![Kirloskar KG645 - User Manual For Genset Controller PDF [PDF]](https://pdfs.asia/img/200x200/kirloskar-kg645-user-manual-for-genset-controller-pdf.jpg)
16 0 5 MB
KG645 CONTROLLER MANUAL
KG645 Kirloskar Genset Controller User Manual
KIRLOSKAR OIL ENGINES LIMITED A Kirloskar Group Company
Laxmanrao Kirloskar Road, Khadki, Pune-411 003, India. Tel : +91(20) 2581 0341 Fax: +91(20) 2581 3208/ 2581 0209 www.kirloskar.com
Page 1 of 123
KG645 CONTROLLER MANUAL
Table of Contents KG-645 Genset Controller 1 Introduction ..................................................................................................................................... 5 1.1 Key Highlights of the Product ............................................................................................................................ 5
2 Specifications ................................................................................................................................... 6 2.1 Terminals............................................................................................................................................................ 6 2.2 Power Supply Specifications .............................................................................................................................. 7
3 Inputs .............................................................................................................................................. 8 3.1 Generator Voltages And Frequency Measurements.......................................................................................... 8 3.2 Generator Current Measurement ...................................................................................................................... 8 3.3 Mains Voltage And Frequency Measurements .................................................................................................. 8 3.4 Digital Inputs ...................................................................................................................................................... 9 3.5 Analogue Inputs ...............................................................................................................................................10 3.6 Sensor Common...............................................................................................................................................11 3.7 Magnetic Pick Up Input....................................................................................................................................11 3.8 D+ Charge Alt ...................................................................................................................................................12
4 Outputs.......................................................................................................................................... 12 4.1 Digital Outputs .................................................................................................................................................12 4.2 Actuator Outputs .............................................................................................................................................13
5 Communication Ports ..................................................................................................................... 13 6 Installation ..................................................................................................................................... 14 6.1 Dimensions ......................................................................................................................................................14 6.2 Mounting on panel ..........................................................................................................................................15 6.3 Terminal Description ........................................................................................................................................16 6.4 Typical Wiring Diagram ....................................................................................................................................18
7 Module Display .............................................................................................................................. 20 7.1 Power on screen ..............................................................................................................................................20 7.2 Monitoring Mode.............................................................................................................................................20
8 Description of Control keys ............................................................................................................. 27 8.1 Mode Selection diagram ..................................................................................................................................27 8.2 Functions of Control keys.................................................................................................................................28 9 Configuration Mode ....................................................................................................................... 29 9.1 Configurable Parameters .................................................................................................................................30
10 Module Operation in Manual Mode……………………………………………………….…………………………………….46 11 Module Operation in Auto Mode .................................................................................................. 46 11.1 Auto Mains Failure (AMF) ..............................................................................................................................46 11.2 Remote start/stop ..........................................................................................................................................47
12 Paralleling support / Speed bias mode .......................................................................................... 47 12.1 Paralleling concept.........................................................................................................................................47 12.2 Configuration in KG-645.................................................................................................................................48
13 Module Operation In Test Mode ................................................................................................... 49 14 Deep Sleep Mode ......................................................................................................................... 49 15 Alarms ......................................................................................................................................... 49 16 Troubleshooting ........................................................................................................................... 53 Communication Protocol 17 Introduction ................................................................................................................................. 56 18 MODBUS Based Protocol .............................................................................................................. 56 18.1 Connection Details .........................................................................................................................................56 18.2 Supported Functions......................................................................................................................................56
Page 2 of 123
KG645 CONTROLLER MANUAL 18.3 Register Map ..................................................................................................................................................56
Expansion Module 19 Introduction ................................................................................................................................. 66 19.1 Expansion Module Integration ......................................................................................................................67
KG-645 – Configuration Utility 20 Introduction ................................................................................................................................. 68 21 Installation Instructions ................................................................................................................ 68 21.1 System Requirements ....................................................................................................................................68 21.2 Installation Process for KG 645 - Configuration Utility...................................................................................68 21.3 Installation Process for USB Driver ................................................................................................................69
22 Usage Instructions ........................................................................................................................ 75 22.1 Starting with KG 645 - Configuration Utility ..................................................................................................75 22.2 Working with KG 645 - Configuration Utility .................................................................................................76 22.3 Establishing Connection with Controller .......................................................................................................76 22.4 Editing Parameters .........................................................................................................................................76 22.5 Tools ...............................................................................................................................................................77
23 Interpretation of Parameters ........................................................................................................ 83 23.1 Module...........................................................................................................................................................83 23.2 Digital Inputs ..................................................................................................................................................85 23.3 Analog Inputs .................................................................................................................................................87 23.4 Outputs ..........................................................................................................................................................94 23.5 Timers ............................................................................................................................................................97 23.6 Generator.....................................................................................................................................................100 23.7 Mains ...........................................................................................................................................................105 23.8 Engine ..........................................................................................................................................................107 23.9 Maintenance ................................................................................................................................................112 23.10 Rotary Actuator..........................................................................................................................................113 23.11 Expansion Module .....................................................................................................................................117
KG-645 – EOL Flashing Utility 24 Menu Bar ................................................................................................................................... 121 25 Writing Configuration To Device.................................................................................................. 122
Page 3 of 123
KG645 CONTROLLER MANUAL
Clarification of notation used within this publication. Highlights an essential element of a procedure to ensure correctness
Indicates a procedure or practice, which, if not strictly observed, could result in damage or destruction of equipment. Indicates a procedure or practice, which could result in injury to personnel or loss of life if not followed correctly.
.
Page 4 of 123
KG645 CONTROLLER MANUAL
1
Introduction This document presents information necessary for operating KOEL's KG-645 genset controller. It also provides the user with the necessary background for using KG-645 genset controller in an application that involves communication of the genset controller with an external system such as a server or a remote data communication system. KOEL's KG-645 is a modern and feature rich genset controller with user-friendly HMI and full graphics LCD. The KG-645 controller comes bundled with highly versatile software & extensive I/O's and thereby supports a wide variety of industry standard features in diesel/gasoline engine gensets. The KG-645 controller's smart software offers flexibility to configure each individual input and output for a specific function or application. KG-645 controller also offers unique feature such as electronic governing for engines with mechanical fuel systems. With the Rotary Actuator as an add-on for air/fuel charge control, these controllers can subsume the electronic governing duty for the engine and offer tight speed governing performance. The KG-645 can be configured through Windows PC utility (Refer section KG 645 - Configuration Utility). Also, all parameters can be configured using the keypad of the genset controller.
1.1 Key Highlights of the Product The KG-645 product is customized for Kirloskar Oil Engines Ltd to offer several key advantages to the end user such as: •
Auto & manual start/stop modes for 1-ph & 3-ph gensets
•
Electronic governor controller integration
•
PC connectivity via USB port, RS485
•
Expansion module interface
•
Real time clock based event logs
•
Configurable fuel theft alarm
•
RPM sensing using frequency & MPU
•
Backlit and full graphics display with power saving feature
Figure 1: Representative drawing of KG-645 genset controller's front
Page 5 of 123
KG645 CONTROLLER MANUAL
2
Specifications 2.1 Terminals The KG-645 hosts two types of terminal blocks as shown in figure 3 and figure 4 below.
2.1.1
5 mm pitch connector suitable for 2 sq mm wire
Figure 3: Representative photograph for 8-pin female (mating) connector of 5 mm pitch
Connector type/ Manufacturer
Male (On genset controller)
Female (Mating)
Male (On genset controller)
Degson (Degson Electronics Co. Ltd.)
Female (Mating)
Phoenix (Phoenix Contact (I) Pvt. Ltd.)
2-Pin
2EDGVC-5.08-02P-14- 2EDGK-5.08-02P-1400AH 00AH
1755516
1754449
4-Pin
2EDGVC-5.08-04P-24- 2EDGK-5.08-04P-2400AH 00AH
NA
NA
2.1.2
3.5 mm pitch connector suitable for 0.5 – 1.5 sq mm wire
Figure 4: Representative photograph for 8-pin female (mating) connector of 3.5 mm pitch
Page 6 of 123
KG645 CONTROLLER MANUAL
Connector type/ Manufacturer
Male (On genset controller)
Female (Mating)
Male (On genset controller)
Degson (Degson Electronics Co. Ltd.)
Female (Mating)
Phoenix (Phoenix Contact (I) Pvt. Ltd.)
4-Pin
15EDGVC-3.5-04P-14- 15EDGK-3.5-04P-1400AH 00AH
1843622
1840382
6-Pin
15EDGVC-3.5-06P-14- 15EDGK-3.5-06P-1400AH 00AH
1843648
1840405
8-Pin
15EDGVC-3.5-08P-14- 15EDGK-3.5-08P-1400AH 00AH
1843664
1840421
10-Pin
15EDGVC-3.5-10P-14- 15EDGK-3.5-10P-1400AH 00AH
1843680
1840447
2.2 Power Supply Specifications Controller terminal number 1, 2 (Ground and Battery positive respectively)
3
Supply voltage range
8 to 32 V-DC continuous (Transient as per ISO 7637-2 test level IV @ 24 V-DC)
Cranking drop out period
50 mS
Maximum reverse voltage
-32V DC continuous
Measurement accuracy
±1 % full scale
Resolution
0.1 V
Maximum current(with all sensors disconnect)
~ 0.2 A @ 12 V-DC (Excluding the current load for the high side driver output's and rotary Actuator's output) ~ 1.2 A @ 12 V-DC (Excluding the current load for the high side driver output's)
Standby current
60 mA @ 12 V-DC
Deep sleep current
15 mA @ 12 V-DC
Inputs 3.1 Generator Voltages And Frequency Measurements Controller terminal number 27, 28, 29, 30 (N, B, Y, R respectively) Measurement type
True RMS
Sample Rate
5 kHz
Harmonics
10th
Input Impedance
0.3 MΩ
Phase to Neutral voltage
15 to 415 V-AC RMS
Phase to Phase voltage
15 to 750 V-AC RMS
Common mode offset from 100 V-AC Earth
Page 7 of 123
KG645 CONTROLLER MANUAL Surge L-L and L-E
As per CE / IEC requirements
Rate of updation of display 1 sec Voltage accuracy
±1 % of full scale Phase to Neutral
Voltage resolution
1 V-AC RMS for Phase to Neutral
Frequency range
3 to 75 Hz
Frequency resolution
0.1 Hz
Frequency accuracy
0.25 % of full scale
Minimum voltage level required to measure
25 V-RMS
For 1 phase genset application, it is mandatory to connect the genset phase and neutral cables to the genset controller's phase R and Neutral terminals respectively.
3.2 Generator Current Measurement Controller terminal number 35 and 36 (for phase B), 37 and 38 (for phase Y), 39 and 40 (for phase R) Measurement type
True RMS
Sample Rate
5 kHz
Harmonics
10th
Nominal CT secondary rating
5A
Maximum continuous current
6A
Overload Measurement
3 X Nominal Range setting
Absolute maximum overload
50 A for 1 sec. As per the short-circuit overload imposed by a 5 VA
Burden
0.25 VA
Resolution
0.1 A
Accuracy
±1 % of Nominal
Follow the recommended phase sequence while connecting the Current Transformer (CT).
3.3 Mains Voltage And Frequency Measurements Controller terminal number
31, 32, 33, 34 (N, B, Y, R respectively)
Measurement type
True RMS
Sample Rate
5 kHz
Harmonics
10th
Page 8 of 123
KG645 CONTROLLER MANUAL Input Impedance
0.3 MΩ
Phase to Neutral voltage
15 to 415 V- AC RMS
Phase to Phase voltage
15 to 750 V-AC RMS
Common mode offset from Earth
100 V-AC
Surge L-L and L-E
As per CE / IEC requirements
Rate of updation of display
1 sec
Voltage accuracy
±2 % of full scale
Voltage resolution
1 V-AC RMS for Phase to Neutral
Frequency range
3 to 75 Hz
Frequency resolution
0.1 Hz
Frequency accuracy
0.25 % of full scale
Minimum voltage level required to measure
25 V-RMS
For 1 phase application, it is mandatory to connect the mains phase and neutral cables to the genset controller's phase R and Neutral terminals respectively.
3.4 Digital Inputs Controller terminal number 10, 11, 12, 21, 22 Number of inputs
5
Type
Negative sensing (connect to ground for activation)
Low level threshold
0.8 V-DC maximum (Measured at the genset controller's terminal and battery ground terminal)
Maximum input voltage
VBATT
Minimum input voltage
0 V (BATT-)
Contact wetting current
2.5 mA typical
Open circuit voltage
(VBATT – 1) V-DC
Surge
As per ISO 7637-3
Protection Level
Short circuit to BATT+ and BATT-
Software configurable options
Lub Oil Pressure Switch, High Temperature Switch and many more. Please refer section 43 for more details.
Page 9 of 123
KG645 CONTROLLER MANUAL
3.5 Analogue Inputs 3.5.1 I/P: ANLG / DIG F Controller terminal number 26 (CANOPY_Temp/LOP sensor) Type
Ratio-metric sensing
Arrangement
Common mode measurement
Full scale
5 KΩ
Open circuit detection
Above 5.5 KΩ or more
Resolution
0.1 Bar
Accuracy
1.5 % of full scale
Maximum common mode voltage
2V
Display range
0 to 10 Bar
Connection method
One should connect the sensor output terminals between the genset controller's terminal and the battery ground terminal.
This input can be configured to accept input from lube oil pressure sensor or canopy temperature sensor or lube oil temperature sensor.
3.5.2
I/P: ANLG (0–5V / 4–20 mA)
This input can be configured to accept lube oil pressure current input or analog voltage input.
3.5.2.1
Lube Oil Pressure (4–20 mA)
Controller terminal number
23
Type
Analog current sensing
Maximum input voltage
6 V (for 20 mA) 7.5 V (for 25 mA)
Maximum current limit
25 mA
Accuracy
1.5 % of full scale
Surge
As per ISO 7637-3
3.5.2.2
Analog Voltage Input
Controller terminal number 23 Type
Analog voltage sensing
Range
0 to 5 V-DC
Accuracy
0.5 % of full scale (5 V-DC)
Page 10 of 123
KG645 CONTROLLER MANUAL While generating genset paralleling application, this input can be configured to accept a 0-5 V-DC speed bias signal generated by a load sharing module (LSM).
Controller terminal number
24 (Eng_temp sensor)
Type
Ratio-metric sensing
Arrangement
Common mode measurement
Full scale
5 KΩ
Open circuit detection
Above 5.5 KΩ
Resolution
1 °C
Accuracy
1 % of full scale (for 50 to 1000 Ω) 15 % of measured value (for 2500 Ω) 17 % of measured value (for 5 KΩ)
Display range
-5 to 300 °C (23 to 572 °F) depending on sensor
3.5.3 I/P: ANLG TEMP / DIG H 3.5.4 I/P: ANLG FL / DIG G Controller terminal number
25 (Fuel_Level sensor)
Type
Ratio-metric sensing
Arrangement
Common mode measurement
Full scale
5 KΩ
Resolution
1 % of tank capacity
Accuracy
±1.5 % of full scale
Display range
0 to 100 %
3.6 Sensor Common Controller terminal number
41 (Connection to Sensor Common)
Important Note: The sensor common point (SCP) terminal (Pin # 41) should be directly connected to the point of engine body which is a common reference point for all the analog sensors. The wire used for the SCP connection should not be shared with any other connection. The SCP connection should not be taken from genset control panel ground because this will let sharing of it with other connections. The connection should be done with a single wire being connected from pin# 41 to the engine body.
Page 11 of 123
KG645 CONTROLLER MANUAL
3.7 Magnetic Pick Up Input Controller terminal number
42
Type
Single ended
Frequency range
10 to 10000 Hz
Input voltage range
200 mV to 70 V-AC RMS
Resolution
1 RPM
Accuracy
0.25 %
Flywheel teeth
1 to 300
The Magnetic Pick Up (MPU) is an inductive sensor fitted on the engine flywheel for the engine speed sensing. The output of MPU is a sine-wave signal.
3.8 D+ Charge Alt Controller terminal number
7
Voltage range
0 to 35 V
Excitation
2.5 W closed loop
Output power
2.5 W @ 12 V-DC
Resolution
0.1 V
Accuracy 2% The D+ Charge Alt input is a combined input and output terminal.When the genset starts cranking, this terminal provides the excitation current to the charge alternator field winding. Excitation will be given for max 2 sec or (Crank hold time – 1) sec. Once excitation is stopped, after 2 sec, monitoring of D+ Charge Alt pin will begin. When the charge alternator correctly charges the battery, the voltage of this terminal is close to or greater than the battery supply voltage. This charging alt voltage is used to detect engine start condition. This detection happens in cranking and crank rest duration as well. In case of failure of charge alternator, the voltage of this terminal is pulled down to a low voltage by the charge alternator. This drop in voltage triggers the charge failure alarm in the genset controller. The level at which this logic operates and whether it triggers a warning or shutdown alarm is configurable.
4 Outputs 4.1 Digital Outputs Controller terminal number
3, 4, 5, 6, 8, 9
Number of outputs
6
Type
High side driver
Rating
0.75 A
Maximum current
1A
Protection Level
Overload, Overcurrent, Short circuit to BATT+ and BATT-
Software configurable options
Start Relay, Fuel Relay, Close Genset Contactor and many more. Please refer section 9.1.8 for more details.
Do not connect “STARTER MOTOR RELAY” and “STOP SOLENOID” directly to the controller's output terminals.
Page 12 of 123
KG645 CONTROLLER MANUAL
4.2 Actuator Outputs Controller terminal number
17, 18, 19, 20
Type
Stepper motor drive
Maximum current
1 A each coil
Actuator outputs are used only for rotary Actuator, if installed. The rotary Actuator is a 4-wire actuator that is used for creating an electronic governing application in case of a mechanical fuel system engine. In diesel engines, the rotary Actuator's shaft output gets mechanically connected to the stop lever or the throttle lever of an inline or rotary fuel injection pump. In case of petrol or natural gas engines, the rotary Actuator's shaft output gets connected to the throttle/charge control valve.
Figure 5: Representing Actuator connector pin out when viewed from the terminal insertion side
The following table provides the connection details while connecting Actuator with KG-645 controller.
Actuator Connector Pin No.
KG-645 Controller Description
Terminal Sr. No.
Description
1
ACT 1 (Red coloured wire)
17
E-GOV OUT 1
4
ACT 4 (Yellow coloured wire)
18
E-GOV OUT 4
2
ACT 2 (Orange coloured wire)
19
E-GOV OUT 2
3
ACT 3 (Blue coloured wire)
20
E-GOV OUT 3
5 Communication Ports USB RS485 Controller terminal number for RS485 CAN Controller terminal number for CAN
Used to flash the firmware USB 2.0 Type B for connection between controller and PC running KG 645 - Configuration Utility Used for data communication 15, 16 Used for communication between controller and the input/output expansion module* (Refer section 18) 13, 14
For further details please refer section Communication Protocol For KG-645 (section 16).
Page 13 of 123
KG645 CONTROLLER MANUAL
6 Installation
6.1 Dimensions Figure 6: Dimensions of the KG-645 genset controller Recommended mounting panel cut-out dimensions: 118 mm X 93 mm
Page 14 of 123
KG645 CONTROLLER MANUAL
6.2 Mounting on panel To mount the controller into the panel use the fixing clips provided along with the controller. Follow the given steps.
Figure 7: Representative drawing of Fixing clip and screw supplied along with controller
Figure 8: Representative drawing of controller mounting on the panel using the fixing clips •
Insert the fixing clip into the slot provided on the side of the controller.
•
Pull the fixing clips backwards (towards the back of the module). Ensure that the fixing clip is properly fitted inside the slot provided on the controller.
•
Fix the screws and tighten the screw (turn clockwise) to mount the controller properly into the panel. Ensure that the screw will be always perpendicular to the panel surface. The maximum tightening torque is 0.19 N-m.
Over tightening of the screws may damage the controller casing.
Page 15 of 123
KG645 CONTROLLER MANUAL
6.3 Terminal Description Following figure shows the rear view of module.
Figure 9: Representative drawing of KG-645 genset controller from backside The following table provides the details of controller's terminals. Terminal Sr. Name No.
Description
1
BATT -
Battery ground
2
BATT +
Battery positive
3
OUT A
High side driver output – A
4
OUT B
High side driver output – B
5
OUT C
High side driver output – C
6
OUT D
High side driver output – D
7
D+ CHARGE ALT
Input for charging alternator
8
OUT E
High side driver output – E
9
OUT F
High side driver output – F
10
DIG_IN A
Input from switch – A
11
DIG_IN B
Input from switch – B
12
DIG_IN C
Input from switch – C
13
CAN H
CAN high
14
CAN L
CAN low
Page 16 of 123
Degson Female (Mating) Connector Part No. 2EDGK-5.08-02P-14-00AH
15EDGK-3.5-04P-14-00AH
15EDGK-3.5-04P-14-00AH
15EDGK-3.5-06P-14-00AH
KG645 CONTROLLER MANUAL Terminal Sr. Name No.
Description
15
RS485_B
RS485 – B
16
RS485_A
RS485 – A
17
E-GOV OUT 1
Output for the rotary Actuator
18
E-GOV OUT 4
Output for the rotary Actuator
19
E-GOV OUT 2
Output for the rotary Actuator
20
E-GOV OUT 3
Output for the rotary Actuator
21
DIG_IN D
Input from switch – D
22
DIG_IN E
Input from switch – E
23
I/P: ANLG (0-5V / 420mA)
Analog (0 to 5V) / (4 to 20mA) input
Degson Female (Mating) Connector Part No.
15EDGK-3.5-10P-14-00AH
24
I/P: ANLG TEMP / DIG G Analog input from Engine Temperature Sensor
25
I/P: ANLG FL / DIG H
Analog input from Fuel Level Sensor
26
I/P: ANLG / DIG F
Analog input from Canopy Temperature Sensor / Lube Oil Pressure Sensor
27
GEN_V IN NTRL
Voltage input from Gen Neutral
28
GEN_V IN B
Voltage input from Gen Phase B
29
GEN_V IN Y
Voltage input from Gen Phase Y
30
GEN_V IN R
Voltage input from Gen Phase R
31
MAINS_V IN NTRL
Voltage input from Mains Neutral
32
MAINS_V IN B
Voltage input from Mains Phase B
33
MAINS_V IN Y
Voltage input from Mains Phase Y
34
MAINS_V IN R
Voltage input from Mains Phase R
35
GEN_CT_IN B1
CT input 1 from Gen Phase B
36
GEN_CT_IN B2
CT input 2 from Gen Phase B
37
GEN_CT_IN Y1
CT input 1 from Gen Phase Y
38
GEN_CT_IN Y2
CT input 2 from Gen Phase Y
39
GEN_CT_IN R1
CT input 1 from Gen Phase R
40
GEN_CT_INR2
CT input 2 from Gen Phase R
41
EBP_IN
Sensor Common
42
MPU_IN
Input from engine speed sensor (Inductive)
2EDGK-5.08-04P-24-00AH
2EDGK-5.08-04P-24-00AH
Page 17 of 123
15EDGK-3.5-08P-14-00AH
KG645 CONTROLLER MANUAL
6.4 Typical Wiring Diagram 6.4.1 Manual Control Application 3-phase Manual Control Application on engine with Analog resistive LOP sensor configuration.
Figure 10: Representative drawing of KG-645 genset controller when used in the 3-phase Manual Control Panel
Page 18 of 123
KG645 CONTROLLER MANUAL 1-phase Manual Control Application on engine with Analog current LOP sensor configuration and Analog resistive CANOPY Temperature sensor configuration.
Figure 13: Representative drawing of KG-645 genset controller when used in the 1-phase Manual Control Panel
Page 19 of 123
KG645 CONTROLLER MANUAL
7
Module Display Following section describes the layout of screens.
7.1 Power on screen Screen 2: PRODUCT INFO
Screen 1: LOGO
(This screen displays product id, engine sr no, date and real time clock)
7.2 Monitoring Mode In monitoring mode, screens will scroll automatically after a predefined time which can be configured in configuration menu. Also, “Navigation UP/DOWN Keys” are provided to scroll/browse the screens. When the controller is displaying any monitoring screen except ALARMS screen, ENGINE STATUS screen will popup when there is change in controller mode or alarm occurs or timer starts/stops. ALARMS screen will pop-up when a new alarm is generated and then second priority will be for ENGINE STATUS screen. It shall keep scrolling between ALARMS screen and ENGINE STATUS screen till there are one or more active alarms unless manually cleared alarms or scrolled screens. Monitoring mode screens are grouped and identified by different symbols at top left corner of screens. Test mode and Off mode are also distinguished by different symbols at bottom left corner of screens. Following tables provides more details.
Symbols for Screen's Group
Name of Screen's Group Status & Info screens Generator screens Mains screens Engine screens
Page 20 of 123
KG645 CONTROLLER MANUAL Symbols for Mode
Controller Mode Test mode Off mode
7.2.1 Group 1: Status & Info screens 7.2.1.1 Status and Operating Mode This screen will show engine status or alarms along with the operating mode of the controller. Screen 3: STATUS
Screen 4: STATUS
(These screens will be visible in Manual mode) Screen 5: STATUS
Screen 6: STATUS
(This screen will be visible in Test mode)
(Test mode can be identified by symbol in bottom left corner)
Page 21 of 123
KG645 CONTROLLER MANUAL Screen 7: STATUS
Screen 8: STATUS
(This screen will be visible in Auto mode)
(This screen will be visible in Manual mode)
Screen 9: STATUS
Screen 10: STATUS
(This screen will be visible in Manual mode)
(This screen will be visible in Manual mode)
Screen 11: STATUS
Screen 12: STATUS
(This screen will be visible in Off mode)
(Off mode can be identified by symbol in bottom left corner)
Page 22 of 123
KG645 CONTROLLER MANUAL
Screen 13: CONTACTORS
Screen 14: GENERATOR VOLTAGE
(This screen will be visible only if output related to genset and mains contactor are configured)
(The “Y” and “B” phase will be visible only if configured for 3 phase genset)
Screen 15: Generator Kw Load
Screen 16: Generator KVA Load
(The “Y” and “B” phase will be visible only if configured for 3 phase genset)
(The “Y” and “B” phase will be visible only if configured for 3 phase genset)
Screen 17: GENERATOR KVAr LOAD
Screen 18: GENERATOR POWER FACTOR
(The “Y” and “B” phase will be visible only if configured for 3 phase genset)
(The “Y” and “B” phase will be visible only if configured for 3 phase genset)
Page 23 of 123
KG645 CONTROLLER MANUAL
Screen 19: GENERATOR OUTPUT
Screen 20: GENERATOR ENERGY
(The “Y” and “B” phase will be visible only if configured for 3 phase genset. Minimum frequency out of 3 phases will be displayed on screen)
MAINS SCREENS Screen 21: MAINS
Screen 22: MAINS
(The “Y” & “B” phase will be visible only if configured for 3 phase mains. This screen will display readings only if “Mains monitoring” is enabled. Minimum frequency out of 3 phases will be displayed on screen) Screen 23: MAINS
(This screen will be visible if “Mains monitoring” is enabled and mains is not available or unhealthy. The “Y” & “B” phase will be visible only if configured for 3 phase mains. )
Page 24 of 123
KG645 CONTROLLER MANUAL
ENGINE SCREENS Screen 24: ENGINE BATTERY
Screen 25: CANOPY TEMPERATURE
(This screen will be visible only if “Canopy Temperature” sensor is configured)
Screen 26: ENGINE TEMPERATURE
Screen 27: ENGINE LUB OIL PRESSURE
(This screen will be visible only if “Engine temperature” sensor is configured)
(This screen will be visible only if “Lube Oil Pressure” sensor is configured)
Screen 28: ENGINE REMAINING FUEL
Screen 29:EXPANSION MODULE ANALO SENSOR 1
(This screen will be visible only if “Fuel Level” sensor is configured)
(This screen will be visible only if Expansion module is enabled and “AN EX-S1” is configured as “Pressure Sensor”)
Page 25 of 123
KG645 CONTROLLER MANUAL
Screen 30: EXT ANALOG SEN 1
Screen 31: ENGINE SPEED
(This screen will be visible only if Expansion module is enabled and “AN EX-S1” is configured as “Temperature Sensor”) Rest of expansion module analog sensor's screens would look same as above*. Screen 32:ENGINE RUN TIME
Screen 33: ALARM
Screen34 : ENGINE LUB OIL temperature
(This screen will be visible only if “Lube Oil Temperature” sensor is configured)
Page 26 of 123
KG645 CONTROLLER MANUAL
8
Description of Control keys
Menu Navigation UP key
Menu Navigation DOWN key
AUTO/MANU AL/ TEST mode select key
STOP key START key
8.1 Mode Selection diagram
Figure 16: Mode selection using control keys in KG-645 3 secs 2 secs 2 secs 2 secs 3 secs 3 secs
Stop long press Stop + Down long press Up + Down long press Auto long press Up long press Down long press
Page 27 of 123
KG645 CONTROLLER MANUAL
8.2 Functions of Control keys Following table provides details of control keys in different modes. #
Mode
Key input
Function
1
Manual/Test
Start
Starts the engine
2
Auto
Enters into Auto mode
3
Auto (long pressed)
Enters into Test mode
Stop (long pressed)
Immediate stops the engine when engine is running
Stop (long pressed)
Enters into Off mode when engine is off
4
Manual
5 6
Manual/Auto
Stop
Stops the engine and enters into Manual mode
7
Manual/Configuration
Up/Down
Scrolls the parameter
8
Manual/Off
Down+Stop (long pressed)
Enters into configuration mode
Up (long pressed)
Displays last group's first screen (Refer section 7.2 for more details about screen's group)
Down (long pressed)
Displays next group's first screen
10
Up+Down (simultaneously press and release while on ALARMS screen)
Clears the alarms
11
Start
Selects/saves the parameter
Up+Down (long pressed)
Enters on event log page
9 Manual/Test/Auto/Off
12
Configuration
Down+Stop (long pressed)
13 14
Auto
Auto/stop
15
Deep sleep
Any key
16
Test
Stop
17
Off
Auto
18
Back to Manual mode
Stop (long pressed)
Programming mode
19
Event log page
Up+Down (long pressed)
Back to configuration mode
20
Programming
Up+Down (long pressed)
Reset the controller
Page 28 of 123
KG645 CONTROLLER MANUAL
9
Configuration Mode To configure the controller please follow the below mentioned instructions. Enter into the configuration mode (Refer section 8). Screen 34: Configuration Mode
Screen 35: Configuration mode: Authentication Page
To enter into edit mode press “START” key. If you wish to read the configuration press “STOP” key.
To access the configuration menu, please enter your 4-Digit PIN here using ''Navigation UP/DOWN” keys. Once you enter into the “EDIT” mode scroll to the parameter that you wish to edit and press “START” key to edit the parameter. At this moment the parameter will start blinking and you can change the parameter value using “UP” and “DOWN” keys (Refer section 9.1 for configuring parameters). After selecting the required value press “START” key to save parameter or “STOP” key to discard the value. After completion of parameter configuration, exit from configuration mode. Before existing from configuration mode controller will show you the following screen.
Screen 36: Saving Settings
Page 29 of 123
KG645 CONTROLLER MANUAL
9.1 Configurable Parameters 9.1.1 Table 1 – List of Configurable Parameters Level 0
Level 1 (On screen)
Level 2 (On screen)
Possible Value (On screen)
Module
General
Profile name (PROFILE NAME)
Profile 1
Power on mode (POWER ON MODE)
Manual, Auto
Power on lamp test (POWER ON LAMP TEST)
Disable, Enable
Deep sleep mode (DEEP SLEEP MODE)
Disable, Enable
Expansion module (EXPANSION MODULE)*
Disable, Enable
Contrast (CONTRAST)
0 – 100 %
Power save mode (POWER SAVE MODE)
Disable, Enable
Communication mode (COMM MODE)
None, MODBUS
Slave ID (MODBUS SLAVE ID)
1 – 247
Modbus baud rate (MODBUS BAUDRATE)
1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200
Parity
None, Even, Odd
Source (SOURCE)
Refer Table 2
Polarity (POLARITY)
Close To Activate, Open To Activate
Action (ACTION)
None, Warning, Electrical Trip, Shutdown
Activation (ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
Activation delay (ACTIVATION DELAY)
1 – 60 sec
Source (SOURCE)
Refer Table 2
Polarity (POLARITY)
Close To Activate, Open To Activate
Action (ACTION)
None, Warning, Electrical Trip, Shutdown
Activation (ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
Activation delay (ACTIVATION DELAY)
1 – 60 sec
Source (SOURCE)
Refer Table 2
Polarity (POLARITY)
Close To Activate, Open To Activate
Action (ACTION)
None, Warning, Electrical Trip, Shutdown
Activation (ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
Activation delay (ACTIVATION DELAY)
1 – 60 sec
Display RS485 communication (RS485 COMM)
Inputs
DIG IN A
DIG IN B
DIG IN C
Page 30 of 123
KG645 CONTROLLER MANUAL Level 0
Level 1 (On screen)
Level 2 (On screen)
Possible Value (On screen)
DIG IN D
Source (SOURCE)
Refer Table 2
Polarity (POLARITY)
Close To Activate, Open To Activate
Action (ACTION)
None, Warning, Electrical Trip, Shutdown
Activation (ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
Activation delay (ACTIVATION DELAY)
1 – 60 sec
Source (SOURCE)
Refer Table 2
Polarity (POLARITY)
Close To Activate, Open To Activate
Action (ACTION)
None, Warning, Electrical Trip, Shutdown
Activation (ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
Activation delay (ACTIVATION DELAY)
1 – 60 sec
Sensor selection (SENSOR SELECTION)
Not used, Dig In G, Anlg In Eng Temp
(Digital) Source ((DIG) SOURCE)
Refer Table 2
(Digital) Polarity ((DIG) POLARITY)
Close To Activate, Open To Activate
(Digital) Action ((DIG) ACTION)
None, Warning, Electrical Trip, Shutdown
(Digital) Activation ((DIG) ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
(Digital) Activation delay ((DIG) ACTIVATION DELAY)
1 – 60 sec
Shutdown (SHUTDOWN)
Disable, Enable
Shutdown threshold (SHUTDOWN THRESHOLD)
26 – 200 °C
Warning (WARNING)
Disable, Enable
Warning threshold (WARNING THRESHOLD)
25 – 199 °C
Open circuit alarm (OPEN CKT ALARM)
None, Warning, Electrical Trip, Shutdown
Engine Temperature Sensor Calibration
Refer Table 3
Sensor selection (SENSOR SELECTION)
Not used, Dig In H, Anlg In Fuel LVL
(Digital) Source ((DIG) SOURCE)
Refer Table 2
(Digital) Polarity ((DIG) POLARITY)
Close To Activate, Open To Activate
(Digital) Action ((DIG) ACTION)
None, Warning, Electrical Trip,
DIG IN E
ENG TEMP/DIG G
Fuel LVL/DIG H
Page 31 of 123
KG645 CONTROLLER MANUAL Level 0
Level 1 (On screen)
Level 2 (On screen)
Possible Value (On screen) Shutdown
Analog Sensor S1 (AN S1 (4 to 20 mA))
Analog Sensor S2 (AN S2 RES/DIG F)
(Digital) Activation ((DIG) ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
(Digital) Activation delay ((DIG) ACTIVATION DELAY)
1 – 60 sec
Shutdown (SHUTDOWN)
Disable, Enable
Shutdown threshold (SHUTDOWN THRESHOLD)
0 – 50 %
Warning (WARNING)
Disable, Enable
Warning threshold (WARNING THRESHOLD)
2 – 55 %
Fuel tank capacity (FUEL TANK CAPACITY)
0 – 1000 Litres
Fuel theft alarm (FUEL THEFT ALARM)
Disable, Enable
Fuel theft threshold (FUEL THEFT THRESHOLD)
0 – 100 % per hour
Fuel Consumption (FUEL CONSUMPTION)
0.0 – 100.0 Litres per hour
Fuel in liters (FUEL IN LITERS)
Disable, Enable
Fuel Level Sensor Calibration
Refer Table 4
Sensor selection (SENSOR SELECTION (pin 23))
Not used, LOP Sensor
Shutdown (SHUTDOWN)
Disable, Enable
Shutdown threshold (SHUTDOWN THRESHOLD)
0.0 – 4.8 Bar
Warning (WARNING)
Disable, Enable
Warning threshold (WARNING THRESHOLD)
0.2 – 5.0 Bar
Circuit fault alarm (CKT FAULT ALARM)
None, Warning, Electrical Trip, Shutdown
LOP (4 to 20mA) Sensor Calibration
Refer Table 5
Sensor selection (SENSOR SELECTION (pin Not used, Dig In F, Anlg In 26)) Canopy Temp, Anlg In Lube Oil Temp, Anlg In LOP (Digital) Source ((DIG) SOURCE)
Refer Table 2
(Digital) Polarity ((DIG) POLARITY)
Close To Activate, Open To Activate
(Digital) Action ((DIG) ACTION)
None, Warning, Electrical Trip, Shutdown
(Digital) Activation ((DIG) ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
(Digital) Activation delay ((DIG) ACTIVATION DELAY)
1 – 60 sec
Shutdown (SHUTDOWN)
Disable, Enable
Page 32 of 123
KG645 CONTROLLER MANUAL Level 0
Outputs
Level 1 (On screen)
OUT A OUT B OUT C OUT D OUT E OUT F
Timers
Cranking timer
General timer
Level 2 (On screen)
Possible Value (On screen)
Shutdown threshold (SHUTDOWN THRESHOLD)
0.0 – 4.8 Bar (for LOP) / 26 – 200 °C (for Canopy Temp / Lube Oil Temp)
Warning (WARNING)
Disable, Enable
Warning threshold (WARNING THRESHOLD)
0.0 – 5.0 Bar (for LOP) / 25 – 199 °C (for Canopy Temp / Lube Oil Temp)
Open circuit alarm (OPEN CKT ALARM)
None, Warning, Electrical Trip, Shutdown
Canopy Temp Sensor Calibration/Lube Oil Temperature Sensor Calibration
Refer Table 6
LOP (Resistive) Sensor Calibration
Refer Table 7 (for LOP)
Source (SOURCE)
Refer Table 8
On activation (ON ACTIVATION)
De-energise, Energise
Source (SOURCE)
Refer Table 8
On activation (ON ACTIVATION)
De-energise, Energise
Source (SOURCE)
Refer Table 8
On activation (ON ACTIVATION)
De-energise, Energise
Source (SOURCE)
Refer Table 8
On activation (ON ACTIVATION)
De-energise, Energise
Source (SOURCE)
Refer Table 8
On activation (ON ACTIVATION)
De-energise, Energise
Source (SOURCE)
Refer Table 8
On activation (ON ACTIVATION)
De-energise, Energise
Crank hold time (CRANK HOLD TIME)
1 – 15 sec
Crank rest time (CRANK REST TIME)
2 – 60 sec
Crank start delay (CRANK START DELAY)
0 – 30 sec
Safety monitor start delay (SAFETY MONITOR DELAY)
10 – 60 sec
Mains detect delay (MAINS DETECT DELAY)
1 – 30 sec
Alternator detect delay (ALT DETECT DELAY)
1 – 30 sec
Warm up delay (WARM UP DELAY)
0 – 60 sec
Return to mains delay (RETN -TO-MAINS DELAY)
0 – 600 sec
Engine cooling time (ENG COOL TIME)
0 – 300 sec
Stop action time (STOP ACTION TIME)
10 – 120 sec
Load transfer delay (LOAD TRANSFER DELAY)
0 – 60 sec
Page 33 of 123
KG645 CONTROLLER MANUAL Level 0
Generator
Level 1 (On screen)
Alternator configuration (ALT CONFIG)
Voltage monitoring (VOLT MONITOR)
Frequency monitoring
Level 2 (On screen)
Possible Value (On screen)
Power save mode delay (PWR SAVE MODE DELAY)
5 – 1800 sec
Screen changeover time (SCRN CHNGOVER TIME)
1 – 1800 sec
Deep sleep mode delay (DEEP SLP MODE DELAY)
5 – 1800 sec
Sounder alarm timer (SOUNDER ALARM TIMER)
1 – 300 sec
Test mode timer (TEST MODE TIMER)
1 – 720 Min
Alternator present (ALT PRESENT)
No, Yes
Number of poles (NUMBER OF POLES)
2, 4, 6, 8 poles
Alternator AC system (ALT AC SYSTEM)
1 Phase, 3 Phase
Minimum healthy voltage (MIN HEALTHY VOLT)
80 – 450 V Ph-N
Minimum healthy frequency (MIN HEALTHY FREQ)
0 – 60 Hz
Phase reversal detect (PHASE REVERSAL DETECT)
Disable, Enable
Phase reversal action (PHASE REVERSAL ACTION)
None, Warning, Electrical Trip, Shutdown
Alternator voltage lost shutdown (ALT VOLT LOST SHUTDOWN)
Disable, Enable
Auto load transfer (AUTO LOAD TRANSFER)
Disable, Enable
Under voltage shutdown (UNDER VOLT SHUTDOWN)
Disable, Enable
Under voltage shutdown threshold (UV SHUTDOWN THRESHOLD)
0 – 398 V Ph-N
Under voltage warning (UNDER VOLT WARNING)
Disable, Enable
Under voltage warning threshold (UV WARNING THRESHOLD)
2 – 400 V Ph-N
Over voltage shutdown (OVER VOLT SHUTDOWN)
Disable, Enable
Over voltage shutdown threshold (OV SHUTDOWN THRESHOLD)
102– 800 V Ph-N
Over voltage warning (OVER VOLT WARNING)
Disable, Enable
Over voltage warning threshold (OV WARNING THERSHOLD)
100 – 798 V Ph-N
Under frequency shutdown (UNDER FREQ SHUTDOWN)
Disable, Enable
Page 34 of 123
KG645 CONTROLLER MANUAL Level 0
Level 1 (On screen)
Level 2 (On screen)
Possible Value (On screen)
(FREQ MONITOR)
Under frequency shutdown threshold (UF SHUTDOWN THRESHOLD)
0.0 – 59.0 Hz
Under frequency warning (UNDER FREQ WARNING)
Disable, Enable
Under frequency warning threshold (UF WARNING THRESHOLD)
1.0 – 60.0 Hz
Over frequency shutdown (OVER FREQ SHUTDOWN)
Disable, Enable
Over frequency shutdown threshold (OF SHUTDOWN THRESHOLD)
26.0 – 70.0 Hz
Over frequency warning (OVER FREQ WARNING)
Disable, Enable
Over frequency warning threshold (OF WARNING THRESHOLD)
25.0 – 69.0 Hz
CT ratio (CT RATIO)
1 – 8000
Over current threshold (OVER CURR THRESHOLD)
5 – 10000 A
Over current delay (OVER CURR DELAY)
1 – 600 sec
Current monitoring (CURR MONITOR)
Over current action (OVER CURR ACTION) None, Warning, Electrical Trip, Shutdown
Load monitoring (LOAD MONITOR)
Mains
Mains Configuration (MAINS CONFIG)
Under voltage monitoring
Unbalanced load action (UNBAL LOAD ACTION)
None, Warning, Electrical trip, Shutdown
Unbalanced load threshold (UNBAL LOAD THRESHOLD)
5 – 200 %
Unbalanced load delay (UNBAL LOAD DELAY)
1– 600 sec
RESERVED
NA
Generator rating (GEN RATING)
1.0 – 800.0 kW
Over load threshold (OVERLOAD THRESHOLD)
50 – 150 %
Overload monitoring delay (OVERLOAD MON DELAY)
1 – 600 sec
Overload action (OVERLOAD ACTION)
None, Warning, Electrical trip, Shutdown
Mains monitoring (MAINS MONITORING)
Disable, Enable
Mains AC system (MAINS AC SYSTEM)
1 Phase, 3 Phase
Phase reversal detect (PHASE REVERSAL DETECT)
Disable, Enable
Phase reversal action (PHASE REVERSAL ACTION)
None, Notification
Enable (ENABLE)
No, Yes
Trip (TRIP)
48 – 398 V Ph-N
Page 35 of 123
KG645 CONTROLLER MANUAL Level 0
Level 1 (On screen)
Level 2 (On screen)
Possible Value (On screen)
(UNDER VOLT MON)
Return (RETURN)
50 – 400 V Ph-N
Over voltage monitoring (OVER VOLT MON)
Enable (ENABLE)
No, Yes
Trip (TRIP)
102 – 800 V Ph-N
Return (RETURN)
100 – 798 V Ph-N
Enable (ENABLE)
No, Yes
Trip (TRIP)
27.0 – 67.0 Hz
Return (RETURN)
28.0 – 68.0 Hz
Enable (ENABLE)
No, Yes
Trip (TRIP)
30.0 – 70.0 Hz
Return (RETURN)
29.0 – 69.0 Hz
Start attempts (START ATTEMPTS)
1–9
Disconnect on oil pressure (DISCONN ON LOP SENS)
Disable, Enable
Disconnect oil pressure (DISCONN LOP SENS)
0.5 – 10.0 Bar
Reserved (RESERVED)
NA
Disconnect on oil pressure switch (DISCONN ON LLOP SW)
Disable, Enable
LLOP switch transient time (LLOP SW TRANS TIME)
0.0 – 3.0 Sec
Alternator frequency (ALT FREQUENCY)
0 – 70 Hz
Engine speed (ENGINE SPEED)
0 – 4000 RPM
Disconnect on charging alternator voltage (DISCONN ON CHG ALT VOLT)
Disable, Enable
Charging alternator threshold (CHG ALT THRESHOLD)
5.0 – 30.0 Volt
Speed sense source (SPEED SENSE SOURCE)
Magnetic pickup, Alternator frequency (Alt Freq)
Flywheel teeth (FLYWHEEL TEETH)
1– 300
Under speed shutdown (UNDER SPEED SHUTDOWN)
Disable, Enable
Under speed threshold (UNDER SPEED THRESHOLD)
0 – 3600 RPM
Under speed delay (UNDER SPEED DELAY)
1– 60 Sec
Over speed level 1 threshold (OVER SPEED THRESHOLD)
800 – 4000 RPM
Over speed delay (OVER SPEED DELAY)
1 – 60 Sec
Over speed level 2 threshold (Gross OS THRESHOLD)
100 – 200 %
Under frequency monitoring (UNDER FREQ MON) Over frequency monitoring (OVER FREQ MON) Engine
Crank disconnect (CRANK DISCONNECT)
Speed monitoring (SPEED MONITOR)
Page 36 of 123
KG645 CONTROLLER MANUAL Level 0
Level 1 (On screen)
Battery monitoring (BATTERY MONITOR)
Charge alternator monitoring (CHARGE ALT MON) Preheat (PREHEAT)
Maintenan ce
Maintenance alarm (MAINT ALARM)
Level 2 (On screen)
Possible Value (On screen)
Healthy speed threshold (HEALTHY SPEED THRES)
300 – 4000 RPM
Low volt action (LOW VOLT ACTION)
None, Warning, Electrical Trip, Shutdown
Low volt threshold (LOW VOLT THRESHOLD)
8.0 – 24.0 V
Low volt delay (LOW VOLT DELAY)
5 – 1800 Sec
High volt action (HIGH VOLT ACTION)
None, Warning, Electrical Trip, Shutdown
High volt threshold (HIGH VOLT THRESHOLD)
12.0 – 36.0 V
High volt delay (HIGH VOLT DELAY)
5 – 1800 Sec
Fail action (FAIL ACTION)
None, Warning, Electrical Trip, Shutdown
Fail threshold (FAIL THRESHOLD)
4.0 – 28.0 V
Fail delay (FAIL DELAY)
5 – 60 Sec
Preheat timer (PREHEAT TIMER)
1 – 60 Sec
Engine Temperature limit (ENG TEMP LIMIT)
Disable, Enable
Engine Temperature limit (ENG TEMP LIMIT)
0 – 300 °C
Action (ACTION)
Notification, Warning
Due at engine hours (DUE AT ENGINE HOURS)
10 – 65000 hrs
Alarm due date (ALARM DUE DATE) Rotary Actuator }
General (GENERAL)
Engine start strategy (ENG START STRGY)
Current day onwards Actuator application (ACTUATOR APPLN)
As E-Governor, As Start/Stop Device
Actuator speed (ACTUATOR SPEED)
1 – 10 x25 Hz
Actuator direction (ACTUATOR DIRECTION)
Clockwise, Anti–Clockwise
Cranking steps (CRANKING STEPS)
10 – 5000
Reserved parameter
NA
Reserved parameter
NA
Reserved parameter
NA
Init low speed delay (INIT LOW SPEED DELAY)
0 – 180 Sec
Init low speed (INIT LOW SPEED)
500 – 1800 RPM
CRANK SENSE SPEED
20 – 2800 RPM
Ramp up time (RAMP UP TIME)
1 – 180 Sec
Reserved parameter
NA
Page 37 of 123
KG645 CONTROLLER MANUAL Level 0
Level 1 (On screen)
Level 2 (On screen)
Possible Value (On screen)
Reserved parameter
NA
Reserved parameter
NA
Reserved parameter
NA
Generator E- Speed set point select (SPEED SET POINT governor SELECT) configuration Droop (DROOP) (GEN EGOV CNFG) Target speed (TARGET SPEED)
0–4% 500 – 4000 RPM
Proportional gain (PROPORTIONAL GAIN)
0 – 1000
Integral gain (INTEGRAL GAIN)
0 – 2000
Derivative gain (DERIVATIVE GAIN)
0 – 1000
Friction set off (FRICTION SETOFF)
0 – 1000
Gain schedule trigger (GAIN SCHEDULE TRIGGER)
0.0 – 100.0 % RPM error
Loading factor (LOADING FACTOR)
0 – 1000
Unloading factor (UNLOADING FACTOR)
0 – 1000
Target speed (TARGET SPEED)
500 – 4000 RPM
Proportional gain (PROPORTIONAL GAIN)
0 – 1000
Integral gain (INTEGRAL GAIN)
0 – 2000
Derivative gain (DERIVATIVE GAIN)
0 – 1000
Friction set off (FRICTION SETOFF)
0 – 1000
Gain schedule trigger (GAIN SCHEDULE TRIGGER)
0.0 – 100.0 % RPM error
Loading factor (LOADING FACTOR)
0 – 1000
Unloading factor (UNLOADING FACTOR)
0 – 1000
Start/stop device configuration (STR/STP DEVICE CNFG)
Running steps (RUNNING STEPS)
0 – 500
DIG IN EX-A
Source (SOURCE)
Refer Table 2
Polarity (POLARITY)
Close To Activate, Open To Activate
Action (ACTION)
None, Warning, Electrical Trip, Shutdown
Activation (ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
Activation delay (ACTIVATION DELAY)
1 – 60 sec
Source (SOURCE)
Refer Table 2
Polarity (POLARITY)
Close To Activate, Open To Activate
Action (ACTION)
None, Warning, Electrical Trip,
Engine E-governor configuration (ENG EGOV CNFG)
Expansion digital inputs (EXP DIG INPUTS)
Fixed (0% droop), Speed bias Inp (0-5V), Load based droop
DIG IN EX-B
Page 38 of 123
KG645 CONTROLLER MANUAL Level 0
Level 1 (On screen)
Level 2 (On screen)
Possible Value (On screen) Shutdown
DIG IN EX-C
DIG IN EX-D
DIG IN EX-E
Expansion AN EX-S1/DIG EX-F analogue inputs (EXP ANLG INPUTS)
Activation (ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
Activation delay (ACTIVATION DELAY)
1 – 60 sec
Source (SOURCE)
Refer Table 2
Polarity (POLARITY)
Close To Activate, Open To Activate
Action (ACTION)
None, Warning, Electrical Trip, Shutdown
Activation (ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
Activation delay (ACTIVATION DELAY)
1 – 60 sec
Source (SOURCE)
Refer Table 2
Polarity (POLARITY)
Close To Activate, Open To Activate
Action (ACTION)
None, Warning, Electrical Trip, Shutdown
Activation (ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
Activation delay (ACTIVATION DELAY)
1 – 60 sec
Source (SOURCE)
Refer Table 2
Polarity (POLARITY)
Close To Activate, Open To Activate
Action (ACTION)
None, Warning, Electrical Trip, Shutdown
Activation (ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
Activation delay (ACTIVATION DELAY)
1 – 60 sec
Sensor selection (SENSOR SELECTION)
Not used, Dig In EX-F, Pressure sensor, Temperature sensor
(Digital) Source ((DIG) SOURCE)
Refer Table 2
(Digital) Polarity ((DIG) POLARITY)
Close To Activate, Open To Activate
(Digital) Action ((DIG) ACTION)
None, Warning, Electrical Trip, Shutdown
(Digital) Activation ((DIG) ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
(Digital) Activation delay ((DIG) ACTIVATION DELAY)
1 – 60 sec
Action
None, Warning, Electrical Trip, Shutdown
Threshold (THRESHOLD)
0.0 – 10.0 Bar (for Pressure) /
Page 39 of 123
KG645 CONTROLLER MANUAL Level 0
Level 1 (On screen)
Level 2 (On screen)
Possible Value (On screen) -5.0 – 1000.0 °C (for Temperature)
AN EX-S2/DIG EX-G
AN EX-S3/DIG EX-H
Threshold type
Less Than Threshold, Greater Than Threshold
Open circuit alarm (OPEN CKT ALARM)
None, Warning, Electrical Trip, Shutdown
Pressure Sensor Calibration / Temperature Sensor Calibration
Refer Table 7 (for Pressure) / Refer Table 9 (for Temperature)
Sensor selection (SENSOR SELECTION)
Not used, Dig In EX-G, Pressure sensor, Temperature sensor
(Digital) Source ((DIG) SOURCE)
Refer Table 2
(Digital) Polarity ((DIG) POLARITY)
Close To Activate, Open To Activate
(Digital) Action ((DIG) ACTION)
None, Warning, Electrical Trip, Shutdown
(Digital) Activation ((DIG) ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
(Digital) Activation delay ((DIG) ACTIVATION DELAY)
1 – 60 sec
Action
None, Warning, Electrical Trip, Shutdown
Threshold (THRESHOLD)
0.0 – 10.0 Bar (for Pressure) / -5.0 – 1000.0 °C (for Temperature)
Threshold type
Less Than Threshold, Greater Than Threshold
Open circuit alarm (OPEN CKT ALARM)
None, Warning, Electrical Trip, Shutdown
Pressure Sensor Calibration / Temperature Sensor Calibration
Refer Table 7 (for Pressure) / Refer Table 9 (for Temperature)
Sensor selection (SENSOR SELECTION)
Not used, Dig In EX-H, Pressure sensor, Temperature sensor
(Digital) Source ((DIG) SOURCE)
Refer Table 2
(Digital) Polarity ((DIG) POLARITY)
Close To Activate, Open To Activate
(Digital) Action ((DIG) ACTION)
None, Warning, Electrical Trip, Shutdown
(Digital) Activation ((DIG) ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
(Digital) Activation delay ((DIG) ACTIVATION DELAY)
1 – 60 sec
Action
None, Warning, Electrical Trip,
Page 40 of 123
KG645 CONTROLLER MANUAL Level 0
Level 1 (On screen)
Level 2 (On screen)
Possible Value (On screen) Shutdown
AN EX-S4/DIG EX-I
AN EX-S5/DIG EX-J
Threshold (THRESHOLD)
0.0 – 10.0 Bar (for Pressure) / -5.0 – 1000.0 °C (for Temperature)
Threshold type
Less Than Threshold, Greater Than Threshold
Open circuit alarm (OPEN CKT ALARM)
None, Warning, Electrical Trip, Shutdown
Pressure Sensor Calibration / Temperature Sensor Calibration
Refer Table 7 (for Pressure) / Refer Table 9 (for Temperature)
Sensor selection (SENSOR SELECTION)
Not used, Dig In EX-I, Pressure sensor, Temperature sensor
(Digital) Source ((DIG) SOURCE)
Refer Table 2
(Digital) Polarity ((DIG) POLARITY)
Close To Activate, Open To Activate
(Digital) Action ((DIG) ACTION)
None, Warning, Electrical Trip, Shutdown
(Digital) Activation ((DIG) ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
(Digital) Activation delay ((DIG) ACTIVATION DELAY)
1– 60 sec
Action
None, Warning, Electrical Trip, Shutdown
Threshold (THRESHOLD)
0.0 – 10.0 Bar (for Pressure) / -5.0 – 1000.0 °C (for Temperature)
Threshold type
Less Than Threshold, Greater Than Threshold
Open circuit alarm (OPEN CKT ALARM)
None, Warning, Electrical Trip, Shutdown
Pressure Sensor Calibration / Temperature Sensor Calibration
Refer Table 7 (for Pressure) / Refer Table 9 (for Temperature)
Sensor selection (SENSOR SELECTION)
Not used, Dig In EX-J, Pressure sensor, Temperature sensor
(Digital) Source ((DIG) SOURCE)
Refer Table 2
(Digital) Polarity ((DIG) POLARITY)
Close To Activate, Open To Activate
(Digital) Action ((DIG) ACTION)
None, Warning, Electrical Trip, Shutdown
(Digital) Activation ((DIG) ACTIVATION)
Never, From Engine Start, From Monitoring On, Always
(Digital) Activation delay ((DIG)
0 – 60 sec
Page 41 of 123
KG645 CONTROLLER MANUAL Level 0
Level 1 (On screen)
Level 2 (On screen)
Possible Value (On screen)
ACTIVATION DELAY)
Expansion digital outputs (EXP OUTPUTS)
Action
None, Warning, Electrical Trip, Shutdown
Threshold (THRESHOLD)
0.0 – 10.0 Bar (for Pressure) / -5.0 – 1000.0 °C (for Temperature)
Threshold type
Less Than Threshold, Greater Than Threshold
Open circuit alarm (OPEN CKT ALARM)
None, Warning, Electrical Trip, Shutdown
Pressure Sensor Calibration / Temperature Sensor Calibration
Refer Table 7 (for Pressure) / Refer Table 9 (for Temperature)
Source (SOURCE)
Refer Table 8
Polarity (POLARITY)
De-energise, Energise
Source (SOURCE)
Refer Table 8
Polarity (POLARITY)
De-energise, Energise
Source (SOURCE)
Refer Table 8
Polarity (POLARITY)
De-energise, Energise
Source (SOURCE)
Refer Table 8
Polarity (POLARITY)
De-energise, Energise
Source (SOURCE)
Refer Table 8
Polarity (POLARITY)
De-energise, Energise
Password 1
####
0 – 9 for each digit
Password 2
####
0 – 9 for each digit
OUT EX-A OUT EX-B OUT EX-C OUT EX-D OUT EX-E
Password
Page 42 of 123
KG645 CONTROLLER MANUAL
Table 2 – Digital Input Sources Selection #
Source (On screen)
1
Not used
2
User configured
3
Low fuel level switch (Low fuel LVL Switch)
4
Low lube oil pressure switch (Low Lube Oil Press Switch)
5
High engine temperature switch (High Engine Temp Switch)
6
Water level switch (Water LVL Switch)
7
Emergency stop switch (Emergency Stop)
8
Remote Start / Stop
9
Simulate Start
10
Simulate Stop
11
Simulate Auto
12
Close generator / open mains switch (Close Gen/Open Mains Switch)
13
Close mains / open generator switch (Close Mains/Open Gen Switch)
14
Simulate Mains
15
Reserved
16
High canopy temperature
17
V-Belt broken switch
Table 3 – Engine Temperature Sensor Resistance (Ω)
Temperature° C
0 – 5000 (R1-R10)
-25 – 200 °C (T1-T10)
Table 4 – Fuel Level Sensor Calibration Resistance (Ω)
Fuel level (%)
0 – 5000 (R1-R10)
0 – 100 % (L1-L10)
Table 5 – LOP (4 to 20 mA) Sensor Calibration Current (mA)
Pressure (Bar)
4 – 20 (I1-I10)
0.0 – 10.0 Bar (V1-V10)
Table 6 – CANOPY Temperature Sensor Calibration/Lube Oil Temperature Sensor Calibration Resistance (Ω)
Temperature° C
0 – 5000 (R1-R10)
-25 – 200 °C (V1-V10)
Page 43 of 123
KG645 CONTROLLER MANUAL
Table 7 – LOP (Resistive) Sensor Calibration Resistance (Ω)
Pressure (Bar)
0 – 5000 (R1-R10)
0.0 – 10.0 Bar (V1-V10)
Table 8 – Digital Output Source Selection #
Output source (On screen)
1
Disable
2
Sounder alarm
3
Battery over voltage
4
Battery under voltage
5
Charge alt shutdown
6
Charge alt warning
7
Close genset contactor (Close Gen Contactor)
8
Close mains contactor
9
Mains failure
10
Common alarm
11
Common electrical trip
12
Common shutdown
13
Common warning
14
Cooling down
15
Digital input A (Dig In A)
16
Digital input B (Dig In B)
17
Digital input C (Dig In C)
18
Digital input D (Dig In D)
19
Digital input E ((Dig In E)
20
Digital input F (Analog Sensor 2 In) (Dig In F (Anlg S2 In))
21
Digital input G (Analog In Engine Temp) (Dig In G (Anlg In Eng Temp))
22
Digital input H (Analog In Fuel Level) (Dig In H (Anlg In Fuel LVL))
23
Emergency stop
24
Stop solenoid
25
Fail to start
26
Fail to stop
27
Fuel relay
28
Generator available (Gen Available)
29
Generator R Phase over voltage shutdown (R Phase OV Shutdown)
30
Generator R Phase under voltage shutdown (R Phase UV Shutdown)
31
Generator Y Phase over voltage shutdown (Y Phase OV Shutdown)
Page 44 of 123
KG645 CONTROLLER MANUAL 32
Generator Y Phase under voltage shutdown (Y Phase UV Shutdown)
33
Generator B Phase over voltage shutdown (B Phase OV Shutdown)
34
Generator B Phase under voltage shutdown (B Phase UV Shutdown)
35
Generator over current (Gen Over Current)
36
High engine temperature (High Engine Temp)
37
Low fuel level (Low Fuel LVL)
38
Low lube oil pressure (Low LOP)
39
Main high voltage (Mains High Volt)
40
Mains low voltage (Mains Low Volt)
41
Oil pressure open circuit
42
Open generator contactor (Open Gen Contactor)
43
Open mains contactor
44
Over frequency shutdown (Over Freq Shutdown)
45
Over speed shutdown
46
Gross over speed shutdown
47
Start relay
48
Temperature sensor open circuit (Temp Sensor Open Circuit)
49
Under frequency shutdown (Under Freq Shutdown)
50
Under speed shutdown
51
Maintenance due (Maintenance Due)
52
Stop mode
53
Auto mode
54
Manual mode
55
Reserved
56
Preheat output
57
Dig In EX-A*
58
Dig In EX-B*
59
Dig In EX-C*
60
Dig In EX-D*
61
Dig In EX-E*
62
Dig In EX-F (AN EX-S1 RES)*
63
Dig In EX-G (AN EX-S2 RES)*
64
Dig In EX-H (AN EX-S3 RES)*
65
Dig In EX-I (AN EX-S4 RES)*
66
Dig In EX-J (AN EX-S5 RES)*
67
Expansion module available (Exp Module Available)*
68
Oil Pressure Circuit Open
Page 45 of 123
KG645 CONTROLLER MANUAL
Table 9 – Temperature Calibration (Expansion Module)* Resistance (Ω)
Temperature° C
0 – 5000 (R1-R10)
-5 – 1000 °C (V1-V10)
*All the expansion module relevant parameters will be applicable, if KG-645 is connected to expansion module.
10 Module Operation in manual Mode In this mode if Start key is pressed, genset will be cranked. Once the preconfigured engine alternator voltage or frequency or RPM or lube oil pressure is detected, then engine will be on. Controller will latch the genset contactor when genset loading voltage and frequency are above the minimum healthy thresholds. Genset contactor will get latched only when Auto Load Transfer option is enabled. Engine run hours will start incrementing when the genset voltage becomes greater than Min Healthy Voltage. During genset running, if Stop key is pressed, Genset contactor if latched will get open after the Load Transfer Delay and then Engine Cooling Timewill start. After this, controller will command genset to stop. When Genset is not running and Mains is healthy and Mains Monitoring is enabled, Mains contacor will get lached. Similarly, if Mains is found to be unhealthy Mains contactor will be opened. If Mains Monitoring is disabled, then Mains contactor will not be operated in this mode. During Crank time, if the Stop key is pressed or warning alarm occurs or shutdown alarm occurs controller will not issue start command. To start the genset it is necessary to clear all the alarms manually and press the Start key again.
11 Module Operation in Auto Mode To enter into Auto mode press “AUTO” key (Refer section 8). The controller can be used in following configurations while in Auto mode. •
Auto Mains Failure (AMF)
•
Remote start/stop
•
RS485 start/stop
11.1 Auto Mains Failure (AMF) When the Mains Monitoring is enabled in the Mains Configuration (Refer section 9.1 and 22.7.1) and the controller is in the Auto mode, AMF mode gets activated. In this mode, if the mains healthy condition is present then the genset remains in Stop mode. When the mains unhealthy condition occurs, mains contactor will get opened and genset will be cranked. Once the preconfigured engine alternator voltage or frequency or RPM or lube oil pressure is detected, then engine will be on. Once, the genset loading voltage and frequency are above the minimum healthy thresholds, warm-updelay will start. At the end of this delay, controller will latch the genset contactor. Engine run hours will start incrementing when the genset voltage becomes greater than Min Healthy Voltage. During genset running, if the mains voltage returns, Mains Detect Delay will start first. If the mains is found to be healthy for this delay then Return To Mains Delay timer will start. After this, genset contactor will get opened and after the Load Transfer Delay, mains contactor will get latched and controller will command genset to stop after Engine Cooling Time. When the genset is taking Engine Cooling Time due to electrical trip and if mains healthy condition is detected, then mains contactor will get latched. In this case, if mains unhealthy condition is detected again, then mains contacor will get unlatched again.
Page 46 of 123
KG645 CONTROLLER MANUAL During Crank Hold Time, if the mains voltage recovers or any stop command or shutdown alarm occurs controller will not issue start command. To start the genset it is necessary to clear all the alarms manually and put the controller in Auto mode again. Once the Mains Monitoring is disabled, then enable option will not appear in configuration menu. To enable the Mains Monitoring again, enable and configure at least one parameter from mains voltage or frequency monitoring. Mains healthy condition will be decided by mains under/over voltage/frequency thresholds. If the Under Voltage monitoring is disabled, controller will display MAINS HEALTHY condition for Under Voltage condition also. Controller will detect unhealthy condition of enabled parameters only.
11.2 Remote start/stop To use the Remote start/stop mode of the controller, first configure one of the digital input as Remote Start/Stop and put the controller in the Auto mode. In this mode, once the Remote start/stop input is configured the GCU will enter into Remote start/stop mode only after pressing the auto key . Also the mains monitoring should be disable. The mains contactor will be latched or unlatched as per the Remote start/stop input only after entering in the auto mode. Screenshot configuration utility representing digital input configured as Remote Start/Stop (Refer figure 17).
Figure 17: Digital input configuration screen in KG 645 - Configuration Utility
12 Paralleling support / Speed bias mode The KG-645 controller offers unique feature of electronic governing for engines with mechanical fuel systems. In conjunction with the external Load Sharing Module, KG-645 controller can control speed of engine and supports genset synchronisation and paralleling feature. Electronic speed governing (E-governor) system is especially applicable to engines used in genset. This system provides precise, fast-acting control of engine speed. This system can be configured for fixed speed (0% droop) application or paralleling support mode. In paralleling support mode, the system maintains the speed in accordance to the speed bias signal provided by supervisory control/Load Sharing Module (LSM).
12.1 Paralleling concept Paralleling is the operation in which multiple gensets, usually two or more, are synchronized and then connected to a common bus. The frequency, voltage, phase angle and phase rotation of all the genset must match within prescribed limits before they can be paralleled. By considering linear relation between speed of the engine and
Page 47 of 123
KG645 CONTROLLER MANUAL frequency of the alternator output, the speed must be controlled until the genset is paralleled with the grid or other genset with the help of electronic governor. A Load Sharing Module controls the speed and the voltage of the genset by controlling the AVR and E-governor of the gesnet. To control these two devices the LSM provides the DC analog voltage signal to the both devices. The analog voltage signal is generally in the range of 0-5 V.
Figure 18: Representing Analog Voltage Input terminal of KG-645
12.2 Configuration in KG-645 Following is the stepwise procedure for configuring KG-645 for paralleling operation. Select the Actuator Application as a E-Governor (Refer figure 19). Configure Actuator speed and direction. Configure generator E-Governor related parameters. Select Set Speed Selection as Speed Bias Input (0-5 V). Set the Target Speed. Then depending upon the voltage applied at terminal no. 23, the RPM will be decided. Genset will run at RPM less than 100 by Target RPM when 0V is applied and will run at RPM greater than 100 than Target RPM when the 5V is applied. There will be linear relationship between RPM and applied voltage (0-5 V). Provide 0-5 V analog signal from the LSM to KG-645 controller at terminal no. 23, as a speed bias signal (Refer figure 18).
Figure 19: Representing Analog Voltage Input terminal of KG-645
Page 48 of 123
KG645 CONTROLLER MANUAL
13 Module Operation In Test Mode To enter into Test mode, press and hold “AUTO” key for longer duration (minimum 3 sec), when the engine is off. Once the controller is in Test mode, “START” key's and “AUTO” key's LED will start blinking. Then, user can start and test the engine by pressing “START key”. The controller will remain in this mode, for the preconfigured Test Mode Timer (Refer section 8). If STOP key is pressed while Test Mode Timer is running, controller will stop engine and will return to Manual mode again.
14 Deep Sleep Mode Deep Sleep Mode is a useful feature to prolong the battery life. In this mode, normal functions of the controller are suspended and controller is placed into its lowest power consumption state. Controller maintains the status and alarms it had before Deep Sleep Mode. When the controller is waked up, normal operations are resumed automatically. The controller goes in Deep Sleep Mode if this mode is enabled in controller's configuration and there is no user interaction for the preset Deep Sleep Mode Delay. When remote start/stop input is used and mains monitoring is disabled Device enters into deep sleep mode on enabling in all conditions except: •
Auto Mode
•
Any mode with main contactor configured to an output and mains monitoring enabled
•
Configuration mode
•
Programming mode
•
When remote start/stop input is configured and mains monitoring is disabled
Press any key to wake up the controller from Deep Sleep Mode.
15 Alarms KG-645 controller allows to configure several Shutdown/Electrical trip, Warning and Notification alarms such as Low Oil Pressure shutdown, Over Load warning and many more. An alarm condition occurs when the preconfigured parameter is out of preset level. On initiation of an alarm, the Alarm LED will start blinking and Sounder alarm will be activated if configured. The controller will display name of alarms along with count on ALARMS screen and the nature of alarm on STATUS screen. For acknowledging the alarms, press “UP+DOWN” key (in case of sounder alarm). All the alarms will be activated at the end of Safety Monitoring Delay duration. The controller will not issue the start command if any of alarm left unacknowledged. #
Alarm Actions
Description
1
Shutdown
Genset is taken off load and immediately stopped by skipping Engine Cooling Time.
2
Electrical trip
Genset is taken off load and engine cooling timer begins, after which genset is stopped.
3
Warning
Warning alarms serves to draw operator's attention to an undesirable condition without affecting genset's operation.
4
Notification
Controller will display message on the display screen.
Page 49 of 123
KG645 CONTROLLER MANUAL
Sr. No.
Alarms
Causes
Action Options
1
Low Oil Pressure
Indicates that the oil pressure measured is below the preset threshold. This condition is detected only when engine is off.
Shutdown Warning
2
Low Oil Pressure (Switch)
Indicates that the oil pressure measured is below the preset threshold. This condition is detected only when engine is off.
Shutdown Electrical Trip Warning
3
Oil Pressure Ckt Open The oil pressure sensor is detected as not being present
4
High Eng Temp
Indicates that the engine temperature is above the preset Shutdown threshold. This condition is detected only when engine is on. Warning
5
High Eng Temp (Switch)
Shutdown Indicates that the engine temperature is above the preset Electrical Trip threshold. This condition is detected only when engine is on. Warning
6
Eng Temp/ pin24-Ckt Opn
The temperature sensor is detected as not being present
7
Low Fuel level
Indicates that the amount of fuel level is below the preset Shutdown threshold. This condition is detected only when engine is on. Warning
8
Low Fuel level (Switch)
Shutdown Indicates that the amount of fuel level is below the preset Electrical Trip threshold. This condition is detected only when engine is on. Warning
9
Fuel Theft
The fuel consumption has exceeded the preset threshold
Warning
10
Low Water Level Switch
Indicates that radiator water level is below the preset threshold
Shutdown Electrical Trip Warning
11
High Canopy Temperature
Indicates that canopy temperature is above the preset threshold
Shutdown Warning
12
High Canopy Temperature (Switch)
Indicates that canopy temperature is above the preset threshold
Shutdown Electrical Trip Warning
13
Canopy Temp Ckt Open
The canopy temperature sensor is detected as not being present
Shutdown Electrical Trip Warning
14
Anlg S1/ pin23-Ckt Opn Analog sensor S1 is detected as not being present / Gnd
Shutdown Electrical Trip Warning
15
Anlg S2 / pin26-Ckt Open
Analog sensor S2 is detected as not being present
Shutdown Electrical Trip Warning
16
Auxiliary Input (for eg.Aux_A) /user defined name
Configured auxiliary input has triggered longer than preset duration
Shutdown Electrical Trip Warning
Page 50 of 123
Shutdown Electrical Trip Warning
Shutdown Electrical Trip Warning
KG645 CONTROLLER MANUAL Sr. No.
Alarms
17
Emergency Stop
When emergency stop switch is pressed and immediate shutdown is required. This condition is detected in both conditions- engine on and off.
Shutdown
18
Fail To Stop
It is detected that genset is still running after sending stop command
Shutdown
19
Fail To Start
Indicates that genset has not started after the preset number of Start Attempts
Shutdown
20
R Phase Over Voltage
Indicates that genset (R) Phase voltage has exceeded the preset over voltage threshold.
Shutdown Warning
21
Y Phase Over Voltage
Indicates that genset (Y) Phase voltage has exceeded the preset over voltage threshold
Shutdown Warning
22
B Phase Over Voltage
Indicates that genset (B) Phase voltage has exceeded the preset over voltage threshold
Shutdown Warning
23
R Phase Under Voltage
Indicates that geset (R) Phase voltage has fallen below preset under voltage threshold.
Shutdown Warning
24
Y Phase Under Voltage
Indicates that geset (Y) Phase voltage has fallen below preset under voltage threshold
Shutdown Warning
25
B Phase Under Voltage
Indicates that geset (B) Phase voltage has fallen below preset under voltage threshold
Shutdown Warning
26
DG Phase Reversed
Alternator phase sequence (R-Y-B) is not correct
Shutdown Electrical Trip Warning
27
Mains Phase Reversed Indicates the mains unhealthy condition
28
Over Frequency
Indicates that genset output frequency has exceeded the preset threshold
29
Under Frequency
Indicates that genset output frequency has fallen below the Shutdown preset threshold Warning
30
Over Current
Indicates that genset current has exceeded the preset shutdown threshold
Shutdown Electrical Trip Warning
31
Anlg S1 / pin23-Over Curr
Indicates that analog sensor S1 current input has exceeded threshold (25mA)
Shutdown Electrical Trip Warning
32
Over Load
Indicates that the measured kW load rating has exceeded the preset threshold
Shutdown Electrical Trip Warning
33
Unbalanced Load
Load on any phase is greater or less than other phases by a threshold value
Shutdown Electrical Trip Warning
34
Over Speed
Indicates that genset speed has exceeded the preset over speed threshold. Genset will shutdown after Over Speed Delay.
Shutdown
35
Gross Over Speed
Indicates that genset speed has exceeded the preset Gross Over Speed Threshold. Genset will shutdown immediately
Shutdown
Causes
Page 51 of 123
Action Options
Notification Shutdown Warning
KG645 CONTROLLER MANUAL Sr. No.
Alarms
Causes
Action Options
without any delay. 36
Under Speed
The engine speed has fallen below the preset RPM
Shutdown
37
Charge Fail
Shutdown The charge alternator voltage has dropped below the preset Electrical Trip threshold Warning
38
No Speed Signal
Indicates that speed sensor connections are absent
Shutdown
39
V Belt Broken
Indicates that there is failure of the V-belt, which is driving the charging alternator
Shutdown Electrical Trip Warning
40
Battery Under Voltage The battery voltage has fallen below the preset threshold
Shutdown Electrical Trip Warning
41
Battery Over Voltage
The battery voltage has exceeded the preset threshold
Shutdown Electrical Trip Warning
42
Alt Voltage Lost
This indicates that alternator voltage have not crossed 50 VShutdown RMS within 2 seconds after crank disconnect event
43
High Oil Press Detected
Lube oil pressure is detected above the crank disconnect threshold when the engine is off.
Warning
44
Engine Speed Fault
This indicates that engine speed have not crossed preset Healthy Speed Threshold within 2 seconds from the crank disconnect event
Shutdown
45
Eng Speed Detected
Controller has detected engine speed even when the start command is not issued.
Warning
46
Maintenance Due
Indicates that engine running hours has exceeded the preset Notification hours limit or maintenance due date has occurred and filter Warning servicing is required.
47
High Lube Oil Temp
Indicates that lube oil temperature is above the preset threshold
48
Exp Module Comm Error*
Shutdown Warning
Expansion module is enabled in the controller configuration but controller is not receiving any response from the Notification expansion module.
49
Auxiliary Input* (for eg.Aux_XA) /user defined name)
The user configured digital input from expansion module is activated longer than the preset duration
Shutdown Electrical Trip Warning
50
Anx S1/S2/S3/S4/S5 Ckt Opn*
Analog sensor EX-(S1/S2/S3/S4/S5) from expansion module is detected as not being present
Shutdown Electrical Trip Warning
Note: Only warning alarms will get auto cleared.
Page 52 of 123
KG645 CONTROLLER MANUAL
16 Troubleshooting This section explains the common faults, their possible causes and remedial actions. Sr. No.
Fault
Remedial Actions
Possible Issues in MANUAL Mode 1
• • •
The controller does not power ON.
• 2
The controller fails to crank-start the engine.
• •
•
•
3
The “Emergency Stop” alarm comes up even when the “Emergency Stop” is not pressed.
• •
4
The controller generates unnecessary “Shutdown Alarms” or “Warning Alarms”
• •
5
The controller reports “Charge Fail” alarm.
•
•
• 6
The controller issues unnecessary “crank-start”
•
Page 53 of 123
Check the battery voltage. Check the fuse on the battery supply. Check continuity between battery +ve and controller terminal # 2. Check continuity between battery ground and controller terminal # 1. Check the battery voltage. Enter the “configuration mode” in controller and verify the configuration for the “START” output. Also, check that “START” output is working correctly by measuring its voltage o/p. Enter the “configuration mode” in controller and verify the configuration of “CRANK DISCONNECT” method. Verify the configuration of “LLOP SWITCH” polarity. Also, ensure that the lube oil pressure switch & sensor are working OK. Check their wiring. Check if the “Emergency Stop” switch is working OK. Check its wiring also. Enter the “configuration mode” in controller and verify the configuration of “EMERGENCY STOP” polarity. Check the respective switch/sensor and wiring. Enter the “configuration mode” in the controller and verify the respective threshold configuration. To check if the controller's charging alternator terminal is working or not: disconnect the charging alternator wiring to the controller's terminal # 7. Short the terminal # 7 to the ground through a DC ammeter. Crank-start the engine. The DC ammeter should indicate the current in the range 200 - 400 mA for ~30 seconds. If yes, the controller's charging alternator terminal is working OK. Disconnect and re-connect the charging alternator ind connection to the controller's terminal # 7. Check if the charging alternator is working OK or not. Ensure that the controller's o/p terminal is
KG645 CONTROLLER MANUAL Sr. No.
Fault
Remedial Actions
command immediately after power on.
• •
7
The engine runs, but the controller shows genset to be “OFF”.
•
• 8
9
The controller displays incorrect PF value or kW or load current.
•
The controller displays incorrect mains voltage or incorrect main alternator voltage.
•
•
•
not directly connected to the starter relay. The controller's o/p should be given to an intermediate relay which should in-turn power the starter relay. The controller can get permanently damaged and will need to be replaced if this precaution is not taken. Check start-relay connection with the suitable controller terminal. Enter the “configuration mode” in the controller and verify the configuration for the “START RELAY” o/p polarity. Check if the MPU signal (if used), and main alternator voltage signal (R phase) are received by the controller terminals. Check if the LOP and LLOP are working OK. Also check their wiring to the controller. Check wiring of the respective alternator phase voltage and the CT to the controller. Check the CT ratio (if kW or current reading is faulty). Check the wiring of the respective phase to the controller. If the problem is not resolved, replace the controller and try again.
10 Controller displays incorrect reading for any of LOP, Fuel Level, Temp sensors.
• •
Check respective sensor and its wiring. Enter the “configuration mode” in the controller and verify the calibration for the respective sensor in configuration.
11 The controller displays incorrect engine RPM.
• •
Check the MPU connection and configuration (if enabled). Check wiring of the main alternator’s Rphase and neutral to the controller.
•
Reset the controller power.
12 The controller screen freezes or hangs up.
Page 54 of 123
KG645 CONTROLLER MANUAL Possible Issues in AUTO Mode 13 The controller does not start the engine even when a “Remote Start” command is sent from an external device.
•
•
• 14 Controller does not stop engine even when a “Remote Stop” command is sent from an external device.
•
•
• 15 While in Auto mode, controller issues “Start” command even if the mains present.
•
•
Page 55 of 123
Check the wiring of the “Remote Start” signal to the controller's respective digital i/p terminal. Enter the “configuration mode” in the controller and verify the configuration for the “Remote Start” digital i/p terminal. Check that the controller is in “Auto” mode. Check the wiring of the “Remote Stop” signal to the controller's respective digital i/p terminal. Enter the “configuration mode” in the controller and verify the configuration for the “Simulate Stop” digital i/p terminal. Check that the controller is in “Auto” mode. Check the wiring of the mains R, Y and B phase to the controller's respective i/p terminal. Enter the “configuration mode” in the controller and verify the configuration for the “MAINS MONITORING”.
KG645 CONTROLLER MANUAL
Communication Protocol for KG-645 17 Introduction The KG-645 genset controller implement a custom protocol based on the standard MODBUS protocol.
18 MODBUS Based Protocol KG-645 genset controller operates in a slave mode and responds to commands received from an external MODBUS master. Genset controller can send alarm messages and receive operational commands over MODBUS communication.
18.1 Connection Details The transmission mode used by KG-645 genset controller is MODBUS RTU (not MODBUS ASCII). The byte format for communication is 1 start bit, 8 data bits, with/without parity bit and 1 stop bit. The baud rate is selectable between 1200 kbps to 115200 kbps through the configuration options. Please refer the sections KG 645 Configuration Utility in this document, for more details on how the baud rate can be set. Similarly, the slave ID can be selected through the genset controller configuration options.
18.2 Supported Functions KG-645 genset or Diesel Genset (DG) controllers operates as a MODBUS slave that responds to certain commands (or functions, as defined by MODBUS standard) received from the MOSBUS master in appropriate format. Supported functions and respective command-response structure is as shown below. If the command received from the MODBUS master is other than the three functions mentioned below, an exception message is generated.
18.2.1 Function 4 (0x04): Read Input Registers This function is used to read measurement parameters and status from the KG-645 genset controller. The command-response pattern is as shown in Table 10 and Table 11. Table 10: Command from MODBUS master for Function 4 Byte
Field
Remarks
0
Slave address
1
Function code (0x04)
2
First register address – high byte
3
First register address – low byte
4
Number of registers to read – high byte
5
Number of registers to read – low byte
6/7
As configured in KG-645
Error check CRC
Page 56 of 123
16-bit register address, register address map is described in Table 16 Number of registers to read must be between 1 to 255
KG645 CONTROLLER MANUAL Table 11: Normal response from KG-645 slave for Function 4 Byte
Field
0
Slave address
1
Function code (0x04)
2
Byte count (n)
3
First register – high byte
4
First register – low byte
. . .
. . .
As configured in KG-645 Equals to number of registers to be read times two. 8-bit even number between 2 to 250
1+n
Last register – high byte
2+n
Last register – low byte
3+n/4+n
Remarks
Error check CRC
18.2.2 Function 16 (0x10): Write Holding Registers This function is used to issue certain commands to the controller. The command-response pattern is as shown in Table 12 and Table 13. Table 12: Command from MODBUS master for Function 16 Byte
Field
Remarks
0
Slave address
1
Function code (0x10)
2
First register address – high byte
3
First register address – low byte
4
Number of registers to write – high byte
5
Number of registers to write – low byte
6
Number of data bytes to follow (n)
7
Value at first register
. . .
. . .
6+n 7+n/8+n
As configured in KG-645
16-bit register address, register address map is described in Table 16 Number of registers to write must be between 1 to 255
Value at last register Error check CRC
Table 13: Normal response from KG-645 slave for Function 16 Byte
Field
Remarks
0
Slave address
As configured in KG-645
1
Function code (0x10)
2
First register address – high byte
Page 57 of 123
16-bit register address, register address map is
KG645 CONTROLLER MANUAL Byte
Field
Remarks
3
First register address – low byte
described in Table 16
4
Number of registers written – high byte
Number of registers that have been written
5
Number of registers written – low byte
6/7
Error check CRC
18.2.3 Function 3 (0x03): Read Holding Registers This function is used to read holding registers that is the commands that have been issued to the controller. The command-response pattern is as shown in Table 14 and Table 15. Table 14: Command from MODBUS master for Function 3 Byte
Field
Remarks
0
Slave address
1
Function code (0x03)
2
First register address – high byte
3
First register address – low byte
4
Number of registers to read – high byte
5
Number of registers to read – low byte
6/7
As configured in KG-645
16-bit register address, register address map is described in Table 16 Number of registers to read must be between 1 to 255
Error check CRC
Table 15: Normal response from KG-645 slave for Function 3 Byte
Field
0
Slave address
1
Function code (0x03)
2
Byte count (n)
3
First register – high byte
4
First register – low byte
. . .
. . .
1+n
Last register – high byte
2+n
Last register – low byte
3+n/4+n
Remarks As configured in KG-645 Equals to number of registers to be read times two. 8-bit even number between 2 to 250
Error check CRC
Page 58 of 123
KG645 CONTROLLER MANUAL
18.3 Register Map The register map for input registers is as shown in Table 16. Table 16: Register map for input registers Register Offset
Value
Scale Factor
Unit/Interpretation
Bits/ Sign
0
Protocol revision
1
--
Unsigned
1
Analog Sensor S1
0.01
Bar
Unsigned
Analog Sensor S2(Canopy Temperature)**
1
Deg C
Unsigned
Analog Sensor S2(Lube Oil Temperature)**
1
Deg C
Unsigned
0.01
Bar
Unsigned
2
Analog Sensor S2(Lube Oil Pressure)** 3
Coolant temperature
1
Deg C
Unsigned
4
Fuel level
1
%
Unsigned
5
Charge alternator voltage
0.1
V
Unsigned
6
Battery voltage
0.1
V
Unsigned
7
Number of starts
1
--
Unsigned
8
Number of trips
1
--
Unsigned
9
Engine run Hours
1
Hrs
Unsigned
10
Engine run Minutes
1
Min
Unsigned
11
Engine speed
1
RPM
Unsigned
12
Generator R frequency
0.1
Hz
Unsigned
13
Generator Y frequency
0.1
Hz
Unsigned
14
Generator B frequency
0.1
Hz
Unsigned
15
Generator R-N voltage
0.1
V
Unsigned
16
Generator Y-N voltage
0.1
V
Unsigned
17
Generator B-N voltage
0.1
V
Unsigned
18
Generator R-Y voltage
0.1
V
Unsigned
19
Generator Y-B voltage
0.1
V
Unsigned
20
Generator B-R voltage
0.1
V
Unsigned
21
Generator R current
0.1
A
Unsigned
22
Generator Y current
0.1
A
Unsigned
23
Generator B current
0.1
A
Unsigned
24
Generator R power
0.1
KW
Unsigned
25
Generator Y power
0.1
KW
Unsigned
26
Generator B power
0.1
KW
Unsigned
27
Generator total power
0.1
KW
Unsigned
28
Generator R apparent power
0.1
KVA
Unsigned
29
Generator Y apparent power
0.1
KVA
Unsigned
Page 59 of 123
KG645 CONTROLLER MANUAL Register Offset
Value
Scale Factor
Unit/Interpretation
Bits/ Sign
30
Generator B apparent power
0.1
KVA
Unsigned
31
Generator total apparent power
0.1
KVA
Unsigned
32
Generator R reactive power
0.1
KVAr
Unsigned
33
Generator Y reactive power
0.1
KVAr
Unsigned
34
Generator B reactive power
0.1
KVAr
Unsigned
35
Generator total reactive power
0.1
KVAr
Unsigned
36
Generator power factor R
0.01
--
Unsigned
37
Generator power factor Y
0.01
--
Unsigned
38
Generator power factor B
0.01
--
Unsigned
39
Generator average power factor
0.01
--
Unsigned
40– 41
Generator cumulative energy
0.1
KWh
Unsigned
42 – 43
Generator cumulative apparent energy
0.1
KVAh
Unsigned
44 – 45
Generator cumulative reactive energy
0.1
KVArh
Unsigned
46
Mains R-N voltage
0.1
V
Unsigned
47
Mains Y-N voltage
0.1
V
Unsigned
48
Mains B-N voltage
0.1
V
Unsigned
49
Mains R-Y voltage
0.1
V
Unsigned
50
Mains Y-B voltage
0.1
V
Unsigned
51
Mains B-R voltage
0.1
V
Unsigned
52
Mains R frequency
0.1
Hz
Unsigned
53
Mains Y frequency
0.1
Hz
Unsigned
54
Mains B frequency
0.1
Hz
Unsigned
55
Alarm 1
--
--
Low oil pressure
--
--
13/16-16/16
High coolant temperature
--
--
9/16-12/16
Low fuel level
--
--
5/16-8/16
Radiator Water level
--
--
1/16-4/16
Alarm 2
--
--
Under speed
--
--
13/16-16/16
Over speed
--
--
9/16-12/16
Fail to start
--
--
5/16-8/16
Fail to stop
--
--
1/16-4/16
Alarm 3
--
--
Reserved
--
--
13/16-16/16
Reserved
--
--
9/16-12/16
Generator low frequency
--
--
5/16-8/16
56
57
Page 60 of 123
KG645 CONTROLLER MANUAL Register Offset 58
59
60
61
62
63
64
Scale Factor
Unit/Interpretation
Bits/ Sign
Generator high frequency
--
--
1/16-4/16
Alarm 4
--
--
Generator high current
--
--
13/16-16/16
Generator overload
--
--
9/16-12/16
Unbalanced load
--
--
5/16-8/16
Emergency stop
--
--
1/16-4/16
Alarm 5
--
--
Charge fail
--
--
13/16-16/16
Filter maintenance
--
--
9/16-12/16
Reserved
--
--
5/16-8/16
Reserved
--
--
1/16-4/16
Alarm 6
--
--
Battery low voltage
--
--
Battery high voltage
--
--
Analog sensor 1/ pin23 circuit open
--
--
5/16-8/16
Engine temperature circuit open
--
--
1/16-4/16
Alarm 7
--
--
Fuel theft
--
--
13/16-16/16
No speed signal
--
--
9/16-12/16
Analog sensor 2/ pin26 circuit open
--
--
5/16-8/16
Analog sensor 1 over current
--
--
1/16-4/16
Alarm 8
--
--
Auxiliary Input A
--
--
13/16-16/16
Auxiliary Input B
--
--
9/16-12/16
Auxiliary Input C
--
--
5/16-8/16
Auxiliary Input D
--
--
1/16-4/16
Alarm 9
--
--
Auxiliary Input E
--
--
13/16-16/16
Auxiliary Input F
--
--
9/16-12/16
Auxiliary Input G
--
--
5/16-8/16
Auxiliary Input H
--
--
1/16-4/16
Alarm 10
--
--
Gen R phase low volt
--
--
13/16-16/16
Gen R phase high volt
--
--
9/16-12/16
Gen Y phase low volt
--
--
5/16-8/16
Gen Y phase high volt
--
--
1/16-4/16
Value
Page 61 of 123
13/16-16/16
KG645 CONTROLLER MANUAL Register Offset 65
66
67
68
69
70
71
Scale Factor
Unit/Interpretation
Alarm 11
--
--
Gen B phase low volt
--
--
13/16-16/16
Gen B phase high volt
--
--
9/16-12/16
DG phase rotation
--
--
5/16-8/16
Mains phase rotation
--
--
1/16-4/16
Alarm 12
--
--
High canopy temperature
--
--
13/16-16/16
V belt broken
--
--
9/16-12/16
Analogue EX-S1 circuit open*
--
--
5/16-8/16
Analogue EX-S2 circuit open*
--
--
1/16-4/16
Alarm 13
--
--
Analogue EX-S3 circuit open*
--
--
13/16-16/16
Analogue EX-S4 circuit open*
--
--
9/16-12/16
Analogue EX-S5 circuit open*
--
--
5/16-8/16
Auxiliary Input EX-A*
--
--
1/16-4/16
Alarm 14
--
--
Auxiliary Input EX-B*
--
--
13/16-16/16
Auxiliary Input EX-XC*
--
--
9/16-12/16
Auxiliary Input EX-XD*
--
--
5/16-8/16
Auxiliary Input EX-XE*
--
--
1/16-4/16
Alarm 15
--
--
Auxiliary Input EX-F*
--
--
13/16-16/16
Auxiliary Input EX-G*
--
--
9/16-12/16
Auxiliary Input EX-H*
--
--
5/16-8/16
Auxiliary Input EX-I*
--
--
1/16-4/16
Alarm 16
--
--
Auxiliary Input EX-J*
--
--
13/16-16/16
Analog sensor 1/pin23 circuit ground
--
--
9/16-12/16
Alternator voltage lost
--
--
5/16-8/16
Engine Speed detected
--
--
1/16-4/16
Exp Module I/O Diagnostics*
--
--
Digital Input EX-A*
--
--
16/16
Digital Input EX-B*
--
--
15/16
Digital Input EX-C*
--
--
14/16
Digital Input EX-D*
--
--
13/16
Digital Input EX-E*
--
--
12/16
Value
Page 62 of 123
Bits/ Sign
KG645 CONTROLLER MANUAL Register Offset
72
73
Scale Factor
Unit/Interpretation
Bits/ Sign
Digital Input EX-F*
--
--
11/16
Digital Input EX-G*
--
--
10/16
Digital Input EX-H*
--
--
9/16
Digital Input EX-I*
--
--
8/16
Digital Input EX-J*
--
--
7/16
Digital Output A*
--
--
6/16
Digital Output B*
--
--
5/16
Digital Output C*
--
--
4/16
Digital Output D*
--
--
3/16
Digital Output E*
--
--
2/16
Expansion module comm error*
--
--
1/16
Input Output Diagnostics
--
--
Digital Input A
--
--
16/16
Digital Input B
--
--
15/16
Digital Input C
--
--
14/16
Digital Input D
--
--
13/16
Digital Input E
--
--
12/16
Digital Input F
--
--
11/16
Digital Input G
--
--
10/16
Digital Input H
--
--
9/16
Digital Output A
--
--
8/16
Digital Output B
--
--
7/16
Digital Output C
--
--
6/16
Digital Output D
--
--
5/16
Digital Output E
--
--
4/16
Digital Output F
--
--
3/16
Unimplemented
--
--
2/16
Unimplemented
--
--
1/16
DG Status
--
--
Load on DG
--
TRUE (1), FALSE (0)
16/16
Current DG Status
--
Running (1), Stopped (0)
15/16
DG Stopped normally
--
TRUE (1), FALSE (0)
14/16
DG Stopped with fault
--
TRUE (1), FALSE (0)
13/16
DG Mode
--
Auto (1), Manual(0)
12/16
Common shutdown
--
11/16
Common electric trip
--
10/16
Value
Page 63 of 123
KG645 CONTROLLER MANUAL Register Offset
Value
Scale Factor
Unit/Interpretation
Bits/ Sign
Common warning
--
9/16
Common notification
--
8/16
Unimplemented
--
--
7/16-1/16
Unsigned
74
Command Status
--
One of the following: DG Started (1) DG Stopped (2) DG already On (3) DG already Off (4) DG in manual mode (5) DG Not started (6)
75
Alarm 17
--
--
High oil pressure detected
--
--
13/16-16/16
Engine Speed Fault
--
--
9/16-12/16
Lube Oil Temperature
--
--
5/16-8/16
Reserved
--
--
1/16-4/16
Actual value = Observed value on MODBUS interface multiplied with scale factor.
Actual value ** Value of the configured sensor will be shown at a time from Analog Sensor S2.
Page 64 of 123
KG645 CONTROLLER MANUAL The register map for holding registers is as shown in Table 17.
Table 17: Register map for holding registers Register Offset 0
1
Description
Note
Bits/ Sign
Command Register
Send (0x01) to Start DG. Send (0x02) to Stop DG. Command Status is updated in Status register.
Unsigned
Operating Mode
Send (0x01) to toggle Current mode of operation between the Auto mode and the Manual mode. Auto Mode is to operate DG remotely. Manual is to operate DG with through key-press events.
Unsigned
The interpretation of alarm status (registers 54-69 and 74 in Table 16) is as shown in Table 18.
Table 18: Interpretation of alarm status results Value of Register
Interpretation
0
Alarm disabled
1
Alarm not active
2
Warning alarm active
3
Shutdown alarm active
4
Electrical trip alarm active
5
Notification alarm active
6 – 14 15
Reserved Unimplemented
Page 65 of 123
KG645 CONTROLLER MANUAL
Expansion Module 19 Introduction The input/output expansion module can be used in conjunction with KG-645 genset controller to provide additional 5 digital inputs, 5 analog inputs and 5 digital outputs. These inputs/outputs have the same specification as given in sections 3.4 , 3.5 and 4.1. Expansion module have two diagnostic LED's as shown in figure 20. Green LED indicates power status of the module and red LED blinks when data communication between KG-645 controller and expansion module is active. Refer section 9.1 and 22.11 for configuration details of module.
Figure 20: expansion module
The following figure shows the expansion module connector.
Figure 21: Representing the expansion module connector when viewed from the terminal insertion side The following table provides the details for connecting expansion module with KG-645 genset controller. Expansion module
KG-645 controller
Connector Pin No.
Description
Terminal Sr. No.
Description
3
CAN L
14
CAN L
16
CAN H
13
CAN H
Page 66 of 123
KG645 CONTROLLER MANUAL
19.1 Expansion Module Integration The following table provides the pin out description of expansion module connector. Pin #
Name
Description
1
ANLG_IN_EX-S1
Analog input from sensor S1
2
ANLG_IN_EX-S2
Analog input from sensor S2
3
CAN L
CAN low
4
ANLG_IN_EX-S5
Analog input from sensor S5
5
DIG_IN EX-D
Input from switch – D
6
DIG_IN EX-E
Input from switch – E
7
Not used
NA
8
OUT EX-E
High side driver output – E
9
OUT EX-D
High side driver output – D
10
OUT EX-C
High side driver output – C
11
OUT EX-B
High side driver output – B
12
OUT EX-A
High side driver output – A
13
BATTERY -
Battery ground
14
ANLG_IN_EX-S3
Analog input from sensor S3
15
SENSOR COMMON
Connection to Sensor Common
16
CAN H
CAN high
17
ANLG_IN_EX-S4
Analog input from sensor S4
18
DIG_IN EX-C
Input from switch – C
19
DIG_IN EX-B
Input from switch – B
20
DIG_IN EX-A
Input from switch – A
21
Not used
NA
22
Not used
NA
23
Not used
NA
24
Not used
NA
25
BATTERY +
Battery positive
26
BATTERY +
Battery positive
Page 67 of 123
KG645 CONTROLLER MANUAL
KG 645 - Configuration Utility 20 Introduction KOEL's KG 645 - Configuration Utility offers greater flexibility to configure each individual input and output, engine and alternator operating parameters, timers and alarms threshold setting for a specific function or application. This configuration utility can be installed on Windows operating system and allows the KG-645 controller to be connected to a laptop/computer via USB.
21 Installation Instructions 21.1 System Requirements Operating System: Windows 7, Windows 8 with Microsoft .Net 4.5 framework Communication: USB 2.0 Type B required for connection between controller and PC running KG 645 Configuration Utility.
21.2 Installation Process for KG 645 - Configuration Utility Following is the stepwise procedure for installation of configuration utility. I.
Locate the installer on your system and double-click the setup.
II. The installation process starts with the following window. Click Install to continue.
Page 68 of 123
KG645 CONTROLLER MANUAL
A progress bar will show installation completion progress. On completion of installation, a window will be shown as below. Click Finish.
21.3 Installation Process for USB Driver For connecting the KG-645 genset controller with PC or laptop, USB driver needs to be installed on the laptop. Following is the stepwise procedure for USB driver installation. I.
Connect a USB cable between the KG-645 controller and laptop. Put the controller in Programming mode (Refer section 8). Ensure that the controller is in Programming mode which is indicated on LCD screen of the controller as shown below.
Page 69 of 123
KG645 CONTROLLER MANUAL Once the controller enters into the Programming mode, go to Device Manager→Other devices→GCUSMPL.
Page 70 of 123
KG645 CONTROLLER MANUAL II. Right click on “GCUSMPL” and select “Update Driver Software”.
Page 71 of 123
KG645 CONTROLLER MANUAL III. Choose “Browse my computer for driver software” to select the correct driver software.
IV. For driver installation on 64-bit Windows system, choose a driver path as “C:\Program Files(x86)\KG-645 Configuration Utility\USB Driver” and then click Next.
Page 72 of 123
KG645 CONTROLLER MANUAL
Please refer following links for Installing Unsigned Drivers in Windows 8. Disabling Driver Signature Verification on 64-Bit Windows 8: http://www.howtogeek.com/167723/how-to-disable-driver-signature-verification-on-64-bit-windows-8.1-so-that-you-can-installunsigned-drivers/
Installing Unsigned Drivers in Windows 8: http://my.okidata.com/idocs2.nsf/f7f729f023d5f3b785257706006556ac/49724794617ca7c885257acb005c2851/$FILE/Installing%20Uns igned%20Drivers%20in%20Windows%208.pdf
V. On successful installation of USB driver, a confirmation screen will be shown as below. Click Close.
Page 73 of 123
KG645 CONTROLLER MANUAL VI. Ensure the successful driver installation by checking the entry of “GCxx” under the “Ports” option in Device Manager.
After successful installation of configuration utility and USB driver, if KG-645 controller is not detected at PC port, then disable serial or virtual serial port (if any used) of PC.
Page 74 of 123
KG645 CONTROLLER MANUAL
22 Usage Instructions
22.1 Starting with KG 645 - Configuration Utility Run configuration utility installed on your system. Start up screen will be displayed as shown below.
The screen prompts the user to select between two options as follows. •
Open a config file: Editing a configuration previously saved to disk by clicking “Open a config file” and browsing to the file.
•
Other options: Creating a new configuration. Click on text “START” on next screen, to start with configuration.
Page 75 of 123
KG645 CONTROLLER MANUAL
22.2 Working with KG 645 - Configuration Utility A configuration is a set of parameter values that determines behaviour of the controller. To create a new configuration file, click on File→New. To save the current set of parameter values as a configuration, click on File→Save To File. To open a previously saved configuration file from disk, click on File→Open. Screenshot of configuration utility representing File dropdown menu.
22.3 Establishing Connection with Controller For establishing a connection with the KG-645 genset controller, first connect a USB cable between the controller and laptop, then put the controller in Programming mode (Refer section 8). A connection status message will be displayed at bottom left corner of screen. It is possible to open, create and modify configurations without an active connection with the controller. However, for read and write operations of the controller, an active connection is required.
22.4 Editing Parameters Configuration utility allows to edit parameter values for intended application of the genset controller. Following are the options available for editing parameters.
Increment/Decrement Arrows
Text entry Box
Slider
Check Box
Page 76 of 123
KG645 CONTROLLER MANUAL •
Check box Check box is typically used to enable/disable a feature.
•
Text entry box A value can be directly entered in a text entry box.
•
Increment/Decrement arrows Increment/Decrement arrows can be used to progressively increase/decrease the corresponding value.
•
Slider A slider can be dragged to change the corresponding parameter value.
22.5 Tools KG 645 - Configuration Utility allows a set of actions to be performed in addition to editing and saving the configurations. These actions can be accessed under the Tools menu as shown in following screenshot. These actions are enabled only if an active connection with a controller is detected.
Page 77 of 123
KG645 CONTROLLER MANUAL
22.5.1 Write Configuration To Device This action writes the currently chosen configuration to the controller. On selecting this action, pop-up window will be shown as below, which summarizes existing values of the parameters.
The user can confirm that these values of parameters are correct. To modify these values, Edit Configuration option should be chosen to go back to the parameter editing page. To write the values, choose Write Configuration To Device option. Following pop-up window will be shown.
Page 78 of 123
KG645 CONTROLLER MANUAL
A confirmation window will be shown when writing is complete.
22.5.2Read Configuration From Device This action reads the configuration of controller and accordingly populates the chosen configuration file.
Select Read From Device option. The configuration will be read from the controller and appropriately populated in the uility. A confirmation window will be shown as below.
Page 79 of 123
KG645 CONTROLLER MANUAL
22.5.3 Preview Configuration From Device This action previews the configuration of controller. On selecting this action, pop-up window will be shown as below, which summarizes existing values from the controller.
22.5.4 Update Firmware On Device This action updates the firmware in the controller without affecting configuration of the controller. First select firmware image from the file system of computer by clicking on browse Browse option.
Page 80 of 123
KG645 CONTROLLER MANUAL Then click Update. The firmware on the controller will be updated. A progress bar will show status of updation.
A confirmation window will be shown as below.
Page 81 of 123
KG645 CONTROLLER MANUAL
22.5.5 Read Event Log From Device This action reads and displays event logs in the connected controller. The pop-up window will be shown as below.
After clicking ‘’Save As PDF’’ this window will be shown.
Page 82 of 123
KG645 CONTROLLER MANUAL
22.5.6 Update Time On Device This action updates date and time in the controller using the system's date and time.
It is necessary, first to check date and time of your computer system are correct. On selecting Yes option, computer system's current date and time will be updated in the controller.
22.5.7 Get Version Information From Device
23 Interpretation of Parameters This section describes interpretation of parameters which are accessed via configuration utility.
23.1 Module The Module allows configuration of a set of module-wide parameters.
Select Module to start GCU configuration
Then select appropriate tab to configure parameters
Page 83 of 123
KG645 CONTROLLER MANUAL
23.1.1 General
Parameter
Interpretation
Profile Name
Allows to enter a text string to identify configuration as a Profile. This ID will be displayed on Active Profile screen of the controller.
Power On Mode
The controller enters into this mode, on application of battery supply. Available options are Manual and Auto mode.
Power On Lamp Test
Enables or disables lamp test sequence. If enabled, all LEDs on front fascia of the controller will illuminate for 3 seconds.
Deep Sleep Mode
Enables or disables Deep Sleep mode. If enabled, the controller enters into lowpower mode after Deep Sleep Mode Delay duration (Refer section 22.5.2 for delay setting).
Expansion Mode*
Enables or disables Expansion module. This enables the Expansion Box option (Refer section 22.11) to configure expansion module parameters. Table 19: General
23.1.2Display
Parameter
Interpretation
Contrast
Decides the percentage contrast of LCD display.
Power Save Mode
Enables or disables power save feature for LCD display backlit. If enabled, the backlit of LCD display will be switched OFF after Power Save Mode Delay duration (Refer section 22.5.2 for delay setting). Table 20: Display
Page 84 of 123
KG645 CONTROLLER MANUAL
23.1.3RS485 Communication
Parameter
Interpretation
Communication Mode
Decides the communication function to be performed by the controller. Available options: None: No communication function will be performed. MODBUS: The controller will communicate through the RS485 port using MODBUS protocol. The relevant parameters such as MODBUS Slave ID and Baudrate will be activated.
MODBUS Slave ID
MODBUS slave ID you wish to communicate with.
MODBUS Baudrate
MODBUS baudrate (bits per second) you wish to connect at.
Parity Bit
Parity bit provides the simple error checking for transmitted data. The available types of parity checking are as follows: None, Even, Odd Table 21: RS485 Communication
23.2 Digital Inputs The Digital Inputs allows configuration of digital inputs.
Page 85 of 123
KG645 CONTROLLER MANUAL Following is an example showing configuration of Digital Input A as User configured.
Parameter
Interpretation
Source
Decides how the digital input will be interpreted by the controller. The input can be assigned as one of a set of Digital Input Source (Refer section 22.2.1).
Name
It is enabled only if the Source is selected as User configured. The text string entered here will be displayed on LCD screen when corresponding user configured input is activated. The text string is also used as the event description for the corresponding input event in the event log.
Polarity
Allows to select polarity of the digital input. Available options: Close to Activate: The input will be interpreted as active if the input is grounded. Open to Activate: The input will be interpreted as active if the input is not grounded.
Action
It is enabled if the Source is selected as User configured or switch or High Canopy Temperature. Allows to select the action taken by the controller when the input is found to be active. Available options: None: No action will be taken. Warning: A warning will be displayed without affecting the operation of genset. Electric Trip: The genset will be first unloaded by deactivating the contactor before genset being stopped. Shutdown: Genset will be shutdown.
Activation
It is enabled only if the Source is selected as User configured or switch or High Canopy Temperature. Decides when to start monitoring of the digital input. Available options: Never: The input will never monitored. From Engine Start: The input will be monitored from the start of genset. From Monitoring On: The input will be monitored when the engine and alternator safety monitoring begins. Always: The input will always monitored.
Activation Delay
Allows to select duration in seconds, for which the input active condition should persist before which preconfigured action will be taken. Table 22: Digital Input A
Refer Table 22 for configuration of Digital Input A, Digital Input B, Digital Input C, Digital Input D and Digital Input
Page 86 of 123
KG645 CONTROLLER MANUAL
23.2.1 List of Digital Input Source Digital Input Source
Interpretation
Not used
The digital input will not be used.
User configured
Allows to enter a text string to identify the digital input.
Low Fuel Level Switch
Engine low fuel level switch input – used for low Fuel Level alarm.
High Engine Temperature Switch
Engine high temperature switch input – used for High Eng Temp alarm.
Low Lube Oil Pressure switch
Engine oil pressure switch – used for Low Oil Pressure alarm.
Low Water Level Switch
Radiator water level switch – used for Radiator Water Level alarm.
Emergency Stop
Emergency stop input.
Remote Start/Stop
In Remote start/stop mode, the genset can be commanded to start/stop by activating/deactivating this input.
Simulate Start
Simulates the “START” button on fascia.
Simulate Stop
Simulates the “STOP” button on fascia.
Simulate Auto
Simulates the “AUTO” button on fascia.
Close Gen/Open Mains Switch
Command to manually transfer the load to genset. (To be used in manual mode. Not recommended to use in auto mode)
Close Mains/Open Gen Switch
Command to manually transfer the load to mains. (To be used in manual mode. Not recommended to use in auto mode)
Simulate Mains
This input allows the controller to act as if mains is healthy, irrespective of actual mains voltage/frequency. This input can be used to over-ride genset starting based on mains monitoring in Auto Mains Failure (AMF) mode.
Reserved
NA
High Canopy Temp Switch
Canopy temperature switch – used for High Canopy Temperature alarm.
V-Belt Broken Switch
V-Belt Broken switch – used for V-Belt Broken alarm. Table 23: Digital Input Source
23.3 Analog Inputs Analog Inputs can be configured as Analog Input or Digital Input.
Page 87 of 123
KG645 CONTROLLER MANUAL
23.3.1 Analog Sensor S1 (4 – 20mA) This allows to configure Analog Sensor S1 as LOP (4 – 20mA) sensor.
Parameter
Interpretation
Use Input As
Decides how the input will be interpreted. Available options: Not used: The input will not be used. Lube Oil Pressure Sensor: The input will be used as LOP (4 – 20 mA) sensor.
Low Level Shutdown
Enables or disables low oil pressure shutdown detection.
Low Level Shutdown Threshold
Allows to select the threshold on the oil pressure value below which selected action for Low Oil Pressure condition will be triggered.
Low Level Warning
Enables or disables low oil pressure warning detection.
Low Level Warning Threshold
Allows to select the threshold on the oil pressure value below which selected action for Low Oil Pressure condition will be triggered.
Oil Pressure Circuit Fault
Allows to select alarm action on detection of following fault conditions: 1. Oil pressure open circuit/ground (Anlg S1 / pin23 - Ckt Opn/Gnd) 2. Analog sensor S1 over current (Anlg S1 / pin23 - Overcurrent) When any of these conditions is detected, an alarm will be triggered. Available options: None: No action will be taken. Warning: A warning will be displayed without affecting the operation of genset. Electric Trip: The genset will be first unloaded by deactivating the contactor before genset being stopped. Shutdown: Genset will be shutdown.
Sensor Calibration Table
A table that defines relation between the sensor value and corresponding physical quantity. Table 24: Analog Sensor S1 (4–20 mA)
Page 88 of 123
KG645 CONTROLLER MANUAL At any given time, user can select either Lube Oil Pressure (4-20mA) current sensor Lube Oil Pressure resistive sensor or Speed bias input (0-5 V) in Generator Egov Configuration.
23.3.2 Analog Sensor S2 (Resistive) Following is an example showing Analog Sensor S2 (Resistive) configured as Canopy Temperature Sensor.
Parameter
Interpretation
Use Input As
Decides how the input will be interpreted. Available options: Not used: The input will not be used. Digital Input F: The selected sensor input will be used as digital input. The parameters identical to digital inputs will be displayed and the input can configured in the same way as that of digital input being configured (Refer section 22.2.1). Canopy Temperature Sensor: The input will be used as analog input for canopy temperature sensor (resistive). Lube Oil Temperature Sensor: The input will be used as analog input for lube oil temperature sensor (resistive). Lube Oil Pressure Sensor: The input will be used as analog input for lube oil pressure sensor (resistive).
High Level Shutdown
Enables or disables shutdown for high canopy temperature value
Shutdown Threshold
Threshold on canopy temperature value above which shutdown will be triggered
High Level Warning
Enables or disables warning for high canopy temperature value
Warning Threshold
Threshold on canopy temperature value above which warning will be triggered
Page 89 of 123
KG645 CONTROLLER MANUAL
Parameter
Interpretation
S2 Sensor Circuit Fault
When the S2 sensor circuit open condition is detected, an alarm will be triggered. Available options: None: No action will be taken. Warning: A warning will be displayed without affecting the operation of genset. Electric Trip: The genset will be first unloaded by deactivating the contactor before genset being stopped. Shutdown: Genset will be shutdown.
Sensor Calibration Table
A table that defines relation between the sensor value and corresponding physical quantity. Table 25: Analog Sensor S2 (Resistive)
Analog Sensor S2 (Resistive) can be configured as Lube Oil Pressure Sensor (resistive) on enabling in all conditions except: • If the Lube Oil Pressure sensor is configured to Analog Sensor S1 (4-20 mA) •
Speed Bias Input (0-5 V) is configured in Generator Egov Configuration
Following is an example showing, Analog Sensor S2 (Resistive) configured as Lube Oil Pressure Sensor(resistive).
Following is an example showing, Analog Sensor S2 (Resistive) configured as Lube Oil Temperature Sensor(resistive).
Page 90 of 123
KG645 CONTROLLER MANUAL
23.3.3 Engine Temperature Sensing (Resistive)
Parameter
Interpretation
Use Input As
Decides how the input will be interpreted. Available options: Not used: The input will not be used. Digital Input G: The selected sensor input will be used as digital input. The parameters identical to digital inputs will be displayed and the input can configured in the same way as that of digital input being configured (Refer section 22.2.1). Engine Temperature Sensor: The input will be used as analog sensor (resistive).
High Temp Shutdown
Enables or disables shutdown for high engine temperature value
Page 91 of 123
KG645 CONTROLLER MANUAL
Parameter
Interpretation
Threshold
Threshold on engine temperature value above which shutdown will be triggered
High Temp Warning
Enables or disables warning for high engine temperature value
Threshold
Threshold on engine temperature value above which warning will be triggered
Engine Temp Circuit Fault
Allows to select the action taken by the controller if engine temperature sensor is detected as open circuit (Eng Temp / pin24 - Ckt Opn). Available options: None: No action will be taken. Warning: A warning will be displayed without affecting the operation of genset. Electric Trip: The genset will be first unloaded by deactivating the contactor before genset being stopped. Shutdown: Genset will be shutdown.
Sensor Calibration Table
A table that defines relation between the sensor value and corresponding physical quantity. Table 26: Engine Temperature Sensing (Resistive)
23.3.4 Fuel Level Sensing (Resistive)
Parameter
Use Input As
Interpretation Decides how the input will be interpreted. Available options: Not Used: The input will not be used. Digital Input H: The selected sensor input will be used as digital input. The parameters identical to digital inputs will be displayed and the input can configured in the same way as that of digital input being configured (Refer section 22.2.1). Fuel Level Sensor: The input will be used as analog sensor (resistive).
Page 92 of 123
KG645 CONTROLLER MANUAL
Parameter
Interpretation
Low Fuel Level Shutdown
Enables or disables an engine shutdown by the controller if Low Fuel Level condition is detected.
Shutdown Threshold
Allows to select the threshold on fuel level value below which Low Fuel Level shutdown alarm will be triggered.
Low Fuel Level Warning
Enables or disables warning generation by the controller if Low Fuel Level condition is detected.
Warning Threshold
Allows to select the threshold on fuel level value below which Low Fuel Level warning will be triggered.
Fuel Theft Warning
Enables or disables Fuel Theft warning alarm.
Fuel Theft Threshold
Allows to select the threshold on percentage fuel consumption per hour, above which Fuel Theft alarm will be triggered.
Fuel Consumption
Fuel consumption in litres per hour.
Display Fuel in Liters
If enabled, fuel level will be displayed in liters on screen.
A table that defines relation between the sensor value and corresponding physical quantity. Table 27: Fuel Level Sensing (Resistive) Analog Sensor S2, Engine Temperature Sensing and Fuel Level Sensing can be configured as Digital Inputs (Refer section 22.2 and 22.2.1).
Sensor Calibration Table
Following is the screenshot of configuration utility representing configuration of Fuel Level sensor as a digital switch.
Page 93 of 123
KG645 CONTROLLER MANUAL
23.4 Outputs The Outputs allows configuration of digital outputs.
Parameter
Interpretation
Source
Allows to select the output as one of the set of Digital Output Source (Refer section 22.4.1). Alternatively, the outputs can be disabled.
On Activation
Allows to select activation polarity of selected output. Available options: De-energise: The output will be disconnected from battery positive supply if the corresponding source condition is active. Energise: The output will be connected to battery positive supply if the corresponding source condition is active. Table 28: Outputs
23.4.1 List of Digital Output Source Digital Output Source
Interpretation Active when...
Inactive when...
Sounder Alarm
An audible alarm is pending.
No audible alarm is pending.
Battery Over Voltage
Battery Over Voltage alarm is pending.
Battery Over Voltage alarm is not pending.
Battery Under Voltage
Battery Under Voltage alarm is pending.
Battery Under Voltage alarm is not pending.
Charge Alt Shutdown
Charge Fail shutdown alarm is pending.
Charge Fail shutdown alarm is not pending.
Charge Alt Warning
Charge Fail warning alarm is pending.
Charge Fail warning alarm is not pending.
Close Gen Contactor
Genset contactor is to be closed.
Genset contactor is not to be closed.
Close Mains Contactor
Mains contactor is to be closed.
Mains contactor is not to be closed.
Page 94 of 123
KG645 CONTROLLER MANUAL
Digital Output Source
Interpretation Active when...
Inactive when...
Mains Failure
Mains is detected as not healthy.
Mains is detected as healthy or mains monitoring is disabled.
Common Alarm
Any warning or shutdown or electric trip alarm is pending.
No alarm is pending.
Common Electric Trip
Any electric trip alarm is pending.
No electric trip alarm is pending.
Common Shutdown
Any shutdown alarm is pending.
No shutdown alarm is pending.
Common Warning
Any warning alarm is pending.
No warning alarm is pending.
Cooling Down
Cooling down timer is active.
Cooling down timer is not active.
Digital Input A
Digital Input A is active.
Digital Input A is not active.
Digital Input B
Digital Input B is active.
Digital Input B is not active.
Digital Input C
Digital Input C is active.
Digital Input C is not active.
Digital Input D
Digital Input D is active.
Digital Input D is not active.
Digital Input E
Digital Input E is active.
Digital Input E is not active.
Digital Input F (Analog S2 Digital Input F is active. Input)
Digital Input F is not active.
Digital Input G (Analog Input Eng Temp)
Digital Input G is active.
Digital Input G is not active.
Digital Input H (Analog Input Fuel LVL)
Digital Input H is active.
Digital Input H is not active.
Emergency Stop
Emergency stop input is active. This output will be active (if configured) in both conditions- engine on and off.
Emergency stop input is not active.
Stop Solenoid
An engine stop command is being issued.
An engine stop command is not being issued.
Fail To Start
Fail To Start alarm is pending.
Fail To Start alarm is not pending.
Fail To Stop
Fail To Stop alarm is pending.
Fail To Stop alarm is not pending.
Fuel Relay
Engine needs to be running.
Engine need not to be running.
Gen Available
Genset voltage and frequency are within acceptable limits.
Genset voltage and frequency are not within acceptable limits.
R Phase OV Shutdown
Genset R Phase Over Voltage shutdown Genset R Phase Over Voltage alarm is pending. shutdown alarm is not pending.
R Phase UV Shutdown
Genset R Phase Under Voltage shutdown alarm is pending.
Y Phase OV Shutdown
Genset Y Phase Over Voltage shutdown Genset Y Phase Over Voltage alarm is pending. shutdown alarm is not pending.
Y Phase UV Shutdown
Genset Y Phase Under Voltage shutdown alarm is pending.
Page 95 of 123
Genset R Phase Under Voltage shutdown alarm is not pending.
Genset Y Phase Under Voltage shutdown alarm is not pending.
KG645 CONTROLLER MANUAL
Interpretation
Digital Output Source
Active when...
Inactive when...
B Phase OV Shutdown
Genset B Phase Over Voltage shutdown Genset B Phase Over Voltage alarm is pending. shutdown alarm is not pending.
B Phase UV Shutdown
Genset B Phase Under Voltage shutdown alarm is pending.
Genset B Phase Over Voltage shutdown alarm is not pending.
Gen Over Current
Genset Over Current alarm is pending.
Genset Over Current alarm is not pending.
High Engine Temperature
High Engine Temperature output is active.
High Engine Temperature output is not active.
Low Fuel LVL
Low Fuel level alarm is pending.
Low Fuel level alarm is not pending.
Low LOP
Low Oil Pressure alarm is pending.
Low Oil Pressure alarm is not pending.
Mains High Volt
Mains voltage is detected to be high.
Mains voltage is not detected to be high.
Mains Low Volt
Mains voltage is detected to be low.
Mains voltage is not detected to be low.
Oil Pressure Open Circuit
Oil pressure circuit is detected to be open.
Oil pressure circuit is not detected to be open.
Open Gen Contactor
Genset contactor is to be open.
Genset contactor is not to be open.
Open Mains Contactor
Mains contactor is to be open.
Mains contactor is not to be open.
Over Freq Shutdown
Over Frequency shutdown alarm is pending.
Over Frequency shutdown alarm is not pending.
Over Speed Shutdown
Over Speed shutdown alarm is pending.
Over Speed shutdown alarm is not pending.
Gross Over Speed Shutdown
Gross Over Speed Shutdown alarm is pending.
Gross Over Speed Shutdown alarm is not pending.
Start Relay
Cranking command is active.
Cranking command is not active.
Temp Sensor Open Circuit
Temperature circuit is detected to be open.
Temperature circuit is not detected to be open.
Under Freq Shutdown
Under Frequency shutdown alarm is pending.
Under Frequency shutdown alarm is not pending.
Under Speed Shutdown
Under Speed shutdown alarm is pending.
Under Speed shutdown alarm is not pending.
Maintenance Due
Maintenance Due alarm is pending.
Maintenance Due alarm is not pending.
Stop Mode
Controller is in Stop mode.
Controller is not in Stop mode.
Auto Mode
Controller is in Auto mode.
Controller is not in Auto mode.
Manual Mode
Controller is in Manual mode.
Controller is not in Manual mode.
Reserved
NA
NA
Page 96 of 123
KG645 CONTROLLER MANUAL
Digital Output Source
Interpretation Active when...
Inactive when...
Preheat Output
Preheat output is to be active as per preheating setting.
Preheat output is not to be active as per preheating setting.
Digital Input XA*
Digital Input XA is active.
Digital Input XA is not active.
Digital Input XB*
Digital Input XB is active.
Digital Input XB is not active.
Digital Input XC*
Digital Input XC is active.
Digital Input XC is not active.
Digital Input XD*
Digital Input XD is active.
Digital Input XD is not active.
Digital Input XE*
Digital Input XE is active.
Digital Input XE is not active.
Digital Input XF (ANX S1 RES)*
Digital Input XF is active.
Digital Input XF is not active.
Digital Input XG (ANX S2 RES)*
Digital Input XG is active.
Digital Input XG is not active.
Digital Input XH (ANX S3 RES)*
Digital Input XH is active.
Digital Input XH is not active.
Digital Input XI (ANX S4 RES)*
Digital Input XI is active.
Digital Input XI is not active.
Digital Input XJ (ANX S5 RES)*
Digital Input XJ is active.
Digital Input XJ is not active.
Expansion Module Available*
Communication between genset Communication between genset controller and expansion module is controller and expansion module is active. not active. Table 29: Digital Output Source
23.5 Timers
23.5.1 Cranking
Page 97 of 123
KG645 CONTROLLER MANUAL
Parameter
Interpretation
Crank Hold Time
The crank output will be active upto this time during cranking.
Crank Rest Time
The time between two crank commands.
Crank Start Delay
Gets executed only when no output is configured for the engine preheat function. Table 30: Cranking
23.5.2 General
Parameter
Interpretation
Safety Monitoring Delay
Decides the time from engine on for which engine and alternator safety parameters will be ignored. This timer should be selected sufficiently large so that no false alarms will be triggered due to transient during genset start-up procedure.
Mains Detect Delay
The time in which a deviation in mains parameters (voltage, frequency) outside the preconfigured range is allowed before corresponding alarm being triggered.
Alternator Detect Delay
The time in which a deviation in genset parameters (voltage, frequency) outside the preconfigured range is allowed before corresponding alarm being triggered.
Page 98 of 123
KG645 CONTROLLER MANUAL
Parameter
Interpretation
Warm-Up delay
The delay between (1) Alternator's developing healthy voltage and frequency, and (2) the load being transferred onto the alternator by suitably actuating contactors.
Return To Mains Delay
A delay between the detection of healthy mains return and issuing genset Stop command in Auto mode operation of genset.
Engine Cooling Time
The time between issuing Stop command and the beginning of actual stopping sequence. This timer will be skipped in case of shutdown alarms, emergency stop and repeated “STOP” key input
Stop Action Time
This timer will start after receiving stop command. After completion of this timer, if LOP or engine speed is detected below threshold, then genset will declared as completely off, otherwise Fail To Stop alarm will be triggered.
Load Transfer Delay
The time between one of the genset or mains contactor being opened and the other contactor being closed during a power transfer event between the genset and mains.
Power Save Mode Delay
The time in which, if no activity is detected and engine is OFF, the backlit of LCD display will be switched OFF. Go on page Module to enable Power Save Mode (Refer section 22.1.2).
Screen Changeover Time
The time after which a display screen will shift to the next screen. When this time is set to 0, then screen will not scroll automatically. User will have to scroll all the screens excluding ALARMS screen using “UP”/“DOWN” keys. ALARMS screen will pop up on detection of any alarm.
Deep Sleep Mode Delay
The time in which, if no activity is detected and engine is OFF, the controller enters into Deep Sleep mode. Go on page Module to enable Deep Sleep Mode (Refer section 22.1.1).
Sounder Alarm Timer
On initiation of an alarm, audible alarm will sound (if configured) upto this time.
Test Mode Timer
The controller will remain in Test mode, for the preconfigured Test Mode Duration. This timer expires only when engine is running, otherwise controller remains in this mode for infinite time. Table 31: General
Page 99 of 123
KG645 CONTROLLER MANUAL
23.6 Generator The genset specific parameters are divided into sections as shown below.
23.6.1Alternator Configuration
Parameter
Interpretation
Alternator Present
Allows to select engine operation with or without the alternator. If the alternator is not fitted, all the relevant parameters will be ignored and disabled. This will be considered as an engine-only operation.
Number Of Poles
Allows to select the number of poles of alternator.
AC System
Allows to select AC System as 3 Phase or 1 Phase.
Min Healthy Voltage
A threshold above which genset is considered healthy for taking electrical load.
Min Healthy Frequency
A threshold above which genset is considered healthy for taking electrical load.
Phase Reversal Detection
If enabled, the alternator phase sequence (R-Y-B) will be checked. This option will be enabled if AC System is configured as 3 Phase.
Phase Reversal Action
Allows to select the action taken by the controller if the alternator phase reversal condition occurs. Available options: None: No action will be taken. Warning: A warning will be displayed. Electric Trip: The genset will be first unloaded by deactivating the contactor before the genset being stopped. Shutdown: Genset will be shutdown.
Alt Voltage Lost Shutdown
This alarm will generate if alternator voltage does not cross 50 V-RMS within 2 seconds after crank disconnect event
Page 100 of 123
KG645 CONTROLLER MANUAL
Parameter Auto Load Transfer
Interpretation An option to actuate genset and mains contactors if configured as outputs in the manual mode. If disabled, it is necessary to manually put the load on genset. Table 32: Alternator Configuration
23.6.2 Voltage Monitoring These parameters will be enabled, if the Alternator Present parameter is selected as Yes (Refer section 22.6.1).
Parameter
Interpretation
Under-voltage Shutdown
Enables or disables Under Voltage shutdown alarm.
Under Voltage Shutdown Threshold
The voltage value below which the Under Voltage shutdown alarm will be triggered.
Under-voltage Warning
Enables or disables Under Voltage warning alarm.
Under Voltage Warning Threshold
The voltage value below which the Under Voltage warning alarm will be triggered.
Over-voltage Shutdown
Enables or disables Over Voltage shutdown alarm.
Over Voltage Shutdown Threshold
The voltage value above which the Over Voltage shutdown alarm will be triggered.
Over-voltage Warning
Enables or disables Over Voltage warning alarm.
Over Voltage Warning Threshold
The voltage value above which the Over Voltage warning alarm will be triggered. Table 33: Voltage Monitoring
Page 101 of 123
KG645 CONTROLLER MANUAL
23.6.3Frequency Monitoring These parameters will be enabled, if the Alternator Present parameter is selected as Yes (Refer section 22.6.1).
Parameter
Interpretation
Under-frequency Shutdown
Enables or disables Under Frequency shutdown alarm.
Under Frequency Shutdown Threshold
The frequency value below which the Under Frequency shutdown alarm will be triggered.
Under-frequency Warning
Enables or disables Under Frequency warning alarm.
Under Frequency Warning Threshold
The frequency value below which the Under Frequency warning alarm will be triggered.
Over-frequency Shutdown
Enables or disables Over Frequency shutdown alarm.
Over Frequency Shutdown Threshold
The frequency value above which the Over Frequency shutdown alarm will be triggered.
Over-frequency Warning
Enables or disables Over Frequency warning alarm.
Over Frequency Warning Threshold
The frequency value above which the Over Frequency warning alarm will be triggered. Table 34: Frequency Monitoring
Page 102 of 123
KG645 CONTROLLER MANUAL
23.6.4 Current Monitoring These parameters will be enabled, if the Alternator Present parameter is selected as Yes (Refer section 22.6.1).
Parameter
Interpretation
CT Ratio
The primary-side factor for interpretation of CT ratio. The controller assumes that the secondary-side factor is 5.
Over-current Threshold
The current value above which the Over Current alarm will be triggered.
Over-current Delay
The time for which a value higher than the preset Over Current Threshold value is allowed before the Over Current alarm being triggered.
Over-current Action
Allows to select the action when Over Current condition is detected. Available options: None: No action will be taken. Warning: A warning will be displayed without affecting the operation of genset. Electric Trip: The genset will be first unloaded by deactivating the contactor before the genset being stopped. Shutdown: Genset will be shutdown.
Unbalanced Load Action
Allows to select the action if an unbalanced load is detected in AC System configured as 3 Phase. Available options: None: No action will be taken. Warning: A warning will be displayed without affecting the operation of genset. Electric Trip: The genset will be first unloaded by deactivating the contactor before the genset being stopped. Shutdown: Genset will be shutdown.
Unbalanced Load Threshold
The threshold on load unbalance, in percentage of per-phase full load. The unbalance load action will be triggered when {[(Max kW from R, Y, B)– (Min kW from R, Y, B)] / [Max kW load allowed per phase assuming 100 % rated load]} * 100 is greater than configured unbalanced load threshold
Unbalanced Load Delay
The time for which an unbalanced load condition is monitored before the corresponding action will be taken. Table 35: Current Monitoring
Page 103 of 123
KG645 CONTROLLER MANUAL
23.6.5 Load Monitoring These parameters will be enabled, if Alternator Present parameter is selected as Yes (Refer section 22.6.1).
Parameter
Interpretation Decides the genset rating in kW.
Generator Rating
This value must be specified as a total load rating and NOT as per phase load rating.
Over-load Threshold
The load value (as a percentage of full load) above which the selected action for Over Load alarm will be triggered.
Over-load Mon Delay
The time for which a value higher than the preset Overload Threshold value is allowed before the Over Load alarm being triggered.
Over-load Action
Allows to select the action when Over Load alarm is detected. Available options: None: No action will be taken. Warning: A warning will be displayed without affecting the operation of genset. Electric Trip: The genset will be first unloaded by deactivating the contactor before genset being stopped. Shutdown: Genset will be shutdown. Table 36: Load Monitoring
Page 104 of 123
KG645 CONTROLLER MANUAL
23.7 Mains The Mains configuration is divided into sections as shown below.
23.7.1Mains Configuration
Parameter
Interpretation
Mains Monitoring
When enabled it displays status of mains on the Mains monitoring screen. Enables or disables Auto Mains Failure (AMF) mode.
Mains AC System
Allows to select Mains AC system as 1 Phase or 3 Phase.
Phase Reversal
If enabled, the mains phase sequence (R-Y-B) will be checked.
Phase Reversal Action
Allows to select the action taken by the controller. In AMF mode, if the mains phase reversal condition occurs then genset will start. Available options: None: No action will be taken. Notification: A notification text will be displayed. Table 37: Mains Configuration
23.7.2Voltage Monitoring
Page 105 of 123
KG645 CONTROLLER MANUAL Parameter
Interpretation
Under Voltage
Enables or disables mains under voltage monitoring. If enabled, the controller monitors the mains under voltage condition.
Under Voltage Trip
The voltage value below which an under voltage condition for mains is detected.
Under Voltage Return
The minimum voltage which must be reached for the mains voltage to be considered healthy. This value is used when an unhealthy mains condition has been detected.
Over Voltage
Enables or disables mains over voltage monitoring. If enabled, the controller monitors the mains over voltage condition.
Over Voltage Return
The maximum value for the mains voltage to be considered healthy. This value is used when an unhealthy mains condition has been detected.
Over Voltage Trip
The voltage value above which an over voltage condition for mains is detected. Table 38: Voltage Monitoring
23.7.3Frequency Monitoring
Parameter
Interpretation
Under Frequency
Enables or disables mains under frequency monitoring. If enabled, the controller monitors the mains under frequency condition.
Under Frequency Trip
The frequency value below which an under frequency condition for mains is detected.
Under Frequency Return
The minimum frequency which must be reached for the mains frequency to be considered healthy. This value is used when an unhealthy mains condition has been detected.
Over Frequency
Enables or disables mains over frequency monitoring. If enabled, the controller monitors the mains over frequency condition.
Over Frequency Return
The maximum value for the mains frequency to be considered healthy. This value is used when an unhealthy mains condition has been detected.
Page 106 of 123
KG645 CONTROLLER MANUAL Parameter Over Frequency Trip
Interpretation The frequency value above which an over frequency condition for mains is detected. Table 39: Frequency Monitoring
23.8 Engine The engine specific parameters are divided into sections as shown below.
23.8.1 Crank Disconnect
Parameter
Interpretation
Start Attempts
Allows to select maximum number of start sequences before Fail To Start alarm is triggered.
Disconnect on LOP Sensor
Decides if the oil pressure value is used for crank disconnect operation. If enabled, crank will be disconnected if oil pressure is sensed to be more than a threshold.
Disconnect Pressure Threshold
The threshold value for the oil pressure above which the cranking command will be withdrawn. This parameter is relevant only if Disconnect on LOP is enabled.
Disconnect on LOP Switch
Decides if the oil pressure switch condition is used for withdrawing the crank command. If enabled, the crank command will be withdrawn as soon as oil pressure switch stops indicating that oil pressure is low.
Page 107 of 123
KG645 CONTROLLER MANUAL
Parameter
Interpretation
LLOP Switch Transient Time
The time for which the oil pressure switch condition should be consistently shown as Low Oil Pressure before the corresponding crank command withdrawal. Note that if some other source for crank command withdrawal (such as engine speed more than Engine Speed Threshold) is reached before this time, then crank is withdrawn before this time.
Alternator Frequency Threshold
Threshold on alternator frequency above which the crank command will be withdrawn.
Allows to select the engine speed above which crank command will be withdrawn.
Engine Speed Threshold
The controller will not issue Start command if any of the enabled crank withdrawal condition is detected.
Disconnect on Charging Alt Voltage
Decides whether the charging alternator voltage is to be used for crank disconnect operation. If enabled, crank will be disconnected if charging alternator voltage is sensed to be more than threshold.
Charging Alt Threshold
Threshold on charging alternator voltage. Above this threshold, cranking command will be withdrawn. This parameter is relevant only if Disconnect on Charging Alt Voltage is enabled. Table 40: Crank Disconnect
Page 108 of 123
KG645 CONTROLLER MANUAL
23.8.2 Speed Monitoring Parameter
Interpretation
Engine Speed Sense Source
Allows to select electrical signal to be use for measurement of engine speed. Available options: Magnetic pickup: Engine speed will be sensed from Magnetic Pickup Unit (MPU). Alternator frequency: Engine speed will be sensed from alternator frequency.
Flywheel Teeth
Allows to select the number of teeth on flywheel ring gear. This option is enabled, if Engine Speed Sense Source is selected as MPU.
Under-speed Shutdown
Enables or disables Under Speed shutdown alarm.
Under-speed Threshold
The engine speed below which Under Speed alarm will be triggered.
Under-speed Delay
The time for which an engine speed value lower than Under Speed Threshold is allowed before Under Speed shutdown alarm being triggered.
Over-speed Threshold
The engine speed in RPM above which Over Speed alarm will be triggered.
Over-speed Delay
The time for which an engine speed value higher than the preset Over Speed Threshold is allowed before Over Speed shutdown alarm being triggered.
The percentage speed above Over Speed Threshold to sense the speed very Gross Over-speed Threshold fast, especially during ramp up and to trip the engine on detecting high speed. It will shutdown engine immediately. Healthy-speed Threshold
Minimum engine speed that the genset must achieve within 2 seconds from crank disconnect event. Table 41: Speed Monitoring
23.8.3Battery Monitoring
Page 109 of 123
KG645 CONTROLLER MANUAL
Parameter
Interpretation
Low Battery Voltage Action
Allows to select the action if the Low Battery Voltage condition is detected. Available options: None: No action will be taken. Warning: A warning will be displayed without affecting the operation of genset. Electric Trip: The genset will be first unloaded by deactivating the contactor before genset being stopped. Shutdown: Genset will be shutdown.
Low Battery Voltage Threshold
The value of battery voltage below which the Battery Under Voltage alarm will be triggered.
Low Battery Voltage Delay
The time for which battery voltage value lower than Low Battery Voltage Threshold is allowed before the Battery Under Voltage alarm being triggered.
High Battery Voltage Action
Allows to select the action if the High Battery Voltage condition is detected. Available options: None: No action will be taken. Warning: A warning will be displayed without affecting the operation of genset. Electric Trip: The genset will be first unloaded by deactivating the contactor before genset being stopped. Shutdown: Genset will be shutdown.
High Battery Voltage Threshold
The value of battery voltage above which the Battery Over Voltage alarm will be triggered.
High Battery Voltage Delay
The time for which battery voltage value higher than High Battery Voltage Threshold is allowed before the Battery Over Voltage alarm being triggered. Table 42: Battery Monitoring
Page 110 of 123
KG645 CONTROLLER MANUAL
23.8.4 Charging Alternator Monitoring Parameter
Interpretation
Charging Alternator Fail Action
Allows to select the action if the charging alternator fail (Charge Fail) condition is detected. Available options: None: No action will be taken. Warning: A warning will be displayed without affecting the operation of genset. Electric Trip: The genset will be first unloaded by deactivating the contactor before genset being stopped. Shutdown: Genset will be shutdown.
Charging Alternator Fail Threshold
The voltage at the charge alternator fail input terminal, below which the Charge Fail alarm will be triggered.
Charging Alternator Fail Delay
The time for which voltage value (at charge alternator fail input terminal) lower than Charging Alternator Fail Threshold is allowed before the Charge Fail alarm being triggered. Table 43: Charging Alternator Monitoring
23.8.5 Preheat To enable the Preheat, configure one of the digital output as the Preheat Output (Refer section 22.4).
Page 111 of 123
KG645 CONTROLLER MANUAL Parameter Preheat Timer Engine Temperature Limit Engine Temperature
Interpretation Preheat Timer is used for engine smoke reduction and better cold start. The Preheat Output will be active for this duration. If this timer is configured, Crank Start Delay will not considered. Temperature Enable decides whether the coolant temperature is used for controlling the Preheat Output. If enabled, the Preheat output is deactivated when the coolant temperature is sensed to be higher than the Temperature Limit. Table 44: Preheat
23.9 Maintenance
Parameter Alarm Action
Due At Engine Hours Alarm Due Date
Interpretation Alarm action on logged engine hours or service due date, which ever occurs first. Available options: Notification: Notification text will be displayed on LCD screen. Warning: A warning will be displayed without affecting the operation of genset. Maintenance Due alarm will be triggered when the engine has run for more than specified number of hours or if maintenance service due date occurred, whichever happens first. Table 45: Maintenance
Page 112 of 123
KG645 CONTROLLER MANUAL
23.10 Rotary Actuator Rotary actuator can be configured as start/stop device or as E-governor.
23.10.1 General
Parameter
Interpretation
Actuator Application
Allows to select the Actuator application. Available options: As E-Governor or As Start/Stop Device
Actuator Speed
Actuator frequency multiplying factor. The frequency at which Actuator controls the engine.
Actuator Direction
23.10.2
Allows to select the Actuator direction to stop the engine. This direction depends on the engine design. The Actuator is viewed from the shaft side. Available options: Clockwise: Actuator will rotate in clockwise direction to stop the engine. Anti clockwise: Actuator will rotate in anti-clockwise direction to stop the engine. Table 46: General
Engine Start Strategy
Page 113 of 123
KG645 CONTROLLER MANUAL Parameter
Interpretation
Cranking Steps
Number of pulses issued to the Actuator.
Initial Low Speed Delay
Time for which engine stays at low idle speed (used for ramping-for smoke reduction)
Initial Low Speed
Low Idle Speed
Crank Sense Speed
The speed governor recognizes that the engine cranking action is initiated once the engine speed exceeds this value. Upon recognition, the governor executes the Cranking Steps and then initiates the low speed governing phase.
Ramp Up Time
Time taken by the engine to ramp the speed from initial low to target speed Table 47: Engine Start Strategy
If Actuator Application is configured As Start/Stop Device, then following tab will popup.
23.10.3
Start/Stop Device Configuration
Number of pulses issued to the Actuator during normal engine running.
Page 114 of 123
KG645 CONTROLLER MANUAL If Actuator Application is configured As E-Governor, then following tabs will popup.
23.10.4
Generator EGov Configuration
This section allows configuration of Generator EGov Configuration whenever alternator is fitted to engine.
Parameter
Interpretation
Set Speed Selection
Allows to select speed governing type. Available options: Fixed Speed (0 % Droop): Fixed speed application. Speed Bias Input (0-5 V): Paralleling support application Load Based Droop: Configurable droop application
Droop
The percentage drop in the speed of engine from no load speed.
Target Speed
Decides the target governing speed.
Proportional Gain (Kp) Derivative Gain (Kd)
Decides the response of the controller in terms of the responsiveness of the controller to an error, the degree of speed oscillations and the degree to which the controller overshoots or undershoots the target governing speed.
Friction Setoff
To ensure wear and tear free operation of linkage and Actuator.
Gain Schedule Trigger
Percentage RPM that triggers the engine overshoot/undershoot condition.
Integral Gain (Ki)
Loading Factor To scale the PID control loop parameters. Unloading Factor Table 48: Generator EGov Configuration
Page 115 of 123
KG645 CONTROLLER MANUAL
23.10.5 Engine EGov Configuration This section allows configuration of Engine EGov Configuration for engine-only application.
Parameter Target Speed
Decides the target governing speed.
Proportional Gain (Kp) Integral Gain (Ki) Derivative Gain (Kd)
Interpretation Decides the response of the controller in terms of the responsiveness of the controller to an error, the degree of speed oscillations and the degree to which the controller overshoots or undershoots the target governing speed.
Friction Setoff
To ensure wear and tear free operation of linkage and Actuator.
Gain Schedule Trigger
Percentage RPM that triggers the engine overshoot/undershoot condition.
Loading Factor To scale the PID control loop parameters. Unloading Factor Table 49: Engine EGov Configuration
Electronic Governor parameters are relevant only if a actuator is used for electronic governing of the engine.
Electronic Governor parameters are not intended to be changed in the field without consulting experts.
Page 116 of 123
KG645 CONTROLLER MANUAL
23.11
Expansion Module
Expansion module parameters will be enabled if the Expansion Module is enabled (Refer section 22.1).
23.11.1
Digital Inputs
Digital Inputs (EX-A, EX-B, EX-C, EX-D, EX-E) of expansion module can be configured same as that of Digital Input A of controller. Refer section 22.2 and 22.2.1 for configuration details. Screenshot of configuration utility representing configuration of extended Digital Input EX-A as a User configured input.
23.11.2
Analog Inputs
Analog Inputs can be configured as Analog Input or Digital Input.
Following is an example showing configuration of Analog Input EX-S1 as a Pressure sensor (resistive).
Page 117 of 123
KG645 CONTROLLER MANUAL
Parameter
Interpretation
Use Input As
Decides how the input will be interpreted. Available options: Not used: The input will not be used. Digital Input XF: The selected sensor input will be used as digital input. The parameters identical to digital inputs will be displayed and the input can configured in the same way as that of digital input being configured (Refer section 22.2 and 22.2.1). Pressure Sensor: The input will be used as analog input for pressure sensor (resistive). Temperature Sensor: The input will be used as analog input for temperature sensor (resistive).
Action
Allows to select the action taken by the controller if undesirable condition is detected. Available options: None: No action will be taken. Warning: A warning will be displayed without affecting the operation of genset. Electric Trip: The genset will be first unloaded by deactivating the contactor before genset being stopped. Shutdown: Genset will be shutdown.
Name
The text string entered here will distinguish the corresponding sensor from the sensors on other terminal.
Threshold Type
Allows to select alarm generation condition. Available options: Less Than Threshold: Alarm will be generated if measured sensor value is less than selected threshold. Greater Than Threshold: Alarm will be generated if measured sensor value is greater than selected threshold.
Threshold
Allows to select the threshold on the measured sensor value above/below which selected action for undesirable condition will be triggered.
Circuit Open Fault
Allows to select alarm generation condition, when the selected sensor circuit open condition is detected. Available options: None: No action will be taken. Warning: A warning will be displayed without affecting the operation of genset. Electric Trip: The genset will be first unloaded by deactivating the contactor before genset being stopped. Shutdown: Genset will be shutdown.
Sensor Calibration Table
A table that defines relation between the sensor value and corresponding physical quantity.
Page 118 of 123
KG645 CONTROLLER MANUAL
Table 50: Analog Input EX-S1 Sensor Following is an example showing Analog Input EX-S1 configured as Temperature sensor (resistive).
Analog Input EX-S1, Analog Input EX-S2, Analog Input EX-S3, Analog Input EX-S4 and Analog Input EX-S5 can be configured as Digital Inputs. Refer section 22.2 and 22.2.1 for configuration details.
Page 119 of 123
KG645 CONTROLLER MANUAL
23.11.3
Digital Outputs
Extended Digital Outputs can be configured same as that of controller Digital Outputs (Refer section 22.4 and 22.4.1).
*Expansion Module parameters are relevant only if a input/output Expansion Module is connected to KG-645 genset controller.
Page 120 of 123
KG645 CONTROLLER MANUAL
KG 645 – EOL Flashing Utility KG 645 – EOL Flashing Utility allows flashing of KG-645 controller.
24 Menu Bar Toolbar is located at the top of the screen.
Following options can be accessed under different Menus. Menu
Available options
Description
File
Exit
Exit the flashing utility
Tools
Get Device Information
Reads product id and engine serial number from device (Refer window below this table)
Help
Mode Selection
Displays diagram of mode selection in device (Refer section Error: Reference source not found)
About
Information about flashing utility
On selecting Get Device Information option following window will be shown:
Page 121 of 123
KG645 CONTROLLER MANUAL
25 Writing Configuration To Device Following is the stepwise procedure for flashing KG-645. •
Locate the installer on PC and double-click the setup.
•
Connect KG-645 controller to PC. Put the controller in Programming mode (Refer section 8).
•
Now, enter the Engine Serial No (optional).
Page 122 of 123
KG645 CONTROLLER MANUAL •
Browse and select configuration file. On selecting this file, profile name will be read from file and displayed on screen of the flashing utility.
•
Now, select Write To Device. This tab will be active only when connection between KG -645 controller and PC is active. Once the configuration is written to device, confirmation window will be shown.
Disclaimer: Due to continuous development, the details provided in this document are subject to change without any prior notice.
Page 123 of 123
