 5 Amperes. The input current rating of the current
transformers may be selected as needed (between 10/5 and 9000/5 amps). Current transformer outputs shall
be connected by separate cable pairs from each transformer, to related inputs. Never use common terminals
or grounding. The power rating of the transformer should be at least 5 VA. It is recommended to use 1%
precision transformers.
If analogue senders (e.g. temperature or oil pressure) are connected to the unit, it is not possible to
use auxiliary displays, otherwise the unit may be destroyed. If temperature or oil pressure 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 necessary
to use an external charge lamp.
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1.3 Wiring the Unit
WARNING: THE UNIT IS NOT FUSED.
Use external fuses for
Mains phases: R-S-T
Generator phase: U-V-W
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.
WARNING: ELECTRICITY CAN KILL
ALWAYS disconnect the power BEFORE connecting the unit.
1) ALWAYS remove the plug connectors when inserting wires with a screwdriver.
2) ALWAYS refer to the National Wiring Regulations when conducting installation.
3) An appropriate and readily accessible set of disconnection devices (e.g.
automatic fuses) MUST be provided as part of the installation.
4) The disconnection device must NOT be fitted in a flexible cord.
5) 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).
6) Use cables of adequate current carrying capacity (at least 0.75mm2) and
temperature range.
2. INPUTS AND OUTPUTS
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 U
3 V
4 W
Generator phase
inputs, 0-300V-AC
Connect the generator phases to these inputs.
The generator phase voltages upper and
lower limits are programmable.
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 T
Mains phase inputs,
0-300V-AC
Connect the mains phases to these inputs.
The mains voltages upper and lower limits are
programmable.
8 S
9 R
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Term Function Technical data Description
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 SPARE SENDER INPUT
Input, 0-5000 ohms No connection to this terminal.
14 OIL PRESSURE SENDER
Input, 0-5000 ohms Analogue oil pressure sender connection. Do
not connect the sender to other devices. The
input has programmable characteristics and
connects to any kind of sender.
15 COOLANT TEMP. SENDER
Input, 0-5000 ohms Analogue high temperature sender
connection. Do not connect the sender to
other devices. The input has programmable
characteristics and connects to any kind of
sender.
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 relay controls the engine cranking.
20 FUEL RELAY
Output 10A/28VDC This relay is used for fuel solenoid control. It is
internally connected to terminal 16 for
supplying the charge alternator’s excitation
current.
21 EMERGENCY STOP
22 SPARE-2
23 PROGRAM LOCK
24 SPARE-1
25 COOLANT LEVEL
26 HIGH TEMP
27 LOW OIL PRESSURE
28 RECTIFIER FAIL
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.
29 CURR_U+
30 CURR_U31 CURR_V+
32 CURR_V33 CURR_W+
34 CURR_W-
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).
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3. DISPLAYS
3.1 Led Displays
The unit has 29 LEDs, divided in 4 groups:
-Group_1: Operating mode: This group indicates the genset function.
-Group_2: Mimic diagram: This group in
dicates 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.
-Group_4: Unit: This group indicates the unit of the value displayed in the bottom display.
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.
GENERATOR
Yellow The LED will turn on when all 3 generator phase
voltages are within the programmed limits.
LOAD GENERATOR
Yellow It turns on when the generator contactor is activated.
LOAD MAINS
Green It turns on when the mains contactor is activated.
LOAD TEST
Yellow
TEST
Yellow
OFF
Yellow
AUTO
Green
It turns on when the related operation mode is
selected. One of these LEDs is always on and
indicates which operation mode is selected.
If the operation of the genset is disabled by the
weekly operation schedule, then the AUTO led will
flash.
SERVICE REQUEST
Red Engine periodic maintenance request indicator. It
turns on when the preset engine hours or time
duration after previous service has elapsed.
ALARM GROUP
Red If a fault condition resulting to the engine shutdown
has occurred, the related alarm led turns on steadily.
If a warning condition has occurred, the related led
flashes. The alarms work on a first occurring basis.
The occurrence of a fault will disable other faults of
lower or equal priority.
UNIT GROUP
Red This group indicates the unit of the value displayed in
the bottom display. When the engine is running the
unit displays the genset frequency, otherwise it
displays the battery voltage. Different values may be
scrolled by pressing the MENU key.
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3.2 Digital Displays
The unit has 3 seven segment displays. They show:
-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:
-(R-S-T) mains phase to neutral voltages
-(U-V-W) generator phase to neutral voltages
-(RS-ST-TR) mains phase to phase voltages
-(UV-VW-WU) 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:
-generator frequency (Hz)
-generator cos
-generator active power (KW)
-oil pressure (bar)
-coolant temperature (ºC)
-battery voltage (V-DC),
In programming mode it displays the program value.
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4. ALARMS AND WARNINGS
Alarms indicate an abnormal situation in the generating set are divided into 2 priority levels:
1- ALARMS: These are the most important fault conditions and cause:
- The related alarm led to be on steadily,
- The genset contactor to be released immediately,
- The engine to be stopped immediately,
- The Horn, Alarm and Alarm+Warning relays output to operate, (if selected via
programming menu)
2- WARNINGS: These conditions cause:
- The related alarm led to flash,
- The Horn and Alarm+Warning relay outputs to operate, (if selected via programming
menu)
If the ALARM MUTE button is pressed, the Horn relay 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 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 settable alarm
limits.
LOW OIL PRESSURE: Set if a signal is detected at the Low Oil Pressure Switch input or the oil pressure
value measured from the sender is below the programmed limit. Warning (P_015) and alarm (P_016) limits
are separately programmable for the oil pressure sender input. This fault will be monitored with holdoff timer
(P_023) 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 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 (P_017) and alarm
(P_018) limits are separately programmable for the temperature sender input.
SPEED: Set if the generator frequency is outside programmed limits (overspeed/Underspeed). This fault will
be monitored with holdoff timer (P_023) delay after the engine is running. Different low and high limits for
warning and alarm are separately programmable. (P_008/P_009/P_010/P_011)
START FAIL: Set if the engine is not running after programmed number of start attempts. (P_035)
STOP FAIL: Set if the engine has not stopped before the expiration of the Stop Timer (P_034).
OVERLOAD: Set if at least one of the genset phase currents goes over the Overcurrent Limit (P_002) or if
the genset power (KW) supplied to the load goes over the Excess Power (P_003) limit for Overcurrent /
Excess Power Timer (P_511). If the currents and power goes below the limits before expiration of the timer
then no alarm will be set.
VOLTAGE: Set if any of the generator phase voltages goes outside programmed limits (P_006/P_007). This
fault will be monitored with holdoff timer (P_023) delay after the engine is running.
COOL: LEVEL: Set when a signal is detected from the coolant level switch input.
BATTERY: Set if the battery voltage goes outside programmed limits. During engine cranking this fault is not
monitored. Warning level for low battery voltage (P_012) and both warning (P_013) and alarm (P_014) levels
for high battery voltage are programmable.
CHARGE: Set if a charge alternator failure (or broken belt) occurs. This fault condition may result to a
warning or alarm following programming. (P_038)
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 in one of the spare fault inputs.
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5. MODES OF OPERATION
The modes of operation are selected by pushing the front panel keys. Changing the operation mode
while the genset is running will result to a behavior suitable for the new operating mode. For example, if the
LOAD TEST mode is selected when genset is running at TEST mode, then the genset will take the load.
OFF: 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 (P_004/P_005), the mains contactor will be deactivated.
The diesel will be started for programmed times (P_035) after the wait period (P_0026). When the engine
runs, the crank relay will be immediately deactivated. The engine will run without load during engine heating
period (P_029). After this, if alternator phase voltages and frequency are within limits, then the unit will wait for
the generator contactor period (P_032) 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 (P_030). At the end of this period the generator contactor is deactivated and the mains contactor will be
energized. If a cooling period is given (P_031), 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.
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.
TEST: It is used to test the generator when the mains are on, or keep the generator running in the emergency
backup mode (P_041). 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.
LOAD 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.
6. OTHER FEATURES
6.1 Remote Start Operation
The unit offers the possibility of REMOTE START mode of operation. If the program parameter
P_042 is set to 1 then the unit will enter to the Remote Start operation. The Remote Start signal should be
connected to the SPARE_2 (22) input.
It is also necessary to set the program parameter P_119 to 3 in order to prevent the alarms generated
from this input.
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.
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 REMOTE START operation overrides SIMULATE MAINS operation.
When both parameters P_042 and P_050 are set then the REMOTE
START operation mode is performed.
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