Teksan tj 509 t инструкция

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

TJ-509-T

GENSET

CONTROLLER

DESCRIPTION

The 509T is a next generation genset control unit combining multi-functionality and wide communication possibilities together with a reliable and low cost design.

The unit complies and mostly exceeds world’s tightest safety, EMC, vibration and environmental standards for the industrial category.

Software features are complete with easy firmware upgrade process through USB port.

The Windows based PC software allows monitoring and programming through USB, RS-485, Ethernet and GPRS.

FUNCTIONALITIES

AMF unit with uninterrupted transfer

ATS unit with uninterrupted transfer

Remote start controller

Manual start controller

Engine controller

Remote display & control unit

Waveform display of V & I

Harmonic analysis of V & I

CTs at genset or load side

COMMUNICATIONS

Ethernet

GSM-GPRS (optional)

Embedded web server

Web monitoring

Web programming

GSM-SMS (optinal) e-mail

Modbus RS-485

Modbus over IP

SNMP

USB Host

USB Device

RS-485

RS-232

J1939-CANBUS

TOPOLOGIES

2 phases 3 wires, L1-L2

2 phases 3 wires, L1-L3

3 phases 3 wires, 3 CTs

3 phases 3 wires, 2 CTs (L1-L2)

3 phases 3 wires, 2 CTs (L1-L3)

3 phases 4 wires, star

3 phases 4 wires, delta

1 phase 2 wires

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

COPYRIGHT NOTICE

Any unauthorized use or copying of the contents or any part of this document is prohibited.

This applies in particular to trademarks, model denominations, part numbers and drawings.

ABOUT THIS DOCUMENT

This document describes minimum requirements and necessary steps for the successful installation of the 509T family units.

Follow carefully advices given in the document. These are often good practices for the installation of genset control units which reduce future issues.

For all technical queries please contact Datakom at below e-mail address: [email protected]

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509TGSM Configuration

509TFirmware Update

509T-MODBUS

DESCRIPTION

Rainbow Plus 509T Installation Guide

Rainbow Plus 509T Usage Guide

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Dynamic DNS Account Setting for 509T

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REVISION HISTORY

REVISION DATE

01 29.09.2011

AUTHOR

MH

TERMINOLOGY

DESCRIPTION

First issue, firmware version 1.06

CAUTION:

Potential risk of injury or death.

WARNING:

Potential risk of malfunction or material damage.

ATTENTION:

Useful hints for the understanding of device operation.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ORDERING CODES

The 509T family units are available in various options and peripheral features. Please use below information for ordering the correct version:

509T -G -T -00

Family Code

Variant

00: standard unit

01…99: customer specific products

With Sealing gasket

With Conformal

Coating

SPARE PARTS

Screw type bracket

Stock Code=J10P01 (per unit)

Self-Retaining type bracket

Stock Code=K16P01 (per unit)

Sealing Gasket, Stock Code= K35P01

K35D01-EN — 3 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

SAFETY NOTICE

Failure to follow below instructions will result in death or serious injury

 Electrical equipment should be installed only by qualified

specialist. No responsibility is assured by the manufacturer or any of its subsidiaries for any consequences resulting from the noncompliance to these instructions.

 Check the unit for cracks and damages due to transportation. Do

not install damaged equipment.

 Do not open the unit. There are no serviceable parts inside.

 Fuses must be connected to the power supply and phase voltage

inputs, in close proximity of the unit.

 Fuses must be of fast type (FF) with a maximum rating of 6A.

 Disconnect all power before working on equipment.

 When the unit is connected to the network do not touch

terminals.

 Short circuit terminals of unused current transformers.

 Any electrical parameter applied to the device must be in the

range specified in the user manual. Although the unit is designed with a wide safety margin, over-range parameters may reduce lifetime, alter operational precision or even damage the unit.

 Do not try to clean the device with solvent or the like. Only clean

with a dump cloth.

 Verify correct terminal connections before applying power.

 Only for front panel mounting.

Current Transformers must be used for current measurement.

No direct connection allowed.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

TABLE OF CONTENTS

COPYRIGHT NOTICE …………………………………………………………………………………………………………………. 2

ABOUT THIS DOCUMENT ………………………………………………………………………………………………………….. 2

RELATED DOCUMENTS …………………………………………………………………………………………………………….. 2

REVISION HISTORY…………………………………………………………………………………………………………………… 2

TERMINOLOGY ……………………………………………………………………………………………………………………….. 2

ORDERING CODES …………………………………………………………………………………………………………………… 2

SPARE PARTS ………………………………………………………………………………………………………………………….. 2

TABLE OF CONTENTS ……………………………………………………………………………………………………………….. 2

INSTALLATION INSTRUCTIONS ………………………………………………………………………………………………….. 2

MOUNTING …………………………………………………………………………………………………………………………….. 2

DIMENSIONS ……………………………………………………………………………………………………………………….. 2

SEALING, GASKET ………………………………………………………………………………………………………………… 2

ELECTRICAL INSTALLATION ……………………………………………………………………………………………………. 2

TERMINAL DESCRIPTIONS ………………………………………………………………………………………………………… 2

BATTERY VOLTAGE INPUT …………………………………………………………………………………………………….. 2

AC VOLTAGE INPUTS ……………………………………………………………………………………………………………. 2

AC CURRENT INPUTS ……………………………………………………………………………………………………………. 2

DIGITAL INPUTS …………………………………………………………………………………………………………………… 2

ANALOG SENDER INPUTS AND SENDER GROUND ……………………………………………………………………. 2

CHARGE INPUT TERMINAL ……………………………………………………………………………………………………. 2

MAGNETIC PICKUP INPUT …………………………………………………………………………………………………….. 2

MAINS CONTACTOR OUTPUT ………………………………………………………………………………………………… 2

GENERATOR CONTACTOR OUTPUT ………………………………………………………………………………………… 2

DIGITAL OUTPUTS………………………………………………………………………………………………………………… 2

INPUT/OUTPUT EXTENSION ………………………………………………………………………………………………….. 2

RS-485 PORT ……………………………………………………………………………………………………………………….. 2

J1939-CANBUS PORT ……………………………………………………………………………………………………………. 2

ETHERNET PORT ………………………………………………………………………………………………………………….. 2

USB DEVICE PORT ………………………………………………………………………………………………………………… 2

USB HOST PORT …………………………………………………………………………………………………………………… 2

RS-232 PORT ……………………………………………………………………………………………………………………….. 2

GSM MODEM (OPTIONAL) ……………………………………………………………………………………………………. 2

TOPOLOGIES …………………………………………………………………………………………………………………………… 2

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

SELECTING THE TOPOLOGY …………………………………………………………………………………………………… 2

3 PHASE, 4 WIRE, STAR …………………………………………………………………………………………………………. 2

3 PHASE, 3 WIRE, DELTA ……………………………………………………………………………………………………….. 2

3 PHASE, 4 WIRE, DELTA ……………………………………………………………………………………………………….. 2

3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L2) …………………………………………………………………………………….. 2

3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L3) …………………………………………………………………………………….. 2

2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L2) …………………………………………………………………………………… 2

2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L3) …………………………………………………………………………………… 2

1 PHASE, 2 WIRE ………………………………………………………………………………………………………………….. 2

FUNCTIONALITIES ……………………………………………………………………………………………………………………. 2

CT LOCATION SELECTION ……………………………………………………………………………………………………… 2

AMF FUNCTIONALITY …………………………………………………………………………………………………………… 2

ATS FUNCTIONALITY …………………………………………………………………………………………………………….. 2

REMOTE START FUNCTIONALITY ……………………………………………………………………………………………. 2

ENGINE CONTROLLER FUNCTIONALITY …………………………………………………………………………………… 2

400HZ OPERATION ………………………………………………………………………………………………………………. 2

REMOTE DISPLAY UNIT FUNCTIONALITY …………………………………………………………………………………. 2

CONNECTION DIAGRAMS …………………………………………………………………………………………………………. 2

AMF FUNCTIONALITY, CTs AT LOAD SIDE ……………………………………………………………………………….. 2

AMF FUNCTIONALITY, CTs AT ALTERNATOR SIDE …………………………………………………………………….. 2

ATS FUNCTIONALITY …………………………………………………………………………………………………………….. 2

REMOTE START FUNCTIONALITY ……………………………………………………………………………………………. 2

ENGINE CONTROL FUNCTIONALITY ………………………………………………………………………………………… 2

REMOTE DISPLAY PANEL FUNCTIONALITY ………………………………………………………………………………. 2

TERMINAL DESCRIPTION ………………………………………………………………………………………………………….. 2

TECHNICAL SPECIFICATIONS ……………………………………………………………………………………………………… 2

DESCRIPTION OF CONTROLS …………………………………………………………………………………………………….. 2

FRONT PANEL FUNCTIONALITY ……………………………………………………………………………………………… 2

PUSHBUTTON FUNCTIONS ……………………………………………………………………………………………………. 2

DISPLAY SCREEN ORGANIZATION …………………………………………………………………………………………… 2

AUTOMATIC DISPLAY SCROLL ……………………………………………………………………………………………….. 2

MEASURED PARAMETERS …………………………………………………………………………………………………….. 2

LED LAMPS ………………………………………………………………………………………………………………………….. 2

WAVEFORM DISPLAY & HARMONIC ANALYSIS ……………………………………………………………………………. 2

DISPLAYING EVENT LOGS …………………………………………………………………………………………………………. 2

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

STATISTICAL COUNTERS …………………………………………………………………………………………………………… 2

OPERATION OF THE UNIT …………………………………………………………………………………………………………. 2

QUICK START GUIDE …………………………………………………………………………………………………………….. 2

STOP MODE ………………………………………………………………………………………………………………………… 2

AUTO MODE ……………………………………………………………………………………………………………………….. 2

RUN MODE, MANUAL CONTROL ……………………………………………………………………………………………. 2

TEST MODE …………………………………………………………………………………………………………………………. 2

PROTECTIONS AND ALARMS …………………………………………………………………………………………………….. 2

DISABLING ALL PROTECTIONS ……………………………………………………………………………………………….. 2

SERVICE REQUEST ALARM …………………………………………………………………………………………………….. 2

SHUTDOWN ALARMS …………………………………………………………………………………………………………… 2

LOADDUMP ALARMS ……………………………………………………………………………………………………………. 2

WARNINGS …………………………………………………………………………………………………………………………. 2

PROGRAMMING ……………………………………………………………………………………………………………………… 2

RESETTING TO FACTORY DEFAULTS ……………………………………………………………………………………….. 2

ENTERING THE PROGRAMMING MODE ………………………………………………………………………………….. 2

NAVIGATING BETWEEN MENUS …………………………………………………………………………………………….. 2

MODIFYING PARAMETER VALUE ……………………………………………………………………………………………. 2

PROGRAMMING MODE EXIT …………………………………………………………………………………………………. 2

PROGRAM PARAMETER LIST …………………………………………………………………………………………………….. 2

CONTROLLER CONFIGURATION GROUP ………………………………………………………………………………….. 2

ELECTRICAL PARAMETERS GROUP …………………………………………………………………………………………. 2

ENGINE PARAMETERS GROUP ………………………………………………………………………………………………. 2

ADJUST DATE AND TIME ………………………………………………………………………………………………………. 2

WEEKLY OPERATION SCHEDULE …………………………………………………………………………………………….. 2

EXERCISER SCHEDULE …………………………………………………………………………………………………………… 2

SENDER CONFIGURATION …………………………………………………………………………………………………….. 2

DIGITAL INPUT CONFIGURATION …………………………………………………………………………………………… 2

OUTPUT CONFIGURATION ……………………………………………………………………………………………………. 2

SITE ID STRING …………………………………………………………………………………………………………………….. 2

ENGINE SERIAL NUMBER ………………………………………………………………………………………………………. 2

MODEM1-2/SMS1-2-3-4 TELEPHONE NUMBERS ……………………………………………………………………… 2

GSM MODEM PARAMETERS …………………………………………………………………………………………………. 2

ETHERNET PARAMETERS ………………………………………………………………………………………………………. 2

SYNCHRONIZATION PARAMETERS …………………………………………………………………………………………. 2

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

CRANK CUTTING ……………………………………………………………………………………………………………………… 2

OVERCURRENT PROTECTION (IDMT) …………………………………………………………………………………………. 2

MOTORIZED CIRCUIT BREAKER CONTROL …………………………………………………………………………………… 2

J1939 CANBUS ENGINE SUPPORT ……………………………………………………………………………………………… 2

ETHERNET CONFIGURATION …………………………………………………………………………………………………….. 2

GSM CONFIGURATION …………………………………………………………………………………………………………….. 2

DYNAMIC DNS FEATURE …………………………………………………………………………………………………………… 2

ACCESSING THE EMBEDDED WEB SERVER ………………………………………………………………………………….. 2

CENTRAL MONITORING OF GENSETS …………………………………………………………………………………………. 2

WEB MONITORING AND CONTROL OF GENSETS …………………………………………………………………………. 2

ETHERNET – MODBUS GATEWAY OPERATION ……………………………………………………………………………. 2

GPRS – MODBUS GATEWAY OPERATION ……………………………………………………………………………………. 2

LOAD TRANSFER MODES ………………………………………………………………………………………………………….. 2

TRANSFER WITH INTERRUPTION ……………………………………………………………………………………………. 2

UNINTERRUPTED TRANSFER …………………………………………………………………………………………………. 2

DATA RECORDING …………………………………………………………………………………………………………………… 2

DATA RECORDING MEDIA …………………………………………………………………………………………………….. 2

DIRECTORY STRUCTURE ……………………………………………………………………………………………………….. 2

UNDERSTANDING THE CSV FORMAT ……………………………………………………………………………………… 2

RECORDED DATA LIST, RECORD PERIOD …………………………………………………………………………………. 2

SOFTWARE FEATURES ……………………………………………………………………………………………………………… 2

Load Shedding / Dummy Load ………………………………………………………………………………………………. 2

Remote Start Operation ……………………………………………………………………………………………………….. 2

Disable Auto Start, Simulate Mains ………………………………………………………………………………………… 2

Battery Charging Operation, Delayed Simulate Mains ……………………………………………………………… 2

Dual Genset Mutual Standby Operation …………………………………………………………………………………. 2

Dual Voltage and Frequency …………………………………………………………………………………………………. 2

Single Phase Operation ………………………………………………………………………………………………………… 2

External Control of the Unit ………………………………………………………………………………………………….. 2

Automatic Exerciser …………………………………………………………………………………………………………….. 2

WEEKLY OPERATION SCHEDULER ………………………………………………………………………………………….. 2

Engine Heating Operation …………………………………………………………………………………………………….. 2

Engine Idle Speed Operation …………………………………………………………………………………………………. 2

Engine Block Heater …………………………………………………………………………………………………………….. 2

Fuel Pump Control ……………………………………………………………………………………………………………….. 2

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

Gas Engine Fuel Solenoid Control ………………………………………………………………………………………….. 2

MODBUS COMMUNICATIONS …………………………………………………………………………………………………… 2

DECLARATION OF CONFORMITY ……………………………………………………………………………………………….. 2

MAINTENANCE ……………………………………………………………………………………………………………………….. 2

DISPOSAL OF THE UNIT ……………………………………………………………………………………………………………. 2

ROHS COMPLIANCE …………………………………………………………………………………………………………………. 2

TROUBLESHOOTING GUIDE ………………………………………………………………………………………………………. 2

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

INSTALLATION INSTRUCTIONS

Before installation:

 Read the user manual carefully, determine the correct connection diagram.





 Remove all connectors and mounting brackets from the unit, then pass the unit through the mounting opening.

 Put mounting brackets and tighten. Do not tighten too much, this can brakmicroe

the enclosure.

Make electrical connections with plugs removed from sockets, then place plugs to their sockets.

Be sure that adequate cooling is provided.

 Be sure that the temperature of the environment will not exceed the maximum operating temperature in any case.





















Below conditions may damage the device:

Incorrect connections.

Incorrect power supply voltage.

Voltage at measuring terminals beyond specified range.

Voltage applied to digital inputs over specified range.

Current at measuring terminals beyond specified range.

Overload or short circuit at relay outputs

Connecting or removing data terminals when the unit is powered-up.

High voltage applied to communication ports.

Ground potential differences at non-isolated communication ports.

Excessive vibration, direct installation on vibrating parts.

Current Transformers must be used for current measurement.

No direct connection allowed.

Below conditions may cause abnormal operation:













Power supply voltage below minimum acceptable level.

Power supply frequency out of specified limits

Phase order of voltage inputs not correct.

Current transformers not matching related phases.

Current transformer polarity incorrect.

Missing grounding.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

MOUNTING

DIMENSIONS

Dimensions:

200x148x47mm (7.9”x5.8”x1.9”)

Panel Cutout:

176x121mm minimum (7.0”x4.8”)

Weight:

450g (1 lb)

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

The unit is designed for panel mounting. The user should not be able to access parts of the unit other than the front panel.

Mount the unit on a flat, vertical surface. Before mounting, remove the mounting brackets and connectors from the unit, then pass the unit through the mounting opening.

Place and tighten mounting brackets.

Panel Cutout

Required Panel Depth

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

Two different types of brackets are provided:

Screw type bracket

Self retaining type bracket

Installation of screw type bracket

Installation of self retaining type bracket

Do not tighten too much, this may break the unit.

K35D01-EN — 13 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

SEALING, GASKET

Panel

Gasket

Module

The rubber gasket provides a watertight means of mounting the module to the genset panel. Together with the gasket, IEC 60529IP65 protection can be reached from the front panel. A short definition of IP protection levels is given below.

1st Digit Description of Protection Level

0 Not protected

1 Protected against solid foreign objects of 50 mm diameter and greater

2 Protected against solid foreign objects of 12,5 mm diameter and greater

3 Protected against solid foreign objects of 2,5 mm diameter and greater

4 Protected against solid foreign objects of 1,0 mm diameter and greater

5 Protected from the amount of dust that would interfere with normal operation

6 Dust tight

2nd Digit Description of Protection Level

0 Not protected

1 Protected against vertically falling water drops

2 Protected against vertically falling water drops when enclosure is tilted up to 15 °

3 Protected against water sprayed at an angle up to 60 ° on either side of the vertical

4 Protected against water splashed against the component from any direction

5 Protected against water projected in jets from any direction

6 Protected against water projected in powerful jets from any direction

7 Protected against temporary immersion in water

8 Protected against continuous immersion in water, or as specified by the user

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ELECTRICAL INSTALLATION

Do not install the unit close to high electromagnetic noise emitting devices like contactors, high current busbars, switchmode power supplies and the like.

Although the unit is protected against electromagnetic disturbance, excessive disturbance can affect the operation, measurement precision and data communication quality.



ALWAYS remove plug connectors when inserting wires with a screwdriver.



Fuses must be connected to the power supply and phase voltage inputs, in close proximity of the unit.







Fuses must be of fast type (FF) with a maximum rating of 6A.

Use cables of appropriate temperature range.

Use adequate cable section, at least 0.75mm

2

(AWG18).





Follow national rules for electrical installation.

Current transformers must have 5A output.



For current transformer inputs, use at least 1.5mm

2

section (AWG15) cable.



The current transformer cable length should not exceed 1.5 meters. If longer cable is used, increase the cable section proportionally.

Current Transformers must be used for current measurement.

No direct connection allowed.

The engine body must be grounded. Otherwise faulty voltage and frequency measurements may occur.

For the correct operation of the exerciser and weekly schedule programs, adjust the real time clock of the unit through programming menu.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

TERMINAL DESCRIPTIONS

BATTERY VOLTAGE INPUT

Supply voltage:

Cranking dropouts:

Overvoltage protection:

Reverse voltage:

9 to 33VDC

Survives 0VDC during 100ms. The voltage before surge should be

9VDC minimum

Withstands 150VDC continuously.

-33VDC continuous

Maximum operating current:

500mA @ 12VDC. (All options included, digital outputs open.)

250mA @ 24VDC. (All options included, digital outputs open.)

Typical operating current:

250mA @ 12VDC. (all options passive, digital outputs open)

125mA @ 24VDC. (all options passive, digital outputs open)

Measurement range:

Display resolution:

Accuracy:

0 to 36VDC

0.1VDC

0.5% + 1 digit @ 24VDC

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

AC VOLTAGE INPUTS

Measurement method:

Sampling rate:

Harmonic analysis:

Input voltage range:

Minimum voltage for frequency detection:

True RMS

8000 Hz up to 31th harmonic

14 to 300 VAC

15 VAC (Ph-N)

Supported topologies:

Measurement range:

Common mode offset:

Input impedance:

Display resolution:

Accuracy:

3 ph 4 wires star

3 ph 3 wires delta

3ph 4 wires delta

2ph 3 wires L1-L2

2ph 3 wires L1-L3

1 ph 2 wires

0 to 330VAC ph-N (0 to 570VAC ph-ph) max 100V between neutral and BAT-

4.5M-ohms

1VDC

0.5% + 1 digit @ 230VAC ph-N (±2VAC ph-N)

0.5% + 1 digit @ 400VAC ph-ph (±3VAC ph-ph)

Frequency range:

Frequency display resolution:

DC to 500Hz

0.1 Hz

Frequency accuracy:

0.2% + 1 digit (±0.1 Hz @ 50Hz)

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

AC CURRENT INPUTS

Measurement method:

Sampling rate:

Harmonic analysis:

Supported topologies:

CT secondary rating:

Measurement range:

Input impedance:

Burden:

True RMS

8000 Hz up to 31th harmonic

3 ph 3 CTs

3 ph 2 CTs L1-L2

3 ph 2 CTs L1-L3

2 ph 2 CTs L1-L2

2 ph 2 CTs L1-L3

1 ph 1 CT

5A

5/5 to 5000/5A minimum

15 mili-ohms

0.375W

6A

Maximum continuous current:

Measurement range:

Common mode offset:

Display resolution:

0.1 to 7.5A

Max 5VAC between BAT- and any CT terminal.

1A

0.5% + 1 digit @ 5A (± 4.5A @ 5/500A full range)

Accuracy:

SELECTING THE CT RATING AND CABLE SECTION:

The load on a CT should be kept minimum in order to minimize phase shift effect of the current transformer. Phase shift in a CT will cause erroneous power and power factor readings, although amp readings are correct.

Datakom advises CT rating to be selected following this table for the best measurement accuracy.

SELECTING THE CT ACCURACY CLASS:

The CT accuracy class should be selected in accordance with the required measurement precision. The accuracy class of the Datakom controller is 0.5%. Thus 0.5% class CTs are advised for the best result.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

CONNECTING CTs:

Be sure of connecting each CT to the related phase input with the correct polarity. Mixing CTs between phases will cause faulty power and pf readings.

Many combinations of incorrect CTs connections are possible, so check both order of CTs and their polarity. Reactive power measurement is affected by incorrect CTs connection in similar way as active power measurement.

CORRECT CT CONNECTIONS

Let’s suppose that the genset is loaded with 100 kW on each phase.

The load Power Factor (PF) is 1.

Measured values are as follows:

kW kVAr kVA pf

Phase L1

Phase L2

Phase L3

100.0

100.0

100.0

0.0

0.0

0.0

100

100

100

1.00

1.00

1.00

Total 300.0 0.0 300 1.00

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

EFFECT OF POLARITY REVERSAL

Phase L1

Phase L2

Phase L3

The generator is still loaded with 100 kW On each phase. The load Power Factor (PF) is 1.

PF in phase L2 will show -1,00 due to reverse CT polarity. The result is that total generator power displayed by the controller is 100 kW.

Measured values are as follows:

kW kVAr kVA pf

100.0

-100.0

100.0

0.0

0.0

0.0

100

100

100

1.00

-1.00

1.00

Total 100.0 0.0 300 0.33

EFFECT OF PHASE SWAPPING

The generator is still loaded with 100 kW on each phase. The load Power Factor (PF) is 1.

PF in phases L2 and L3 will show -0,50 due to phase shift between voltages and currents which is caused by CT swapping. The result is that total generator power displayed by controller is 0 kW.

Measured values are as follows:

kW kVAr kVA pf

Phase L1

Phase L2

Phase L3

100.0

-50.0

-50.0

0.0

86.6

-86.6

100

100

100

1.00

-0.50

-0.50

Total 0.0 0.0 300 0.0

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

DIGITAL INPUTS

Number of inputs:

Function selection:

Contact type:

Switching:

Structure:

Measurement:

Open circuit voltage:

Low level threshold:

High level threshold:

Maximum input voltage:

Minimum input voltage:

Noise filtering:

8 inputs, all configurable from list

Normally open or normally closed (programmable)

Battery negative or battery positive (programmable)

47 k-ohms resistor to battery positive, 110k-ohms to battery negative.

Analog voltage measurement.

70% of battery voltage

35% of battery voltage

85% of battery voltage

+100VDC with respect to battery negative

-70VDC with respect to battery negative yes

ANALOG SENDER INPUTS AND SENDER GROUND

Number of inputs:

Function selection:

Structure:

Measurement:

Open circuit voltage:

Short circuit current:

Measurement range:

Open circuit threshold:

Resolution:

Accuracy:

Common mode voltage range:

4 inputs, all configurable, additional sender ground input from list

667 ohms resistor polarizing to 3.3VDC

Analog resistor measurement.

+3.3VDC

5mA

0 to 5000 ohms.

5000 ohms.

1 ohms @ 300 ohms or lower

2 %+1 ohm (±7 ohms @300 ohms)

± 3VDC

Noise filtering:

yes

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

CHARGE INPUT TERMINAL

The Charge terminal is both an input and output.

When the engine is ready to run, this terminal supplies the excitation current to the charge alternator.

The excitation circuit is equivalent to a 2W lamp.

The threshold voltages for warning and shutdown alarm are adjustable through program parameter.

Structure:

 battery voltage output through 20 ohm PTC

 voltage measurement input

Output current:

Voltage measurement resolution:

160mA @12VDC

80mA @24VDC

0.1VDC

Voltage measurement accuracy:

2% + 0.1V (0.9V @30VDC)

Charge Fail Warning

Threshold:

adjustable

Charge Fail Shutdown

Alarm Threshold:

adjustable

Open circuit voltage:

Overvoltage protection:

Reverse voltage protection:

battery positive

> 500VDC continuous, with respect to battery negative

-30VDC with respect to battery negative

MAGNETIC PICKUP INPUT

Structure:

Input impedance:

Input voltage:

Max common mode voltage:

Differential frequency measurement input

50 k-ohms

0.5VAC-RMS to 30VAC-RMS

± 5VDC

Frequency range:

Resolution:

Accuracy:

Flywheel teeth range:

10Hz to 10 kHz

1 rpm

0.2% + 1 rpm (±3rpm @1500 rpm

)

1 to 500

Do not share MPU with other devices.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

MAINS CONTACTOR OUTPUT

Structure:

Max switching current:

Max switching voltage:

Max switching power:

Relay output, normally closed contact. One terminal is internally connected to mains phase L1 input.

12A @250VAC

440VAC

3000VA

GENERATOR CONTACTOR OUTPUT

Structure:

Max switching current:

Max switching voltage:

Max switching power:

Relay output, normally open contact. One terminal is internally connected to genset phase L1 input.

16A @250VAC

440VAC

4000VA

DIGITAL OUTPUTS

The unit offers 6 digital outputs with programmable function, selectable from list.

Structure:

Max continuous current:

Max switching voltage:

Overvoltage protection:

Short circuit protection:

Reverse voltage protection:

Negative pulling protected semiconductor output. One terminal is connected to battery negative.

1.0 ADC

33 VDC

40 VDC

> 1.7 ADC

500 VDC

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

INPUT/OUTPUT EXTENSION

I/O Extension

Connector

The module provides resources for 32 additional digital inputs and 32 additional digital outputs.

Digital inputs can be extended using DKG-188

Digital Input Extension

modules, each one providing 8 inputs. Digital inputs are programmable through the main controller. The switching characteristic is not programmable and must be battery negative. Any function can be assigned to digital inputs.

Digital outputs can be extended using DKG-186

Fet Extension

modules, each one providing 8 outputs. Digital outputs have the same electrical characteristics as on board outputs. They have programmable functions through the main controller. Any function can be assigned to any output.

Input and output extension modules are connected to the main controller in a cascade structure, in any order. The connection cable is provided with each extension module.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

RS-485 PORT

Structure:

Connection:

Baud rate:

Data type:

RS-485, non-isolated.

3 wires (A-B-GND). Half duplex.

2400-115200 bauds, selectable

8 bit data, no parity, 1 bit stop

Termination:

Common mode voltage:

External 120 ohms required

-0.5 VDC to +7VDC, internally clamped by transient suppressors.

Max distance:

1200m @ 9600 bauds (with 120 ohms balanced cable)

200m @ 115200 bauds (with 120 ohms balanced cable)

The RS-485 port features MODBUS-RTU protocol. Multiple modules (up to 128) can be paralleled on the same RS-485 bus for data transfer to automation or building management systems.

The Modbus register list is available at Datakom technical support.

The RS-485 port provides also a good solution for distant PC connection where RainbowPlus program will enable programming, control and monitoring.

For more details about programming, control and monitoring through RS-485 port please refer to

RainbowPlus user manual.

J1939-CANBUS PORT

Structure:

Connection:

Data rate:

Termination:

Common mode voltage:

Max distance:

CANBUS, non-isolated.

3 wires (CANH-CANL-GND).

250 kbps

Internal 120 ohms provided

-0.5 VDC to +15 VDC, internally clamped by transient suppressors.

200m with 120 ohm balanced cable

K35D01-EN — 25 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ETHERNET PORT

Ethernet

Connector

Data Flow led

Link

Established led

Description:

Data rate:

Connector:

Cable type:

Isolation:

Max distance:

Functionality:

IEEE802.3 compliant, 10/100

Base-TX RJ45 ethernet port with indicating leds

10/100 Mbits/s, auto detecting

RJ45

CAT5 or CAT6

1500 VAC, 1 minute

30m.

Embedded TCP-IP, Web Server,

Web Client, SMTP, e-mail, SNMP,

Modbus over IP

LED FUNCTIONS:

GREEN:

This led turns on when the ethernet link is established (connector inserted)

YELLOW:

This led blinks when data transfer occurs inwards or outwards. Periodic blinking will witness data flow.

STANDARD

ETHERNET CABLE

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

USB DEVICE PORT

USB Device

Connector

Description:

Data rate:

Connector:

Cable length:

USB 2.0, not isolated, HID mode

Full Speed 1.5/12 Mbits/s, auto detecting

USB-B (printer connector)

Max 6m

Functionality:

Modbus, FAT32 for firmware upgrade (boot loader mode only)

The USB-Device port is designed to connect the module to a PC. Using the RainbowPlus software, programming, control of the genset and monitoring of measured parameters are achieved.

The RainbowPlus software can be downloaded from www.datakom.com.tr website.

The connector on the module is of USB-B type. Thus A to B type USB cable should be used. This is the same cable used for USB printers.

For more details about programming, control and monitoring please refer to RainbowPlus user manual.

The battery voltage must be connected.

If USB-Device is plugged then USB-Host port will not function.

K35D01-EN — 27 —

USB A to B

Cable

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

USB HOST PORT

USB FLASH MEMORY

USB HOST

Port

The USB-Host port is available in units with COMM option.

Description:

Power Supply

Output:

USB 2.0, not isolated

5V, 300mA max

Data rate:

Connector:

Cable length:

Functionality:

Full Speed 1.5/12 Mbits/s, auto detecting

USB-A (PC type connector)

Max 1.5m

USB memory, FAT32, data recording

Memory capacity:

all USB flash memories.

The USB-Host port is designed for detailed data recording. The period of recording is adjustable through program parameter.

As soon as a USB flash memory is inserted, the unit will start data recording and continue until the memory is removed.

For more details about data recording please review chapter “Data Recording”.

If USB-Device is plugged then USB-Host port will not function.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

RS-232 PORT

Description:

Functionality:

Connector:

Connection:

Baud rate:

Data type:

Max distance:

Cable type:

Terminal description:

RS-232, non-isolated.

External GSM modem, external PSTN modem

DB-9 (9 pins male)

5 wires (Rx-Tx-DTR-CxD-GND). Full duplex.

2400-115200 bauds, selectable

8 bit data, no parity, 1 bit stop

15m

Standard modem cable

1: CxD input 6: NC

2: Rx input 7:NC

3: Tx output 8: NC

4: DTR output 9: NC

5: GND

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

GSM MODEM (OPTIONAL)

The optional internal GSM modem offers the advantage of being internally powered and is fully compatible with the unit. It does not require any special setup.

The 1800/1900 MHz magnetic antenna together with its 2 meter cable is supplied with the internal modem option. The antenna is intended to be placed outside of the genset panel for the best signal reception.

SIM Card extraction tab

SIM Card slot

Antenna connector

Magnetic antenna

The module requires a GPRS enabled SIM card for full functionality. Voice-only type SIM cards will usually not function properly.

Please refer to GSM Modem Configuration Guide for more details.

K35D01-EN — 30 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

Push the extraction tab

SIM CARD EXTRACTION SIM CARD EXTRACTION / INSERTION

SIM CARD PLACEMENT

Description:

Functionality:

Quad-band GSM/GPRS 850/900/1800/1900MHz module.

GPRS multi-slot class 10/8

GPRS mobile station class B

Compliant to GSM phase 2/2+.

– Class 4 (2 W @850/ 900 MHz)

– Class 1 (1 W @ 1800/1900MHz)

Embedded TCP-IP, Web Client, SMTP, SNMP, Modbus over IP,

SMS, e-mail

Data speed:

SIM card type:

Antenna:

-40°C to +85 °C max. 85.6 kbps (download), 42.8 kbps (upload) external SIM 3V/1.8V, GPRS enabled

Quad band, magnetic, with 2m cable

K35D01-EN — 31 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

Module certificates:

CE, FCC, ROHS, PTCRB, GCF, IC, ICASA, REACH

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

TOPOLOGIES

Various topologies are selectable through program parameter.

The topology is independently selectable for both genset and mains sections.

In following drawings the connections are shown for the alternator. Current transformers are supposed connected to the alternator side.

Similar topologies re available for the mains side as well.

SELECTING THE TOPOLOGY

Generator

Parameters s

Topology

Selection

Mains

Parameters s

Topology

Selection

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

3 PHASE, 4 WIRE, STAR

3 PHASE, 3 WIRE, DELTA

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

3 PHASE, 4 WIRE, DELTA

3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L2)

K35D01-EN — 35 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L3)

2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L2)

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L3)

1 PHASE, 2 WIRE

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

FUNCTIONALITIES

The same unit provides different functionalities through parameter setting. Thus a single stock item will fulfill various duties, minimizing stock cost.

CT LOCATION SELECTION

CTs may be placed at alternator or load busbars. The CT location selection is configured with Controller

Configuration > CT Location

parameter.

When CTs are located at the alternator side, them mains current and power parameters will not be displayed.

When CTs are located at load side, then both mains and genset currents and power parameters will be displayed, based on contactor positions.

Please review AMF functionality connection diagrams for CT connection details.

AMF FUNCTIONALITY

When AMF functionality is selected, the unit will monitor mains voltages, provide mains and genset contactor control, run the engine and provide engine and alternator instrumentation and fault monitoring.

The unit features both MPU and J1939 CANBUS inputs. Thus both mechanical and electronic engines are supported.

The unit provides control outputs for both contactors and motorized circuit breakers.

ATS FUNCTIONALITY

When ATS functionality is selected, the unit will monitor mains voltages, provide mains and genset contactor control and issue a Remote Start signal to the engine controller. It will provide alternator instrumentation and fault monitoring.

Engine instrumentation and protection will be insured by the engine controller.

REMOTE START FUNCTIONALITY

When the Remote Start functionality is selected, the unit will wait for a Remote Start signal from external controller. Upon reception of this signal, it will run the engine, and provide engine and alternator instrumentation and fault monitoring. The genset contactor/MCB control functionality will be available.

The unit features both MPU and J1939 CANBUS inputs. Thus both mechanical and electronic engines are supported.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ENGINE CONTROLLER FUNCTIONALITY

When the Engine Controller functionality is selected, genset electrical measurements and protections will be disabled. The unit is supposed to control an engine without alternator.

When the Engine Control Mode is activated:

-the unit will not display genset AC parameters (volts, amps, kW and pf).

-genset voltage and frequency protections are disabled. However engine rpm protections will be active.

Note that the engine controller functionality is compatible with both AMF and Remote Start modes.

When AMF and Engine controller modes are selected, the unit will monitor the mains and will run the engine upon mains failure. This functionality is useful for the backup electric motor driven systems during mains failures, like fire pump or irrigation systems.

When Remote Start and Engine controller modes are selected, the unit will start and stop the engine with external signal only.

The unit features both MPU and J1939 CANBUS inputs. Thus both mechanical and electronic engines are supported.

It is strongly recommended to wire speed detection through MPU or J1939-CANBUS and enter correct low and high rpm limit values in order to preserve engine speed protection.

400HZ OPERATION

The standard unit is also 400Hz enabled. The nominal frequency setting accepts up to 500Hz. Usual low and high limits will apply without any special setting.

The measurement system of the unit allows frequencies up to 1000Hz to be measured precisely.

However the display is limited to 650Hz. Frequencies over 650Hz will be displayed as 650Hz.

The bandwidth of the harmonic analyzer is limited to 1800Hz. Thus in case of a 400Hz system, only the

3 rd

harmonic will be displayed.

The waveform display of a 400Hz signal will be represented with 10 points. It will not be as accurate as

50/60Hz signals.

For more details please read chapter: “Waveform Display & Harmonic Analysis”.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

REMOTE DISPLAY UNIT FUNCTIONALITY

The unit is able to become the remote display and control panel of another identical module.

The connection between two modules is done through RS-485 ports. For the best results, a 120 ohms balanced, low capacitance cable should be used.

The data rate between modules is selectable between 2400 and 115200 bauds.

A high data rate offers better synchronization between modules, but the distance will be limited.

Typically at 115200 bauds and with adequate cable, the distance will be 200m maximum.

At 9600 bauds and adequate cable the distance can go up to 1200m.

Below settings are necessary:

PARAMETER

Annunciator Mode

RS-485 Enable

RS-485 Baud Rate

Modbus Slave Address

MAIN UNIT REMOTE DISPLAY UNIT

0 1

1 any any

1 same as main unit same as main unit

The remote display panel should be powered up with an isolated voltage source, like a wall adapter.

Otherwise damages due to ground potential differences may occur.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

CONNECTION DIAGRAMS

AMF FUNCTIONALITY, CTs AT LOAD SIDE

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

AMF FUNCTIONALITY, CTs AT ALTERNATOR SIDE

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ATS FUNCTIONALITY

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

REMOTE START FUNCTIONALITY

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ENGINE CONTROL FUNCTIONALITY

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

REMOTE DISPLAY PANEL FUNCTIONALITY

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

TERMINAL DESCRIPTION

Term Function

1 BATTERY POSITIVE

2 —

3 BATTERY NEGATIVE

Term Function

4 DIGITAL OUTPUT 1

5 DIGITAL OUTPUT 2

Technical data

+12 or 24VDC

—

O VDC

Technical data

Protected

Semiconductor

Outputs

1A/28VDC

6 DIGITAL OUTPUT 3

7 DIGITAL OUTPUT 4

8 DIGITAL OUTPUT 5

9 DIGITAL OUTPUT 6

10 CHARGE

11 DIGITAL INPUT 1

12 DIGITAL INPUT 2

Input and output

Digital Inputs,

0-30Vdc

Description

The positive terminal of the DC Supply.

Do not connect this terminal.

Power supply negative connection.

Description

This relay has programmable function, selectable from a list. Factory set as

CRANK

output.

This relay has programmable function, selectable from a list. Factory set as FUEL output.

This relay has programmable function, selectable from a list. Factory set as

ALARM

output.

This relay has programmable function, selectable from a list. Factory set as

PREHEAT

output.

This relay has programmable function, selectable from a list. Factory set as STOP output.

This relay has programmable function, selectable from a list. Factory set as IDLE

SPEED

output.

Connect the charge alternator’s D+ terminal to this terminal. This terminal will supply the excitation current and measure the voltage of the charge alternator.

The input has programmable function.

Factory set as LOW OIL PRESSURE

SWITCH

.

The input has programmable function.

Factory set as HIGH TEMP SWITCH.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

Term Function

13 DIGITAL INPUT 3

14 DIGITAL INPUT 4

15 DIGITAL INPUT 5

16 DIGITAL INPUT 6

17 DIGITAL INPUT 7

18 DIGITAL INPUT 8

19 SENDER GROUND

20 ANALOG SENDER 1

(OIL PRESSURE SENDER)

21 ANALOG SENDER 2

(COOLANT TEMP. SENDER)

22 ANALOG SENDER 3

(FUEL LEVEL SENDER)

23 ANALOG SENDER 4

(OIL TEMP SENDER)

Technical data Description

The input has programmable function.

Factory set as EMERGENCY STOP.

The input has programmable function.

Factory set as LOW COOLANT LEVEL

SWITCH

.

The input has programmable function.

Factory set as SPARE INPUT-1.

The input has programmable function.

Factory set as SPARE INPUT-2.

The input has programmable function.

Factory set as SPARE INPUT-3.

The input has programmable function.

Factory set as FORCE OFF MODE.

Ground potential for analog senders.

Connect to the engine body, close to senders.

Connect to the oil pressure sender.

Do not connect the sender to other devices.

Connect to the coolant temperature sender. Do not connect the sender to other devices.

Connect to the fuel level sender.

Do not connect the sender to other devices.

Connect to the oil temperature sender.

Do not connect the sender to other devices.

Term Function

24 PROTECTION GROUND

25 RS-485 B

26 RS-485 A

27 MPU +

28 MPU —

29 PROTECTION GROUND

30 CANBUS-H

31 CANBUS-L

Technical data

Output 0Vdc

Digital communication port

Analog input, 0.5 to

30V-AC

Output 0Vdc

Digital communication port

Description

Connect the protective shield of the RS-

485 cable to this terminal, from one end only.

Connect the A-B data lines of the RS-485 link to these terminals.

Connect the MPU unit to these inputs

Use a twisted cable pair or coaxial cable for best results.

Connect the protective shield of the MPU and CANBUS-J1939 cables to this terminal, from one end only.

Connect the J1939 port of an electronic engine to these terminals.

The 120 ohm terminating resistors are inside the unit. Please do not connect external resistors.

Use a twisted cable pair or coaxial cable for best results.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

Term Function

Technical data Description

51 GENERATOR CONTACTOR

Relay output, 16A-AC This output provides energy to the generator contactor. If the generator phases do not have acceptable voltage or frequency values, the generator contactor will be de-energized. In order to provide extra security, the normally closed contact of the mains contactor should be serially

52

54

56

58

GEN-L1

GEN-L2

GEN-L3

GENERATOR NEUTRAL

Generator phase inputs, 0-300V-AC

Input, 0-300V-AC connected to this output.

Connect the generator phases to these inputs. The generator phase voltages upper and lower limits are programmable.

Neutral terminal for the generator phases.

Term Function

59 CURR_1+

60 CURR_1-

61 CURR_2+

62 CURR_2-

63 CURR_3+

64 CURR_3-

Technical data

Current transformer inputs, 5A-AC

Description

Connect the generator current transformer terminals to these inputs.

Do not connect the same current transformer to other instruments otherwise a unit fault will occur.

Connect each terminal of the transformer to the unit’s related terminal.

Do not use common terminals. Do not use grounding.

Correct polarity of connection is vital.

The rating of the transformers should be identical for each of the 3 phases.

The secondary winding rating shall be 5

Amperes. (ex: 200/5 Amps).

Term Function

65 MAINS NEUTRAL

67 MAINS-L3

Technical data

Input, 0-300V-AC

Mains phase inputs,

0-300V-AC

Description

Neutral terminal for the mains phases.

Connect the mains phases to these inputs.

The mains voltages upper and lower limits are programmable.

69 MAINS-L2

71 MAINS-L1

72 MAINS CONTACTOR

Relay output, 16A-AC This output provides energy to the mains contactor. If the mains phases do not have acceptable voltages, the mains contactor will be de-energized. In order to provide extra security, the normally closed contact of the generator contactor should be serially connected to this output.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

TECHNICAL SPECIFICATIONS

DC Supply Range:

9.0 to 33.0 V-DC.

DC power consumption:

250 mA-DC typical @12V-DC

125 mA-DC typical @24V-DC

500 mA-DC max. @12V-DC

250 mA-DC max. @24V-DC

Alternator voltage:

0 to 330 V-AC (Ph-N), 0 to 570V Ph-Ph

Alternator frequency:

0-500 Hz.

Mains voltage:

0 to 330 V-AC (Ph-N) , 0 to 570V Ph-Ph

Mains frequency:

0-500 Hz.

Current Inputs:

from current transformers. ../5A.

CT Range:

5/5A to 5000/5A

VT Range:

0.1/1 to 6500 / 1

kW Range:

0.1kW to 65000 kW

Accuracy:

Voltage:

Current:

Frequency:

0.5%+1digit

0.5%+1 digit

0.5%+1 digit

1.0%+2digit

Power(kW,kVAr):

Power factor:

0.5 %+1digit

Digital inputs:

input voltage 0 to 36 V-DC.

Analog input range:

0-5000 ohms.

Mains and genset contactor outputs:

[email protected]

DC Outputs:

Protected mosfet semiconductor outputs, rated [email protected]

Cranking dropouts:

survives 0V for 100ms.

Magnetic pickup voltage:

0.5 to 30V-RMS.

Magnetic pickup frequency:

10 to 10000 Hz.

Charge Alternator Excitation:

160mA @12VDC, 80mA @24VDC

Ethernet Port:

10/100 Mbits

USB Device:

USB 2.0 Full speed

USB Host:

USB 2.0 Full speed

RS-485 Port:

selectable baud rate

RS-232 Port:

selectable baud rate

Operating temperature:

-20°C to 70°C (-4 to +158 °F).

Storage temperature:

-40°C to 80°C (-40 to +176°F).

Maximum humidity:

95% non-condensing.

IP Protection:

IP54 from front panel, IP30 from the rear.

Dimensions:

200 x 148 x 46mm (WxHxD)

Panel Cut-out Dimensions:

176 x 121 mm minimum.

Weight:

450 g (approx.)

Case Material:

High Temperature, non-flammable, ROHS compliant ABS/PC

Mounting:

Flush mounted with rear retaining plastic brackets.

EU Directives Conformity

-2006/95/EC (low voltage)

-2004/108/EC (electro-magnetic compatibility)

Norms of reference:

EN 61010 (safety requirements)

EN 61326 (EMC requirements)

UL Compatibility:

UL 508 — Industrial Control Equipment

CSA Compatibility:

CAN/CSA C22.2 No. 14-2005 – Industrial Control Equipment

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

DESCRIPTION OF CONTROLS

FRONT PANEL FUNCTIONALITY

AUTO READY indicator

Graphic LCD screen

Mimic Diagram

(sysem status)

Mains Contactor control in RUN mode

Fault condition indicators

Next screen in the same group.

LAMP TEST if held pressed

Previous display group

TEST mode button

RUN mode button

AUTO mode button

Next display group

Genset

Contactor control in

RUN mode

Previous screen in the same group.

ALARM Mute

STOP mode button

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

PUSHBUTTON FUNCTIONS

BUTTON FUNCTION

Selects TEST mode. The genset runs and takes the load.

Selects RUN mode. The genset runs off-load.

Selects AUTO mode. The genset runs when necessary and takes the load.

Selects OFF mode. The genset stops.

BUTTON FUNCTION

Selects next display screen in the same display group.

LAMP TEST when held pressed.

Selects previous display group.

Selects next display group.

Selects previous display screen in the same display group.

Resets the ALARM RELAY.

Manual MAINS CONTACTOR control in RUN mode.

Manual GENSET CONTACTOR control in RUN mode.

When held pressed for 5 seconds, enters PROGRAMMING mode.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

DISPLAY SCREEN ORGANIZATION

The unit measures a large number of electrical and engine parameters. The display of the parameters is organized as PARAMETER GROUPS and items in a group.

Navigation between different groups are made with and buttons.

Each depression of the button will cause the display to switch to the next group of parameters. After the last group the display will switch to the first group.

Each depression of the button will cause the display to switch to the previous group of parameters.

After the first group the display will switch to the last group.

Navigation inside a groups is made with and buttons.

Each depression of the button will cause the display to switch to the next parameter in the same group. After the last parameter the display will switch to the first parameter.

Each depression of the button will cause the display to switch to the previous parameter in the same group. After the first parameter the display will switch to the last parameter.

Below is a basic list of parameter groups:

Genset Parameters:

Genset voltages, currents, kW, kVA, kVAr, pf etc…

Engine Parameters:

Analog sender readings, rpm, battery voltage, engine hours, etc…

J1939 Parameters:

Opens only if the J1939 port is enabled. The unit is able to display a long list of parameters, under the condition that the engine sends this information. A complete list of available readings is found at chapter J1939 CANBUS ENGINE SUPPORT.

Mains Parameters:

Mains voltages, currents, kW, kVA, kVAr, pf etc… Mains currents and power parameters are displayed only when CT Selection is made as LOAD SIDE. Otherwise mains current and power related parameters will not be displayed.

Synchronization Display:

A graphical synchroscope is displayed. The synchroscope display is updated

10 times a second in order to have smooth sweep.

Scopemeter Display:

This group display waveforms of voltages and currents as an oscilloscope. All Ph-

N and Ph-Ph voltages as well as phase currents are available. This feature is especially useful to investigate waveform distortions and harmonic loads.

Graphical Harmonic Analysis Results:

This group displays harmonic composition of voltages and currents. All Ph-N and Ph-Ph voltages as well as phase currents are available. This feature is especially useful to investigate the harmonic caused by complex loads. Only harmonics above 2% are represented in the graphics because of the display resolution. In order to see all harmonic levels please use the

Alphanumerical Harmonic Analysis Results.

Alphanumerical Harmonic Analysis Results:

This group displays harmonic composition of voltages and currents with 0.1% resolution. All Ph-N and Ph-Ph voltages as well as phase currents are available.

This feature is especially useful to investigate the harmonic caused by complex loads.

Alarm Display:

This group displays all existing alarms, one screen per alarm. When there is no more alarm to display it will show “END OF ALARM LIST”.

GSM Modem Parameters:

Signal strength, counters, communication status, IP addresses etc…

Ethernet Parameters:

Ethernet connection status, counters, IP addresses etc…

Status & Counters Groups:

This group includes various parameters like genset status, service counters, date-time, firmware version etc…

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

AUTOMATIC DISPLAY SCROLL

The unit will automatically scroll all Mains, Genset and Engine measurements with programmable interval. The scroll period setting can be performed using the RainbowPlus program through Module >

Screen

options.

Eventually the same parameter can be modified through the front panel programming menu. The related parameter is Controller Configuration > Screen Scroll Timer.

If the Screen Scroll Timer is set to zero, then scrolling will be disabled.

When a front panel button is pressed, the scrolling is suspended during 2 minutes.

If a fault condition occurs, the display will automatically switch to the ALARM LIST page.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

MEASURED PARAMETERS

The unit performs a detailed set of AC measurements.

Mains currents and power parameters (listed in blue color) are measured and displayed only if CTs are placed at load side. please see connection diagrams section for more details.

The list of measured AC parameters is below:

Mains voltage phase L1 to neutral

Mains voltage phase L2 to neutral

Mains voltage phase L3 to neutral

Mains average voltage phase to neutral

Mains voltage phase L1-L2

Mains voltage phase L2-L3

Mains voltage phase L3-L1

Mains frequency

Mains current phase L1

Mains current phase L2

Mains current phase L3

Mains average current

Mains kW phase L1

Mains kW phase L2

Mains kW phase L3

Mains total kW

Mains kVA phase L1

Mains kVA phase L2

Mains kVA phase L3

Mains kVAr phase L1

Mains kVAr phase L2

Mains kVAr phase L3

Mains pf phase L1

Mains pf phase L2

Mains pf phase L3

Mains total pf

Mains neutral current

Below engine parameters are always measured:

Gen voltage phase L1 to neutral

Gen voltage phase L2 to neutral

Gen voltage phase L3 to neutral

Gen average voltage phase to neutral

Gen voltage phase L1-L2

Gen voltage phase L2-L3

Gen voltage phase L3-L1

Gen frequency

Gen current phase L1

Gen current phase L2

Gen current phase L3

Gen average current

Gen kW phase L1

Gen kW phase L2

Gen kW phase L3

Gen total kW

Gen kVA phase L1

Gen kVA phase L2

Gen kVA phase L3

Gen kVAr phase L1

Gen kVAr phase L2

Gen kVAr phase L3

Gen pf phase L1

Gen pf phase L2

Gen pf phase L3

Gen total pf

Gen Neutral current

Engine speed (rpm)

Battery voltage,

The unit features 4 analog senders, fully configurable for the name and function.

Below is a typical list of analog senders, capable of changing following configuration:

Coolant temperature

Oil pressure (bar, kPa)

Fuel level (%, lt)

Oil temperature (°C, °F)

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

LED LAMPS

AUTO READY indicator

Shutdown alarm indicator

Warning indicator

Service request indicator

TEST mode indicator

RUN mode indicator

AUTO mode indicator

Mains available led

Mains

Contactor

On led

Genset

Contactor on led

Genset available led

STOP mode indicator

STATUS LEDS:

AUTO READY

: Turns on when the AUTO mode is selected and there is no condition preventing engine start.

ALARM:

Turns on when a shutdown alarm or loaddump condition exists.

WARNING:

Turns on when a warning condition exists

SERVICE REQUEST:

Turns on when at least one of the service counters has expired.

MODE LEDS:

Each led turns on when the related mode is selected, either locally or remotely.

MIMIC DIAGRAM LEDS:

MAINS AVAILABLE:

This led turns on when all mains phase voltages and the mains frequency are within limits. If enabled, the mains phase rotation order must be also right. When any digital input is defined as Remote Start, this led will reflect the status of the input. When a Simulate

Mains signal is present, then mains status will become “available”. When a Force to Start signal is present, then the mains status will become “not available”.

MAINS CONTACTOR ON:

Turns on when the mains contactor is activated.

GENSET CONTACTOR ON:

Turns on when the genset contactor is activated.

GENSET AVAILABLE:

This led turns on when all genset phase voltages and the genset frequency are within limits. If enabled, the genset phase rotation order must be also right.

If a Remote Start input is defined, then the Mains led will reflect the input status.

Simulate Mains and Force to Start signals will also affect this led.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

WAVEFORM DISPLAY & HARMONIC ANALYSIS

The unit features waveform display together with a precision harmonic analyzer for both mains and genset voltages and currents. Both phase to neutral and phase to phase voltages are available for analysis, thus 18 channels in total are possible.

In order to enable display and analysis of mains currents, current transformers must be placed at load side.

Available channels are:

Mains volts: V1, V2, V3, U12, U23, U31

Mains currents: I1, I2, I3

Genset volts: V1, V2, V3, U12, U23, U31

Genset currents: I1, I2, I3

Scopemeter Display

The waveform display memory is of 100 samples length and 13 bit resolution, with a sampling rate of

4096 s/s. Thus one cycle of a a 50Hz signal is represented with 82 points. The vertical scale is automatically adjusted in order to avoid clipping of the signal.

The waveform is displayed on the device screen, and with more resolution on PC screen through the

RainbowPlus program.

The display memory is also available in the Modbus register area for third party applications. For more details please check chapter “MODBUS Communications”.

The waveform display is updated twice a second. All channels may be scrolled using buttons.

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The harmonic analyzer consists on a Fast Fourier Transform (FFT) algorithm which is run twice a second on the selected channel.

The sample memory is 1024 samples length and 13 bits resolution with a sampling rate of 4096 s/s.

The theory says that a periodic signal may have only odd multiples of the main frequency. Thus in a 50Hz network, harmonics will be found only at 150, 250, 350, 450 Hz etc…

The unit is able to analyze up to 1800Hz and up to 31th harmonic, whichever is smaller. Thus in a 50Hz system all 31 harmonics will be displayed, but in a 60Hz system only 29 harmonics will come to the screen.

In case of a 400Hz system, only the 3 rd

harmonic will be displayed.

Graphical Harmonic Table Alphanumeric Harmonics Table

Harmonic are represented by 2 different ways on the device display. The first one is a graphical representation allowing one sight perception of the harmonic structure. Because of the display resolution, only harmonics above 2% are displayed.

The second display is alphanumeric, thus all harmonics are displayed with 0.1% resolution in order to provide more detailed information.

On RainbowPlus program, harmonics and waveform are displayed on a single screen with more resolution.

RainbowPlus Scada section: Harmonic Analysis and Waveform Display

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

DISPLAYING EVENT LOGS

The unit features more than 400 event logs with date-time stamp and full snapshot of measured values at the moment that the event has occurred.

Stored values in an event record are listed below:

-event number

-event type / fault definition (see below for various event sources)

-date and time

-operation mode

-operation status (on-load, on-mains, cranking, etc…)

-mains phase voltages: L1-L2-L3

-mains frequency

-genset phase voltages: L1-L2-L3

-genset phase currents: L1-L2-L3

-genset frequency

-genset total active power (kW)

-genset total power factor

-oil pressure

-engine temperature

-fuel level

-oil temperature

-canopy temperature

-ambient temperature

-engine rpm

-battery voltage

-charge voltage

Possible event sources are various. Every source can be individually enabled or disabled:

Event enable selection tab

Periodic event:

recorded every 30 minutes when the engine is running, and every 60 minutes anyway.

Mode change event:

recorded when the operation mode is changed.

Mains fail event:

recorded when mains status is changed to fail

Mains restore event:

recorded when mains is restored.

Shutdown alarm event:

recorded when a shutdown alarm occurs.

Loaddump alarm event:

recorded when a loaddump alarm occurs.

Warning event:

recorded when a warning occurs.

Program mode entrance event:

recorded when program mode is entered. The password level is also saved.

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Event logs are displayed within the program mode menu. This is designed in order to reduce the interference of event logs with other measurement screens.

To enter the event display, press together and buttons for 5 seconds.

When the program mode is entered, below password entry screen will be displayed.

Press 2 buttons for 5 seconds

Skip the password entry screen by pressing the button 4 times. The screen below left will come.

Press again the button. The last stored event will open, as in the below-right picture.

The first page will display the event number, event type, fault type and date-time information.

When displaying event logs: button will display the next information in the same event

button will display the previous information in the same event

button will display the same information of the previous event

button will display the same information of the next event.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

STATISTICAL COUNTERS

The unit provides a set of non resettable incremental counters for statistical purposes.

The counters consist on:

-total genset kWh

-total genset kVArh inductive

-total genset kVArh capacitive

-total engine hours

-total engine starts

-engine hours to service-1

-time to service-1

-engine hours to service-2

-time to service-2

-engine hours to service-3

-time to service-3

These counters are kept in a non-volatile memory and are not affected from power failures.

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OPERATION OF THE UNIT

QUICK START GUIDE

STOPPING THE ENGINE:

Press STOP button

STARTING THE ENGINE:

Press RUN button

MANUAL LOAD TRANSFER:

Use MAINS and GENSET

LOAD TEST:

Press TEST

buttons. button. The genset will run and take the load.

AUTOMATIC OPERATION:

Press AUTO button. Check that AUTO READY led is illuminated.

Mode can be changed anytime without negative effect.

Changing the operation mode while the genset is running will result into a behavior suitable for the new operating mode.

STOP MODE

The STOP mode is entered by pressing the

In this mode, the genset will be in a rest state.

button.

When STOP mode is selected, if the genset is running under load, then it will be immediately unloaded. The engine will continue to run during Cooldown Timer and will stop afterwards.

If the STOP button is pressed again, then the engine will immediately stop.

If the engine fails to stop after the expiration of Stop Timer then a Fail to Stop warning will occur.

In this mode, the mains contactor will be energized only if mains phase voltages and frequency are within the programmed limits. If enabled, the mains phase order is also checked.

If a Remote Start or Force to Start signal arrives in STOP mode, the genset will not start until AUTO mode is selected.

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AUTO MODE

The AUTO mode is entered by pressing the button.

The AUTO mode is used for the automatic transfer between genset and mains. The controller will constantly monitor the mains availability. It will run the engine and transfer the load when a mains failure occurs.

If a panel lock input is defined and signal is applied, then mode change will not occur. However display navigation buttons are still enabled and parameters may be visualized.

The mains availability evaluation sequence is below:

 If at least one of the mains phase voltages or the mains frequency is outside limits, the mains will be supposed failing. Otherwise mains is available.

 If a Simulate Mains signal is present, then mains are made available

 If a Force to Start signal is present, then mains are unavailable

 If a Remote Start input is defined, then this signal decides of mains availability.

When mains are evaluated as “unavailable” then an engine start sequence begins:

 The unit waits during Engine Start Delay for skipping short mains failures. If the mains is restored before the end of this timer, the genset will not start.

 The unit turns on the fuel and preheat glow plugs (if any) and waits for preheat timer.

 The engine will be cranked for programmed times during crank timer. When the engine fires, the crank relay will be immediately deactivated. See section Crank Cutting for more details.

 The engine will run at idle speed during Idle Speed Timer.

 The engine will run unloaded during engine heating timer.

 If alternator phase voltages, frequency and phase order are correct, the unit will wait for the generator contactor period and the generator contactor will be energized.

When mains are evaluated as “available” again then an engine stop sequence begins:

 The engine will continue to run for the mains waiting period to allow mains voltages to stabilize.

 Then the generator contactor is deactivated and the mains contactor will be energized after mains contactor timer.

 If a cooldown period is given, the generator will continue to run during the cooldown period.

 Before the end of cooldown, the unit will reduce the engine speed to idle speed.

 At the end of cooldown, the fuel solenoid will be de-energized, the stop solenoid will be energized for

Stop Solenoid timer and the diesel will stop.

 The unit will be ready for the next mains failure.

If the operation of the genset is disabled by the weekly schedule, then the AUTO led will flash, and the operation of the genset will be as in the OFF mode.

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RUN MODE, MANUAL CONTROL

The RUN mode is entered by pressing the button.

When the RUN mode is selected, the engine will be started regardless of the mains availability.

The starting sequence is as described below:

 The unit turns on the fuel and preheat glow plugs (if any) and waits for preheat timer.

 The engine will be cranked for programmed times during crank timer. When the engine fires, the crank relay will be immediately deactivated. See section Crank Cutting for more details.

 The engine will run at idle speed during Idle Speed Timer.

 The engine will run unloaded until another mode is selected..

The RUN mode allows also manual contactor control through MC and GC buttons.

When a contactor button is pressed, the related contactor will change position. Thus if it was on, then it will turn off. If it was off then it will turn on.

If the other contactor was on, then it will turn off, the controller will wait for the related contactor timer and the contactor will turn on. This will prevent manual closure of both contactors.

If uninterrupted transfers are allowed, then the unit will check the synchronization. If synchronization is complete, then it will make an uninterrupted transfer, where both contactors will be on for a short while.

If Emergency Backup mode is enabled and if the mains are off, then the mains contactor will be deactivated and the generator contactor will be activated.

When the mains are on again, a reverse changeover to the mains will be performed, but the engine will be kept running unless another mode is selected.

In order to stop the engine press button or select another mode of operation.

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TEST MODE

The TEST mode is entered by pressing the button.

The TEST mode is used in order to test the genset under load.

Once this mode is selected, the engine will run as described in the AUTO mode, regardless of the mains availability and the load will be transferred to the genset.

The genset will feed the load indefinitely unless another mode is selected.

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PROTECTIONS AND ALARMS

The unit provides 3 different protection levels, being warnings, loaddumps and shutdown alarms.

1- SHUTDOWN ALARMS: These are the most important fault conditions and cause:

—

The ALARM led to turn on steadily,

—

The genset contactor to be released immediately,

—

The engine to be stopped immediately,

—

The Alarm digital output to operate.

2- LOAD_DUMPS: These fault conditions come from electrical trips and cause:

—

The ALARM led to turn on steadily,

—

The genset contactor to be released immediately,

—

The engine to be stopped after Cooldown period,

—

The Alarm digital output to operate.

3- WARNINGS: These conditions cause:

—

The WARNING led to turn on steadily,

—

The Alarm digital output to operate.

If a fault condition occurs, the display will automatically switch to the ALARM LIST page.

Alarms operate in a first occurring basis:

-If a shutdown alarm is present, following shutdown alarms, loaddumps and warnings will not be accepted,

-If a loaddump is present, following loaddumps and warnings will not be accepted,

-If a warning is present, following warnings will not be accepted.

If the ALARM MUTE button is pressed, the Alarm output will be deactivated; however the existing alarms will persist and disable the operation of the genset.

Alarms may be of LATCHING type following programming.

For latching alarms, even if the alarm condition is removed, the alarms will stay on and disable the operation of the genset.

Existing alarms may be canceled by pressing one of the operating mode buttons:

Most of the alarms have programmable trip levels. See the programming chapter for adjustable alarm limits.

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DISABLING ALL PROTECTIONS

The unit allows any digital input to be configured as “Disable Protections”.

This input configuration is used in cases where the engine is required to run until destruction. This may be the case under critical conditions like fire fighting or other emergency cases.

This input should be configured as a “Warning”. Thus when protections are disabled

, a warning message will immediately appear on the screen.

When protections are disabled, all shutdown alarms and loaddumps will become warnings. They will appear on the screen, but will not affect genset operation.

The input may be constantly activated, or preferably it may be activated by an external key activated switch in order to prevent unauthorized activation.

Disabling protections will allow the genset run until destruction.

Place written warnings about this situation in the genset room.

SERVICE REQUEST ALARM

The SERVICE REQUEST led is designed to help the periodic maintenance of the genset to be made consistently.

The periodic maintenance is basically carried out after a given engine hours (for example 200 hours), but even if this amount of engine hours is not fulfilled, it is performed after a given time limit (for example 12 months).

The unit offers 3 independent service counter sets in order to enable different service periods with different priorities.

The fault level created upon expiration of service timers may be set as Warning, Loaddump or Shutdown.

Thus different levels of fault conditions may be generated at different overrun levels.

Each service counter set has both programmable engine hours and maintenance time limit. If any of the programmed values is zero, this means that the parameter will not be used. For example a maintenance period of 0 months indicates that the unit will request maintenance only based on engine hours, there will be no time limit. If the engine hours is also selected as 0 hours this will mean that this service counter set is not operative.

When the engine hours OR the time limit is over, the SERVICE REQUEST led (red) will start to flash and the service request output function will be active. The service request can also create a fault condition of any level following parameter setting.

The service request output function may be assigned to any digital output using Relay Definition program parameters. Also relays on an extension module may be assigned to this function.

To turn off the SERVICE REQUEST led, and reset the service period, press together the ALARM MUTE and LAMP TEST keys for

5 seconds.

The remaining engine hours and the remaining time limits are kept stored in a non-volatile memory and are not affected from power supply failures.

The time and engine hours to service are displayed in the GENSET STATUS menu group.

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SHUTDOWN ALARMS

Digital input and analog sender alarms are fully programmable for the alarm name, sampling and action.

Only internal alarms are explained in this section.

GENSET LOW / HIGH

FREQUENCY

Set if the generator frequency is outside programmed limits. These faults will be monitored with Fault Holdoff Timer delay after the engine is running.

Low and high limits are separately programmable. The detection delay is also programmable. Another high frequency shutdown limit which is 12% above the high limit is always monitored and stops the engine immediately.

GENSET LOW / HIGH

RPM

GENSET LOW / HIGH

VOLTAGE

LOW / HIGH BATTERY

VOLTAGE

Set if the generator rpm is outside programmed limits. These faults will be monitored with Fault Holdoff Timer delay after the engine is running. Low and high limits are separately programmable. The detection delay is also programmable. The high rpm overshoot limit is always monitored and stops the engine immediately.

Set if any of the generator phase voltages goes outside programmed limits for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running.

Set if the genset battery voltage is outside programmed limits. Low and high limits are separately programmable. The detection delay is also programmable.

FAIL TO START

Set if the engine is not running after programmed number of start attempts.

LOW CHARGE VOLTAGE

Set if the charge alternator voltage is below the programmed limit. This fault will be monitored with Fault Holdoff Timer delay after the engine is running.

J1939 ECU FAIL

Set if no information has been received during 3 seconds from the ECU of the electronic engine. This fault condition is only controlled when fuel is on.

VOLTAGE UNBALANCE

Set if any of the generator phase voltages differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running.

CURRENT UNBALANCE

Set if any of the generator phase currents differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running. The action taken at fault condition is programmable.

OVERCURRENT

PICKUP SIGNAL LOST

SERVICE REQUEST

Set if at least one of the genset phase currents goes over the Overcurrent

Limit

for the period allowed by the IDMT curve setting. The allowed timer is dependent of the overcurrent level. If currents go below the limit before expiration of the timer then no alarm will be set. Please check chapter

Overcurrent Protection (IDMT) for more details. The action taken at fault condition is programmable.

Set if the rpm measured from the magnetic pickup input falls below the

Crank Cut RPM

level during Loss of Speed Signal Timer. The action of signal loss is programmable.

Set if at least one of the service counters has expired. In order to reset the service counters please hold pressed both with and buttons during 5 seconds. The screen will display “Completed!”

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

LOADDUMP ALARMS

Digital input and analog sender alarms are fully programmable for the alarm name, sampling and action.

Only internal alarms are explained in this section.

VOLTAGE UNBALANCE

Set if any of the generator phase voltages differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running.

CURRENT UNBALANCE

Set if any of the generator phase currents differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running. The action taken at fault condition is programmable.

OVERCURRENT

OVERLOAD

REVERSE POWER

REVERSE POWER

GENSET PHASE ORDER

FAIL

MAINS CB FAIL TO

OPEN

PICKUP SIGNAL LOST

SERVICE REQUEST

Set if at least one of the genset phase currents goes over the Overcurrent

Limit

for the period allowed by the IDMT curve setting. The allowed timer is dependent of the overcurrent level. If currents go below the limit before expiration of the timer then no alarm will be set. Please check chapter

Overcurrent Protection (IDMT) for more details. The action taken at fault condition is programmable.

Set if the genset power (kW) supplied to the load goes over the Overload

Load Dump

limit for Overload Timer. If the power goes below the limit before expiration of the timer then no alarm will be set.

Set if the genset power (kW) is negative and goes over the Reverse Power limit for Reverse Power Timer. If the power goes below the limit before expiration of the timer then no alarm will be set.

Set if the genset power (kW) is negative and goes over the Reverse Power limit for Reverse Power Timer. If the power goes below the limit before expiration of the timer then no alarm will be set.

Set if the fault is enabled and the genset phase order is reverse.

Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor

Open/Close Fail Timer.

Set if the rpm measured from the magnetic pickup input falls below the

Crank Cut RPM

level during Loss of Speed Signal Timer. The action of signal loss is programmable.

Set if at least one of the service counters has expired. In order to reset the service counters please hold pressed both with and buttons during

5 seconds. The screen will display “Completed!”

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WARNINGS

Digital input and analog sender alarms are fully programmable for the alarm name, sampling and action.

Only internal alarms are explained in this section.

All warnings can be made latching by enabling a single program parameter: Controller Configuration >Latch All Warnings

Latch All Warnings

GENSET LOW / HIGH

FREQUENCY

GENSET LOW / HIGH

RPM

GENSET LOW / HIGH

VOLTAGE

LOW / HIGH BATTERY

VOLTAGE

FAIL TO STOP

Set if the generator frequency is outside programmed limits. These faults will be monitored with Fault Holdoff Timer delay after the engine is running.

Low and high limits are separately programmable. The detection delay is also programmable. Another high frequency shutdown limit which is 12% above the high limit is always monitored and stops the engine immediately.

Set if the generator rpm is outside programmed limits. These faults will be monitored with Fault Holdoff Timer delay after the engine is running. Low and high limits are separately programmable. The detection delay is also programmable. The high rpm overshoot limit is always monitored and stops the engine immediately.

Set if any of the generator phase voltages goes outside programmed limits for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running.

Set if the genset battery voltage is outside programmed limits. Low and high limits are separately programmable. The detection delay is also programmable.

Set if the engine has not stopped before the expiration of the Stop Timer.

LOW CHARGE VOLTAGE

Set if the charge alternator voltage is below the programmed limit. This fault will be monitored with Fault Holdoff Timer delay after the engine is running.

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J1939 ECU FAIL

Set when an engine fault code is received from the ECU of the electronic engine. This fault will not cause an engine stop. If necessary, the engine will be stopped by the ECU.

VOLTAGE UNBALANCE

Set if any of the generator phase voltages differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running.

CURRENT UNBALANCE

Set if any of the generator phase currents differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running. The action taken at fault condition is programmable.

OVERCURRENT

Set if at least one of the genset phase currents goes over the Overcurrent

Limit

for the period allowed by the IDMT curve setting. The allowed timer is dependent of the overcurrent level. If currents go below the limit before expiration of the timer then no alarm will be set. Please check chapter

Overcurrent Protection (IDMT) for more details. The action taken at fault condition is programmable.

OVERCURRENT

REVERSE POWER

Set if at least one of the genset phase currents goes over the Overcurrent

Limit

.

Set if the genset power (kW) is negative and goes over the Reverse Power limit for Reverse Power Timer. If the power goes below the limit before expiration of the timer then no alarm will be set.

MAINS PHASE ORDER

FAIL

Set if the mains phase order checking is enabled, mains phases are present and mains phase order is reversed. This fault prevents the Mains Contactor to close.

GENSET CB FAIL TO

CLOSE / OPEN

MAINS CB FAIL TO

CLOSE

SYNCHRONIZATION

FAIL

PICKUP SIGNAL LOST

SERVICE REQUEST

Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor

Open/Close Fail Timer.

Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor

Open/Close Fail Timer.

Set if the uninterrupted transfer is enabled and voltage, frequency and phase matching is not found before the expiration of the Synchronization

Fail Timer

Set if the rpm measured from the magnetic pickup input falls below the

Crank Cut RPM

level during Loss of Speed Signal Timer. The action of signal loss is programmable.

Set if at least one of the service counters has expired. In order to reset the service counters please hold pressed both with and buttons during

5 seconds. The screen will display “Completed!”

K35D01-EN — 72 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

PROGRAMMING

RESETTING TO FACTORY DEFAULTS

In order to resume to the factory set parameter values:

-hold pressed the OFF, LAMP TEST and ALARM MUTE buttons for 5 seconds,

-“RETURN TO FACTORY SET” will be displayed

-immediately press and hold pressed the ALARM MUTE button for 5 seconds

-factory set values will be reprogrammed to the parameter memory.

Hold pressed OFF, LAMP TEST and ALARM MUTE

Hold pressed ALARM MUTE

K35D01-EN — 73 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

The program mode is used to adjust timers, operational limits and the configuration of the unit.

Although a free PC program is provided for programming, every parameter may be modified through the front panel, regardless of the operating mode.

When modified, program parameters are automatically recorded into a non-erasable memory and take effect immediately.

The program mode will not affect the operation of the unit. Thus programs may be modified anytime, even while the genset is running.

ENTERING THE PROGRAMMING MODE

To enter the program mode, press together

◄

MENU

and MENU

►

buttons for 5 seconds.

When the program mode is entered, below password entry screen will be displayed.

Press 2 buttons for 5 seconds

A 4 digit password must be entered using

▼, ▲

, MENU

►

and

◄

MENU

buttons.

The

▼, ▲ buttons modify the value of the current digit. The MENU between digits.

►, ◄

MENU

buttons navigate

The unit supports 3 password levels. The level_1 is designed for field adjustable parameters. The level_2 is designed for factory adjustable parameters. The level_3 is reserved. It allows recalibration of the unit.

The password level-1 is factory set to ‘1234’ and the password level-2 is factory set to ‘9876’.

Passwords are not front panel adjustable.

If a wrong password is entered, the unit will still allow access to the program parameters, but in read-only mode.

If password “0000” is entered, only EVENT LOG file will be available.

K35D01-EN — 74 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

NAVIGATING BETWEEN MENUS

The program mode is driven with a two level menu system. The top menu consists on program groups and each group consists on various program parameters.

When program mode is entered, a list of available groups will be displayed. Navigation between different groups are made with order to enter inside a group, please press MENU please press

▼ and

◄

MENU

button.

▲ buttons. Selected group is shown in reverse video (blue on white). In

►

button. In order to exit from the group to the main list

If inside the group then exit to main

PGM menu

Enter inside the group

Next group

Previous group value of this parameter, please press MENU with

▼ and

▲ buttons. A list of available parameters will be displayed. Selected parameter is shown in reverse video (blue on white). In order display/change the

▼

Navigation inside a group is made also with and

▲

►

button. Parameter value may be increased and decreased buttons. If these keys are hold pressed, the program value will be increased/decreased by steps of 10. When a program parameter is modified, it is automatically saved in memory. If

MENU

►

button is pressed, next parameter will be displayed. If

◄

MENU

button is pressed, then the list of parameters in this group will be displayed.

Return to the main menu

Edit parameter value

Next parameter inside the same group

Previous parameter inside the same group

K35D01-EN — 75 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

MODIFYING PARAMETER VALUE

Decrease parameter value

Increase parameter value

Previous parameter

Long Press:

Return to the upper menu

Next parameter

PROGRAMMING MODE EXIT

To exit the program mode press one of the mode selection keys. If no button is pressed during 2 minutes the program mode will be cancelled automatically.

Press any mode button

K35D01-EN — 76 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

PROGRAM PARAMETER LIST

CONTROLLER CONFIGURATION GROUP

Parameter Definition Unit Min Max Factory

Set

LCD Contrast

Screen Scroll Timer

Language

Genset Default Display

Status Prompt Window

Enable

Fault Holdoff Timer

Alarm Relay Timer

Intermittent Alarm Relay

Emergency Backup

Operation

Exerciser Enable

Exercise Period

Exercise Off/On Load

— sec

—

—

— sec sec

—

—

—

—

—

30

0

0

0

0

0

0

0

0

0

0

0

50

250

1

4

1

120

120

1

1

1

1

1

39

0

0

0

0

12

60

0

0

0

0

1

Description

This parameter is used to set LCD contrast. Adjust for the best viewing angle.

The screen will scroll between different measurements with this interval. If set to zero, the screen scroll will be disabled.

0:

English language selected.

1:

Local language selected. This language may depend on the country where the unit is intended to be used.

This parameter selects the screen which is displayed during genset on load operation.

0:

genset voltages table

1:

genset currents and freq. table

2:

genset kW and pf table

3:

genset kVA and kVAr table

4:

genset average measurements

0:

Status prompts disabled

1:

Status prompts enabled

This parameter defines the delay after the engine runs and before the fault monitoring is enabled.

This is the period during which the

ALARM

relay is active. If the period is set to 0, this will mean that the period is unlimited.

0:

continuous

1:

intermittent (turns on and off every second)

0:

In RUN mode, the load will not be transferred to the genset even if the mains fails.

1:

In RUN mode, the load will be transferred to the genset if the mains fails.

0:

automatic exerciser disabled

1:

automatic exerciser enabled

0:

exercise once per week

1:

exercise once per month

The exact exerciser day and time is adjusted within the EXERCISE

SCHEDULE section.

0:

Exercise at RUN mode

1:

Exercise at TEST mode

K35D01-EN — 77 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

CONTROLLER CONFIGURATION GROUP (continued)

Parameter Definition Unit Min Max Factory

Set

Delayed Simulate Mains

Modem Selection

External Modem Baud

Rate

GSM Sim Card Pin

SMS Enable

GPRS Connection

Enable

Web Programming

Enable

Web Control Enable

Web Refresh Rate

Ping Period

Ping Period

Rainbow Refresh Rate

Rainbow Address-1 Port

Rainbow Address-2 Port

Web Server Port

Modbus TCP/IP Port

SMTP Port

Ethernet to RS-485

Modbus Gateway Enable

GPRS to RS-485

Modbus Gateway Enable

Description

—

—

0

0

1

4

0

0

0:

delayed simulate mains disabled

1:

delayed simulate mains enabled

0:

not used

1:

Internal GSM modem

2:

external GSM Datakom modem

3:

external GSM generic modem

4:

external PSTN (land) modem bps 2400 115200 115200 This is the data rate for accessing the

— 0000 9999 0

If the GSM SIM card uses pin number, enter the pin number here. If incorrect

—

—

—

— sec sec min sec

—

—

—

—

—

—

—

0

0

0

0

0

30

0

0

0

0

0

0

0

0

0

1

1

1

1

240

900

240

65535

65535

65535

65535

65535

65535

1

1

0

0

0

0

5

120

0

5

0

0

80

502

587

0

0 pin number is entered, then the SIM card will not operate.

0:

SMS messages disabled

1:

SMS messages enabled

0:

GPRS disabled

1:

GPRS enabled

0:

Web programming disabled

1:

Web programming enabled

0:

Web control disabled

1:

Web control enabled

The unit will refresh the web page with this interval.

The unit will check the availability of the internet connection with this interval.

The unit will check the availability of the internet connection with this interval.

The unit will update the distant monitoring terminal with this rate.

This is the port number of the first monitoring terminal address.

This is the port number of the second monitoring terminal address.

This is the port number of the internal web server. The unit will answer queries to this port only.

Internal Modbus TCP/IP server’s port number. The unit answers Modbus requests to this port only.

This is the port number used for e-mail sending.

0:

ethernet-modbus gateway function disabled.

1:

ethernet-modbus gateway function enabled. The unit will redirect Modbus requests from ethernet to the RS-485 port.

0:

gprs-modbus gateway function disabled.

1:

gprs-modbus gateway function enabled. The unit will redirect Modbus requests from GPRS to the RS-485 port.

K35D01-EN — 78 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

CONTROLLER CONFIGURATION GROUP (continued)

Parameter Definition

RS-485 Enable

Modbus Address

Unit

—

—

Min Max Factory

0

0

1

255

1

1

Description

0:

RS-485 port disabled

1:

RS-485 port enabled

This is the modbus controller identity used in Modbus communication.

RS-485 Baud Rate

Ethernet Enable

Oil Pressure Switch

Priority

Flashing Relay OFF

Timer

RPM from genset frequency bps 2400 115200 9600 This is the data rate of the RS-485

— 0 1 1

0:

ethernet port disabled

1:

ethernet port enabled

—

Flashing Relay ON Timer min

Real Time Clock Adjust

Hysteresis Voltage

Engine Control Only

Alternator Pole Pairs

Crank Teeth Count

Secondary Volt/Freq min

—

V-AC

—

—

—

—

—

0

0

0

0

0

0

1

0

1

0

1

1200

1200

255

30

1

8

1

244

1

0

0

0

117

8

0

2

1

30

0

0:

crank cut is performed through oil pressure switch and oil pressure sender reading

1:

crank cut is performed only through oil pressure switch

Delayed Simulate Mains Operation:

max genset running time after Simulate

Mains signal disappears.

Dual Genset Systems:

flashing relay

ON state duration timer.

Dual Genset Systems:

flashing relay

OFF state duration.

This parameter trims precisely the real time clock circuit. Values from 0 to 63 speed up the clock with 0.25sec/day steps. Values from 127 to 64 slow down the clock with 0.25sec/day steps.

This parameter provides the mains and genset voltage limits with a hysteresis feature in order to prevent faulty decisions.

For example, when the mains are present, the mains voltage low limit will be used as the programmed low limit.

When the mains fail, the low limit will be incremented by this value. It is advised to set this value to 8 volts.

0:

Genset control

1:

Engine control (no alternator)

This parameter is used for frquency to rpm conversion. For a 1500/1800 rpm engine select 2. For a 3000/3600 rpm engine select 1.

0: read rpm from the MPU input

1: convert frequency to rpm (using

Alternator Pole Pairs)

This is the number of pulses generated by the magnetic pickup sensing unit in one turn of the flywheel.

0:

Use primary volt/frequency limits

1:

Use secondary volt/frequency limits

K35D01-EN — 79 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

CONTROLLER CONFIGURATION GROUP (continued)

Parameter Definition Unit Min Max Factory

Set

SMS on Mains Change

SMS on IP Change

E-mail on IP Change

Fuel Pump Low Limit

Fuel Pump High Limit

Warning Before Start

Latch all Warnings

Remote Control Enable

Annunciator Mode

CT Location

Reverse CT Direction

—

—

—

%

%

—

—

—

—

—

—

0

0

0

0

0

0

0

0

0

Gen

0

1

1

1

100

100

1

1

1

1

Load

1

0

0

0

20

80

1

0

1

0

Gen

0

Description

This parameter controls SMS sending when mains voltages status is changed.

No warnings generated.

0:

no SMS on mains failed or restored

1:

SMS sent on mains failed or restored

This parameter controls SMS sending when IP address of GPRS connection is changed. No warnings generated.

0:

no SMS on IP change

1:

SMS sent on IP change

This parameter controls e-mail sending when IP address of GPRS or ethernet connection is changed. No warnings generated.

0:

no e-mail on IP change

1:

e-mail sent on IP change

If the fuel level measured from the sender input falls below this level, then the FUEL PUMP function will become active.

If the fuel level measured from the sender input goes above this level, then the FUEL PUMP function will become passive.

This parameter controls the activation of the ALARM output during “Engine Start

Delay” timer before en gine run.

0:

no warning before start

1:

warning before start

0:

warnings are latching/non-latching on parameter control

1:

all warnings are latched. Even if the fault source is removed, warnings will persist until manually reset.

This parameter controls remote control of the unit through Rainbow, Modbus and Modbus-IP.

0:

remote control disabled

1:

remote control enabled

0:

normal operation

1:

the unit becomes an annunciator of the remote unit. Engine/genset control functions are disabled.

0:

CTs are at the genset side. Mains currents are not measured.

1:

CTs are at load side. Both mains and genset currents are monitored following contactor status.

This parameter is useful to invert all CT polarities at the same time.

0:

normal CT polarity assumed.

1:

reverse CT polarity assumed.

K35D01-EN — 80 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

CONTROLLER CONFIGURATION GROUP (continued)

Parameter Definition

Buzzer Enable

Unit Functionality

Unit

—

—

Min Max Factory

Description

0

0

1

3

1

AMF

Internal buzzer control (not functional in

509T)

0:

buzzer disabled

1:

buzzer enabled

0:

AMF functionality. The unit controls both engine and load transfer. The genset starts based on mains status.

1:

ATS functionality. The unit controls the load transfer and issues genset start signal based on mains status.

2:

REMOTE START functionality. The unit controls engine and alternator. The genset starts with external signal.

3:

RESERVED. Not used.

K35D01-EN — 81 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ELECTRICAL PARAMETERS GROUP

Parameter Definition Unit Min Max Factory

Set

Current Transformer

Primary

Voltage Transformer

Ratio

Nominal Voltage

Nominal Frequency

Nominal Voltage-2

Nominal Frequency-2

Mains Voltage Low Limit

Mains Voltage High Limit

Mains Voltage Fail Timer

Instant Mains Dropout

Amp

—

V-AC

Hz

V-AC

Hz

%

% sec

%

1

0

0

0

0

0

0

0

5000

5000

300

500

300

500

500

1.0

230

50

120

60

V-100 V+100 V-20%

V-100 V+100 V+20%

10

50

1

0

Description

This is the rated value of current transformers. All transformers must have the same rating. The secondary of the transformer will be 5 Amps.

This is the voltage transformer ratio.

This value will multiply all voltage and power readings. If transformers are not used, the ratio should be set to 1.0

The nominal value of genset and mains voltages. Voltage limits are defined by reference to this value.

The nominal value of genset and mains frequency. Frequency limits are defined by reference to this value.

When secondary voltage is selected, this is the nominal value of genset and mains voltages. Voltage limits are defined by reference to this value.

When secondary frequency is selected, this is nominal value of genset and mains frequency. Frequency limits are defined by reference to this value.

If one of the mains phases goes under this limit, it means that the mains are off and starts the transfer to the genset in

AUTO

mode. The value is defined with reference to Nominal Voltage.

If one of the mains phases goes over this limit, it means that the mains are off and starts the transfer to the genset in

AUTO

mode. The value is defined with reference to Nominal Voltage.

If at least one of the mains phase voltages goes outside of the limits during this timer, it means that the mains are off and it starts the transfer to the genset in AUTO mode.

If the mains phase voltages are outside limits, but not more than this parameter

(with reference to nominal voltage), then the genset will run without releasing the mains contactor. When the genset is ready to take the load, the load will be transferred.

If this parameter is set to zero then the mains contactor is immediately released at mains failure.

K35D01-EN — 82 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ELECTRICAL PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory

Set

Mains Frequency Low

Limit

Mains Frequency High

Limit

Mains Frequency Fail

Timer

Genset Low Voltage

Warning Limit

Genset Low Voltage

Shutdown Limit

Genset High Voltage

Warning Limit

Genset High Voltage

Shutdown Limit

Genset Voltage Fail

Timer

Genset Low Frequency

Warning Limit

Genset Low Frequency

Shutdown Limit

%

% sec

%

%

%

% sec

%

%

F-100 F+100 F-10%

F-100 F+100 F+10%

0

0

10

10

1

V-100 V+100 V-15%

V-100 V+100 V-20%

V-100 V+100 V+15%

V-100 V+100 V+20%

1

F-100 F+100 V-15%

F-100 F+100 F-20%

Description

If the mains frequency goes under this limit, it means that the mains are off and starts the transfer to the genset in

AUTO

mode. The value is defined with reference to Nominal Frequency.

If the mains frequency goes over this limit, it means that the mains are off and starts the transfer to the genset in

AUTO

mode. The value is defined with reference to Nominal Frequency.

If the mains frequency goes outside of the limits during this timer, it means that the mains are off and starts the transfer to the genset in AUTO mode.

If one of the genset phase voltages goes under this limit when feeding the load, this will generate a GENSET LOW

VOLTAGE

warning.

If one of the genset phase voltages goes under this limit when feeding the load, this will generate a GENSET LOW

VOLTAGE

shutdown alarm and the engine will stop.

If one of the genset phase voltages goes over this limit when feeding the load, this will generate a GENSET HIGH

VOLTAGE

warning.

If one of the genset phase voltages goes over this limit when feeding the load, this will generate a GENSET HIGH

VOLTAGE

shutdown alarm and the engine will stop.

If at least one of the genset phase voltages goes outside of the limits during this timer, a genset voltage fault will occur.

If the genset frequency goes under this limit when feeding the load, this will generate a GENSET LOW

FREQUENCY

warning.

If the genset frequency goes under this limit when feeding the load, this will generate a GENSET LOW

FREQUENCY

shutdown alarm and the engine will stop.

K35D01-EN — 83 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ELECTRICAL PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory

Set

Genset High Frequency

Warning Limit

Genset High Frequency

Shutdown Limit

Genset Frequency Fail

Timer

Low Battery Voltage

Warning Limit

Low Battery Voltage

Shutdown Limit

High Battery Voltage

Warning Limit

High Battery Voltage

Shutdown Limit

Battery Voltage Fail

Timer

Genset Voltage

Unbalance Limit

Genset Voltage

Unbalance Action

Genset Current

Unbalance Limit

Genset Current

Unbalance Action

%

% sec

V-DC

V-DC

V-DC

V-DC sec

%

—

%

—

F-100 F+100 F+15%

F-100 F+100 F+20%

0

5.0

5.0

5.0

5.0

0

0

0

0

0

10

35.0

35.0

35.0

35.0

10

100

3

100

3

1

12.0

9.0

29.0

30.0

3

0.0

0

0.0

0

Description

If the genset frequency goes over this limit when feeding the load, this will generate a GENSET HIGH

FREQUENCY

warning.

If the genset frequency goes over this limit when feeding the load, this will generate a GENSET HIGH

FREQUENCY

shutdown alarm and the engine will stop.

If the genset frequency goes outside of the limits during this timer, a genset frequency fault will occur.

If the battery voltage falls below this limit, this will generate a LOW

BATTERY

warning.

If the battery voltage falls below this limit, this will generate a LOW

BATTERY

shutdown alarm and the engine will stop. f the battery voltage goes over this limit, this will generate a HIGH BATTERY warning.

If the battery voltage goes over this limit, this will generate a HIGH

BATTERY

shutdown alarm and the engine will stop.

If the battery voltage goes outside of the limits during this timer, a battery voltage fault will occur.

If any genset phase voltage differs from the average more than this limit, it will generate a Voltage Unbalance fault condition. The action taken upon fault condition is programmable.

If this parameter is set to 0.0 then voltage unbalance is not monitored

0:

no action

1:

shutdown alarm

2:

loaddump alarm

3:

warning

If any genset phase current differs from the average more than this limit, it will generate a Current Unbalance fault condition. The action taken upon fault condition is programmable.

If this parameter is set to 0.0 then voltage unbalance is not monitored

0:

no action

1:

shutdown alarm

2:

loaddump alarm

3:

warning

K35D01-EN — 84 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ELECTRICAL PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory

Set

Genset Reverse Power

Warning Limit

Genset Reverse Power

Loaddumpg Limit

Genset Reverse Power

Fail Timer

Genset Overcurrent Limit Amp

Genset Overcurrent

Limit-2

Genset Overcurrent

Action

Overcurrent Time

Multiplier

Genset Overload Limit

Genset Overload Fail

Timer

Load Shedding High

Limit kW kW sec

Amp

—

0 kW sec

Load Shedding Low Limit kW kW

0

0

0

0

0

0

1

0

0

0

0

50000

50000

120

50000

50000

3

64

50000

120

50000

50000

0

0

5

0

0

0

16

0

3

0

0

Description

If the genset power is negative and goes above this limit then a REVERSE

POWER

warning will be generated. If this parameter is set to 0 then reverse power fault is not monitored.

If the genset power is negative and goes above this limit then a REVERSE

POWER

loaddump will be generated.

If the genset power is negative and over limits during this timer, a reverse power fault will occur.

If one of the genset phase currents goes over this limit when feeding the load, this will generate a genset overcurrent fault condition. The action taken upon fault condition is programmable. If this parameter is set to 0 then overcurrent fault is not monitored.

When secondary voltage is selected, if one of the genset phase currents goes over this limit when feeding the load, this will generate a genset overcurrent fault condition. The action taken upon fault condition is programmable. If this parameter is set to 0 then overcurrent fault is not monitored.

0:

shutdown alarm

1:

loaddump alarm

This parameter defines the reaction speed of the overcurrent detector. A higher number means higher sensitivity.

Detailed explanation is given at chapter:

“Overcurrent Protection”

If the total genset active power goes over this limit when feeding the load, this will generate a genset overload loaddump alarm. If this parameter is set to 0 then overload fault is not monitored.

If the genset active power is over the limit during this timer, an overload fault will occur.

If the genset power goes below this limit then the load shedding relay will be deactivated. Review chapter “Load

Shedding” for more details.

If the genset power goes above this limit then the load shedding relay will be activated. Review chapter “Load

Shedding” for more details.

K35D01-EN — 85 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ELECTRICAL PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory

Set

Load Add Delay

Mains Connection

Topology

Genset Connection

Topology sec

Load Subtract-Add Delay min

Mains Waiting Timer

Mains Contactor Timer sec

—

— sec

0

0

0

0

0

0

240

120

50000

7

7

600

0

0

30

5

5

0.5

Description

This is the minimum delay between 2 load_add pulses. Review chapter “Load

Shedding” for more details.

This is the minimum delay required for a load_add pulse after a load_substract pulse. Review chapter “Load Shedding” for more details.

This is the time between the mains voltages and frequency entered within the limits and the generator contactor is deactivated.

This is the connection topology of mains voltages and CTs. Detailed explanations are given in the chapter:

“TOPOLOGIES”.

0:

2 phase, 3 wire L1-L2

1:

2 phase, 3 wire L1-L3

2:

3 phase, 3 wire

3:

3 phase, 3 wire, 2CTs L1-L2

4:

3 phase, 3 wire, 2CTs L1-L3

5:

3 phase, 4 wire star

6:

3 phase, 4 wire delta

7:

single phase, 2 wire

This is the connection topology of genset voltages and CTs. Detailed explanations are given in the chapter:

TOPOLOGIES.

0:

2 phase, 3 wire L1-L2

1:

2 phase, 3 wire L1-L3

2:

3 phase, 3 wire

3:

3 phase, 3 wire, 2CTs L1-L2

4:

3 phase, 3 wire, 2CTs L1-L3

5:

3 phase, 4 wire star

6:

3 phase, 4 wire delta

7:

single phase, 2 wire

This is the period after the generator contactor has been deactivated and before the mains contactor has been activated.

K35D01-EN — 86 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ELECTRICAL PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory

Set

Mains MCB Close Pulse

Mains MCB Open Pulse

Mains MCB

Undervoltage Coil Timer

Mains MCB Fail Timer

Mains Phase Order

Check Enable

Genset Contactor Timer

Genset MCB

Undervoltage Coil Timer

Genset Phase Order

Check Enable sec sec sec sec

— sec

Genset MCB Close Pulse sec

Genset MCB Open Pulse sec

Genset MCB Fail Timer sec sec

—

0

0

0

0

0

0

0

0

0

0

0

10

10

10

10

1

600

10

10

10

10

1

0.5

0.5

0.5

2.0

0

0.5

0.5

0.5

0.5

2.0

0

Description

After the mains MCB_undervoltage coil is energized and mains

MCB_undervoltage coil timer is elapsed, the mains MCB_close relay will be activated during this period.

Review chapter “Motorized Circuit

Breaker Control

” for more details.

The mains MCB_open relay will be activated during this period.

Review chapter “Motorized Circuit

Breaker Control

” for more details

.

The mains MCB_undervoltage coil is energized during this period before the mains MCB_close relay is activated.

Review chapter “Motorized Circuit

Breaker Control

” for more details.

If a mains MCB feedback input is defined and if the mains MCB fails to change position before the expiration of this timer, then a fault condition occurs.

0:

mains phase order checking disabled

1:

if mains phase order is faulty, then a warning is given and mains contactor deenergized.

This is the period after the mainscontactor has been deactivated and before the genset contactor has been activated.

After the genset MCB_undervoltage coil is energised and genset

MCB_undervoltage coil timer is elapsed, the genset MCB_close relay will be activated during this period.

Review chapter “Motorized Circuit

Breaker Control

” for more details.

The genset MCB_open relay will be activated during this period.

Review chapter “Motorized Circuit

Breaker Control

” for more details.

The genset MCB_undervoltage coil is energised during this period before the genset MCB_close relay is activated.

Review chapter “Motorized Circuit

Breaker Control

” for more details.

If a genset MCB feedback input is defined and if the genset MCB fails to change position before the expiration of this timer, then a fault condition occurs.

0:

genset phase order checking disabled

1:

if genset phase order is faulty, then a genset phase order fail loaddump alarm is given.

K35D01-EN — 87 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ENGINE PARAMETERS GROUP

Parameter Definition Unit Min Max Factory

Set

Nominal RPM

Nominal RPM-2

Low RPM Warning Limit

Low RPM Shutdown

Limit

High RPM Warning Limit

High RPM Shutdown

Limit

RPM Fail Timer

Overspeed Overshoot

Limit

Loss of Signal Check

Loss of Speed Signal

Action

Loss of Speed Signal

Timer

Low Charge Voltage

Warning Limit

Low Charge Voltage

Shutdown Limit

Charge Voltage Fail

Timer rpm rpm

%

%

%

% sec

%

—

— sec

V-DC

V-DC sec

0

0

0

HRSL-

100

0

0

0

0

0

0

50000

50000

1500

1800

R-100 R+100 R-10%

R-100 R+100 R-15%

R-100 R+100 R+10%

R-100 R+100 R+15%

10

HRSL

+100

1

2

240

40

40

120

3

HRSL

+10%

0

0

0

6.0

4.0

1

Description

The nominal value of engine rpm. Lowhigh rpm limits are defined by reference to this value.

When secondary frequency is selected, this is the nominal value of engine rpm.

Low-high rpm limits are defined by reference to this value.

If the engine rpm goes under this limit when feeding the load, this will generate a GENSET LOW RPM warning.

If the engine rpm goes under this limit when feeding the load, this will generate a GENSET LOW RPM shutdown alarm and the engine will stop.

If the engine rpm goes over this limit when feeding the load, this will generate a GENSET HIGH RPM warning.

If the engine rpm goes over this limit when feeding the load, this will generate a GENSET HIGH RPM shutdown alarm and the engine will stop.

If the engine rpm goes outside of the limits during this timer, an engine speed fault will occur.

If the engine rpm goes over the “High

RPM Shutdown Limit” by this quantity, this will generate immediately a GENSET

HIGH RPM

shutdown alarm and the engine will stop.

0: speed signal existency not checked

1:If the speed signal is lost, it will generate a Speed Signal Lost fault condition. The action taken upon fault condition is programmable.

0:

shutdown alarm

1:

loaddump alarm

2:

warning

If the speed signal is lost during this timer, a Speed Signal Lost fault will occur.

If the charge alternator voltage goes under this limit, a charge alternator voltage warning will occur.

If the charge alternator voltage goes under this limit, a charge alternator voltage shutdown will occur and the engine will stop.

If the charge alternator voltage goes under limits during this timer, a charge alternator voltage fault will occur.

K35D01-EN — 88 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ENGINE PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory

Engine Heating

Temperature

Engine Start Delay

Preheat Timer

Crank Timer

Wait Between Starts

Engine Heating Timer

Engine Heating Method

Cooldown Timer

Stop Solenoid Timer

Number of Starts

Choke Timer

°C sec sec sec sec sec

— sec sec

— sec

0

0

0

1

1

0

0

0

0

1

0

80

240

30

15

240

240

1

600

90

6

240

Description

Set

0

1

0

6

10

4

0

120

If it is requested that the engine runs without load until reaching a certain temperature, this parameter defines the temperature.

This is the time between the mains fails and the fuel solenoid turns on before starting the genset. It prevents unwanted genset operation in battery backed-up loads.

This is the time after the fuel solenoid is energized and before the genset is started. During this period the

PREHEAT

relay output is energized (if assigned by Relay Definitions)

This is the maximum start period.

Starting will be automatically cancelled if the genset fires before the timer.

This is the waiting period between two start attempts.

This is the period used for engine heating before load transfer.

The genset will not take the load before engine heating is completed.

0:

engine is heated during Engine

Heating Timer

.

1:

engine is heated until the coolant temperature reaches the Engine

Heating Temperature

and at least during the Engine Heating Timer.

This is the period that the generator runs for cooling purpose after the load is transferred to mains.

10

This is the maximum time duration for the engine to stop. During this period the STOP relay output is energized (if assigned by Relay Definitions). If the genset has not stopped after this period, a FAIL TO STOP warning occurs.

3 Number of Starts

5

This is the control delay of CHOKE output.

The choke output is activated together with the crank output. It is released after this delay or when engine runs

(whichever occurs first).

K35D01-EN — 89 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ENGINE PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory

Set

Idle Speed Timer

Idle Holdoff Timer

Gas Solenoid Delay

Crank Cut Voltage

Crank Cut Frequency

Crank Cut RPM

Crank Cut Charge

Voltage

Crank Cut with Oil

Pressure

Crank Cut with Oil

Pressure Delay

Charge Input Connected

Fuel Tank Capacity

Fuel Consumption per

Hour sec sec sec

V-AC

Hz rpm

V-DC

— sec

—

Lt

%

0

0

0

0

0

0

0

0

0

0

0

0

240

30

240

65000

100

65000

40

1

30

1

65000

100

0

10

5

100

10

500

6

0

2

0

0

0.0

Description

When the engine runs, the Idle output relay function will be active during this timer. While the IDLE output is active, low voltage, low frequency and low rpm checks are disabled.

While the IDLE periode is over, low voltage, low frequency and low speed checks are enabled after the expiration of this timer.

The gas solenoid of the gas engine (if assigned by Relay Definitions) will be opened after this delay during cranking.

The crank relay output is deenergized when the genset phase L1 voltage reaches this limit.

The crank relay output is deenergized when the genset frequency reaches this limit.

The crank relay output is deenergized when the engine rpm reaches this limit.

The crank relay output is deenergized when the charge alternator voltage reaches this limit.

0:

no crank cut with oil pressure

1:

cranking is cut when oil pressure switch is open or the oil pressure measured is above shutdown limit.

If crank cutting with oil pressure is enabled, cranking is cut after this delay when oil pressure switch is open or the oil pressure measured is above shutdown limit.

0:

Crank cutting with charge input disabled

1:

Crank cutting with charge input enabled

The full capacity of the fuel tank. If this parameter is zero, the fuel quantity in the tank is not displayed.

This parameter is the threshold for sending FUEL THEFT and FUELLING sms messages.

If this parameter is set to 0, then no

Fuel Theft and Fuelling sms messages will be sent.

If SMS is required, set this parameter to a value above the hourly fuel consumption of the genset.

K35D01-EN — 90 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ENGINE PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory

Set

Coolant Cooler On

Coolant Cooler Off

Coolant Heater On

Coolant Heater Off

Fan Overrun Timer

Canopy Fan Turn-On

Canopy Fan Turn-Off

Ambient Fan Turn-On

Ambient Fan Turn-Off

Service-1 Engine Hours

Service-1 Period

Service-1 Alarm Level

°C

°C

°C

°C

°C

°

C

°C

°C

— sec hours month

0

0

0

0

0

0

0

0

0

0

0

0

250

250

250

250

240

250

250

250

250

5000

24

3

90

80

50

60

0

90

80

90

80

250

6

3

Description

If the coolant temp is above this limit then the cooler relay function will become active.

If the coolant temp is below this limit then the cooler relay function will become inactive.

If the coolant temp is below this limit then the heater relay function will become active.

If the coolant temp is above this limit then the heater relay function will become inactive.

The cooler relay will stay active during this timer after the coolant temp is below

“Coolant Cooler Off” limit.

If the canopy temp is above this limit then the canopy fan relay function will become active.

If the canopy temp is below this limit then the canopy fan relay function will become inactive.

If the ambient temp is above this limit then the ambient fan relay function will become active.

If the ambient temp is below this limit then the ambient fan relay function will become inactive.

The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last service. If the period is set to ‘0’ no SERVICE REQUEST

will be generated depending on service-1 engine hours.

The SERVICE REQUEST led indicator will turn on after this amount of time from the last service. If the period is set to ‘0’ no SERVICE REQUEST will be indicated depending on Service-1

Period.

0:

no action

1:

shutdown alarm

2:

loaddump alarm

3:

warning

K35D01-EN — 91 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ENGINE PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory

Set

Service-2 Engine Hours

Service-2 Period

Service-2 Alarm Level

Service-3 Engine Hours

Service-3 Period

Service-3 Alarm Level hours month

— hours month

—

0

0

0

0

0

0

5000

24

3

5000

24

3

250

6

0

250

6

0

Description

The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last service. If the period is set to ‘0’ no SERVICE REQUEST

will be generated depending on service-2 engine hours.

The SERVICE REQUEST led indicator will turn on after this amount of time from the last service. If the period is set to ‘0’ no SERVICE REQUEST

will be indicated depending on Service-2

Period.

0:

no action

1:

shutdown alarm

2:

loaddump alarm

3:

warning

The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last service. If the period is set to ‘0’ no SERVICE REQUEST

will be generated depending on service-3 engine hours.

The SERVICE REQUEST led indicator will turn on after this amount of time from the last service. If the period is set to ‘0’ no SERVICE REQUEST

will be indicated depending on Service-3

Period.

0:

no action

1:

shutdown alarm

2:

loaddump alarm

3:

warning

K35D01-EN — 92 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ENGINE PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory

Set

J1939 Enable

J1939 Engine Brand

J1939 ECU Type

—

—

—

0

0

0

1

15

7

0

0

0

Description

0:

The J1939 port is inoperative.

1:

The analog measurements (oil, temp, rpm) are picked_up from the ECU. If the

ECU communication is lost, then the engine will be stopped.

0:

GENERIC

1:

CUMMINS

2:

DETROIT DIESEL

3:

DEUTZ

4:

JOHN DEERE

5:

PERKINS

6:

VOLVO

7:

CATERPILLAR

8:

SCANIA

9:

IVECO

10:

MTU-MDEC

11:

BOSCH

Other values:

Reserved. Do not use.

GENERIC ENGINE BRAND

0: Generic

CUMMINS ENGINE

0: Generic

DETROIT DIESEL ENGINE

0: Generic

DEUTZ ENGINE

0: Generic

1: EMR2

2: EMR3

JOHN DEERE ENGINE

0: Generic

PERKINS ENGINE

0: Generic

1: ADEM3

2: ADEM 1.3

VOLVO ENGINE

0: Generic

1: without CIU unit

2: EDC4

CATERPILLAR ENGINE

0: Generic

SCANIA ENGINE

0: Generic

1: Single Speed

2: All Speed

IVECO ENGINE

0: Generic

MTU-MDEC ENGINE

0: MDEC 302

1: MDEC 201

2: MDEC 303

3: MDEC 304

4: MDEC 506

BOSCH INJECTION SYSTEM

0: Generic

1: EDC 731

2: EDC 9.3

K35D01-EN — 93 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ENGINE PARAMETERS GROUP (continued)

Parameter Definition Unit Min Max Factory

Set

J1939 Speed Adjust

High Air Inlet

Temperature Warning

Limit

High Air Inlet

Temperature Alarm Limit

High Air Inlet

Temperature Alarm

Action

Low Coolant Level

Warning Limit

%

°C

°C

—

%

-100

0

0

0

0

+100

200

200

1

100

0.0

0

0

0

Description

This parameter adjusts the speed of an

ECU controlled engine by +/- 8%.

If the air inlet temperature measured through ECU is over this limit, then a high air inlet temperature warning will occur.

If the air inlet temperature measured through ECU is over this limit, then a high air inlet temperature shutdown/loaddump alarm will occur.

0:

shutdown alarm

1:

loaddump alarm

Low Coolant Level Alarm

Limit

Low Coolant Level Alarm

Action

%

—

0

0

100

1

0

0

If the coolant level measured through

ECU is below this limit, then a low coolant level warning will occur.

If the coolant level measured through

ECU is below this limit, then a low coolant level shutdown/loaddump alarm will occur.

0:

shutdown alarm

1:

loaddump alarm

K35D01-EN — 94 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ADJUST DATE AND TIME

These parameters allow adjusting the battery backup real time clock of the module. Once set, the clock will continue to run even if DC power is removed from the unit.

Parameter Definition

Date

Month

Year

Hours

Minutes

Seconds

Unit

—

—

—

—

—

—

Min

01

01

00

00

00

00

Max

31 Current day of the month.

12

99

23

59

59

Current month.

Description

Last two digits of the current year.

Current hour of the day.

Current minute of the hour.

Current second of the minute.

WEEKLY OPERATION SCHEDULE

In AUTO mode, it is possible to define the periods where automatic operation is desired. It may be required that the genset does not start at night or weekends.

Weekly schedule programs allow an hourly setting of automatic operation of the unit during one week.

There are 7days x 24hours =144 parameters. Each hour of the week can be independently defined as

AUTO or OFF period.

If automatic operation is disabled by the weekly exerciser, the AUTO led will flash.

K35D01-EN — 95 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

EXERCISER SCHEDULE

The unit provides 7 independent automatic exerciser programs. Automatic exercise may be done in weekly or monthly basis.

If monthly exercise is selected, the week, day and hour is adjustable for each exercise item.

If weekly exercise is selected, the day and hour is adjustable for each exercise item.

Exercise can be done with or without load.

Thus the genset can be instructed to run automatically in given days and times of a week and take the load.

K35D01-EN — 96 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

SENDER CONFIGURATION

The unit has 4 analog sender inputs. Only parameters of one sender are explained below. Other senders have identical parameter set.

Each sender has 16 step programmable curves. The sender name and reading unit is freely programmable, thus the sender can be adapted to any type through programming.

Each sender has below programmable parameters:

Parameter Definition Unit Min Max Factory

Set

Sender Type

Alarm Level

Alarm Handling

Sender Open Alarm

Low Alarm Check Enable

Low Warning Check

Enable

High Alarm Check

Enable

High Warning Check

Enable

Low Alarm Level

Low Warning Level

High Alarm Level

High Warning Level

—

—

—

—

0

0

0

0 x x x x

0

0

0

0

0

0

0

0

0

0

0

0

15

1

3

3

1

1

1

1

10000

10000

10000

10000

Description

Selects between predefined sender functions. If this parameter is set to 13-

14-15 then the sender name string can be freely entered.

0:

shutdown alarm

1:

loaddump alarm

0:

always

1:

on engine running

2:

after hold-off timer

3:

reserved

If sender resistor is above 5000 ohms, a fault case is generated. This parameter defines the action taken upon fault case.

0:

no alarm

1:

shutdown alarm

2:

loaddump alarm

3:

warning

The low alarm may be selected as shutdown or loaddump with “alarm level” parameter.

0:

low value alarm disabled

1:

low value alarm enabled

0:

low value warning disabled

1:

low value warning enabled

The high alarm may be selected as shutdown or loaddump with “alarm level” parameter.

0:

high value alarm disabled

1:

high value alarm enabled

0:

high value warning disabled

1:

high value warning enabled

If enabled, defines the low alarm limit.

The low alarm may be selected as shutdown or loaddump with “alarm level” parameter.

If defined, defines the low warning.

If enabled, defines the high alarm limit.

The high alarm may be selected as shutdown or loaddump with “alarm level” parameter.

If defined, defines the high warning.

K35D01-EN — 97 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

Parameter Definition Unit

Sender Curve-1 ohm

Sender Curve-1 value

Sender Curve-2 ohm

Sender Curve-2 value

Sender Curve-3 ohm

Sender Curve-3 value

Sender Curve-4 ohm

Sender Curve-4 value

Sender Curve-5 ohm

Sender Curve-5 value

Sender Curve-6 ohm

Sender Curve-6 value

Sender Curve-7 ohm

Sender Curve-7 value

Sender Curve-8 ohm

Sender Curve-8 value

Sender Curve-9 ohm

Sender Curve-9 value

Sender Curve-10 ohm

Sender Curve-10 value

Sender Curve-11 ohm

Sender Curve-11 value

Sender Curve-12 ohm

Sender Curve-12 value

Sender Curve-13 ohm

Sender Curve-13 value

Sender Curve-14 ohm

Sender Curve-14 value

Sender Curve-15 ohm

Sender Curve-15 value

Sender Curve-16 ohm

Sender Curve-16 value

Min Max

ohms x

0 5000

0 10000 ohms x

0 5000

0 10000 ohms x

0 5000

0 10000 ohms x

0 5000

0 10000 ohms x

0 5000

0 10000 ohms x

0 5000

0 10000 ohms x

0 5000

0 10000 ohms x

0 5000

0 10000 ohms x

0 5000

0 10000 ohms x

0 5000

0 10000 ohms x

0 5000

0 10000 ohms x

0 5000

0 10000 ohms x

0 5000

0 10000 ohms x

0 5000

0 10000 ohms x

0 5000

0 10000 ohms x

0 5000

0 10000

Sender Name

Sender Low Fault String

Sender High Fault String

—

—

—

—

—

—

—

—

—

Factory

Set

Description

Point-1 ohm value

Point-1 reading

Point-2 ohm value

Point-2 reading

Point-3 ohm value

Point-3 reading

Point-4 ohm value

Point-4 reading

Point-5 ohm value

Point-5 reading

Point-6 ohm value

Point-6 reading

Point-7 ohm value

Point-7 reading

Point-8 ohm value

Point-8 reading

Point-9 ohm value

Point-9 reading

Point-10 ohm value

Point-10 reading

Point-11 ohm value

Point-11 reading

Point-12 ohm value

Point-12 reading

Point-13 ohm value

Point-13 reading

Point-14 ohm value

Point-14 reading

Point-15 ohm value

Point-15 reading

Point-16 ohm value

Point-16 reading

If the sender type parameter is set to zero (not used), this string is used as sender name while displaying the sender reading.

If the sender type parameter is set to zero (not used), this string is used as sender low value fault in the alarm display.

If the sender type parameter is set to zero (not used), this string is used as sender high value fault in the alarm display.

K35D01-EN — 98 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

DIGITAL INPUT CONFIGURATION

The unit has 8 digital inputs. By using external input extension modules, up to 40 inputs in total are available.

Only parameters of one input are explained below. Other inputs have identical parameter set.

The input name is freely programmable, thus the input can be adapted to any functionality through programming.

The input name entry is made through RainbowPlus program only.

Each sender has below programmable parameters:

Parameter Definition Unit Min Max Factory

Set

Input Function

Action

Sampling

Latching

Contact type

Switching

Response delay

—

—

—

—

—

—

—

0

0

0

0

0

0

0

99

3

3

1

1

1

3

Description

Selects between predefined input functions. Selected input name is displayed in the line below.

If this parameter is set to 0 then the input name string can be freely entered.

0:

shutdown alarm

1:

loaddump alarm

2:

warning

3:

no fault condition from this input.

0:

always

1:

on engine running

2:

after hold-off timer

3:

reserved

0:

non-latching. The fault disappears when cause is removed.

1:

latching. The fault persists even if the cause is removed. Requires manual reset.

0:

Normally open

1:

Normally closed

0:

Battery negative

1:

Battery positive

0:

No delay

1:

Delayed (1sec)

2:

Delayed (5sec)

3:

Delayed (10sec)

K35D01-EN — 99 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

INPUT FUNCTION LIST

No Description

1 User Defined Function

2 Low Oil Press. Switch

3 High Temp. Switch

4 Coolant Level Switch

5 Rectifier Fail Switch

6 Emergency Stop

7 Alternator High Temp

8 Excitation Loss Sw.

9 Low Fuel Switch

10 Earthquake Detector

11 Gen Cont Auxiliary

12 Mains Cont Auxiliary

13 Force AUTO Mode

14 Force OFF Mode

15 Force TEST Mode

16 Over Load Switch

17 Manual Fuel Fill!

18 Priority

19 Remote Start

20 Disable Auto Start

21 Force to Start

22 Fault Reset

23 Alarm Mute

24 Panel Lock

25 Fuel Pump Switch

26 Secondary Volt&Freq

27 Disable Protections

28 Auto Restore Inhibit

29 GensetLoadingInhibit

30 Air Flap Fault

31 Canopy Door Open

32 Station Door Open

33 Station Over-Heat Sw

34 Weather Cloudy

35 Weather Rainy

36 Lightning

37 Cooler Fan Fault

38 Heater Fan Fault

39 Canopy Fan Fault

40 Station Fan Fault

No Description

41 Over Resonance

42 Short-Circuit Alarm

43 Reset Service 1 Alm

44 Reset Service 2 Alm

45 Reset Service 3 Alm

46 reserved for future use

47 reserved for future use

48 reserved for future use

49 reserved for future use

50 reserved for future use

51 reserved for future use

52 reserved for future use

53 reserved for future use

54 reserved for future use

55 reserved for future use

56 reserved for future use

57 reserved for future use

58 reserved for future use

59 reserved for future use

60 reserved for future use

61 reserved for future use

62 reserved for future use

63 reserved for future use

64 reserved for future use

65 reserved for future use

66 reserved for future use

67 reserved for future use

68 reserved for future use

69 reserved for future use

70 reserved for future use

71 reserved for future use

72 reserved for future use

73 reserved for future use

74 reserved for future use

75 reserved for future use

76 reserved for future use

77 reserved for future use

78 reserved for future use

79 reserved for future use

80 reserved for future use

No Description

81 reserved for future use

82 reserved for future use

83 reserved for future use

84 reserved for future use

85 reserved for future use

86 reserved for future use

87 reserved for future use

88 reserved for future use

89 reserved for future use

90 reserved for future use

91 reserved for future use

92 reserved for future use

93 reserved for future use

94 reserved for future use

95 reserved for future use

96 reserved for future use

97 reserved for future use

98 reserved for future use

99 reserved for future use

100 reserved for future use

K35D01-EN — 100 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

OUTPUT CONFIGURATION

Relay-01

Relay-02

Relay-03

Relay-04

Relay-05

Relay-06

Relay-07

Relay-08

Relay-09

Relay-10

Relay-11

Relay-12

Relay-13

Relay-14

Relay-15

Relay-16

Relay-17

Relay-18

Relay-19

Relay-20

Relay-21

Relay-22

Relay-23

Relay-24

Relay-25

Relay-26

Relay-27

Relay-28

Relay-29

Relay-30

Relay-31

Relay-32

Relay-33

Relay-34

Relay-35

Relay-36

Relay-37

Relay-38

Relay-39

Relay-40

The parameters below define the functions of relay outputs. The unit has 8 relay outputs. All relays have programmable functions, selected from a list.

Relays may be extended up to 40 using Relay Extension Modules.. Other relays are in the optional

Extension Modules.

Parameter Definition Factory Terminal Description

8

4

7

6

5

set

3

1

2

number

4

5

6

Factory set as Crank Relay output

Factory set as Fuel Relay output

Factory set as Horn Relay output

Factory set as Preheat Relay output 7

8

9

Factory set as Stop Relay output

Factory set as Idle Speed Relay output

72 Factory set as Mains Contactor Relay output

51 Factory set as Genset Contactor Relay output

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

Relay extension module – 1

Relay extension module – 1

Relay extension module – 1

Relay extension module – 1

Relay extension module – 1

Relay extension module – 1

Relay extension module – 1

Relay extension module – 1

Relay extension module – 2

Relay extension module – 2

Relay extension module – 2

Relay extension module — 2

Relay extension module — 2

Relay extension module — 2

Relay extension module — 2

Relay extension module — 2

Relay extension module — 3

Relay extension module — 3

Relay extension module — 3

Relay extension module — 3

Relay extension module — 3

Relay extension module — 3

Relay extension module — 3

Relay extension module — 3

Relay extension module — 4

Relay extension module — 4

Relay extension module — 4

Relay extension module — 4

Relay extension module — 4

Relay extension module — 4

Relay extension module — 4

Relay extension module — 4

K35D01-EN — 101 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

No Description

1 Fuel

2 Horn

3 Crank

4 Stop Solenoid

5 Genset Contactor

6 Mains Contactor

7 Idle Speed

8 Preheat

9 Alternate Crank

10 Fuel Main Winding

11 Genset Close Pulse

12 Genset Open Pulse

13 Genset UV Coil

14 Mains Close Pulse

15 Mains Open Pulse

16 Mains UV Coil

17 Flashing Relay

18 Gas Solenoid

19 Fuel Pump Control

20 Choke

21 Block Heater

22 Coolant Cooler

23 Coolant Heater

24 Fan Control

25 Air Flap Control

26 Canopy Fan Control

27 Ambient Fan Control

28 Remote Start Output

29 Genset Ready

30 Bus Bar Contactor

31 Bus Bar Close Pulse

32 Bus Bar Open Pulse

33 Bus Bar UV Coil

34 Load Shedding

35 Load Add

36 Load Substract

37 Service 1 Request

38 Service 2 Request

39 Service 3 Request

40 Mains Ph.Order Fail

Below is a short list for reference purposes. Please use the RainbowPlus program for complete selection list.

OUTPUT FUNCTION LIST

No Description

41 Genset Ph.Order Fail

42 Auto Ready

43 Weekly Schedule On

44 Exerciser On

45 Mains Fail

46 Pgm Mode Active

47 Engine Running

48 Genset Voltage Ok

49 Alarm Check Enable

50 Oil Pressure Ok!

51 Shutdown Alarm

52 Loaddump Alarm

53 Warning Alarm

54 Shutdown or Loaddump

55 Secondary Volt & Freq

56 Test Mode

57 Auto Mode

58 Manual Mode

59 Off Mode

60 Not In Auto

61 Genset At Rest

62 Waiting Before Fuel

63 Preheating

64 Waiting Oil Flash Off

65 Engine Heating

66 Synchronizing

67 Cooling Down

68 Stopping

69 Protections Disabled

70 Remote Start Input

71 Disable Auto Start

72 Force to Start

73 Auto Restore Inhibited

74 Gen.Loading Inhibited

75 Inp.Expansion1Mounted

76 Inp.Expansion2Mounted

77 Out.Expansion1Mounted

78 Out.Expansion2Mounted

79 Master Unit

80 —

No Description

105 —

106 —

107 —

108 —

109 —

110 —

111 —

112 —

97 —

98 —

99 —

100 —

101 —

102 —

103 —

104 —

113 —

114 —

115 —

116 —

117 —

118 —

119 —

120

89 —

90 —

91 —

92 —

93 —

94 —

95 —

96 —

81 —

82 —

83 —

84 —

85 —

86 —

87 —

88 —

K35D01-EN — 102 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

SITE ID STRING

The site identity string is designed to identify the current controller.

This is the site Id string sent at the beginning of SMS messages, e-mails and web page headers for the identification of the genset sending the message. Any 20 character long string may be entered.

ENGINE SERIAL NUMBER

The engine serial number string is designed to identify the current controller.

Th s string is added to GSM-SMS messages, e-mails, web page headers etc.

MODEM1-2/SMS1-2-3-4 TELEPHONE NUMBERS

These telephone number buffers accept up to 16 digits, including the wait character (“,”) in order to enable dialing through a pabx.

If Modem Selection= External PSTN Modem:

First 2 numbers are used for modem calls.

Other selections:

all numbers are used for SMS sending.

Enter numbers starting from first character. Do not leave blank characters at the beginning.

K35D01-EN — 103 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

GSM MODEM PARAMETERS

Parameter Definition

APN User Name

APN Password

APN Name

SMS Service Center

Number

Description

The APN (access point name) username may be required by the GSM operator. However some GSM operators may allow access without username.

The exact information should be obtained from the GSM operator.

Please search the GSM operator’s website with “APN” string.

If the APN (access point name) username is required by the GSM operator, most probably the APN password will also be required. However some GSM operators may allow access without password.

The exact information should be obtained from the GSM operator.

Please search the GSM operator’s website with “APN” string.

The APN (access point name) is always required by the GSM operator.

The exact information should be obtained from the GSM operator.

Please search the GSM operator’s website with “APN” string.

The SMS service center number may be required by the GSM operator.

However some GSM operators may allow SMS sending without SMS service center number.

The exact information should be obtained from the GSM operator.

Please search the GSM operator’s website with “ sms service center” string.

Below GSM modem related parameters are found in the

Controller Configuration group.

Parameter Definition

GSM Sim Card Pin

SMS Enable

GPRS Connection

Enable

SMS on Mains Change

SMS on IP Change

Unit

—

—

—

—

—

Min Max

0000 9999

0

0

0

0

1

1

1

1

Factory

Set

Description

0

0

0

0

0

If the GSM SIM card uses pin number, enter the pin number here. If incorrect pin number is entered, then the SIM card will not operate.

0:

SMS messages disabled

1:

SMS messages enabled

0:

GPRS disabled

1:

GPRS enabled

This parameter controls SMS sending when mains voltages status is changed. No warnings generated.

0: no SMS on mains failed or restored

1: SMS sent on mains failed or restored

This parameter controls SMS sending when IP address of GPRS connection is changed. No warnings generated.

0: no SMS on IP change

1: SMS sent on IP change

K35D01-EN — 104 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ETHERNET PARAMETERS

Parameter Definition

Network IP Address

Gateway IP Address

Subnet Mask

User IP Mask 1 (2) (3)

Domain Name

Membership Address members.dyndns.org

Username/Password

Ping Address

Factory Set

0.0.0.0

0.0.0.0

255.255.255.0 d500.dyndns-ip.com www.google.com

Description

This is the IPv4 (internet protocol version 4) address that the unit will require from the DHCP (dynamic host control protocol) server.

If this parameter is set to 0.0.0.0 then the unit will require any IPv4 address from the DHCP server.

If you are not an IP professional please leave this address as “0.0.0.0”.

This is the router IPv4 address, If the Network IP address and Gateway IP Address are set to “

0.0.0.0” then the unit will get the gateway address automatically.

If you are not an IP professional please leave this address as “0.0.0.0”.

Reserved for IP professionals.

If you are not an IP professional please leave this address as “255.255.255.0”.

These 3 registers control the IPv4 access to the unit.

The remote IPv4 address is logical AND’ed with these

IP addresses. If the result gives the remote IP address, then access is enabled.

Thus access may be limited to the same LAN members (x.x.x.255) or strictly to predefined IPv4 addresses.

This string is used in “Dynamic DNS” feature. The unit will register itself to the dynamic DNS server under this name.

For more detailed information please review chapter on “Dynamic DNS Feature” and the document

“Dynamic DNS Account Setting”.

This string is used in “Dynamic DNS” feature. This is the address used in registering to the dynamic DNS server.

For more detailed information please review chapter on “Dynamic DNS Feature” and the document

“Dynamic DNS Account Setting”.

These strings are used in “Dynamic DNS” feature while registering to the dynamic DNS server.

For more detailed information please review chapter on “Dynamic DNS Feature” and the document

“Dynamic DNS Account Setting”.

This internet address is regularly accessed in order to check the availability of internet access.

The access period is defined in parameter Controller

Configuration>Ping Period

.

IP Confirmation

Address

255.255.255.255

0.0.0.0

0.0.0.0

Rainbow Address-1

Rainbow Address-2

—

These parameters accept both internet addresses (like http://datakom.com.tr) and IPv4 addresses (like

78.192.238.116). Information for remote monitoring is sent to these addresses.

The port information of these addresses are found in

Controller Configuration group.

K35D01-EN — 105 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ETHERNET PARAMETERS (continued)

Parameter Definition

Mail Account Name

Mail Account

Password

Factory Set

d500_a d500_1234

Description

This is the account name appearing in the “from” tab of the e-mail recipient. (ex: [email protected])

This is the e-mail password of above e-mail account.

Mail Server Address smtp.mail.yahoo.com This is the Outgoing Mail Server Address of the above

E-mail Address-1

E-mail Address-2

E-mail Address-3

—

—

—

These are e-mail recipient addresses where the unit is intended to send e-mail messages. Up to 3 e-mails can be sent at once.

Below ETHERNET related parameters are found in the

Controller Configuration group.

Parameter Definition

Web Programming

Enable

Web Control Enable

Web Refresh Rate

Ping Period

Rainbow Refresh Rate

Rainbow Address-1 Port

Rainbow Address-2 Port

Web Server Port

Modbus over IP Port

SMTP Port

Ethernet Enable

E-mail on IP Change

Unit

—

— sec min sec

—

—

—

—

—

—

—

Min

0

0

0

0

0

0

0

0

0

0

0

0

Max

1

1

240

240

65535

65535

65535

65535

65535

65535

1

1

Factory

Set

0

0

5

0

5

0

0

80

502

587

1

0

Description

0:

Web programming disabled

1:

Web programming enabled

0:

Web control disabled

1:

Web control enabled

The unit will refresh the web page with this interval.

The unit will check the availability of the internet connection with this interval.

The unit will update the distant monitoring terminal with this rate.

This is the port number of the first monitoring terminal address.

This is the port number of the second monitoring terminal address.

This is the port number of the internal web server. The unit will answer queries to this port only.

This is the port number of the internal

Modbus over IP terminal. The unit will answer Modbus requests to this port only.

This is the port number used for e-mail sending.

0:

ethernet port disabled

1:

ethernet port enabled

This parameter controls e-mail sending when IP address of GPRS or ethernet connection is changed. No warnings generated.

0:

no e-mail on IP change

1:

e-mail sent on IP change

K35D01-EN — 106 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

SYNCHRONIZATION PARAMETERS

Parameter Definition

No Break Transfer

Enable

Synchronization Fail

Timeout

Synchronization

Contactor Timeout

Max Freq Difference

Max Volt Difference

Max Phase Difference

Unit Min Max

— sec sec

0

0

0

Hz 0.1

VAC deg.

0

0

1

240

25

2.0

20

20

Factory

Set

0

30

0.5

0.5

5

10

Description

0:

only interrupted transfer enabled

1:

no break transfer enabled

If the phase and voltage synchronization is not successful before the expiration of this timer, then a

Synchronization Fail

warning is given and the transfer will be performed with interruption.

When synchronization is detected, both contactors will stay closed during this timer.

This is the maximum difference between mains and genset frequencies to close both contactors.

This is the maximum difference between the mains phase-L1 and the genset phase-L1 voltages to close both contactors. If voltage transformer is used, this quantity is multiplied with voltage transformer ratio.

This is the maximum phase angle between the mains phase-L1 and the genset phase-L1 voltages to close both contactors.

K35D01-EN — 107 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

CRANK CUTTING

In order to insure fast and reliable crank cutting, the unit uses various resources for engine running condition detection.

Cranking is stopped when at least one of below conditions is met:

— Crank timer expired:

The crank timer is adjusted through Engine Parameters > Crank Timer. The maximum allowed timer is 15 seconds.

— Genset AC voltage over threshold:

If the genset phase L1 AC voltage reaches Engine Parameters > Crank Cut Voltage, then cranking is immediately stopped.

— Genset frequency over threshold:

If the genset phase L1 frequency reaches Engine Parameters > Crank Cut Frequency, then cranking is immediately stopped.

— Genset rpm over threshold:

If the genset rpm reaches Engine Parameters > Crank Cut RPM, then cranking is immediately stopped.

— Charge alternator voltage over threshold

Following setting is necessary: Engine Parameters > Charge Input Connected = 1

If the charge alternator voltage reaches Engine Parameters > Crank Cut Charge Voltage, then cranking is immediately stopped.

— Oil pressure above threshold

Following setting is necessary: Engine Parameters > Crank Cut with Oil Pressure = 1

The crank cutting with oil pressure offers a programmable delay through Engine Parameters >

Crank Cut with Oil Pressure Delay

. The parameter is factory set to 2 seconds.

Both low oil pressure switch and oil pressure sender readings may be used for crank cutting. The oil pressure switch is always used. The sender may be disabled through Controller

Configuration > Oil Pressure Switch Priority

parameter.

If enabled, when oil pressure is detected, cranking is stopped after adjustable timer delay.

K35D01-EN — 108 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

OVERCURRENT PROTECTION (IDMT)

The unit offers a programmable IDMT protection function in order to protect the alternator against excessive currents.

The IDMT (Inverse Definite Minimum Time) protection function has such tripping characteristics that the tripping time varies inversely with the value of current. Beyond a certain current limit the tripping time becomes constant (definite) and causes tripping in minimum time.

The tripping formula is defined as below:

I

Where:

TMS

is the IDMT time multiplier setting. This is also the tripping time at 100% overload.

I

is the current of the most loaded phase

set

is the programmed overcurrent limit

t

is the tripping time in seconds

Currents below the overcurrent limit are allowed to flow for unlimited time. Currents above the limit will cause the IDMT protection to trigger with a delay depending on the strength of the overcurrent. Higher the current, faster the protection will trip.

When a non-tripping overcurrent condition occurs, the unit will keep trace of it. In case of a consecutive overcurrent, the controller will take into account the residual heat caused by the previous overcurrent and will trip faster than usual.

The IDMT multiplier adjusts the sensitivity of the IDMT detector. When the multiplier is low, then tripping will be faster for the same current.

The unit provides separate Overcurrent limits for primary and secondary volt/speed/amp settings.

Switching from primary volt/freq/amps to secondary values will also switch the IDMT detector to the secondary setting.

The action of the tripping may be selected as a Loaddump (stop after cooldown) or shutdown alarm

(immediate stop).

Screenshot from RainbowPlus configuration program, Generator>Current section

K35D01-EN — 109 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

Below is a table showing the tripping delay in function of the percent load level (with TMS=36):

100% unlimited

110% 3600s

120% 900s

130% 400s

140% 225s

150% 144s

160% 100s

170% 73s

180% 56s

190% 44s

200% 36s

210% 30s

220% 25s

230% 21s

240% 18s

250% 16s

260% 14s

270% 12s

280% 11s

290% 10s

300% 9s

Below is the tripping delay curve in function of the load level (with TMS=36):

K35D01-EN — 110 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

MOTORIZED CIRCUIT BREAKER CONTROL

The unit offers full control for any brand and model of motorized circuit breakers (MCB).

The MCB control is performed through 3 digital output functions, namely Open, Close and Undervoltage coil controls. Only 2 of these outputs are used in a single application.

Any digital output can be assigned to MCB control signals through programming menu.

The MCB CLOSE sequence is below:

Activate UV output, wait for undervoltage coil timer (t uv

)

Activate CLOSE output, wait for close pulse timer (t cl

)

Deactivate CLOSE output

The MCB OPEN sequence is below:

Deactivate UV output

Activate OPEN output, wait for open pulse timer (t op

)

Deactivate OPEN output

Open Pulse, Close Pulse and Undervoltage Coil timers are adjusted through programming menu.

If MCB feedback input is defined and the MCB fails to change position after the expiration of MCB Fail timer, then a fault condition will occur.

K35D01-EN — 111 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

MCB modules can be operated by 2 different ways. The unit supports both configurations.

Below is the terminology used:

M:

gear motor

PF:

ready to close contact

XF:

close coil

MX:

open coil

MN:

undervoltage trip (release)

AUX:

auxiliary contacts

MCB WITH OPEN-CLOSE COILS MCB WITH CLOSE-UV COILS

In the diagram at left, relay function assignments should be as below:

OUTx:

Mains (or Genset) Close Pulse

OUTy:

Mains (or Genset) Open Pulse

In the diagram at right, relay function assignments should be as below:

OUTx:

Mains (or Genset) Close Pulse

OUTy:

Mains (or Genset) Undervoltage Coil

K35D01-EN — 112 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

J1939 CANBUS ENGINE SUPPORT

The unit offers a special J1939 port in order to communicate with electronic engines controlled by an ECU

(electronic control unit). The J1939 port consists of 2 terminals which are J1939+ and J1939-.

The connection between the unit and the engine should be made with an appropriate balanced 120 ohms low capacitance coaxial cable. The external conductor should be grounded at one end only.

A 120 ohms termination resistor is installed inside the unit. Please do not connect external resistor.

The J1939 port is activated by setting the program parameter J1939 Enable to 1. The J1939 Engine

Type

parameter should be set accordingly. The list of available engines is given at the programming section. Please contact DATAKOM for the most current list of engines.

If the J1939 port is enabled then the oil pressure, coolant temperature and the engine rpm information are picked up from the ECU unit. If connected, the MPU unit and related analog senders are discarded.

The controller is able to read and display all below parameters, under condition that the engine sends these information. Most engines send only some of them. If the engine does not send a parameter, the unit will simply skip it. Thus only available information are displayed.

The complete list of J1939 display parameters is below:

1. Engine Brand, ECU Type, J1939 SW version

2. Engine Coolant Level

3. Engine Oil Level

4. Engine Coolant Pressure

5. Engine Fuel Delivery Pressure

6. Barometric Pressure

7. Engine Crankcase Pressure

8. Engine Turbocharger Boost Pressure

9. Engine Air Inlet Pressure

10. Engine Air Filter1 Differential Pressure

11. Engine Fuel Temperature

12. Ambient Air Temperature

13. Engine Air Inlet Temperature

14. Engine Intake Manifold1 Temperature

15. Engine Exhaust Gas Temperature

16. Engine Fuel Rate

17. Engine Instantaneous Fuel Economy

18. Engine Average Fuel Economy

19. Engine Total Fuel Used

20. Engine Total Hours

21. Engine Percent Load at Current Speed

22. Actual Engine Percentage Torque

23. Drivers Demand Engine Percentage Torque

24. Accelerator Pedal Position

24. Battery Potential Switched

The J1939 measurements are also available for Modbus operation. Please check chapter Modbus

Communications

for more details.

When the fuel output is active, if no information is received from the ECU during last 3 seconds, then the unit will give a ECU FAIL alarm and stop the engine. This feature prevents uncontrolled engine operation.

The fault conditions of an electronic engine are considered by the unit as warnings and do not cause engine stop. The engine is supposed protected by the ECU which will stop it when necessary.

The electronic engine fault codes are displayed in text within the alarm list table, together with their

SPN-FMI

codes. The complete list of fault codes is given in the engine manufacturer’s user manual.

K35D01-EN — 113 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

Below is a basic list of fault conditions (x denotes any FMI)

SPN FMI DESCRIPTION

94 x Fuel filter restriction

Fuel pressure sensor fail

98

100 x Low oil level

High oil level

Oil level sensor fail x Low oil pressure

102

Oil pressure sensor fail x High boost pressure

Turbo outlet pressure sensor fail

105 x Intake manifold temp high

107

108

110

111

164

168

172

174

Intake manifold temp sensor fail x Air filter restriction

Air filter sensor fail x Athmospheric pressure sensor fail x High coolant temperature

Coolant temperature sensor fail x Low coolant level

Coolant level sensor fail x High injector activation pressure

Injector activation pressure sensor fail x Battery voltage failure x High inlet air temperature

High inlet manifold air temperature

Inlet manifold air temperature sensor fail x High fuel temperature

Fuel temperature sensor fail

175

190

228

234

620

629

651

652

653

654

655

656

657

657 x High oil temperature

Oil temperature sensor fail x Overspeed

Speed sensor loss of signal x x x x x x x x x x x

Speed sensor mechanical failure

Timing calibration required

Incorrect ecm software

ECU internal +5V fail

ECU hardware fail

Injector cylinder #1 fault

Injector cylinder #2 fault

Injector cylinder #3 fault

Injector cylinder #4 fault

Injector cylinder #5 fault

Injector cylinder #6 fault

Injector cylinder #7 fault

678

723 x Injector cylinder #8 fault x ECU internal power supply fail x Secondary engine speed sensor fail

1108 x Critical override enabled

1111 x Check configuration parameters

2000 x ECU failure

K35D01-EN — 114 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

Below is a basic list of FMI codes.

Please be aware that these codes may differ slightly depending on the engine brand and model.

FMI DESCRIPTION

0 Value too high” Valid data, but above the normal working range

1

“Value too low” Valid data, but below the normal working range

2

“Faulty data” Intermittent or faulty data or

Short circuit to battery voltage, injector high voltage side

3

“Electrical fault” Abno rmally high voltage or short circuit to battery voltage, injector low voltage side

4

“Electrical fault” Abnormally low voltage or short circuit to battery negative, injector low voltage or high voltage side

5

“Electrical fault” Abnormally low current or open circuit

6

“Electrical fault” Abnormally high current or short circuit to battery negative

7

“Mechanical fault” Faulty response from mechanical system

8

“Mechanical or electrical fault” Abnormal frequency

9

“Communication fault” Abnormal updating r ate or

Open circuit in injector circuit

10

“Mechanical or electrical fault” Abnormally large variations

11

“Unknown fault” Unidentified fault

12

“Component fault” Faulty unit or component

13

“Faulty calibration” Calibration values outside the limits

14

“Unknown fault” Special instructions

15 Data valid but above normal operating range — least severe level

16 Data valid but above normal operating range — moderately severe level

17 Data valid but below normal operating range — least severe level

18 Data valid but below normal operating range — moderately severe level

19 Received network data in error

20 not used (reserved)

21 not used (reserved)

22 not used (reserved)

23 not used (reserved)

24 not used (reserved)

25 not used (reserved)

26 not used (reserved)

27 not used (reserved)

28 not used (reserved)

29 not used (reserved)

30 not used (reserved)

31 Condition exist

K35D01-EN — 115 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

ETHERNET CONFIGURATION

Please see related document.

GSM CONFIGURATION

Please see related document.

DYNAMIC DNS FEATURE

Please see related document.

ACCESSING THE EMBEDDED WEB SERVER

Please see related document.

CENTRAL MONITORING OF GENSETS

Please see related document.

WEB MONITORING AND CONTROL OF GENSETS

Please see related document.

E-MAIL SENDING

Please see related document.

ETHERNET

– MODBUS GATEWAY OPERATION

This feature is not available yet.

GPRS

– MODBUS GATEWAY OPERATION

This feature is not available yet.

K35D01-EN — 116 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

LOAD TRANSFER MODES

The unit offers 2 ways of transferring the load from genset to mains and vice versa:

-transfer with interruption,

-no break transfer, (with or without synchronization)

TRANSFER WITH INTERRUPTION

This is the most conventional way of transferring the load between the genset and mains. There will be a power interruption period during the transfer. Note that the program parameters Mains Contactor Timer and Genset Contactor Timer define the power interruption period.

If this transfer method is used, it is advised to make an electrical interlock between the two contactors to prevent an accidental phase to phase short circuit.

Transfer from genset to mains:

-The generator contactor releases,

-The unit waits for Mains Contactor Timer

-The mains contactor is energized.

Transfer from mains to genset:

-The mains contactor releases,

-The unit waits for Generator Contactor Timer

-The generator contactor is energized.

K35D01-EN — 117 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

UNINTERRUPTED TRANSFER

In this mode, the transfer will be made without power interruption. This implies that both of the mains and generator contactors will be active during transfer.

The maximum duration that both contactors will be active is programmable. However this process may be quicker with the use of one auxiliary feedback contact from each contactor. Thus the changeover will be quite instantaneous, preventing any excess or reverse power condition.

To prevent a phase to phase short circuit below criteria must be met:

-The mains and generator voltages must be equal,

-The mains and generator voltages must have the same phase,

-The mains and generator voltages must have the same phase sequence order.

The unit will allow an Uninterrupted Transfer only if all of the below conditions are fulfilled:

-Mains phase voltages within the programmed limits,

-Mains frequency within the programmed limits,

-Genset phase voltages within the programmed limits,

-Genset frequency within the programmed limits,

-Mains phase order correct (or phase order check must be disabled),

-Genset phase order correct (or phase order check must be disabled),

-The difference between mains and genset frequencies not more than programmed limit,

-The voltage difference mains-L1 and genset-L1 not more than programmed limit,

-The phase angle between mains-L1 and genset-L1 not more than programmed limit,

When an uninterrupted transfer cycle is started, the unit will wait until the expiration of the

Synchronization Fail Timer

, to find a matching frequency, phase and voltage.

Usually, with frequencies matching at +/- 2Hz and voltages matching at +/-10 volts an Uninterrupted

Transfer

is expected to successful.

If matching is found before the expiration of the Synchronization Fail Timer, then both contactors will be activated. If contactor auxiliary contacts are used, the other contactor will release immediately. If contactor auxiliary contacts are not used, the other contactor will release after contactor timeout .

The unit offers below parameters for the setup of the Uninterrupted transfer feature.

Parameter Definition Description

No Break Transfer

Enable

Synchronization Fail

Timeout

Synchronization

Contactor Timeout

0:

only interrupted transfer enabled

1:

no break transfer enabled

If the phase and voltage synchronization is not successful before the expiration of this timer, then a Synchronization Fail warning is given and the transfer will be performed with interruption.

When synchronization is detected, both contactors will stay closed during this timer.

Max Volt Difference

This is the maximum difference between the mains phase-L1 and the genset phase-L1 voltages to close both contactors. If voltage transformer is used, this quantity is multiplied with voltage transformer ratio.

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DATA RECORDING

DATA RECORDING MEDIA

Data can be recorded in USB flash memory.

As soon as a USB flash memory is inserted, the unit will start data recording and continue until the memory is removed.

USB HOST

Port

USB FLASH MEMORY

The USB-Host port is available with COMM option.

If USB-Device is plugged then USB-Host port will not function.

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DIRECTORY STRUCTURE

The unit will record data in either an USB-Flash memory. The record structure is the same in both cases.

SITE-ID Year 2012

Year 2011

Last day of the year

Previous years

First day of the year

The unit will record data in a directory named with the first 11 characters of its site-id parameter. In order to avoid confusion between records, it is highly recommended to configure the site-id parameter accordingly to the genset installation place. Thus the same memory module may be used for recording in different controllers,

Inside the <SITE-ID> directory, the unit will open a separate directory for each year of recording. The directory will be simply named by the year, like 2012, 2013 etc…

Inside the year directory, the controller will record data in a different file for each day of recording. The record file will be named YYYYMMDD like “20120331” representing March

’31, 2012. Thus alphabetical listing will produce a sorted list by date of recording.

The recorded file is of CSV (comma separated values) type. This is a text file which can be directly opened with Microsoft Excel program without any loss of information. It can be also opened with any text editor (like Notepad program).

Inside the file, each record consists of a line including a large set of measured parameters. The recorded parameters list is not adjustable. The controller records all practically necessary parameters.

UNDERSTANDING THE CSV FORMAT

The “.csv” file is basically a text file format. Thanks to this, it can be opened by any text editor in any operating system.

When opened with the Microsoft Excel program, the values will appear in tabulated form, enabling application of formulas, graphs and other features of Excel program.

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RECORDED DATA LIST, RECORD PERIOD

The recording period is adjustable between 2 seconds and 18 hours by program parameter.

A short period will give better resolution, but it will generate more data in the memory card.

One data record is typically 250 bytes long, thus with a minimum period of 2 seconds, the unit will store

10.8 MB of data per day (250x30x60x24). A typical memory of 4GB will store data during 370 days, more than 1 year.

With a recording period of 1 minute, 4GB memory card will store data during 30 years.

Below parameters are recorded:

Date and time of recording

Operating mode

Mains voltage phase L1 to neutral

Mains voltage phase L2 to neutral

Mains voltage phase L3 to neutral

Mains voltage phase L1-L2

Mains voltage phase L2-L3

Mains voltage phase L3-L1

Mains frequency

Mains current phase L1

Mains current phase L2

Mains current phase L3

Mains average current

Mains frequency

Mains kW phase L1

Mains kW phase L2

Mains kW phase L3

Mains total kW

Mains kVA phase L1

Mains kVA phase L2

Mains kVA phase L3

Mains kVAr phase L1

Mains kVAr phase L2

Mains kVAr phase L3

Mains pf phase L1

Mains pf phase L2

Mains pf phase L3

Mains total pf

Mains neutral current

Gen voltage phase L1 to neutral

Gen voltage phase L2 to neutral

Gen voltage phase L3 to neutral

Gen average voltage phase to neutral

Gen voltage phase L1-L2

Gen voltage phase L2-L3

Gen voltage phase L3-L1

Gen current phase L1

Gen current phase L2

Gen current phase L3

Gen average current

Gen frequency

Gen kW phase L1

Gen kW phase L2

Gen kW phase L3

Gen total kW

Gen kVA phase L1

Gen kVA phase L2

Gen kVA phase L3

Gen kVAr phase L1

Gen kVAr phase L2

Gen kVAr phase L3

Gen pf phase L1

Gen pf phase L2

Gen pf phase L3

Gen total pf

Neutral current

Oil pressure (bar & psi)

Coolant temperature (°C & °F)

Fuel level (%)

Oil temperature (°C &

°F)

Canopy temperature (°C & °F)

Engine speed (rpm)

Battery voltage

Engine hours

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

SOFTWARE FEATURES

Load Shedding / Dummy Load

The load shedding feature consists on the disconnection of the least crucial loads when the genset power approaches to its limits. These loads will be supplied again when the genset power falls below the programmed limit. The internal Load Shedding function is always active. Any digital output may be used as the load shedding output.

The dummy load function consists on the connection of a dummy load if the total genset load is below a limit and to disconnection of the dummy load when the total power exceeds another limit. The dummy load function is the inverse of the load shedding function, thus the same output may be used for both purposes.

It is also possible to control more complex external systems with multiple steps, using LOAD_ADD and

LOAD_SUBSTRACT output functions. Any digital output may be assigned to these signals.

When the load is below the Load Shedding Low Limit, the controller will activate the Load Add output.

The external system will increase the load until it goes over the low limit, where the Load Add output will become inactive.

When the load is above the Load Shedding High Limit, the controller will activate the Load Substract output. The external system will decrease the load until it goes below the high limit, where the Load

Substract output will become inactive.

There are protection delays between two pulses.

The parameters used in Load Shedding feature are in the Electrical Parameters Group:

Parameter Definition Unit Min Max

Factory

Set

Description

Load Shedding Low Limit kW

Load Shedding High

Limit

Load Add Delay kW sec

Load Subtract-Add Delay min

0 509T00 0

0 509T00 0

0

0

240

120

0

0

If the genset power goes below this limit then the load shedding relay will be deactivated.

If the genset power goes above this limit then the load shedding relay will be activated.

This is the minimum delay between 2 load_add pulses.

This is also the minimum delay between 2 load_substract pulses.

This is the minimum delay between load_add and load_substract pulses.

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Remote Start Operation

The unit offers the possibility of Remote Start mode of operation. Any digital input may be assigned as

Remote Start Input

using Input Function Select program parameters.

The Remote Start signal may be a NO or NC contact, switching to either battery positive or battery negative.

These selections are made using programming menu.

It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarm from this input.

When a Remote Start input is defined, the mains phases are not monitored. When the Remote Start signal is present then the mains will be supposed to fail, inversely when the Remote Start signal is absent then mains voltages will be supposed to be present.

The front panels mimic diagram’s mains LEDs will always reflect the status of the Remote Start input.

Disable Auto Start, Simulate Mains

The unit offers an optional Disable Auto Start signal input. Any digital input may be assigned as Disable

Auto Start

using Input Function Select program parameters.

It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarms generated from this input.

The Disable Auto Start signal may be a NO or NC contact, switching to either battery positive or battery negative. These selections are made using the programming menu.

If the Disable Auto Start input is defined and the input signal is active, the mains phases are not monitored and supposed to be inside limits. This will prevent the genset from starting even in case of a mains failure. If the genset is running when the signal is applied, then usual Mains Waiting and Cooldown cycles will be performed before engine stop. When the Disable Auto Start signal is present, the front panels mimic diagram’s mains LEDs will reflect the mains voltages as present.

When the signal is passive, the unit will revert to normal operation and monitor the mains voltage status.

The REMOTE START operation overrides DISABLE AUTO

START and FORCE TO START operations.

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Battery Charging Operation, Delayed Simulate Mains

The Delayed Mains Simulation feature is used in battery backed up telecom systems where batteries are able to supply the load during a certain period. The genset is requested to run only when battery voltage drops below the critical level. Once the engine runs, the rectifier system starts charging the batteries and the battery voltage goes up immediately. Thus the engine should continue to run a programmed period for effective charging. The critical battery voltage level will be detected by an external unit which provides the digital Disable Auto Start signal for the genset control unit.

The unit offers an optional Disable Auto Start signal input. Any digital input may be assigned as

Simulate Mains

using Input Function Select program parameters.

It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarms generated from this input.

The Disable Auto Start signal may be a NO or NC contact, switching to either battery positive or battery negative. These selections are made using the programming menu.

If the Delayed Simulate Mains program parameter is set to 1 and the input signal is active when the genset is not feeding the load, the mains phases are not monitored and supposed to be inside limits. This will prevent the genset from starting when the simulate mains signal is present (batteries charged). The genset will start when mains voltages are out of limits and the simulate mains signal not present.

If the genset is running when the signal is applied, then MAINS SIMULATION will be prevented during

Flashing Relay On Timer

program parameter. After this, usual Mains Waiting and Cooldown cycles will be performed before engine stop. When the SIMULATE MAINS signal is present, the front panels mimic diagram’s mains LEDs will reflect the mains voltages as present.

When the signal is passive, the unit will revert to normal operation and monitor the mains voltage status.

The REMOTE START operation overrides Disable

Auto Start operation. When both “Remote Start

Operation” and “Delayed Simulate Mains” are enabled then REMOTE START operation mode is performed.

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Dual Genset Mutual Standby Operation

Dual genset intermittent operation consists of regular switching of the load between 2 gensets. The use of

2 gensets instead of one is due either to safety purposes in case of a genset failure or to a continuous operation requesting service stops.

The running period for each genset is adjustable using Flashing Relay On Timer and Flashing Relay

Off Timer

program parameters. If the time is adjusted as 0 hours, it will be actually set to 2 minutes for faster testing purposes.

A flashing relay output function is provided, based on the parameter Flashing Relay On/Off Timers.

Each time the period programmed using Flashing Relay Timer elapses, the relay output will change position.

The flashing relay function may be assigned to any digital output using Output Configuration program parameters.

The dual genset intermittent operation uses also the Disable Auto Start feature. Please review related chapter for a detailed explanation of this feature.

Priority In Dual Genset Mutual Standby Operation:

It may be required that the dual genset system starts the same genset at every mains failure. This is achieved using the PRIORITY input.

Any digital input may be assigned as Priority using Input Function Select program parameters.

It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarms generated from this input.

The Priority signal may be a NO or NC contact, switching to either battery positive or battery negative. These selections are made using the programming menu.

If a Priority input is defined, then the system will work in priority mode. If the priority signal is applied, the unit will become master after each mains failure. If the priority signal is not applied, then the unit will become the slave one and the other genset will start.

Please contact DATAKOM for a complete application manual.

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Dual Voltage and Frequency

The unit offers 2 sets of voltage and frequency protection limit values. The user is allowed to switch between these 2 sets anytime.

This feature is especially useful in dual voltage or frequency gensets for easy switching between 2 operating conditions.

The switching to the second set of limit values can be done in 2 ways:

-by setting the program parameter Secondary Volt/Freq to 1

-with digital input signal

Thus the user has full flexibility for manual or external switching.

If switching is done with digital input signal, one of digital inputs has to be defined as “2

nd

Select

” using “INPUT FUNCTION SELECT“program

group.

Volt-Freq

Below parameters are available for second voltage-frequency selection:

Nominal Voltage

Nominal Frequency

Nominal RPM

Genset Overcurrent Limit

Single Phase Operation

If the unit is used in a single phase electrical network, it is advised to select the topology as Single

Phase 2 Wires

.

When the topology is set to Single Phase 2 Wires, then the unit will measure electrical parameters only on phases L1 of genset and mains.

Voltage and overcurrent checks will be performed on phases L1 only.

Phases L2 and L3 parameters, as well as phase-to-phase voltages are removed from display screens.

External Control of the Unit

The unit offers total external control through programmable digital inputs. Any digital input may be programmed for below functions:

— Force STOP mode

— Force AUTO mode

— Force TEST mode

— Disable Auto Start

— Force to Start

— Fault Reset

— Alarm Mute

— Panel Lock

External mode select signals have priority on mode buttons of the unit. If the mode is selected by external signal, it is impossible to change this mode with front panel pushbuttons. However if the external mode select signal is removed, the unit will revert to the last selected mode via pushbuttons.

It is also possible to lock the front panel completely for remote command.

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Automatic Exerciser

The unit offers 7 independent automatic exercisers. The exercise operation may be done on a weekly or monthly basis.

The start day and time of the exercise is programmable as well as its duration. The exercise may be done with or without load following programming.

Program parameters related to the exerciser are:

Exercise start day and hour

Exercise duration

Exercise off_load/on_load

Please refer to the programming section for a more detailed description of the above parameters.

When the start day and hour of exercise has come, the unit will automatically switch to either RUN or

TEST

mode. The engine will run. If the on_load exercise is selected then the load will be transferred to the genset.

If a mains failure occurs during the off-load exercise, the load will not be transferred to the genset unless the Emergency Backup Operation is allowed by setting the related program parameter to 1. Thus it is highly recommended that the Emergency Backup mode enabled with off-load exerciser.

At the end of the exercise duration, the unit will switch back to the initial mode of operation.

If any of the mode selection keys are pressed during exercise, then the exercise will be immediately terminated.

Using the weekly exercise mode and with suitable parameter setting, the unit may feed the load from the genset during predefined hours of each day. This operation may be used in high tariff periods of the day.

WEEKLY OPERATION SCHEDULER

In most applications, the genset is requested to operate only in working hours. Thanks to the weekly program feature, unwanted operation of the genset may be prohibited.

The scheduler is active only in AUTO mode. When the scheduler prevents genset operation in AUTO mode, the AUTO led will flash.

When the scheduler prevents genset operation in

AUTO mode, the AUTO led will flash.

The scheduler consists of 144 programmable parameters, one for each hour in a week. Thus every hour of the week may be independently selected as ON or OFF times.

These programmable parameters allow the genset to operate automatically only in allowed time limits.

The unit has a battery backed-up precision real time clock circuit. The real time clock circuit will continue its operation even in power failures. The real time clock is precisely trimmed using the Real Time Clock

Adjust

program parameter. For more details check the programming section.

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Engine Heating Operation

Especially on engines without a body heater, or with a failing one, it may be desired that the genset should not take the load before reaching a suitable temperature. The unit offers 2 different ways of engine heating.

1. Timer controlled heating:

This operation mode is selected when the Engine Heating Method parameter is set to 0. In this mode, the engine will run during parameter Engine Heating Timer, and then the genset will take the load.

2. Timer and temperature controlled heating:

This operation mode is selected when the Engine Heating Method parameter is set to 1. In this mode, at first the engine will run during parameter Engine Heating Timer, then it will continue to run until the measured coolant temperature reaches the limit defined in parameter Engine Heating Temperature.

When the requested temperature is reached, the load will be transferred to the genset. This operation mode may be used as a backup to the engine body heater. If the engine body is warm the heating will be skipped.

Engine Idle Speed Operation

It may be required that the engine runs at the idle speed for a programmed duration for engine heating.

The idle operation duration is adjusted with the parameter Idle Speed Timer. The idle speed will be set by the governor control unit of the engine.

Any digital output may be assigned as IDLE output using Relay Definition program parameters.

The Idle speed operation is performed both in engine start-up and cool-down sequences. Low speed and low voltage protections are disabled during idle speed operation.

Engine Block Heater

The unit is able to provide a digital output in order to drive the block heater resistor. The temperature reference is the coolant temperature measured from the analog sender input.

The block heater output function may be assigned to any digital output using Relay Definition program parameters.

The engine body temperature limit is adjusted using the parameter Engine Heating Temperature. The same parameter is used for engine heating operation.

The relay will become active if the body temperature falls to 4 degrees below the limit set by Engine

Heating Temperature

. It turns off when the body temperature exceeds Engine Heating Temperature.

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Fuel Pump Control

The unit is able to provide a digital output function in order to drive the fuel pump motor. The fuel pump is used in order to transfer fuel from the large capacity main tank (if exists), to the genset daily tank which is generally integrated in the chassis and has a limited capacity.

The fuel level reference is measured through the analog fuel level sender. When the measured fuel level falls below Fuel Pump Low Limit parameter, the fuel pump output function will become active. When the fuel level reaches Fuel Pump High Limit parameter, the output function will become passive. Thus the chassis fuel tank level will be always kept between Fuel Pump Low Limit and Fuel Pump High Limit parameters.

The fuel pump relay function may be assigned to any digital output using Relay Definition program parameters.

Gas Engine Fuel Solenoid Control

The unit provides a special function for the fuel solenoid control of a gas engine.

The fuel solenoid of a gas engine is different from a diesel engine. It should be opened after the cranking has been started and should be closed between crank cycles. The delay between the crank start and solenoid opening is adjusted using the Gas Solenoid Delay program parameter.

The gas engine fuel solenoid relay function may be assigned to any digital output using Relay Definition program parameters.

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MODBUS COMMUNICATIONS

This chapter is a brief description of the Modbus properties of the controller. For a complete documentation please use

“DKG-509T Modbus Application Manual”

The unit offers the possibility of MODBUS communication through below carriers:

-RS485 serial port, with adjustable baud rate between 2400 and 115200 bauds

-MODBUS-TCP/IP through Ethernet port (10/100Mb)

-MODBUS-TCP/IP through GSM-GPRS modem. (84/42kb)

The MODBUS properties of the unit are:

-Data transfer mode: RTU

-Serial data: selectable baud rate, 8 bit data, no parity, 1 bit stop

-Modbus-TCP/IP: Ethernet 10/100Mb or GPRS Class 10.

-Supported functions:

-Function 3 (Read multiple registers)

-Function 6 (Write single register)

-Function 16 (Write multiple registers)

Each register consists of 2 bytes (16 bits). A larger data structure will contain multiple registers.

The Modbus communications requires a slave address to be assigned to each device in the Modbus network. This address ranges between 1 and 240 and allows the addressing of different slave devices in the same network.

Each device in the same RS-485 serial network must be assigned a different slave address. Otherwise the Modbus communications will not be performed.

Devices using Modbus-TCP/IP with different IP or port addresses may use any slave address. It is advised to set these slave addresses to the default setting which is 1.

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Parameters required for RS-485 Modbus operation

Modbus Slave Address:

may be set between 1 and 240

RS-485 Enable:

must be set to 1 (or checkbox enabled)

RS-485 Baud Rate:

selectable between 2400 and 115200 bauds. All devices in the same network must use the same Baud Rate.

The complete RS-485 port specifications are found in the D-500/700 User Manual.

Selecting a higher baud rate will allow faster communication, but will reduce the communication distance.

Selecting a lower baud rate will increase the communication distance, but will cause slower response times.

Typically 9600 bauds will allow 1200m distance with special balanced 120 ohms cable.

Parameters required for Modbus-TCP/IP through Ethernet port

Modbus Slave Address:

may be set between 1 and 240. If only one unit is available in the same IP address, it is advised to keep the default address (1).

Ethernet Enable:

This parameter should be set to 1 (or checked) in order to enable the ethernet port.

Modbus TCP/IP Port:

The usual setting is 502. However the unit is able to work on any port address.

User IP Mask:

There are 3 mask registers available. The use of the registers are emphasized in the D-

500/700 User Manual. Please set the first mask as 255.255.255.0 for the proper operation.

Ethernet Network IP:

May be left as 0.0.0.0 for automatic address claim or set to a value in order to claim a defined address.

Ethernet Gateway IP:

Should be set in accordance with your local switch configuration.

Ethernet Subnet Mask:

Should be set in accordance with your local switch configuration.

The complete Ethernet port specifications are found in the D-500/700 User Manual.

Please rewiev the document Ethernet Configuration Guide for D-500/700 for more details about the ethernet port setup.

Parameters required for Modbus-TCP/IP through GSM_GPRS Modem

Modbus Slave Address:

may be set between 1 and 240. If only one unit is available in the same IP address, it is advised to keep the default address (1).

Modem Selection:

Internal or external following your configuration.

Modem Baud Rate:

Selectable only for external modem. 115200 bauds advised. Selecting a lower baud rate will slow down communication between the controller and the modem.

GPRS Connection Enable:

This parameter should be set to 1 (or checked).

Modbus TCP/IP Port:

Set this value to 80.

User IP Mask:

There are 3 mask registers available. The use of the registers are emphasized in the D-

500/700 User Manual. Please set the first mask as 255.255.255.0 for the proper operation.

Data Formats

16bit variables:

These variables are stored in a single register. Bit_0 denotes the LSB and bit 15 denotes the MSB.

32 bit variables:

These variables are stored in 2 consecutive registers. The high order 16 bits are in the first register and the low order 16 bits are in the second register

Bit arrays:

Arrays larger than 16 bits are stored in multiple registers. The LSB of the first register is bit_0.

The MSB of the first register is bit_15. The LSB of the second register is bit_16. The MSB of the second register is bit_31, and so on.

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10272

10274

10276

10278

10292

10294

10308

10310

10324

10326

10334

10335

10338

10339

10341

10361

10240

10242

10244

10246

10248

10250

10252

10254

10256

10258

10260

10262

10264

10266

10268

10270

10362

10363

10364

10365

10366

10376

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

32bit

32bit

16bit

16bit

16bit

16bit

16bit

16bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

16bit

16bit

16bit

16bit

16bit

16bit

Below is a shortlist of available Modbus registers. For complete register map please refer to D-500/700

Modbus Application Manual.

COEFF. DESCRIPTION ADDRESS

(decimal)

8193

R / W DATA

W

SIZE

16bit x10 Pushbutton simulation

BIT 0.Simulate Stop button

BIT 1.Simulate Manual button

BIT 2.Simulate Auto button

BIT 3.Simulate Test button

BIT 4.Simulate Run button

BIT 5.Simulate GCB button

BIT 7.Simulate Menu+ button

BIT 8.Simulate Menu- button

BIT 9.Simulate Up button

BIT10.Simulate Down button

BIT14.Button Long pressed

BIT15.Button Very Long Pressed x10 Mains phase L1 voltage x10 Mains phase L2 voltage x10 Mains phase L3voltage x10 Genset phase L1 voltage x10 Genset phase L2 voltage x10 Genset phase L3 voltage x10 Mains phase L1-L2 voltage x10 Mains phase L2-L3 voltage x10 Mains phase L3-L1voltage x10 Genset phase L1-L2 voltage x10 Genset phase L2-L3 voltage x10 Genset phase L3-L1 voltage x10 Mains phase L1 current x10 Mains phase L2 current x10 Mains phase L3 current x10 Genset phase L1 current x10 Genset phase L2 current x10 Genset phase L3 current x10 Mains neutral current x10 Genset neutral current x10 Mains total active power x10 Genset total active power x10 Mains total reactive power x10 Genset total reactive power x10 Mains total apparent power x10 Genset total apparent power x10 Mains total power factor x10 Genset total power factor x100 Mains frequency x100 Genset frequency x100 Battery voltage x10 Oil pressure in bars (multiply by 14.50 to for psi) x10

Engine temp in °C (multiply by 1.8 then add 32 for °F) x10 Fuel level in % x10

Oil temp in °C (multiply by 1.8 then add 32 for °F) x10

Canopy temp in °C (multiply by 1.8 then add 32 for °F) x10

Ambient temp in °C (multiply by

1.8 then add 32 for °F) x1 Engine rpm

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ADDRESS

(decimal)

10504-

10519

10520-

10535

10536-

10551

10604

10605

10606

10610

10611

10616

10618

10620

10622

10624

10626

10628

10630

10632

10634

10636

10638

10640

10642

10644

R / W DATA

R

SIZE

256bit

R

R

R

R

R

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

32bit

16bit

16bit

32bit

32bit

32bit

32bit

32bit

32bit

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

256bit

256bit

16bit

16bit

16bit

COEFF. DESCRIPTION

—

—

—

—

Shutdown alarm bits. Bit definitions are given at the end of the document.

Loaddump alarm bits. Bit definitions are given at the end of the document.

Warning alarm bits. Bit definitions are given at the end of the document.

Unit operation status

0= genset at rest

1= wait before fuel

2= engine preheat

3= wait oil flash off

4=crank rest

5=cranking

6= engine run idle speed

7= engine heating

8= running off load

9= synchronizing to mains

10= load transfer to genset

11= gen cb activation

12= genset cb timer

13= master genset on load,

14= peak lopping

15= power exporting

16= slave genset on load

17= synchronizing back to mains

18= load transfer to mains

19= mains cb activation

20= mains cb timer

21= stop with cooldown

22= cooling down

23= engine stop idle speed

24= immediate stop

— x1

25= engine stopping

Unit mode

0= STOP mode

1= AUTO mode

2= MANUAL mode

3= TEST mode

Genset operation timer. In various wait statuses, the genset operation status will change at the expiration of this timer.

—

— x1 x1

Device hardware version information

Device software version information

Counter: number of genset runs

Counter: number of genset cranks x1 Counter: number of genset on load x100 Counter: engine hours run x100 Counter: engine hours since last service x100 Counter: engine days since last service x10 Counter: genset total active energy (kWh) x10 Counter: genset total inductive reactive energy (kVArh-ind) x10 Counter: genset total capacitive reactive energy (kVArh-cap) x100 Counter: remaining engine hours to service-1 x100 Counter: remaining engine days to service-1 x100 Counter: remaining engine hours to service-2 x100 Counter: remaining engine days to service-2 x100 Counter: remaining engine hours to service-3 x100 Counter: remaining engine days to service-3

K35D01-EN — 133 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

DECLARATION OF CONFORMITY

The unit conforms to the EU directives

-2006/95/EC (low voltage)

-2004/108/EC (electro-magnetic compatibility)

Norms of reference:

EN 61010 (safety requirements)

EN 61326 (EMC requirements)

The CE mark indicates that this product complies with the European requirements for safety, health environmental and customer protection.

UL / CSA Conformity:

certification teting in progress

UL 508, Edition 17

UL 2200, 1st Edition.

UL 840 Edition 3

CSA C22.2 NO. 14 — Edition 10

MAINTENANCE

DO NOT OPEN THE UNIT !

There are NO serviceable parts inside the unit.

Wipe the unit, if necessary with a soft damp cloth. Do not use chemical agents

DISPOSAL OF THE UNIT

Following DIRECTIVE 2002/96/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL

of 27 January 2003 on waste electrical and electronic equipment (WEEE)

, this unit should be stored and disposed separately from the usual waste.

ROHS COMPLIANCE

The european ROHS directive restricts and prohibits the use of some chemical materials in electronic devices.

Following the “DIRECTIVE 2011/65/EU OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of

8 June 2011 on the restriction of the use of certain hazardous substances in electrical and electronic equipment

”,

this product is listed in annex-I under category: “Monitoring and control

instruments including industrial monitoring and control instruments

”

and exempted from ROHS directive.

However Datakom is not using any ROHS uncompliant electronic components in the production. Only the solder contains lead. The switching to unleaded solderin is in progress.

K35D01-EN — 134 —

TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

TROUBLESHOOTING GUIDE

Below is a basic list of most often encountered troubles. More detailed investigation may be required in some cases.

The genset operates while AC mains are OK or continues to operate after AC mains are OK:

-Check engine body grounding.

-AC mains voltages may be outside programmed limits, measure the phase voltages.

-Check the AC voltage readings on the screen.

-Upper and lower limits of the mains voltages may be too tight. Check the parameters Mains Voltage

Low Limit

and Mains Voltage High Limit. Standard values are 170/270 volts.

-The hysteresis voltage may be given to excessive. The standard value is 8 volts.

AC voltages or frequency displayed on the unit are not correct:

-Check engine body grounding, it is necessary.

-The error margin of the unit is +/- 2 volts.

-If there are faulty measurements only when the engine is running, there may be a faulty charging alternator or voltage regulator on the engine. Disconnect the charging alternator connection of the engine and check if the error is removed.

-If there are faulty measurements only when mains are present, then the battery charger may be failed.

Turn off the rectifier fuse and check again.

KW and cosΦ readings are faulty although the Amp readings are correct:

-Current transformers are not connected to the correct inputs or some of the CTs are connected with reverse polarity. Determine the correct connections of each individual CT in order to obtain correct KW and cosΦ for the related phase, and then connect all CTs. Please review chapter “AC CURRENT

INPUTS

”

Short circuit outputs of unused Current Transformers.

When the AC mains fails the unit energizes the fuel solenoid, but does not start and OIL

PRESSURE EXISTS ! message is displayed:

The unit is not supplied with battery (-) voltage at the oil pressure input.

-Oil pressure switch not connected.

-Oil pressure switch connection wire cut.

-Oil pressure switch faulty.

-Oil pressure switch closes too lately. If oil pressure switch closes, the unit will start. Optionally oil pressure switch may be replaced.

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TJ-509T User Manual Rev_01 PRELIMINARY VERSION V-1.4

The engine does not run after the first start attempt, then the unit does not start again and OIL

PRESSURE EXISTS ! message is displayed:

-The oil pressure switch closes very lately. As the unit senses an oil pressure, it does not start. When oil pressure switch closes the unit will start. Optionally the oil pressure switch may be replaced.

When the AC mains fails, the engine starts to run but the unit gives START FAIL alarm and then the engine stops:

-The generator phase voltages are not connected to the unit. Measure the AC voltage between terminals GEN L1-L2-L3 and Generator Neutral at the rear of the unit while the engine is running. A fuse protecting the generator phases may be failed. A misconnection may be occurred. If everything is

OK, turn all the fuses off, and then turn all the fuses on, starting from the DC supply fuse. Then test the unit again.

The unit is late to remove engine cranking:

-The generator voltage rises lately. Also the generator remnant voltage is below 15 volts. The unit removes starting with the generator frequency, and needs at least 15 volts to measure the frequency.

-The unit is also able to cut cranking from charge alternator voltage and oil pressure input. Please read chapter “CRANK CUTTING”

The unit is inoperative:

Measure the DC-supply voltage between terminals BAT+ and BAT- at the rear of the unit. If OK, turn all fuses off, then turn all the fuses on, starting from the DC supply fuse. Then test the unit again.

Programming mode can not be entered:

The program lock input disables programming mode entry. Disconnect the program lock input from battery negative before modification. Do not forget to make this connection again to prevent unauthorized program modifications.

Some program parameters are skipped:

These parameters are reserved for factory setting and cannot be modified.

AUTO led flashes and the genset does not run when mains fail:

The unit is in Weekly Schedule OFF time. Please check date and time setting of the unit. Please check also Weekly Schedule program parameters.

The genset runs but does not take the load:

Check that the genset Yellow led is on steadily. Adjust genset voltage and frequency limits if necessary.

Check that the digital output-8 is configured as “Genset Contactor”

Check “Genset Contactor Timer” program parameter.

Check that a Genset Loading Inhibit input signal is not active. Check input functions. If an input is configured as “Genset Loading Inhibit” then check the signal is not present at this input.

K35D01-EN — 136 —

Teksan Generator Control Panels GENERATOR SET CONTROL PANELS All measured and statistical parameters,operating modes,warnings and alarms and the current status of the mains and generator set can be viewed from the generator set control panel. The control panels are manufactured with following features and dimensions. Structure:

The control panels are made of A1 quality steel sheet and painted with electrostatics powder against corrosion.

Control Panel Mounting:

The control panels are mounted on the base frame until 825 kVA generator sets. The control panels are mounted on the alternator isolated from the vibration for bigger sized generator sets.

Control Panel Dimensions: Width: 220 mm, Length: 600 mm, Height: 400 mm1 Please contact with Teksan for project based special panel and control systems. 1-Except TJ9MS5N,TJ10MS5N,TJ11MS5N,TJ15MS5N,TJ20MS5N,TJ10PE5N, TJ14PE5N

AUTOMATIC CONTROL PANEL — TJPA Automatic control panel, provided with emergency generator sets, starts and stops generator set automatically in case of a mains failure with complete control and protection functions. These functions are realized with micro processor based control module. The modes of operation are selected by pushing the front panel bottons.

MANUAL CONTROL PANEL — TJPM It is designed to be used when mains power is not available or when it is aimed to start/stop the generator set manually. Control and protection functions are realized with micro processor based control module. The modes of operation are selected by pushing the front panel bottons.

TJ509

1

TJ519

www.teksangenerator.com

18.01.2012

TJPA TJPM MANUAL PANEL AUTOMATIC PANEL

CONTROL PANEL PROPERTIES

• Manual operation • Automatic operation

x

• Control module type

TJ519

TJ509

• Emergency stop button • Phase — Neutral generator set voltage measurement [V] • Phase — Phase generator set voltage measurement [V] • 3 phase generator set current measurement [A] • Generator set frequency measurement [Hz]

x x x

• Phase — Neutral mains voltage measurement [V] • Phase — Phase mains voltage measurement [V] • Mains frequency measurement [Hz] • Battery DC voltage measurement [VDC] • 3 phase generator set active power measurement [kW] • Generator set total active power measurement [kW] • 3 phase generator set power factor measurement • Generator set total power factor measurement • Engine oil pressure measurement [bar]1 • Engine oil temperature measurement [°C] • Engine coolant temperature measurement [°C]1 • Engine speed measurement [rpm] • Fuel level measurement [%]2 • 12/24 VDC operation • Earth leakage protection • Battery charger (rectifier) • Automatic exerciser operation [daily/weekly/monthly] • Load shedding/Dummy load3 • Event logging with date-time stamp (number)

200

200

• Event logging with date-time stamp and complete measurements (number)

18

18

• Statistical counters : engine hours run,generator set total active power[kWh],engine hours to service,time to service,total engine cranks,total engine runs • 3 level password protection • Adjustable setting parameters • Remote monitoring (On RS-232 port through software) • Remote start operation with dry contact • RS-232 serial port • RS-485 serial port • MODBUS communications • Electronic engine control and monitoring through J1939 CAN • Alarm/Warning indicator • Periodic maintenance (service) request indicator • Graphic LCD display

x

2

: Standard

1-Except TJ9MS5N,TJ10MS5N,TJ11MS5N,TJ15MS5N,TJ20MS5N

: Optional

2-Analogue fuel level gauge exists on the base frame fuel tank.

: Not applicable : NA

3-The load shedding feature consists on the disconnection of the least crucial loads in a single step when the generator set power approaches to its programmed limits.An additional breaker is needed in the ATS panel for the disconnection.

www.teksangenerator.com

18.01.2012

TJPA TJPM MANUAL PANEL AUTOMATIC PANEL

CONTROL PANEL PROPERTIES

• Multiple language support • Mimic diagram indicating the current status of the mains and generator set voltages and contactors

x

• Configurable analogue inputs • Configurable digital inputs • Configurable digital outputs • Relay output expansion capability

up to 22

up to 22

• Dual generator set mutual standby operation • Lockable control panel door • Spring clamp type terminals • Alarm horn • Space heater • Lighting inside control panel • Lighting outside control panel • Analogue measurement gauges

x

3

: Standard : Optional : Not applicable : NA

www.teksangenerator.com

18.01.2012

TJPA TJPM MANUAL PANEL AUTOMATIC PANEL

CONTROL PANEL WARNINGS

• Generator set low/high speed • High coolant temperature • Low coolant temperature • Low oil pressure • High oil temperature

x

• Mains phase order fail • Battery charger (rectifier) failure • Charge alternator (or broken belt) failure • Low battery voltage • High battery voltage • Low fuel level • Stop fail • Reverse power • Service request

TJPM TJPA MANUAL PANEL AUTOMATIC PANEL

CONTROL PANEL ALARMS

• Generator set low/high speed • High coolant temperature • Low oil pressure • High oil temperature • High battery voltage • Low fuel level • Start fail • Overload • Excess power • Genset low/high voltage • Low coolant level (above 275 kVA) • Reverse power

x

4

: Standard : Optional : Not applicable : NA

www.teksangenerator.com

18.01.2012

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

TJ-509-T GENSET CONTROLLER

DESCRIPTION The 509T is a next generation genset control unit combining multi-functionality and wide communication possibilities together with a reliable and low cost design. The unit complies and mostly exceeds world’s tightest safety, EMC, vibration and environmental standards for the industrial category. Software features are complete with easy firmware upgrade process through USB port. The Windows based PC software allows monitoring and programming through USB, RS-485, Ethernet and GPRS.

FUNCTIONALITIES AMF unit with uninterrupted transfer ATS unit with uninterrupted transfer Remote start controller Manual start controller Engine controller Remote display & control unit Waveform display of V & I Harmonic analysis of V & I CTs at genset or load side

COMMUNICATIONS Ethernet GSM-GPRS (optional) Embedded web server Web monitoring Web programming GSM-SMS (optinal) e-mail Modbus RS-485 Modbus over IP SNMP USB Host USB Device RS-485 RS-232 J1939-CANBUS

TOPOLOGIES 2 phases 3 wires, L1-L2 2 phases 3 wires, L1-L3 3 phases 3 wires, 3 CTs 3 phases 3 wires, 2 CTs (L1-L2) 3 phases 3 wires, 2 CTs (L1-L3) 3 phases 4 wires, star 3 phases 4 wires, delta 1 phase 2 wires

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

COPYRIGHT NOTICE Any unauthorized use or copying of the contents or any part of this document is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings.

ABOUT THIS DOCUMENT This document describes minimum requirements and necessary steps for the successful installation of the 509T family units. Follow carefully advices given in the document. These are often good practices for the installation of genset control units which reduce future issues. For all technical queries please contact Datakom at below e-mail address: [email protected]

RELATED DOCUMENTS FILENAME

DESCRIPTION

509TRainbow Installation

Rainbow Plus 509T Installation Guide

509TRainbow Usage

Rainbow Plus 509T Usage Guide RainbowPlus User Manual Dynamic DNS Account Setting for 509T Ethernet Configuration Guide for 509T GSM Configuration Guide for 509T Firmware Update Guide for 509T Modbus Application Manual for 509T

RainbowPlus_USER 509TDYNdns account setting.pdf 509TEthernet Configuration 509TGSM Configuration 509TFirmware Update 509T-MODBUS

REVISION HISTORY REVISION

DATE

AUTHOR

01

29.09.2011

MH

DESCRIPTION First issue, firmware version 1.06

TERMINOLOGY CAUTION: Potential risk of injury or death.

WARNING: Potential risk of malfunction or material damage.

ATTENTION: Useful hints for the understanding of device operation.

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ORDERING CODES The 509T family units are available in various options and peripheral features. Please use below information for ordering the correct version:

509T -G -T -00 Variant 00: standard unit 01…99: customer specific products

Family Code

With Conformal Coating With Sealing gasket

SPARE PARTS

Screw type bracket Stock Code=J10P01 (per unit)

Self-Retaining type bracket Stock Code=K16P01 (per unit)

Sealing Gasket, Stock Code= K35P01

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TJ-509T User Manual Rev_01

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V-1.4

SAFETY NOTICE Failure to follow below instructions will result in death or serious injury  Electrical equipment should be installed only by qualified specialist. No responsibility is assured by the manufacturer or any of its subsidiaries for any consequences resulting from the noncompliance to these instructions.  Check the unit for cracks and damages due to transportation. Do not install damaged equipment.  Do not open the unit. There are no serviceable parts inside.  Fuses must be connected to the power supply and phase voltage inputs, in close proximity of the unit.  Fuses must be of fast type (FF) with a maximum rating of 6A.  Disconnect all power before working on equipment.  When the unit is connected to the network do not touch terminals.  Short circuit terminals of unused current transformers.  Any electrical parameter applied to the device must be in the range specified in the user manual. Although the unit is designed with a wide safety margin, over-range parameters may reduce lifetime, alter operational precision or even damage the unit.  Do not try to clean the device with solvent or the like. Only clean with a dump cloth.  Verify correct terminal connections before applying power.  Only for front panel mounting.

Current Transformers must be used for current measurement. No direct connection allowed.

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TABLE OF CONTENTS COPYRIGHT NOTICE …………………………………………………………………………………………………………………. 2 ABOUT THIS DOCUMENT………………………………………………………………………………………………………….. 2 RELATED DOCUMENTS …………………………………………………………………………………………………………….. 2 REVISION HISTORY…………………………………………………………………………………………………………………… 2 TERMINOLOGY ……………………………………………………………………………………………………………………….. 2 ORDERING CODES …………………………………………………………………………………………………………………… 2 SPARE PARTS ………………………………………………………………………………………………………………………….. 2 TABLE OF CONTENTS ……………………………………………………………………………………………………………….. 2 INSTALLATION INSTRUCTIONS ………………………………………………………………………………………………….. 2 MOUNTING …………………………………………………………………………………………………………………………….. 2 DIMENSIONS……………………………………………………………………………………………………………………….. 2 SEALING, GASKET ………………………………………………………………………………………………………………… 2 ELECTRICAL INSTALLATION……………………………………………………………………………………………………. 2 TERMINAL DESCRIPTIONS ………………………………………………………………………………………………………… 2 BATTERY VOLTAGE INPUT …………………………………………………………………………………………………….. 2 AC VOLTAGE INPUTS ……………………………………………………………………………………………………………. 2 AC CURRENT INPUTS ……………………………………………………………………………………………………………. 2 DIGITAL INPUTS …………………………………………………………………………………………………………………… 2 ANALOG SENDER INPUTS AND SENDER GROUND ……………………………………………………………………. 2 CHARGE INPUT TERMINAL ……………………………………………………………………………………………………. 2 MAGNETIC PICKUP INPUT …………………………………………………………………………………………………….. 2 MAINS CONTACTOR OUTPUT ………………………………………………………………………………………………… 2 GENERATOR CONTACTOR OUTPUT ………………………………………………………………………………………… 2 DIGITAL OUTPUTS………………………………………………………………………………………………………………… 2 INPUT/OUTPUT EXTENSION ………………………………………………………………………………………………….. 2 RS-485 PORT ……………………………………………………………………………………………………………………….. 2 J1939-CANBUS PORT ……………………………………………………………………………………………………………. 2 ETHERNET PORT ………………………………………………………………………………………………………………….. 2 USB DEVICE PORT ………………………………………………………………………………………………………………… 2 USB HOST PORT …………………………………………………………………………………………………………………… 2 RS-232 PORT ……………………………………………………………………………………………………………………….. 2 GSM MODEM (OPTIONAL) ……………………………………………………………………………………………………. 2 TOPOLOGIES …………………………………………………………………………………………………………………………… 2

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SELECTING THE TOPOLOGY …………………………………………………………………………………………………… 2 3 PHASE, 4 WIRE, STAR …………………………………………………………………………………………………………. 2 3 PHASE, 3 WIRE, DELTA……………………………………………………………………………………………………….. 2 3 PHASE, 4 WIRE, DELTA……………………………………………………………………………………………………….. 2 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L2) …………………………………………………………………………………….. 2 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L3) …………………………………………………………………………………….. 2 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L2) …………………………………………………………………………………… 2 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L3) …………………………………………………………………………………… 2 1 PHASE, 2 WIRE ………………………………………………………………………………………………………………….. 2 FUNCTIONALITIES ……………………………………………………………………………………………………………………. 2 CT LOCATION SELECTION ……………………………………………………………………………………………………… 2 AMF FUNCTIONALITY …………………………………………………………………………………………………………… 2 ATS FUNCTIONALITY …………………………………………………………………………………………………………….. 2 REMOTE START FUNCTIONALITY ……………………………………………………………………………………………. 2 ENGINE CONTROLLER FUNCTIONALITY …………………………………………………………………………………… 2 400HZ OPERATION ………………………………………………………………………………………………………………. 2 REMOTE DISPLAY UNIT FUNCTIONALITY …………………………………………………………………………………. 2 CONNECTION DIAGRAMS …………………………………………………………………………………………………………. 2 AMF FUNCTIONALITY, CTs AT LOAD SIDE ……………………………………………………………………………….. 2 AMF FUNCTIONALITY, CTs AT ALTERNATOR SIDE …………………………………………………………………….. 2 ATS FUNCTIONALITY …………………………………………………………………………………………………………….. 2 REMOTE START FUNCTIONALITY ……………………………………………………………………………………………. 2 ENGINE CONTROL FUNCTIONALITY ………………………………………………………………………………………… 2 REMOTE DISPLAY PANEL FUNCTIONALITY ………………………………………………………………………………. 2 TERMINAL DESCRIPTION ………………………………………………………………………………………………………….. 2 TECHNICAL SPECIFICATIONS……………………………………………………………………………………………………… 2 DESCRIPTION OF CONTROLS …………………………………………………………………………………………………….. 2 FRONT PANEL FUNCTIONALITY ……………………………………………………………………………………………… 2 PUSHBUTTON FUNCTIONS ……………………………………………………………………………………………………. 2 DISPLAY SCREEN ORGANIZATION …………………………………………………………………………………………… 2 AUTOMATIC DISPLAY SCROLL ……………………………………………………………………………………………….. 2 MEASURED PARAMETERS …………………………………………………………………………………………………….. 2 LED LAMPS………………………………………………………………………………………………………………………….. 2 WAVEFORM DISPLAY & HARMONIC ANALYSIS ……………………………………………………………………………. 2 DISPLAYING EVENT LOGS …………………………………………………………………………………………………………. 2

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STATISTICAL COUNTERS …………………………………………………………………………………………………………… 2 OPERATION OF THE UNIT …………………………………………………………………………………………………………. 2 QUICK START GUIDE …………………………………………………………………………………………………………….. 2 STOP MODE ………………………………………………………………………………………………………………………… 2 AUTO MODE ……………………………………………………………………………………………………………………….. 2 RUN MODE, MANUAL CONTROL ……………………………………………………………………………………………. 2 TEST MODE …………………………………………………………………………………………………………………………. 2 PROTECTIONS AND ALARMS …………………………………………………………………………………………………….. 2 DISABLING ALL PROTECTIONS ……………………………………………………………………………………………….. 2 SERVICE REQUEST ALARM …………………………………………………………………………………………………….. 2 SHUTDOWN ALARMS …………………………………………………………………………………………………………… 2 LOADDUMP ALARMS ……………………………………………………………………………………………………………. 2 WARNINGS …………………………………………………………………………………………………………………………. 2 PROGRAMMING ……………………………………………………………………………………………………………………… 2 RESETTING TO FACTORY DEFAULTS ……………………………………………………………………………………….. 2 ENTERING THE PROGRAMMING MODE ………………………………………………………………………………….. 2 NAVIGATING BETWEEN MENUS …………………………………………………………………………………………….. 2 MODIFYING PARAMETER VALUE ……………………………………………………………………………………………. 2 PROGRAMMING MODE EXIT …………………………………………………………………………………………………. 2 PROGRAM PARAMETER LIST …………………………………………………………………………………………………….. 2 CONTROLLER CONFIGURATION GROUP ………………………………………………………………………………….. 2 ELECTRICAL PARAMETERS GROUP …………………………………………………………………………………………. 2 ENGINE PARAMETERS GROUP ………………………………………………………………………………………………. 2 ADJUST DATE AND TIME ………………………………………………………………………………………………………. 2 WEEKLY OPERATION SCHEDULE …………………………………………………………………………………………….. 2 EXERCISER SCHEDULE …………………………………………………………………………………………………………… 2 SENDER CONFIGURATION …………………………………………………………………………………………………….. 2 DIGITAL INPUT CONFIGURATION …………………………………………………………………………………………… 2 OUTPUT CONFIGURATION ……………………………………………………………………………………………………. 2 SITE ID STRING …………………………………………………………………………………………………………………….. 2 ENGINE SERIAL NUMBER ………………………………………………………………………………………………………. 2 MODEM1-2/SMS1-2-3-4 TELEPHONE NUMBERS ……………………………………………………………………… 2 GSM MODEM PARAMETERS …………………………………………………………………………………………………. 2 ETHERNET PARAMETERS ………………………………………………………………………………………………………. 2 SYNCHRONIZATION PARAMETERS …………………………………………………………………………………………. 2

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V-1.4

CRANK CUTTING ……………………………………………………………………………………………………………………… 2 OVERCURRENT PROTECTION (IDMT) …………………………………………………………………………………………. 2 MOTORIZED CIRCUIT BREAKER CONTROL …………………………………………………………………………………… 2 J1939 CANBUS ENGINE SUPPORT ……………………………………………………………………………………………… 2 ETHERNET CONFIGURATION …………………………………………………………………………………………………….. 2 GSM CONFIGURATION …………………………………………………………………………………………………………….. 2 DYNAMIC DNS FEATURE …………………………………………………………………………………………………………… 2 ACCESSING THE EMBEDDED WEB SERVER ………………………………………………………………………………….. 2 CENTRAL MONITORING OF GENSETS …………………………………………………………………………………………. 2 WEB MONITORING AND CONTROL OF GENSETS …………………………………………………………………………. 2 ETHERNET – MODBUS GATEWAY OPERATION ……………………………………………………………………………. 2 GPRS – MODBUS GATEWAY OPERATION ……………………………………………………………………………………. 2 LOAD TRANSFER MODES ………………………………………………………………………………………………………….. 2 TRANSFER WITH INTERRUPTION ……………………………………………………………………………………………. 2 UNINTERRUPTED TRANSFER …………………………………………………………………………………………………. 2 DATA RECORDING …………………………………………………………………………………………………………………… 2 DATA RECORDING MEDIA …………………………………………………………………………………………………….. 2 DIRECTORY STRUCTURE ……………………………………………………………………………………………………….. 2 UNDERSTANDING THE CSV FORMAT ……………………………………………………………………………………… 2 RECORDED DATA LIST, RECORD PERIOD …………………………………………………………………………………. 2 SOFTWARE FEATURES ……………………………………………………………………………………………………………… 2 Load Shedding / Dummy Load ………………………………………………………………………………………………. 2 Remote Start Operation ……………………………………………………………………………………………………….. 2 Disable Auto Start, Simulate Mains ………………………………………………………………………………………… 2 Battery Charging Operation, Delayed Simulate Mains ……………………………………………………………… 2 Dual Genset Mutual Standby Operation …………………………………………………………………………………. 2 Dual Voltage and Frequency …………………………………………………………………………………………………. 2 Single Phase Operation ………………………………………………………………………………………………………… 2 External Control of the Unit ………………………………………………………………………………………………….. 2 Automatic Exerciser …………………………………………………………………………………………………………….. 2 WEEKLY OPERATION SCHEDULER ………………………………………………………………………………………….. 2 Engine Heating Operation …………………………………………………………………………………………………….. 2 Engine Idle Speed Operation …………………………………………………………………………………………………. 2 Engine Block Heater …………………………………………………………………………………………………………….. 2 Fuel Pump Control ……………………………………………………………………………………………………………….. 2

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Gas Engine Fuel Solenoid Control ………………………………………………………………………………………….. 2 MODBUS COMMUNICATIONS …………………………………………………………………………………………………… 2 DECLARATION OF CONFORMITY ……………………………………………………………………………………………….. 2 MAINTENANCE ……………………………………………………………………………………………………………………….. 2 DISPOSAL OF THE UNIT ……………………………………………………………………………………………………………. 2 ROHS COMPLIANCE …………………………………………………………………………………………………………………. 2 TROUBLESHOOTING GUIDE ………………………………………………………………………………………………………. 2

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PRELIMINARY VERSION

V-1.4

INSTALLATION INSTRUCTIONS Before installation: 

Read the user manual carefully, determine the correct connection diagram.

 Remove all connectors and mounting brackets from the unit, then pass the unit through the mounting opening. 

Put mounting brackets and tighten. Do not tighten too much, this can brakmicroe the enclosure.



Make electrical connections with plugs removed from sockets, then place plugs to their sockets.



Be sure that adequate cooling is provided.

 Be sure that the temperature of the environment will not exceed the maximum operating temperature in any case. Below conditions may damage the device: 

Incorrect connections.



Incorrect power supply voltage.



Voltage at measuring terminals beyond specified range.



Voltage applied to digital inputs over specified range.



Current at measuring terminals beyond specified range.



Overload or short circuit at relay outputs



Connecting or removing data terminals when the unit is powered-up.



High voltage applied to communication ports.



Ground potential differences at non-isolated communication ports.



Excessive vibration, direct installation on vibrating parts.

Current Transformers must be used for current measurement. No direct connection allowed.

Below conditions may cause abnormal operation: 

Power supply voltage below minimum acceptable level.



Power supply frequency out of specified limits



Phase order of voltage inputs not correct.



Current transformers not matching related phases.



Current transformer polarity incorrect.



Missing grounding.

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MOUNTING DIMENSIONS Dimensions: 200x148x47mm (7.9”x5.8”x1.9”) Panel Cutout: 176x121mm minimum (7.0”x4.8”) Weight: 450g (1 lb)

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V-1.4

The unit is designed for panel mounting. The user should not be able to access parts of the unit other than the front panel. Mount the unit on a flat, vertical surface. Before mounting, remove the mounting brackets and connectors from the unit, then pass the unit through the mounting opening. Place and tighten mounting brackets.

Panel Cutout

Required Panel Depth

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V-1.4

Two different types of brackets are provided:

Screw type bracket

Self retaining type bracket

Installation of screw type bracket

Installation of self retaining type bracket

Do not tighten too much, this may break the unit.

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V-1.4

SEALING, GASKET

Panel

Gasket

Module

The rubber gasket provides a watertight means of mounting the module to the genset panel. Together with the gasket, IEC 60529-IP65 protection can be reached from the front panel. A short definition of IP protection levels is given below.

1st Digit Description of Protection Level

0 Not protected 1 Protected against solid foreign objects of 50 mm diameter and greater 2 Protected against solid foreign objects of 12,5 mm diameter and greater 3 Protected against solid foreign objects of 2,5 mm diameter and greater 4 Protected against solid foreign objects of 1,0 mm diameter and greater 5 Protected from the amount of dust that would interfere with normal operation 6 Dust tight

2nd Digit Description of Protection Level

0 Not protected 1 Protected against vertically falling water drops 2 Protected against vertically falling water drops when enclosure is tilted up to 15 ° 3 Protected against water sprayed at an angle up to 60 ° on either side of the vertical 4 Protected against water splashed against the component from any direction 5 Protected against water projected in jets from any direction 6 Protected against water projected in powerful jets from any direction 7 Protected against temporary immersion in water 8 Protected against continuous immersion in water, or as specified by the user

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TJ-509T User Manual Rev_01

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V-1.4

ELECTRICAL INSTALLATION Do not install the unit close to high electromagnetic noise emitting devices like contactors, high current busbars, switchmode power supplies and the like. Although the unit is protected against electromagnetic disturbance, excessive disturbance can affect the operation, measurement precision and data communication quality. 

ALWAYS remove plug connectors when inserting wires with a screwdriver.

 Fuses must be connected to the power supply and phase voltage inputs, in close proximity of the unit. 

Fuses must be of fast type (FF) with a maximum rating of 6A.



Use cables of appropriate temperature range.



Use adequate cable section, at least 0.75mm2 (AWG18).



Follow national rules for electrical installation.



Current transformers must have 5A output.



For current transformer inputs, use at least 1.5mm2 section (AWG15) cable.

 The current transformer cable length should not exceed 1.5 meters. If longer cable is used, increase the cable section proportionally.

Current Transformers must be used for current measurement. No direct connection allowed. The engine body must be grounded. Otherwise faulty voltage and frequency measurements may occur. For the correct operation of the exerciser and weekly schedule programs, adjust the real time clock of the unit through programming menu.

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TJ-509T User Manual Rev_01

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V-1.4

TERMINAL DESCRIPTIONS BATTERY VOLTAGE INPUT Supply voltage:

9 to 33VDC

Cranking dropouts:

Survives 0VDC during 100ms. The voltage before surge should be 9VDC minimum

Overvoltage protection:

Withstands 150VDC continuously.

Reverse voltage:

-33VDC continuous

Maximum operating current:

500mA @ 12VDC. (All options included, digital outputs open.) 250mA @ 24VDC. (All options included, digital outputs open.)

Typical operating current:

250mA @ 12VDC. (all options passive, digital outputs open) 125mA @ 24VDC. (all options passive, digital outputs open)

Measurement range:

0 to 36VDC

Display resolution:

0.1VDC

Accuracy:

0.5% + 1 digit @ 24VDC

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AC VOLTAGE INPUTS Measurement method:

True RMS

Sampling rate:

8000 Hz

Harmonic analysis:

up to 31th harmonic

Input voltage range:

14 to 300 VAC

Minimum voltage for frequency detection:

15 VAC (Ph-N)

Supported topologies:

3 ph 4 wires star 3 ph 3 wires delta 3ph 4 wires delta 2ph 3 wires L1-L2 2ph 3 wires L1-L3 1 ph 2 wires

Measurement range:

0 to 330VAC ph-N (0 to 570VAC ph-ph)

Common mode offset:

max 100V between neutral and BAT-

Input impedance:

4.5M-ohms

Display resolution:

1VDC

Accuracy:

0.5% + 1 digit @ 230VAC ph-N (±2VAC ph-N) 0.5% + 1 digit @ 400VAC ph-ph (±3VAC ph-ph)

Frequency range:

DC to 500Hz

Frequency display resolution:

0.1 Hz

Frequency accuracy:

0.2% + 1 digit (±0.1 Hz @ 50Hz)

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AC CURRENT INPUTS Measurement method:

True RMS

Sampling rate:

8000 Hz

Harmonic analysis:

up to 31th harmonic

Supported topologies:

3 ph 3 CTs 3 ph 2 CTs L1-L2 3 ph 2 CTs L1-L3 2 ph 2 CTs L1-L2 2 ph 2 CTs L1-L3 1 ph 1 CT

CT secondary rating:

5A

Measurement range:

5/5 to 5000/5A minimum

Input impedance:

15 mili-ohms

Burden:

0.375W

Maximum continuous current:

6A

Measurement range:

0.1 to 7.5A

Common mode offset:

Max 5VAC between BAT- and any CT terminal.

Display resolution:

1A

Accuracy:

0.5% + 1 digit @ 5A (± 4.5A @ 5/500A full range)

SELECTING THE CT RATING AND CABLE SECTION: The load on a CT should be kept minimum in order to minimize phase shift effect of the current transformer. Phase shift in a CT will cause erroneous power and power factor readings, although amp readings are correct. Datakom advises CT rating to be selected following this table for the best measurement accuracy.

SELECTING THE CT ACCURACY CLASS: The CT accuracy class should be selected in accordance with the required measurement precision. The accuracy class of the Datakom controller is 0.5%. Thus 0.5% class CTs are advised for the best result.

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CONNECTING CTs: Be sure of connecting each CT to the related phase input with the correct polarity. Mixing CTs between phases will cause faulty power and pf readings. Many combinations of incorrect CTs connections are possible, so check both order of CTs and their polarity. Reactive power measurement is affected by incorrect CTs connection in similar way as active power measurement.

CORRECT CT CONNECTIONS

Let’s suppose that the genset is loaded with 100 kW on each phase. The load Power Factor (PF) is 1. Measured values are as follows: kW

kVAr

kVA

pf

Phase L1

100.0

0.0

100

1.00

Phase L2

100.0

0.0

100

1.00

Phase L3

100.0

0.0

100

1.00

Total

300.0

0.0

300

1.00

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V-1.4

EFFECT OF POLARITY REVERSAL

The generator is still loaded with 100 kW On each phase. The load Power Factor (PF) is 1. PF in phase L2 will show -1,00 due to reverse CT polarity. The result is that total generator power displayed by the controller is 100 kW. Measured values are as follows: kW

kVAr

kVA

pf

Phase L1

100.0

0.0

100

1.00

Phase L2

-100.0

0.0

100

-1.00

Phase L3

100.0

0.0

100

1.00

Total

100.0

0.0

300

0.33

EFFECT OF PHASE SWAPPING

The generator is still loaded with 100 kW on each phase. The load Power Factor (PF) is 1. PF in phases L2 and L3 will show -0,50 due to phase shift between voltages and currents which is caused by CT swapping. The result is that total generator power displayed by controller is 0 kW. Measured values are as follows: kW

kVAr

kVA

pf

Phase L1

100.0

0.0

100

1.00

Phase L2

-50.0

86.6

100

-0.50

Phase L3

-50.0

-86.6

100

-0.50

0.0

0.0

300

0.0

Total

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DIGITAL INPUTS Number of inputs:

8 inputs, all configurable

Function selection:

from list

Contact type:

Normally open or normally closed (programmable)

Switching:

Battery negative or battery positive (programmable)

Structure:

47 k-ohms resistor to battery positive, 110k-ohms to battery negative.

Measurement:

Analog voltage measurement.

Open circuit voltage:

70% of battery voltage

Low level threshold:

35% of battery voltage

High level threshold:

85% of battery voltage

Maximum input voltage:

+100VDC with respect to battery negative

Minimum input voltage:

-70VDC with respect to battery negative

Noise filtering:

yes

ANALOG SENDER INPUTS AND SENDER GROUND Number of inputs:

4 inputs, all configurable, additional sender ground input

Function selection:

from list

Structure:

667 ohms resistor polarizing to 3.3VDC

Measurement:

Analog resistor measurement.

Open circuit voltage:

+3.3VDC

Short circuit current:

5mA

Measurement range:

0 to 5000 ohms.

Open circuit threshold:

5000 ohms.

Resolution:

1 ohms @ 300 ohms or lower

Accuracy:

2 %+1 ohm (±7 ohms @300 ohms)

Common mode voltage range:

± 3VDC

Noise filtering:

yes

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CHARGE INPUT TERMINAL The Charge terminal is both an input and output. When the engine is ready to run, this terminal supplies the excitation current to the charge alternator. The excitation circuit is equivalent to a 2W lamp. The threshold voltages for warning and shutdown alarm are adjustable through program parameter. Structure:



battery voltage output through 20 ohm PTC



voltage measurement input

Output current:

160mA @12VDC 80mA @24VDC

Voltage measurement resolution:

0.1VDC

Voltage measurement accuracy:

2% + 0.1V (0.9V @30VDC)

Charge Fail Warning Threshold:

adjustable

Charge Fail Shutdown Alarm Threshold:

adjustable

Open circuit voltage:

battery positive

Overvoltage protection:

> 500VDC continuous, with respect to battery negative

Reverse voltage protection:

-30VDC with respect to battery negative

MAGNETIC PICKUP INPUT Structure:

Differential frequency measurement input

Input impedance:

50 k-ohms

Input voltage:

0.5VAC-RMS to 30VAC-RMS

Max common mode voltage:

± 5VDC

Frequency range:

10Hz to 10 kHz

Resolution:

1 rpm

Accuracy:

0.2% + 1 rpm (±3rpm @1500 rpm)

Flywheel teeth range:

1 to 500

Do not share MPU with other devices.

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MAINS CONTACTOR OUTPUT Structure:

Relay output, normally closed contact. One terminal is internally connected to mains phase L1 input.

Max switching current:

12A @250VAC

Max switching voltage:

440VAC

Max switching power:

3000VA

GENERATOR CONTACTOR OUTPUT Structure:

Relay output, normally open contact. One terminal is internally connected to genset phase L1 input.

Max switching current:

16A @250VAC

Max switching voltage:

440VAC

Max switching power:

4000VA

DIGITAL OUTPUTS The unit offers 6 digital outputs with programmable function, selectable from list.

Structure:

Negative pulling protected semiconductor output. One terminal is connected to battery negative.

Max continuous current:

1.0 ADC

Max switching voltage:

33 VDC

Overvoltage protection:

40 VDC

Short circuit protection:

> 1.7 ADC

Reverse voltage protection:

500 VDC

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V-1.4

INPUT/OUTPUT EXTENSION

I/O Extension Connector

The module provides resources for 32 additional digital inputs and 32 additional digital outputs. Digital inputs can be extended using DKG-188 Digital Input Extension modules, each one providing 8 inputs. Digital inputs are programmable through the main controller. The switching characteristic is not programmable and must be battery negative. Any function can be assigned to digital inputs. Digital outputs can be extended using DKG-186 Fet Extension modules, each one providing 8 outputs. Digital outputs have the same electrical characteristics as on board outputs. They have programmable functions through the main controller. Any function can be assigned to any output. Input and output extension modules are connected to the main controller in a cascade structure, in any order. The connection cable is provided with each extension module.

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RS-485 PORT Structure:

RS-485, non-isolated.

Connection:

3 wires (A-B-GND). Half duplex.

Baud rate:

2400-115200 bauds, selectable

Data type:

8 bit data, no parity, 1 bit stop

Termination:

External 120 ohms required

Common mode voltage:

-0.5 VDC to +7VDC, internally clamped by transient suppressors.

Max distance:

1200m @ 9600 bauds (with 120 ohms balanced cable) 200m @ 115200 bauds (with 120 ohms balanced cable)

The RS-485 port features MODBUS-RTU protocol. Multiple modules (up to 128) can be paralleled on the same RS-485 bus for data transfer to automation or building management systems. The Modbus register list is available at Datakom technical support. The RS-485 port provides also a good solution for distant PC connection where RainbowPlus program will enable programming, control and monitoring. For more details about programming, control and monitoring through RS-485 port please refer to RainbowPlus user manual.

J1939-CANBUS PORT Structure:

CANBUS, non-isolated.

Connection:

3 wires (CANH-CANL-GND).

Data rate:

250 kbps

Termination:

Internal 120 ohms provided

Common mode voltage:

-0.5 VDC to +15 VDC, internally clamped by transient suppressors.

Max distance:

200m with 120 ohm balanced cable

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ETHERNET PORT

Ethernet Connector Data Flow led Link Established led

Description:

IEEE802.3 compliant, 10/100 Base-TX RJ45 ethernet port with indicating leds

Data rate:

10/100 Mbits/s, auto detecting

Connector:

RJ45

Cable type:

CAT5 or CAT6

Isolation:

1500 VAC, 1 minute

Max distance:

30m.

Functionality:

Embedded TCP-IP, Web Server, Web Client, SMTP, e-mail, SNMP, Modbus over IP

LED FUNCTIONS: GREEN: This led turns on when the ethernet link is established (connector inserted) YELLOW: This led blinks when data transfer occurs inwards or outwards. Periodic blinking will witness data flow.

STANDARD ETHERNET CABLE

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USB DEVICE PORT

USB Device Connector

Description:

USB 2.0, not isolated, HID mode

Data rate:

Full Speed 1.5/12 Mbits/s, auto detecting

Connector:

USB-B (printer connector)

Cable length:

Max 6m

Functionality:

Modbus, FAT32 for firmware upgrade (boot loader mode only)

The USB-Device port is designed to connect the module to a PC. Using the RainbowPlus software, programming, control of the genset and monitoring of measured parameters are achieved. The RainbowPlus software can be downloaded from www.datakom.com.tr website. The connector on the module is of USB-B type. Thus A to B type USB cable should be used. This is the same cable used for USB printers. For more details about programming, control and monitoring please refer to RainbowPlus user manual.

The battery voltage must be connected.

If USB-Device is plugged then USB-Host port will not function.

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USB HOST PORT

USB FLASH MEMORY

USB HOST Port

The USB-Host port is available in units with COMM option.

Description:

USB 2.0, not isolated

Power Supply Output:

5V, 300mA max

Data rate:

Full Speed 1.5/12 Mbits/s, auto detecting

Connector:

USB-A (PC type connector)

Cable length:

Max 1.5m

Functionality:

USB memory, FAT32, data recording

Memory capacity:

all USB flash memories.

The USB-Host port is designed for detailed data recording. The period of recording is adjustable through program parameter. As soon as a USB flash memory is inserted, the unit will start data recording and continue until the memory is removed. For more details about data recording please review chapter “Data Recording”.

If USB-Device is plugged then USB-Host port will not function.

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RS-232 PORT Description:

RS-232, non-isolated.

Functionality:

External GSM modem, external PSTN modem

Connector:

DB-9 (9 pins male)

Connection:

5 wires (Rx-Tx-DTR-CxD-GND). Full duplex.

Baud rate:

2400-115200 bauds, selectable

Data type:

8 bit data, no parity, 1 bit stop

Max distance:

15m

Cable type:

Standard modem cable

Terminal description:

1: CxD input 2: Rx input 3: Tx output 4: DTR output 5: GND

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V-1.4

GSM MODEM (OPTIONAL) The optional internal GSM modem offers the advantage of being internally powered and is fully compatible with the unit. It does not require any special setup. The 1800/1900 MHz magnetic antenna together with its 2 meter cable is supplied with the internal modem option. The antenna is intended to be placed outside of the genset panel for the best signal reception.

SIM Card extraction tab SIM Card slot Antenna connector

Magnetic antenna

The module requires a GPRS enabled SIM card for full functionality. Voice-only type SIM cards will usually not function properly. Please refer to GSM Modem Configuration Guide for more details.

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Push the extraction tab

SIM CARD EXTRACTION

SIM CARD EXTRACTION / INSERTION

SIM CARD PLACEMENT Description:

Functionality:

Quad-band GSM/GPRS 850/900/1800/1900MHz module. GPRS multi-slot class 10/8 GPRS mobile station class B Compliant to GSM phase 2/2+. – Class 4 (2 W @850/ 900 MHz) – Class 1 (1 W @ 1800/1900MHz) Embedded TCP-IP, Web Client, SMTP, SNMP, Modbus over IP, SMS, e-mail -40°C to +85 °C

Data speed:

max. 85.6 kbps (download), 42.8 kbps (upload)

SIM card type:

external SIM 3V/1.8V, GPRS enabled

Antenna:

Quad band, magnetic, with 2m cable

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TJ-509T User Manual Rev_01 Module certificates:

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PRELIMINARY VERSION

CE, FCC, ROHS, PTCRB, GCF, IC, ICASA, REACH

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TJ-509T User Manual Rev_01

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V-1.4

TOPOLOGIES Various topologies are selectable through program parameter. The topology is independently selectable for both genset and mains sections. In following drawings the connections are shown for the alternator. Current transformers are supposed connected to the alternator side. Similar topologies re available for the mains side as well.

SELECTING THE TOPOLOGY

Generator Parameters s

Topology Selection

Mains Parameters s

Topology Selection

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3 PHASE, 4 WIRE, STAR

3 PHASE, 3 WIRE, DELTA

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3 PHASE, 4 WIRE, DELTA

3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L2)

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3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L3)

2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L2)

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2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L3)

1 PHASE, 2 WIRE

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V-1.4

FUNCTIONALITIES The same unit provides different functionalities through parameter setting. Thus a single stock item will fulfill various duties, minimizing stock cost.

CT LOCATION SELECTION CTs may be placed at alternator or load busbars. The CT location selection is configured with Controller Configuration > CT Location parameter. When CTs are located at the alternator side, them mains current and power parameters will not be displayed. When CTs are located at load side, then both mains and genset currents and power parameters will be displayed, based on contactor positions. Please review AMF functionality connection diagrams for CT connection details.

AMF FUNCTIONALITY When AMF functionality is selected, the unit will monitor mains voltages, provide mains and genset contactor control, run the engine and provide engine and alternator instrumentation and fault monitoring. The unit features both MPU and J1939 CANBUS inputs. Thus both mechanical and electronic engines are supported. The unit provides control outputs for both contactors and motorized circuit breakers.

ATS FUNCTIONALITY When ATS functionality is selected, the unit will monitor mains voltages, provide mains and genset contactor control and issue a Remote Start signal to the engine controller. It will provide alternator instrumentation and fault monitoring. Engine instrumentation and protection will be insured by the engine controller.

REMOTE START FUNCTIONALITY When the Remote Start functionality is selected, the unit will wait for a Remote Start signal from external controller. Upon reception of this signal, it will run the engine, and provide engine and alternator instrumentation and fault monitoring. The genset contactor/MCB control functionality will be available. The unit features both MPU and J1939 CANBUS inputs. Thus both mechanical and electronic engines are supported.

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ENGINE CONTROLLER FUNCTIONALITY When the Engine Controller functionality is selected, genset electrical measurements and protections will be disabled. The unit is supposed to control an engine without alternator. When the Engine Control Mode is activated: -the unit will not display genset AC parameters (volts, amps, kW and pf). -genset voltage and frequency protections are disabled. However engine rpm protections will be active. Note that the engine controller functionality is compatible with both AMF and Remote Start modes. When AMF and Engine controller modes are selected, the unit will monitor the mains and will run the engine upon mains failure. This functionality is useful for the backup electric motor driven systems during mains failures, like fire pump or irrigation systems. When Remote Start and Engine controller modes are selected, the unit will start and stop the engine with external signal only. The unit features both MPU and J1939 CANBUS inputs. Thus both mechanical and electronic engines are supported.

It is strongly recommended to wire speed detection through MPU or J1939-CANBUS and enter correct low and high rpm limit values in order to preserve engine speed protection. 400HZ OPERATION The standard unit is also 400Hz enabled. The nominal frequency setting accepts up to 500Hz. Usual low and high limits will apply without any special setting. The measurement system of the unit allows frequencies up to 1000Hz to be measured precisely. However the display is limited to 650Hz. Frequencies over 650Hz will be displayed as 650Hz. The bandwidth of the harmonic analyzer is limited to 1800Hz. Thus in case of a 400Hz system, only the 3rd harmonic will be displayed. The waveform display of a 400Hz signal will be represented with 10 points. It will not be as accurate as 50/60Hz signals. For more details please read chapter: “Waveform Display & Harmonic Analysis”.

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REMOTE DISPLAY UNIT FUNCTIONALITY The unit is able to become the remote display and control panel of another identical module. The connection between two modules is done through RS-485 ports. For the best results, a 120 ohms balanced, low capacitance cable should be used. The data rate between modules is selectable between 2400 and 115200 bauds. A high data rate offers better synchronization between modules, but the distance will be limited. Typically at 115200 bauds and with adequate cable, the distance will be 200m maximum. At 9600 bauds and adequate cable the distance can go up to 1200m. Below settings are necessary: PARAMETER

MAIN UNIT

REMOTE DISPLAY UNIT

Annunciator Mode

0

1

RS-485 Enable

1

1

RS-485 Baud Rate

any

same as main unit

Modbus Slave Address

any

same as main unit

The remote display panel should be powered up with an isolated voltage source, like a wall adapter. Otherwise damages due to ground potential differences may occur.

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CONNECTION DIAGRAMS AMF FUNCTIONALITY, CTs AT LOAD SIDE

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AMF FUNCTIONALITY, CTs AT ALTERNATOR SIDE

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ATS FUNCTIONALITY

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REMOTE START FUNCTIONALITY

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ENGINE CONTROL FUNCTIONALITY

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REMOTE DISPLAY PANEL FUNCTIONALITY

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V-1.4

TERMINAL DESCRIPTION Term 1 2 3

Function BATTERY POSITIVE BATTERY NEGATIVE

Term Function 4 DIGITAL OUTPUT 1

Technical data +12 or 24VDC O VDC

Description The positive terminal of the DC Supply. Do not connect this terminal. Power supply negative connection.

Technical data Protected Semiconductor Outputs 1A/28VDC

Description This relay has programmable function, selectable from a list. Factory set as CRANK output. This relay has programmable function, selectable from a list. Factory set as FUEL output. This relay has programmable function, selectable from a list. Factory set as ALARM output. This relay has programmable function, selectable from a list. Factory set as PREHEAT output. This relay has programmable function, selectable from a list. Factory set as STOP output. This relay has programmable function, selectable from a list. Factory set as IDLE SPEED output. Connect the charge alternator’s D+ terminal to this terminal. This terminal will supply the excitation current and measure the voltage of the charge alternator. The input has programmable function. Factory set as LOW OIL PRESSURE SWITCH. The input has programmable function. Factory set as HIGH TEMP SWITCH.

5

DIGITAL OUTPUT 2

6

DIGITAL OUTPUT 3

7

DIGITAL OUTPUT 4

8

DIGITAL OUTPUT 5

9

DIGITAL OUTPUT 6

10

CHARGE

Input and output

11

DIGITAL INPUT 1

Digital Inputs, 0-30Vdc

12

DIGITAL INPUT 2

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TJ-509T User Manual Rev_01

Term Function 13 DIGITAL INPUT 3 14

DIGITAL INPUT 4

15

DIGITAL INPUT 5

16

DIGITAL INPUT 6

17

DIGITAL INPUT 7

18

DIGITAL INPUT 8

19

SENDER GROUND

20

ANALOG SENDER 1 (OIL PRESSURE SENDER)

21

ANALOG SENDER 2 (COOLANT TEMP. SENDER)

22

ANALOG SENDER 3 (FUEL LEVEL SENDER)

23

ANALOG SENDER 4 (OIL TEMP SENDER)

Term Function 24 PROTECTION GROUND

25 26 27 28

RS-485 B RS-485 A MPU + MPU —

29

PROTECTION GROUND

30 31

CANBUS-H CANBUS-L

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Technical data

Technical data Output 0Vdc

V-1.4

Description The input has programmable function. Factory set as EMERGENCY STOP. The input has programmable function. Factory set as LOW COOLANT LEVEL SWITCH. The input has programmable function. Factory set as SPARE INPUT-1. The input has programmable function. Factory set as SPARE INPUT-2. The input has programmable function. Factory set as SPARE INPUT-3. The input has programmable function. Factory set as FORCE OFF MODE. Ground potential for analog senders. Connect to the engine body, close to senders. Connect to the oil pressure sender. Do not connect the sender to other devices. Connect to the coolant temperature sender. Do not connect the sender to other devices. Connect to the fuel level sender. Do not connect the sender to other devices. Connect to the oil temperature sender. Do not connect the sender to other devices.

Description Connect the protective shield of the RS485 cable to this terminal, from one end only. Digital communication Connect the A-B data lines of the RS-485 port link to these terminals. Analog input, 0.5 to Connect the MPU unit to these inputs 30V-AC Use a twisted cable pair or coaxial cable for best results. Output 0Vdc Connect the protective shield of the MPU and CANBUS-J1939 cables to this terminal, from one end only. Digital communication Connect the J1939 port of an electronic port engine to these terminals. The 120 ohm terminating resistors are inside the unit. Please do not connect external resistors. Use a twisted cable pair or coaxial cable for best results.

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TJ-509T User Manual Rev_01

Term Function 51 GENERATOR CONTACTOR

52 54 56 58

GEN-L1 GEN-L2 GEN-L3 GENERATOR NEUTRAL

Term Function 59 CURR_1+ 60

CURR_1-

61

CURR_2+

62

CURR_2-

63

CURR_3+

64

CURR_3-

Term Function 65 MAINS NEUTRAL 67 MAINS-L3

69 71 72

MAINS-L2 MAINS-L1 MAINS CONTACTOR

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V-1.4

Technical data Description Relay output, 16A-AC This output provides energy to the generator contactor. If the generator phases do not have acceptable voltage or frequency values, the generator contactor will be de-energized. In order to provide extra security, the normally closed contact of the mains contactor should be serially connected to this output. Generator phase Connect the generator phases to these inputs, 0-300V-AC inputs. The generator phase voltages upper and lower limits are programmable. Input, 0-300V-AC Neutral terminal for the generator phases. Technical data Description Current transformer Connect the generator current transformer terminals to these inputs. inputs, 5A-AC Do not connect the same current transformer to other instruments otherwise a unit fault will occur. Connect each terminal of the transformer to the unit’s related terminal. Do not use common terminals. Do not use grounding. Correct polarity of connection is vital. The rating of the transformers should be identical for each of the 3 phases. The secondary winding rating shall be 5 Amperes. (ex: 200/5 Amps). Technical data Input, 0-300V-AC Mains phase inputs, 0-300V-AC

Description Neutral terminal for the mains phases. Connect the mains phases to these inputs. The mains voltages upper and lower limits are programmable.

Relay output, 16A-AC This output provides energy to the mains contactor. If the mains phases do not have acceptable voltages, the mains contactor will be de-energized. In order to provide extra security, the normally closed contact of the generator contactor should be serially connected to this output.

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TECHNICAL SPECIFICATIONS DC Supply Range: 9.0 to 33.0 V-DC. DC power consumption: 250 mA-DC typical @12V-DC 125 mA-DC typical @24V-DC 500 mA-DC max. @12V-DC 250 mA-DC max. @24V-DC Alternator voltage: 0 to 330 V-AC (Ph-N), 0 to 570V Ph-Ph Alternator frequency: 0-500 Hz. Mains voltage: 0 to 330 V-AC (Ph-N) , 0 to 570V Ph-Ph Mains frequency: 0-500 Hz. Current Inputs: from current transformers. ../5A. CT Range: 5/5A to 5000/5A VT Range: 0.1/1 to 6500 / 1 kW Range: 0.1kW to 65000 kW Accuracy: Voltage: 0.5%+1digit Current: 0.5%+1 digit Frequency: 0.5%+1 digit Power(kW,kVAr): 1.0%+2digit Power factor: 0.5 %+1digit Digital inputs: input voltage 0 to 36 V-DC. Analog input range: 0-5000 ohms. Mains and genset contactor outputs: [email protected] DC Outputs: Protected mosfet semiconductor outputs, rated [email protected] Cranking dropouts: survives 0V for 100ms. Magnetic pickup voltage: 0.5 to 30V-RMS. Magnetic pickup frequency: 10 to 10000 Hz. Charge Alternator Excitation: 160mA @12VDC, 80mA @24VDC Ethernet Port: 10/100 Mbits USB Device: USB 2.0 Full speed USB Host: USB 2.0 Full speed RS-485 Port: selectable baud rate RS-232 Port: selectable baud rate Operating temperature: -20°C to 70°C (-4 to +158 °F). Storage temperature: -40°C to 80°C (-40 to +176°F). Maximum humidity: 95% non-condensing. IP Protection: IP54 from front panel, IP30 from the rear. Dimensions: 200 x 148 x 46mm (WxHxD) Panel Cut-out Dimensions: 176 x 121 mm minimum. Weight: 450 g (approx.) Case Material: High Temperature, non-flammable, ROHS compliant ABS/PC Mounting: Flush mounted with rear retaining plastic brackets. EU Directives Conformity -2006/95/EC (low voltage) -2004/108/EC (electro-magnetic compatibility) Norms of reference: EN 61010 (safety requirements) EN 61326 (EMC requirements) UL Compatibility: UL 508 — Industrial Control Equipment CSA Compatibility: CAN/CSA C22.2 No. 14-2005 – Industrial Control Equipment

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V-1.4

DESCRIPTION OF CONTROLS FRONT PANEL FUNCTIONALITY

AUTO READY indicator

Graphic LCD screen

Mimic Diagram (sysem status)

Fault condition indicators

Next display group Genset Contactor control in RUN mode

Next screen in the same group. LAMP TEST if held pressed Previous display group

TEST mode button

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Mains Contactor control in RUN mode

Previous screen in the same group. ALARM Mute RUN mode button

AUTO mode button

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STOP mode button

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

PUSHBUTTON FUNCTIONS BUTTON

FUNCTION Selects TEST mode. The genset runs and takes the load.

Selects RUN mode. The genset runs off-load.

Selects AUTO mode. The genset runs when necessary and takes the load.

Selects OFF mode. The genset stops.

BUTTON

FUNCTION Selects next display screen in the same display group. LAMP TEST when held pressed. Selects previous display group.

Selects next display group. Selects previous display screen in the same display group. Resets the ALARM RELAY. Manual MAINS CONTACTOR control in RUN mode.

Manual GENSET CONTACTOR control in RUN mode.

When held pressed for 5 seconds, enters PROGRAMMING mode.

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V-1.4

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

DISPLAY SCREEN ORGANIZATION The unit measures a large number of electrical and engine parameters. The display of the parameters is organized as PARAMETER GROUPS and items in a group. Navigation between different groups are made with

and

buttons.

Each depression of the button will cause the display to switch to the next group of parameters. After the last group the display will switch to the first group. Each depression of the button will cause the display to switch to the previous group of parameters. After the first group the display will switch to the last group. Navigation inside a groups is made with

and

buttons.

Each depression of the button will cause the display to switch to the next parameter in the same group. After the last parameter the display will switch to the first parameter. Each depression of the button will cause the display to switch to the previous parameter in the same group. After the first parameter the display will switch to the last parameter. Below is a basic list of parameter groups: Genset Parameters: Genset voltages, currents, kW, kVA, kVAr, pf etc… Engine Parameters: Analog sender readings, rpm, battery voltage, engine hours, etc… J1939 Parameters: Opens only if the J1939 port is enabled. The unit is able to display a long list of parameters, under the condition that the engine sends this information. A complete list of available readings is found at chapter J1939 CANBUS ENGINE SUPPORT. Mains Parameters: Mains voltages, currents, kW, kVA, kVAr, pf etc… Mains currents and power parameters are displayed only when CT Selection is made as LOAD SIDE. Otherwise mains current and power related parameters will not be displayed. Synchronization Display: A graphical synchroscope is displayed. The synchroscope display is updated 10 times a second in order to have smooth sweep. Scopemeter Display: This group display waveforms of voltages and currents as an oscilloscope. All PhN and Ph-Ph voltages as well as phase currents are available. This feature is especially useful to investigate waveform distortions and harmonic loads. Graphical Harmonic Analysis Results: This group displays harmonic composition of voltages and currents. All Ph-N and Ph-Ph voltages as well as phase currents are available. This feature is especially useful to investigate the harmonic caused by complex loads. Only harmonics above 2% are represented in the graphics because of the display resolution. In order to see all harmonic levels please use the Alphanumerical Harmonic Analysis Results. Alphanumerical Harmonic Analysis Results: This group displays harmonic composition of voltages and currents with 0.1% resolution. All Ph-N and Ph-Ph voltages as well as phase currents are available. This feature is especially useful to investigate the harmonic caused by complex loads. Alarm Display: This group displays all existing alarms, one screen per alarm. When there is no more alarm to display it will show “END OF ALARM LIST”. GSM Modem Parameters: Signal strength, counters, communication status, IP addresses etc… Ethernet Parameters: Ethernet connection status, counters, IP addresses etc… Status & Counters Groups: This group includes various parameters like genset status, service counters, date-time, firmware version etc…

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V-1.4

AUTOMATIC DISPLAY SCROLL The unit will automatically scroll all Mains, Genset and Engine measurements with programmable interval. The scroll period setting can be performed using the RainbowPlus program through Module > Screen options.

Eventually the same parameter can be modified through the front panel programming menu. The related parameter is Controller Configuration > Screen Scroll Timer.

If the Screen Scroll Timer is set to zero, then scrolling will be disabled.

When a front panel button is pressed, the scrolling is suspended during 2 minutes.

If a fault condition occurs, the display will automatically switch to the ALARM LIST page.

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TJ-509T User Manual Rev_01

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V-1.4

MEASURED PARAMETERS The unit performs a detailed set of AC measurements. Mains currents and power parameters (listed in blue color) are measured and displayed only if CTs are placed at load side. please see connection diagrams section for more details. The list of measured AC parameters is below: Mains voltage phase L1 to neutral Mains voltage phase L2 to neutral Mains voltage phase L3 to neutral Mains average voltage phase to neutral Mains voltage phase L1-L2 Mains voltage phase L2-L3 Mains voltage phase L3-L1 Mains frequency Mains current phase L1 Mains current phase L2 Mains current phase L3 Mains average current Mains kW phase L1 Mains kW phase L2 Mains kW phase L3 Mains total kW Mains kVA phase L1 Mains kVA phase L2 Mains kVA phase L3 Mains kVAr phase L1 Mains kVAr phase L2 Mains kVAr phase L3 Mains pf phase L1 Mains pf phase L2 Mains pf phase L3 Mains total pf Mains neutral current

Gen voltage phase L1 to neutral Gen voltage phase L2 to neutral Gen voltage phase L3 to neutral Gen average voltage phase to neutral Gen voltage phase L1-L2 Gen voltage phase L2-L3 Gen voltage phase L3-L1 Gen frequency Gen current phase L1 Gen current phase L2 Gen current phase L3 Gen average current Gen kW phase L1 Gen kW phase L2 Gen kW phase L3 Gen total kW Gen kVA phase L1 Gen kVA phase L2 Gen kVA phase L3 Gen kVAr phase L1 Gen kVAr phase L2 Gen kVAr phase L3 Gen pf phase L1 Gen pf phase L2 Gen pf phase L3 Gen total pf Gen Neutral current

Below engine parameters are always measured: Engine speed (rpm) Battery voltage, The unit features 4 analog senders, fully configurable for the name and function. Below is a typical list of analog senders, capable of changing following configuration: Coolant temperature Oil pressure (bar, kPa) Fuel level (%, lt) Oil temperature (°C, °F)

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V-1.4

LED LAMPS AUTO READY indicator

Mains available led

Shutdown alarm indicator

Mains Contactor On led

Warning indicator

Genset Contactor on led

Service request indicator

Genset available led RUN mode indicator

TEST mode indicator

AUTO mode indicator

STOP mode indicator

STATUS LEDS: AUTO READY: Turns on when the AUTO mode is selected and there is no condition preventing engine start. ALARM: Turns on when a shutdown alarm or loaddump condition exists. WARNING: Turns on when a warning condition exists SERVICE REQUEST: Turns on when at least one of the service counters has expired. MODE LEDS: Each led turns on when the related mode is selected, either locally or remotely. MIMIC DIAGRAM LEDS: MAINS AVAILABLE: This led turns on when all mains phase voltages and the mains frequency are within limits. If enabled, the mains phase rotation order must be also right. When any digital input is defined as Remote Start, this led will reflect the status of the input. When a Simulate Mains signal is present, then mains status will become “available”. When a Force to Start signal is present, then the mains status will become “not available”. MAINS CONTACTOR ON: Turns on when the mains contactor is activated. GENSET CONTACTOR ON: Turns on when the genset contactor is activated. GENSET AVAILABLE: This led turns on when all genset phase voltages and the genset frequency are within limits. If enabled, the genset phase rotation order must be also right.

If a Remote Start input is defined, then the Mains led will reflect the input status. Simulate Mains and Force to Start signals will also affect this led.

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PRELIMINARY VERSION

V-1.4

WAVEFORM DISPLAY & HARMONIC ANALYSIS The unit features waveform display together with a precision harmonic analyzer for both mains and genset voltages and currents. Both phase to neutral and phase to phase voltages are available for analysis, thus 18 channels in total are possible.

In order to enable display and analysis of mains currents, current transformers must be placed at load side. Available channels are: Mains volts: V1, V2, V3, U12, U23, U31 Mains currents: I1, I2, I3 Genset volts: V1, V2, V3, U12, U23, U31 Genset currents: I1, I2, I3

Scopemeter Display The waveform display memory is of 100 samples length and 13 bit resolution, with a sampling rate of 4096 s/s. Thus one cycle of a a 50Hz signal is represented with 82 points. The vertical scale is automatically adjusted in order to avoid clipping of the signal. The waveform is displayed on the device screen, and with more resolution on PC screen through the RainbowPlus program. The display memory is also available in the Modbus register area for third party applications. For more details please check chapter “MODBUS Communications”. The waveform display is updated twice a second. All channels may be scrolled using

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TJ-509T User Manual Rev_01

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V-1.4

The harmonic analyzer consists on a Fast Fourier Transform (FFT) algorithm which is run twice a second on the selected channel. The sample memory is 1024 samples length and 13 bits resolution with a sampling rate of 4096 s/s. The theory says that a periodic signal may have only odd multiples of the main frequency. Thus in a 50Hz network, harmonics will be found only at 150, 250, 350, 450 Hz etc… The unit is able to analyze up to 1800Hz and up to 31th harmonic, whichever is smaller. Thus in a 50Hz system all 31 harmonics will be displayed, but in a 60Hz system only 29 harmonics will come to the screen. In case of a 400Hz system, only the 3rd harmonic will be displayed.

Graphical Harmonic Table

Alphanumeric Harmonics Table

Harmonic are represented by 2 different ways on the device display. The first one is a graphical representation allowing one sight perception of the harmonic structure. Because of the display resolution, only harmonics above 2% are displayed. The second display is alphanumeric, thus all harmonics are displayed with 0.1% resolution in order to provide more detailed information. On RainbowPlus program, harmonics and waveform are displayed on a single screen with more resolution.

RainbowPlus Scada section: Harmonic Analysis and Waveform Display

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V-1.4

DISPLAYING EVENT LOGS The unit features more than 400 event logs with date-time stamp and full snapshot of measured values at the moment that the event has occurred. Stored values in an event record are listed below: -event number -event type / fault definition (see below for various event sources) -date and time -operation mode -operation status (on-load, on-mains, cranking, etc…) -mains phase voltages: L1-L2-L3 -mains frequency -genset phase voltages: L1-L2-L3 -genset phase currents: L1-L2-L3 -genset frequency -genset total active power (kW) -genset total power factor -oil pressure -engine temperature -fuel level -oil temperature -canopy temperature -ambient temperature -engine rpm -battery voltage -charge voltage Possible event sources are various. Every source can be individually enabled or disabled:

Event enable selection tab

Periodic event: recorded every 30 minutes when the engine is running, and every 60 minutes anyway. Mode change event: recorded when the operation mode is changed. Mains fail event: recorded when mains status is changed to fail Mains restore event: recorded when mains is restored. Shutdown alarm event: recorded when a shutdown alarm occurs. Loaddump alarm event: recorded when a loaddump alarm occurs. Warning event: recorded when a warning occurs. Program mode entrance event: recorded when program mode is entered. The password level is also saved.

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Event logs are displayed within the program mode menu. This is designed in order to reduce the interference of event logs with other measurement screens. To enter the event display, press together

and

buttons for 5 seconds.

When the program mode is entered, below password entry screen will be displayed.

Press 2 buttons for 5 seconds

Skip the password entry screen by pressing the Press again the

button 4 times. The screen below left will come.

button. The last stored event will open, as in the below-right picture.

The first page will display the event number, event type, fault type and date-time information.

When displaying event logs: button will display the next information in the same event button will display the previous information in the same event button will display the same information of the previous event button will display the same information of the next event.

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STATISTICAL COUNTERS The unit provides a set of non resettable incremental counters for statistical purposes. The counters consist on: -total genset kWh -total genset kVArh inductive -total genset kVArh capacitive -total engine hours -total engine starts -engine hours to service-1 -time to service-1 -engine hours to service-2 -time to service-2 -engine hours to service-3 -time to service-3 These counters are kept in a non-volatile memory and are not affected from power failures.

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V-1.4

TJ-509T User Manual Rev_01

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V-1.4

OPERATION OF THE UNIT QUICK START GUIDE STOPPING THE ENGINE: Press STOP STARTING THE ENGINE: Press RUN

button button

MANUAL LOAD TRANSFER: Use MAINS LOAD TEST: Press TEST

and GENSET

buttons.

button. The genset will run and take the load.

AUTOMATIC OPERATION: Press AUTO

button. Check that AUTO READY led is illuminated.

Mode can be changed anytime without negative effect. Changing the operation mode while the genset is running will result into a behavior suitable for the new operating mode.

STOP MODE The STOP mode is entered by pressing the

button.

In this mode, the genset will be in a rest state. When STOP mode is selected, if the genset is running under load, then it will be immediately unloaded. The engine will continue to run during Cooldown Timer and will stop afterwards. If the STOP button is pressed again, then the engine will immediately stop. If the engine fails to stop after the expiration of Stop Timer then a Fail to Stop warning will occur. In this mode, the mains contactor will be energized only if mains phase voltages and frequency are within the programmed limits. If enabled, the mains phase order is also checked. If a Remote Start or Force to Start signal arrives in STOP mode, the genset will not start until AUTO mode is selected.

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V-1.4

AUTO MODE The AUTO mode is entered by pressing the

button.

The AUTO mode is used for the automatic transfer between genset and mains. The controller will constantly monitor the mains availability. It will run the engine and transfer the load when a mains failure occurs.

If a panel lock input is defined and signal is applied, then mode change will not occur. However display navigation buttons are still enabled and parameters may be visualized. The mains availability evaluation sequence is below: 

If at least one of the mains phase voltages or the mains frequency is outside limits, the mains will be supposed failing. Otherwise mains is available.



If a Simulate Mains signal is present, then mains are made available



If a Force to Start signal is present, then mains are unavailable



If a Remote Start input is defined, then this signal decides of mains availability.

When mains are evaluated as “unavailable” then an engine start sequence begins: 

The unit waits during Engine Start Delay for skipping short mains failures. If the mains is restored before the end of this timer, the genset will not start.



The unit turns on the fuel and preheat glow plugs (if any) and waits for preheat timer.



The engine will be cranked for programmed times during crank timer. When the engine fires, the crank relay will be immediately deactivated. See section Crank Cutting for more details.



The engine will run at idle speed during Idle Speed Timer.



The engine will run unloaded during engine heating timer.



If alternator phase voltages, frequency and phase order are correct, the unit will wait for the generator contactor period and the generator contactor will be energized.

When mains are evaluated as “available” again then an engine stop sequence begins: 

The engine will continue to run for the mains waiting period to allow mains voltages to stabilize.



Then the generator contactor is deactivated and the mains contactor will be energized after mains contactor timer.



If a cooldown period is given, the generator will continue to run during the cooldown period.



Before the end of cooldown, the unit will reduce the engine speed to idle speed.



At the end of cooldown, the fuel solenoid will be de-energized, the stop solenoid will be energized for Stop Solenoid timer and the diesel will stop.



The unit will be ready for the next mains failure.

If the operation of the genset is disabled by the weekly schedule, then the AUTO led will flash, and the operation of the genset will be as in the OFF mode.

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RUN MODE, MANUAL CONTROL The RUN mode is entered by pressing the

button.

When the RUN mode is selected, the engine will be started regardless of the mains availability. The starting sequence is as described below: 

The unit turns on the fuel and preheat glow plugs (if any) and waits for preheat timer.



The engine will be cranked for programmed times during crank timer. When the engine fires, the crank relay will be immediately deactivated. See section Crank Cutting for more details.



The engine will run at idle speed during Idle Speed Timer.



The engine will run unloaded until another mode is selected..

The RUN mode allows also manual contactor control through MC

and GC

buttons.

When a contactor button is pressed, the related contactor will change position. Thus if it was on, then it will turn off. If it was off then it will turn on. If the other contactor was on, then it will turn off, the controller will wait for the related contactor timer and the contactor will turn on. This will prevent manual closure of both contactors.

If uninterrupted transfers are allowed, then the unit will check the synchronization. If synchronization is complete, then it will make an uninterrupted transfer, where both contactors will be on for a short while. If Emergency Backup mode is enabled and if the mains are off, then the mains contactor will be deactivated and the generator contactor will be activated. When the mains are on again, a reverse changeover to the mains will be performed, but the engine will be kept running unless another mode is selected. In order to stop the engine press

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TEST MODE The TEST mode is entered by pressing the

button.

The TEST mode is used in order to test the genset under load. Once this mode is selected, the engine will run as described in the AUTO mode, regardless of the mains availability and the load will be transferred to the genset. The genset will feed the load indefinitely unless another mode is selected.

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PROTECTIONS AND ALARMS The unit provides 3 different protection levels, being warnings, loaddumps and shutdown alarms. 1- SHUTDOWN ALARMS: These are the most important fault conditions and cause: — The ALARM led to turn on steadily, — The genset contactor to be released immediately, — The engine to be stopped immediately, — The Alarm digital output to operate. 2- LOAD_DUMPS: These fault conditions come from electrical trips and cause: — The ALARM led to turn on steadily, — The genset contactor to be released immediately, — The engine to be stopped after Cooldown period, — The Alarm digital output to operate. 3- WARNINGS: These conditions cause: — The WARNING led to turn on steadily, — The Alarm digital output to operate.

If a fault condition occurs, the display will automatically switch to the ALARM LIST page. Alarms operate in a first occurring basis: -If a shutdown alarm is present, following shutdown alarms, loaddumps and warnings will not be accepted, -If a loaddump is present, following loaddumps and warnings will not be accepted, -If a warning is present, following warnings will not be accepted.

If the ALARM MUTE button is pressed, the Alarm output will be deactivated; however the existing alarms will persist and disable the operation of the genset. Alarms may be of LATCHING type following programming. For latching alarms, even if the alarm condition is removed, the alarms will stay on and disable the operation of the genset.

Existing alarms may be canceled by pressing one of the operating mode buttons:

Most of the alarms have programmable trip levels. See the programming chapter for adjustable alarm limits.

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DISABLING ALL PROTECTIONS The unit allows any digital input to be configured as “Disable Protections”. This input configuration is used in cases where the engine is required to run until destruction. This may be the case under critical conditions like fire fighting or other emergency cases. This input should be configured as a “Warning”. Thus when protections are disabled, a warning message will immediately appear on the screen. When protections are disabled, all shutdown alarms and loaddumps will become warnings. They will appear on the screen, but will not affect genset operation. The input may be constantly activated, or preferably it may be activated by an external key activated switch in order to prevent unauthorized activation.

Disabling protections will allow the genset run until destruction. Place written warnings about this situation in the genset room.

SERVICE REQUEST ALARM The SERVICE REQUEST led is designed to help the periodic maintenance of the genset to be made consistently. The periodic maintenance is basically carried out after a given engine hours (for example 200 hours), but even if this amount of engine hours is not fulfilled, it is performed after a given time limit (for example 12 months). The unit offers 3 independent service counter sets in order to enable different service periods with different priorities. The fault level created upon expiration of service timers may be set as Warning, Loaddump or Shutdown. Thus different levels of fault conditions may be generated at different overrun levels. Each service counter set has both programmable engine hours and maintenance time limit. If any of the programmed values is zero, this means that the parameter will not be used. For example a maintenance period of 0 months indicates that the unit will request maintenance only based on engine hours, there will be no time limit. If the engine hours is also selected as 0 hours this will mean that this service counter set is not operative. When the engine hours OR the time limit is over, the SERVICE REQUEST led (red) will start to flash and the service request output function will be active. The service request can also create a fault condition of any level following parameter setting. The service request output function may be assigned to any digital output using Relay Definition program parameters. Also relays on an extension module may be assigned to this function.

To turn off the SERVICE REQUEST led, and reset the service period, press together the ALARM MUTE and LAMP TEST keys for 5 seconds. The remaining engine hours and the remaining time limits are kept stored in a non-volatile memory and are not affected from power supply failures. The time and engine hours to service are displayed in the GENSET STATUS menu group.

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V-1.4

SHUTDOWN ALARMS Digital input and analog sender alarms are fully programmable for the alarm name, sampling and action. Only internal alarms are explained in this section. GENSET LOW / HIGH FREQUENCY

Set if the generator frequency is outside programmed limits. These faults will be monitored with Fault Holdoff Timer delay after the engine is running. Low and high limits are separately programmable. The detection delay is also programmable. Another high frequency shutdown limit which is 12% above the high limit is always monitored and stops the engine immediately.

GENSET LOW / HIGH RPM

Set if the generator rpm is outside programmed limits. These faults will be monitored with Fault Holdoff Timer delay after the engine is running. Low and high limits are separately programmable. The detection delay is also programmable. The high rpm overshoot limit is always monitored and stops the engine immediately.

GENSET LOW / HIGH VOLTAGE

Set if any of the generator phase voltages goes outside programmed limits for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running.

LOW / HIGH BATTERY VOLTAGE

Set if the genset battery voltage is outside programmed limits. Low and high limits are separately programmable. The detection delay is also programmable.

FAIL TO START

Set if the engine is not running after programmed number of start attempts.

LOW CHARGE VOLTAGE

Set if the charge alternator voltage is below the programmed limit. This fault will be monitored with Fault Holdoff Timer delay after the engine is running.

J1939 ECU FAIL

Set if no information has been received during 3 seconds from the ECU of the electronic engine. This fault condition is only controlled when fuel is on.

VOLTAGE UNBALANCE

Set if any of the generator phase voltages differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running.

CURRENT UNBALANCE

Set if any of the generator phase currents differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running. The action taken at fault condition is programmable.

OVERCURRENT

Set if at least one of the genset phase currents goes over the Overcurrent Limit for the period allowed by the IDMT curve setting. The allowed timer is dependent of the overcurrent level. If currents go below the limit before expiration of the timer then no alarm will be set. Please check chapter Overcurrent Protection (IDMT) for more details. The action taken at fault condition is programmable.

PICKUP SIGNAL LOST

Set if the rpm measured from the magnetic pickup input falls below the Crank Cut RPM level during Loss of Speed Signal Timer. The action of signal loss is programmable.

SERVICE REQUEST

Set if at least one of the service counters has expired. In order to reset the service counters please hold pressed both with and seconds. The screen will display “Completed!”

K35D01-EN

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buttons during 5

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

LOADDUMP ALARMS Digital input and analog sender alarms are fully programmable for the alarm name, sampling and action. Only internal alarms are explained in this section. VOLTAGE UNBALANCE

Set if any of the generator phase voltages differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running.

CURRENT UNBALANCE

Set if any of the generator phase currents differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running. The action taken at fault condition is programmable.

OVERCURRENT

Set if at least one of the genset phase currents goes over the Overcurrent Limit for the period allowed by the IDMT curve setting. The allowed timer is dependent of the overcurrent level. If currents go below the limit before expiration of the timer then no alarm will be set. Please check chapter Overcurrent Protection (IDMT) for more details. The action taken at fault condition is programmable.

OVERLOAD

Set if the genset power (kW) supplied to the load goes over the Overload Load Dump limit for Overload Timer. If the power goes below the limit before expiration of the timer then no alarm will be set.

REVERSE POWER

Set if the genset power (kW) is negative and goes over the Reverse Power limit for Reverse Power Timer. If the power goes below the limit before expiration of the timer then no alarm will be set.

REVERSE POWER

Set if the genset power (kW) is negative and goes over the Reverse Power limit for Reverse Power Timer. If the power goes below the limit before expiration of the timer then no alarm will be set.

GENSET PHASE ORDER FAIL

Set if the fault is enabled and the genset phase order is reverse.

MAINS CB FAIL TO OPEN

Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor Open/Close Fail Timer.

PICKUP SIGNAL LOST

Set if the rpm measured from the magnetic pickup input falls below the Crank Cut RPM level during Loss of Speed Signal Timer. The action of signal loss is programmable.

SERVICE REQUEST

Set if at least one of the service counters has expired. In order to reset the service counters please hold pressed both with 5 seconds. The screen will display “Completed!”

K35D01-EN

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buttons during

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

WARNINGS Digital input and analog sender alarms are fully programmable for the alarm name, sampling and action. Only internal alarms are explained in this section. All warnings can be made latching by enabling a single program parameter: Controller Configuration >Latch All Warnings

Latch All Warnings

GENSET LOW / HIGH FREQUENCY

Set if the generator frequency is outside programmed limits. These faults will be monitored with Fault Holdoff Timer delay after the engine is running. Low and high limits are separately programmable. The detection delay is also programmable. Another high frequency shutdown limit which is 12% above the high limit is always monitored and stops the engine immediately.

GENSET LOW / HIGH RPM

Set if the generator rpm is outside programmed limits. These faults will be monitored with Fault Holdoff Timer delay after the engine is running. Low and high limits are separately programmable. The detection delay is also programmable. The high rpm overshoot limit is always monitored and stops the engine immediately.

GENSET LOW / HIGH VOLTAGE

Set if any of the generator phase voltages goes outside programmed limits for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running.

LOW / HIGH BATTERY VOLTAGE

Set if the genset battery voltage is outside programmed limits. Low and high limits are separately programmable. The detection delay is also programmable.

FAIL TO STOP

Set if the engine has not stopped before the expiration of the Stop Timer.

LOW CHARGE VOLTAGE

Set if the charge alternator voltage is below the programmed limit. This fault will be monitored with Fault Holdoff Timer delay after the engine is running.

K35D01-EN

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TJ-509T User Manual Rev_01

J1939 ECU FAIL

VOLTAGE UNBALANCE

PRELIMINARY VERSION

V-1.4

Set when an engine fault code is received from the ECU of the electronic engine. This fault will not cause an engine stop. If necessary, the engine will be stopped by the ECU. Set if any of the generator phase voltages differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running.

CURRENT UNBALANCE

Set if any of the generator phase currents differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer. This fault will be monitored with Fault Holdoff Timer delay after the engine is running. The action taken at fault condition is programmable.

OVERCURRENT

Set if at least one of the genset phase currents goes over the Overcurrent Limit for the period allowed by the IDMT curve setting. The allowed timer is dependent of the overcurrent level. If currents go below the limit before expiration of the timer then no alarm will be set. Please check chapter Overcurrent Protection (IDMT) for more details. The action taken at fault condition is programmable.

OVERCURRENT

Set if at least one of the genset phase currents goes over the Overcurrent Limit .

REVERSE POWER

Set if the genset power (kW) is negative and goes over the Reverse Power limit for Reverse Power Timer. If the power goes below the limit before expiration of the timer then no alarm will be set.

MAINS PHASE ORDER FAIL

Set if the mains phase order checking is enabled, mains phases are present and mains phase order is reversed. This fault prevents the Mains Contactor to close.

GENSET CB FAIL TO CLOSE / OPEN

Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor Open/Close Fail Timer.

MAINS CB FAIL TO CLOSE

Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor Open/Close Fail Timer.

SYNCHRONIZATION FAIL

Set if the uninterrupted transfer is enabled and voltage, frequency and phase matching is not found before the expiration of the Synchronization Fail Timer

PICKUP SIGNAL LOST

Set if the rpm measured from the magnetic pickup input falls below the Crank Cut RPM level during Loss of Speed Signal Timer. The action of signal loss is programmable.

SERVICE REQUEST

Set if at least one of the service counters has expired. In order to reset the service counters please hold pressed both with 5 seconds. The screen will display “Completed!”

K35D01-EN

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buttons during

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

PROGRAMMING RESETTING TO FACTORY DEFAULTS In order to resume to the factory set parameter values: -hold pressed the OFF, LAMP TEST and ALARM MUTE buttons for 5 seconds, -“RETURN TO FACTORY SET” will be displayed -immediately press and hold pressed the ALARM MUTE button for 5 seconds -factory set values will be reprogrammed to the parameter memory.

Hold pressed OFF, LAMP TEST and ALARM MUTE

Hold pressed ALARM MUTE

K35D01-EN

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V-1.4

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

The program mode is used to adjust timers, operational limits and the configuration of the unit. Although a free PC program is provided for programming, every parameter may be modified through the front panel, regardless of the operating mode. When modified, program parameters are automatically recorded into a non-erasable memory and take effect immediately. The program mode will not affect the operation of the unit. Thus programs may be modified anytime, even while the genset is running.

ENTERING THE PROGRAMMING MODE To enter the program mode, press together ◄MENU and MENU►buttons for 5 seconds. When the program mode is entered, below password entry screen will be displayed.

Press 2 buttons for 5 seconds

A 4 digit password must be entered using ▼, ▲ , MENU►and ◄MENU buttons. The ▼, ▲buttons modify the value of the current digit. The MENU►, ◄MENU buttons navigate between digits. The unit supports 3 password levels. The level_1 is designed for field adjustable parameters. The level_2 is designed for factory adjustable parameters. The level_3 is reserved. It allows recalibration of the unit. The password level-1 is factory set to ‘1234’ and the password level-2 is factory set to ‘9876’.

Passwords are not front panel adjustable. If a wrong password is entered, the unit will still allow access to the program parameters, but in read-only mode. If password “0000” is entered, only EVENT LOG file will be available.

K35D01-EN

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

NAVIGATING BETWEEN MENUS The program mode is driven with a two level menu system. The top menu consists on program groups and each group consists on various program parameters. When program mode is entered, a list of available groups will be displayed. Navigation between different groups are made with ▼and ▲buttons. Selected group is shown in reverse video (blue on white). In order to enter inside a group, please press MENU►button. In order to exit from the group to the main list please press ◄MENU button.

If inside the group then exit to main PGM menu

Enter inside the group

Next group

Previous group

Navigation inside a group is made also with ▼and ▲buttons. A list of available parameters will be displayed. Selected parameter is shown in reverse video (blue on white). In order display/change the value of this parameter, please press MENU►button. Parameter value may be increased and decreased with ▼and ▲buttons. If these keys are hold pressed, the program value will be increased/decreased by steps of 10. When a program parameter is modified, it is automatically saved in memory. If MENU►button is pressed, next parameter will be displayed. If ◄MENU button is pressed, then the list of parameters in this group will be displayed.

Edit parameter value

Return to the main menu

Next parameter inside the same group

K35D01-EN

Previous parameter inside the same group

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

MODIFYING PARAMETER VALUE

Decrease parameter value

Increase parameter value

Previous parameter Long Press: Return to the upper menu

Next parameter

PROGRAMMING MODE EXIT To exit the program mode press one of the mode selection keys. If no button is pressed during 2 minutes the program mode will be cancelled automatically.

Press any mode button

K35D01-EN

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

PROGRAM PARAMETER LIST CONTROLLER CONFIGURATION GROUP Parameter Definition

Unit

Min

Max

Factory Set

—

30

50

39

sec

0

250

0

Language

—

0

1

0

Genset Default Display

—

0

4

0

Status Prompt Window Enable

—

0

1

0

Fault Holdoff Timer

sec

0

120

12

Alarm Relay Timer

sec

0

120

60

Intermittent Alarm Relay

—

0

1

0

Emergency Backup Operation

—

0

1

0

Exerciser Enable

—

0

1

0

Exercise Period

—

0

1

0

Exercise Off/On Load

—

0

1

1

LCD Contrast

Screen Scroll Timer

K35D01-EN

— 77 —

Description This parameter is used to set LCD contrast. Adjust for the best viewing angle. The screen will scroll between different measurements with this interval. If set to zero, the screen scroll will be disabled. 0: English language selected. 1: Local language selected. This language may depend on the country where the unit is intended to be used. This parameter selects the screen which is displayed during genset on load operation. 0: genset voltages table 1: genset currents and freq. table 2: genset kW and pf table 3: genset kVA and kVAr table 4: genset average measurements 0: Status prompts disabled 1: Status prompts enabled This parameter defines the delay after the engine runs and before the fault monitoring is enabled. This is the period during which the ALARM relay is active. If the period is set to 0, this will mean that the period is unlimited. 0: continuous 1: intermittent (turns on and off every second) 0: In RUN mode, the load will not be transferred to the genset even if the mains fails. 1: In RUN mode, the load will be transferred to the genset if the mains fails. 0: automatic exerciser disabled 1: automatic exerciser enabled 0: exercise once per week 1: exercise once per month The exact exerciser day and time is adjusted within the EXERCISE SCHEDULE section. 0: Exercise at RUN mode 1: Exercise at TEST mode

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

CONTROLLER CONFIGURATION GROUP (continued) Parameter Definition

Unit

Min

Delayed Simulate Mains

—

0

Modem Selection

—

0

bps

2400

GSM Sim Card Pin

—

0000

SMS Enable

—

0

—

0

—

0

—

0

Web Refresh Rate

sec

0

Ping Period

sec

30

Ping Period

min

0

Rainbow Refresh Rate

sec

0

Rainbow Address-1 Port

—

0

Rainbow Address-2 Port

—

0

Web Server Port

—

0

Modbus TCP/IP Port

—

0

SMTP Port

—

0

Ethernet to RS-485 Modbus Gateway Enable

—

0

GPRS to RS-485 Modbus Gateway Enable

—

0

External Modem Baud Rate

GPRS Connection Enable Web Programming Enable Web Control Enable

K35D01-EN

Max

Factory Set

Description

0: delayed simulate mains disabled 1: delayed simulate mains enabled 0: not used 1: Internal GSM modem 4 0 2: external GSM Datakom modem 3: external GSM generic modem 4: external PSTN (land) modem This is the data rate for accessing the 115200 115200 external modem. If the GSM SIM card uses pin number, enter the pin number here. If incorrect 9999 0 pin number is entered, then the SIM card will not operate. 0: SMS messages disabled 1 0 1: SMS messages enabled 0: GPRS disabled 1 0 1: GPRS enabled 0: Web programming disabled 1 0 1: Web programming enabled 0: Web control disabled 1 0 1: Web control enabled The unit will refresh the web page with 240 5 this interval. The unit will check the availability of the 900 120 internet connection with this interval. The unit will check the availability of the 240 0 internet connection with this interval. The unit will update the distant 65535 5 monitoring terminal with this rate. This is the port number of the first 65535 0 monitoring terminal address. This is the port number of the second 65535 0 monitoring terminal address. This is the port number of the internal 65535 80 web server. The unit will answer queries to this port only. Internal Modbus TCP/IP server’s port 65535 502 number. The unit answers Modbus requests to this port only. This is the port number used for e-mail 65535 587 sending. 0: ethernet-modbus gateway function disabled. 1: ethernet-modbus gateway function 1 0 enabled. The unit will redirect Modbus requests from ethernet to the RS-485 port. 0: gprs-modbus gateway function disabled. 1: gprs-modbus gateway function 1 0 enabled. The unit will redirect Modbus requests from GPRS to the RS-485 port. 1

0

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

CONTROLLER CONFIGURATION GROUP (continued) Parameter Definition

Unit

Min

RS-485 Enable

—

0

Modbus Address

—

0

bps

2400

Ethernet Enable

—

0

Oil Pressure Switch Priority

—

0

Flashing Relay ON Timer

min

0

Flashing Relay OFF Timer

min

0

—

0

V-AC

0

Engine Control Only

—

0

Alternator Pole Pairs

—

1

RPM from genset frequency

—

0

Crank Teeth Count

—

1

Secondary Volt/Freq

—

0

RS-485 Baud Rate

Real Time Clock Adjust

Hysteresis Voltage

K35D01-EN

Factory Description Set 0: RS-485 port disabled 1 1 1: RS-485 port enabled This is the modbus controller identity 255 1 used in Modbus communication. This is the data rate of the RS-485 115200 9600 Modbus port. 0: ethernet port disabled 1 1 1: ethernet port enabled 0: crank cut is performed through oil pressure switch and oil pressure sender 1 0 reading 1: crank cut is performed only through oil pressure switch Delayed Simulate Mains Operation: max genset running time after Simulate 1200 0 Mains signal disappears. Dual Genset Systems: flashing relay ON state duration timer. Dual Genset Systems: flashing relay 1200 0 OFF state duration. This parameter trims precisely the real time clock circuit. Values from 0 to 63 255 117 speed up the clock with 0.25sec/day steps. Values from 127 to 64 slow down the clock with 0.25sec/day steps. This parameter provides the mains and genset voltage limits with a hysteresis feature in order to prevent faulty decisions. For example, when the mains are 30 8 present, the mains voltage low limit will be used as the programmed low limit. When the mains fail, the low limit will be incremented by this value. It is advised to set this value to 8 volts. 0: Genset control 1 0 1: Engine control (no alternator) This parameter is used for frquency to rpm conversion. For a 1500/1800 rpm 8 2 engine select 2. For a 3000/3600 rpm engine select 1. 0: read rpm from the MPU input 1 1 1: convert frequency to rpm (using Alternator Pole Pairs) This is the number of pulses generated 244 30 by the magnetic pickup sensing unit in one turn of the flywheel. 0: Use primary volt/frequency limits 1 0 1: Use secondary volt/frequency limits Max

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

CONTROLLER CONFIGURATION GROUP (continued) Parameter Definition

Unit

Min

Max

Factory Set

SMS on Mains Change

—

0

1

0

SMS on IP Change

—

0

1

0

E-mail on IP Change

—

0

1

0

Fuel Pump Low Limit

%

0

100

20

Fuel Pump High Limit

%

0

100

80

Warning Before Start

—

0

1

1

Latch all Warnings

—

0

1

0

Remote Control Enable

—

0

1

1

Annunciator Mode

—

0

1

0

CT Location

—

Gen

Load

Gen

Reverse CT Direction

—

0

1

0

K35D01-EN

— 80 —

Description This parameter controls SMS sending when mains voltages status is changed. No warnings generated. 0: no SMS on mains failed or restored 1: SMS sent on mains failed or restored This parameter controls SMS sending when IP address of GPRS connection is changed. No warnings generated. 0: no SMS on IP change 1: SMS sent on IP change This parameter controls e-mail sending when IP address of GPRS or ethernet connection is changed. No warnings generated. 0: no e-mail on IP change 1: e-mail sent on IP change If the fuel level measured from the sender input falls below this level, then the FUEL PUMP function will become active. If the fuel level measured from the sender input goes above this level, then the FUEL PUMP function will become passive. This parameter controls the activation of the ALARM output during “Engine Start Delay” timer before engine run. 0: no warning before start 1: warning before start 0: warnings are latching/non-latching on parameter control 1: all warnings are latched. Even if the fault source is removed, warnings will persist until manually reset. This parameter controls remote control of the unit through Rainbow, Modbus and Modbus-IP. 0: remote control disabled 1: remote control enabled 0: normal operation 1: the unit becomes an annunciator of the remote unit. Engine/genset control functions are disabled. 0: CTs are at the genset side. Mains currents are not measured. 1: CTs are at load side. Both mains and genset currents are monitored following contactor status. This parameter is useful to invert all CT polarities at the same time. 0: normal CT polarity assumed. 1: reverse CT polarity assumed.

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

CONTROLLER CONFIGURATION GROUP (continued) Parameter Definition

Unit

Min

Max

Buzzer Enable

—

0

1

Unit Functionality

—

0

3

K35D01-EN

Factory Description Set Internal buzzer control (not functional in 509T) 1 0: buzzer disabled 1: buzzer enabled 0: AMF functionality. The unit controls both engine and load transfer. The genset starts based on mains status. 1: ATS functionality. The unit controls the load transfer and issues genset start AMF signal based on mains status. 2: REMOTE START functionality. The unit controls engine and alternator. The genset starts with external signal. 3: RESERVED. Not used.

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

ELECTRICAL PARAMETERS GROUP Parameter Definition

Unit

Min

Max

Current Transformer Primary

Amp

1

5000

Voltage Transformer Ratio

—

0

5000

V-AC

0

300

Nominal Frequency

Hz

0

500

Nominal Voltage-2

V-AC

0

300

Nominal Frequency-2

Hz

0

500

Mains Voltage Low Limit

%

V-100 V+100

Mains Voltage High Limit

%

V-100 V+100

Mains Voltage Fail Timer

sec

0

10

%

0

50

Nominal Voltage

Instant Mains Dropout

K35D01-EN

Factory Set

Description

This is the rated value of current transformers. All transformers must 500 have the same rating. The secondary of the transformer will be 5 Amps. This is the voltage transformer ratio. This value will multiply all voltage and 1.0 power readings. If transformers are not used, the ratio should be set to 1.0 The nominal value of genset and mains 230 voltages. Voltage limits are defined by reference to this value. The nominal value of genset and mains 50 frequency. Frequency limits are defined by reference to this value. When secondary voltage is selected, this is the nominal value of genset and 120 mains voltages. Voltage limits are defined by reference to this value. When secondary frequency is selected, this is nominal value of genset and 60 mains frequency. Frequency limits are defined by reference to this value. If one of the mains phases goes under this limit, it means that the mains are off V-20% and starts the transfer to the genset in AUTO mode. The value is defined with reference to Nominal Voltage. If one of the mains phases goes over this limit, it means that the mains are off V+20% and starts the transfer to the genset in AUTO mode. The value is defined with reference to Nominal Voltage. If at least one of the mains phase voltages goes outside of the limits 1 during this timer, it means that the mains are off and it starts the transfer to the genset in AUTO mode. If the mains phase voltages are outside limits, but not more than this parameter (with reference to nominal voltage), then the genset will run without releasing the mains contactor. When 0 the genset is ready to take the load, the load will be transferred. If this parameter is set to zero then the mains contactor is immediately released at mains failure.

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition

Unit

Min

Max

Factory Set

Mains Frequency Low Limit

%

F-100

F+100

F-10%

Mains Frequency High Limit

%

F-100

F+100

F+10%

Mains Frequency Fail Timer

sec

0

10

1

Genset Low Voltage Warning Limit

%

V-100 V+100

V-15%

Genset Low Voltage Shutdown Limit

%

V-100 V+100

V-20%

Genset High Voltage Warning Limit

%

V-100 V+100

V+15%

Genset High Voltage Shutdown Limit

%

V-100 V+100

V+20%

Genset Voltage Fail Timer

sec

0

10

1

Genset Low Frequency Warning Limit

%

F-100

F+100

V-15%

Genset Low Frequency Shutdown Limit

%

F-100

F+100

F-20%

K35D01-EN

— 83 —

Description If the mains frequency goes under this limit, it means that the mains are off and starts the transfer to the genset in AUTO mode. The value is defined with reference to Nominal Frequency. If the mains frequency goes over this limit, it means that the mains are off and starts the transfer to the genset in AUTO mode. The value is defined with reference to Nominal Frequency. If the mains frequency goes outside of the limits during this timer, it means that the mains are off and starts the transfer to the genset in AUTO mode. If one of the genset phase voltages goes under this limit when feeding the load, this will generate a GENSET LOW VOLTAGE warning. If one of the genset phase voltages goes under this limit when feeding the load, this will generate a GENSET LOW VOLTAGE shutdown alarm and the engine will stop. If one of the genset phase voltages goes over this limit when feeding the load, this will generate a GENSET HIGH VOLTAGE warning. If one of the genset phase voltages goes over this limit when feeding the load, this will generate a GENSET HIGH VOLTAGE shutdown alarm and the engine will stop. If at least one of the genset phase voltages goes outside of the limits during this timer, a genset voltage fault will occur. If the genset frequency goes under this limit when feeding the load, this will generate a GENSET LOW FREQUENCY warning. If the genset frequency goes under this limit when feeding the load, this will generate a GENSET LOW FREQUENCY shutdown alarm and the engine will stop.

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition

Unit

Min

Max

Genset High Frequency Warning Limit

%

F-100

F+100

Genset High Frequency Shutdown Limit

%

F-100

F+100

sec

0

10

Low Battery Voltage Warning Limit

V-DC

5.0

35.0

Low Battery Voltage Shutdown Limit

V-DC

5.0

35.0

High Battery Voltage Warning Limit

V-DC

5.0

35.0

High Battery Voltage Shutdown Limit

V-DC

5.0

35.0

Battery Voltage Fail Timer

sec

0

10

Genset Voltage Unbalance Limit

%

0

100

Genset Voltage Unbalance Action

—

0

3

Genset Current Unbalance Limit

%

0

100

Genset Current Unbalance Action

—

0

3

Genset Frequency Fail Timer

K35D01-EN

Factory Set

Description

If the genset frequency goes over this limit when feeding the load, this will F+15% generate a GENSET HIGH FREQUENCY warning. If the genset frequency goes over this limit when feeding the load, this will F+20% generate a GENSET HIGH FREQUENCY shutdown alarm and the engine will stop. If the genset frequency goes outside of 1 the limits during this timer, a genset frequency fault will occur. If the battery voltage falls below this 12.0 limit, this will generate a LOW BATTERY warning. If the battery voltage falls below this limit, this will generate a LOW 9.0 BATTERY shutdown alarm and the engine will stop. f the battery voltage goes over this limit, 29.0 this will generate a HIGH BATTERY warning. If the battery voltage goes over this limit, this will generate a HIGH 30.0 BATTERY shutdown alarm and the engine will stop. If the battery voltage goes outside of the 3 limits during this timer, a battery voltage fault will occur. If any genset phase voltage differs from the average more than this limit, it will generate a Voltage Unbalance fault 0.0 condition. The action taken upon fault condition is programmable. If this parameter is set to 0.0 then voltage unbalance is not monitored 0: no action 1: shutdown alarm 0 2: loaddump alarm 3: warning If any genset phase current differs from the average more than this limit, it will generate a Current Unbalance fault 0.0 condition. The action taken upon fault condition is programmable. If this parameter is set to 0.0 then voltage unbalance is not monitored 0: no action 1: shutdown alarm 0 2: loaddump alarm 3: warning

— 84 —

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition

Unit

Min

Max

Factory Set

Genset Reverse Power Warning Limit

kW

0

50000

0

Genset Reverse Power Loaddumpg Limit

kW

0

50000

0

Genset Reverse Power Fail Timer

sec

0

120

5

Genset Overcurrent Limit

Amp

0

50000

0

Genset Overcurrent Limit-2

Amp

0

50000

0

Genset Overcurrent Action

—

0

3

0

Overcurrent Time Multiplier

0

1

64

16

Genset Overload Limit

kW

0

50000

0

Genset Overload Fail Timer

sec

0

120

3

Load Shedding Low Limit

kW

0

50000

0

Load Shedding High Limit

kW

0

50000

0

K35D01-EN

— 85 —

Description If the genset power is negative and goes above this limit then a REVERSE POWER warning will be generated. If this parameter is set to 0 then reverse power fault is not monitored. If the genset power is negative and goes above this limit then a REVERSE POWER loaddump will be generated. If the genset power is negative and over limits during this timer, a reverse power fault will occur. If one of the genset phase currents goes over this limit when feeding the load, this will generate a genset overcurrent fault condition. The action taken upon fault condition is programmable. If this parameter is set to 0 then overcurrent fault is not monitored. When secondary voltage is selected, if one of the genset phase currents goes over this limit when feeding the load, this will generate a genset overcurrent fault condition. The action taken upon fault condition is programmable. If this parameter is set to 0 then overcurrent fault is not monitored. 0: shutdown alarm 1: loaddump alarm This parameter defines the reaction speed of the overcurrent detector. A higher number means higher sensitivity. Detailed explanation is given at chapter: “Overcurrent Protection” If the total genset active power goes over this limit when feeding the load, this will generate a genset overload loaddump alarm. If this parameter is set to 0 then overload fault is not monitored. If the genset active power is over the limit during this timer, an overload fault will occur. If the genset power goes below this limit then the load shedding relay will be deactivated. Review chapter “Load Shedding” for more details. If the genset power goes above this limit then the load shedding relay will be activated. Review chapter “Load Shedding” for more details.

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition

Unit

Min

Max

Factory Set

Load Add Delay

sec

0

240

0

Load Subtract-Add Delay

min

0

120

0

Mains Waiting Timer

sec

0

50000

30

Mains Connection Topology

—

0

7

5

Genset Connection Topology

—

0

7

5

sec

0

600

0.5

Mains Contactor Timer

K35D01-EN

— 86 —

Description This is the minimum delay between 2 load_add pulses. Review chapter “Load Shedding” for more details. This is the minimum delay required for a load_add pulse after a load_substract pulse. Review chapter “Load Shedding” for more details. This is the time between the mains voltages and frequency entered within the limits and the generator contactor is deactivated. This is the connection topology of mains voltages and CTs. Detailed explanations are given in the chapter: “TOPOLOGIES”. 0: 2 phase, 3 wire L1-L2 1: 2 phase, 3 wire L1-L3 2: 3 phase, 3 wire 3: 3 phase, 3 wire, 2CTs L1-L2 4: 3 phase, 3 wire, 2CTs L1-L3 5: 3 phase, 4 wire star 6: 3 phase, 4 wire delta 7: single phase, 2 wire This is the connection topology of genset voltages and CTs. Detailed explanations are given in the chapter: TOPOLOGIES. 0: 2 phase, 3 wire L1-L2 1: 2 phase, 3 wire L1-L3 2: 3 phase, 3 wire 3: 3 phase, 3 wire, 2CTs L1-L2 4: 3 phase, 3 wire, 2CTs L1-L3 5: 3 phase, 4 wire star 6: 3 phase, 4 wire delta 7: single phase, 2 wire This is the period after the generator contactor has been deactivated and before the mains contactor has been activated.

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition

Unit

Min

Max

Factory Set

Mains MCB Close Pulse

sec

0

10

0.5

Mains MCB Open Pulse

sec

0

10

0.5

Mains MCB Undervoltage Coil Timer

sec

0

10

0.5

Mains MCB Fail Timer

sec

0

10

2.0

—

0

1

0

Genset Contactor Timer

sec

0

600

0.5

Genset MCB Close Pulse

sec

0

10

0.5

Genset MCB Open Pulse

sec

0

10

0.5

Genset MCB Undervoltage Coil Timer

sec

0

10

0.5

Genset MCB Fail Timer

sec

0

10

2.0

—

0

1

0

Mains Phase Order Check Enable

Genset Phase Order Check Enable

K35D01-EN

— 87 —

Description After the mains MCB_undervoltage coil is energized and mains MCB_undervoltage coil timer is elapsed, the mains MCB_close relay will be activated during this period. Review chapter “Motorized Circuit Breaker Control” for more details. The mains MCB_open relay will be activated during this period. Review chapter “Motorized Circuit Breaker Control” for more details. The mains MCB_undervoltage coil is energized during this period before the mains MCB_close relay is activated. Review chapter “Motorized Circuit Breaker Control” for more details. If a mains MCB feedback input is defined and if the mains MCB fails to change position before the expiration of this timer, then a fault condition occurs. 0: mains phase order checking disabled 1: if mains phase order is faulty, then a warning is given and mains contactor deenergized. This is the period after the mainscontactor has been deactivated and before the genset contactor has been activated. After the genset MCB_undervoltage coil is energised and genset MCB_undervoltage coil timer is elapsed, the genset MCB_close relay will be activated during this period. Review chapter “Motorized Circuit Breaker Control” for more details. The genset MCB_open relay will be activated during this period. Review chapter “Motorized Circuit Breaker Control” for more details. The genset MCB_undervoltage coil is energised during this period before the genset MCB_close relay is activated. Review chapter “Motorized Circuit Breaker Control” for more details. If a genset MCB feedback input is defined and if the genset MCB fails to change position before the expiration of this timer, then a fault condition occurs. 0: genset phase order checking disabled 1: if genset phase order is faulty, then a genset phase order fail loaddump alarm is given.

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

ENGINE PARAMETERS GROUP Parameter Definition

Unit

Min

Max

Factory Set

Nominal RPM

rpm

0

50000

1500

Nominal RPM-2

rpm

0

50000

1800

Low RPM Warning Limit

%

R-100

R+100

R-10%

Low RPM Shutdown Limit

%

R-100

R+100

R-15%

High RPM Warning Limit

%

R-100

R+100

R+10%

High RPM Shutdown Limit

%

R-100

R+100

R+15%

sec

0

10

3

Overspeed Overshoot Limit

%

HRSL100

HRSL +100

HRSL +10%

Loss of Signal Check

—

0

1

0

Loss of Speed Signal Action

—

0

2

0

Loss of Speed Signal Timer

sec

0

240

0

Low Charge Voltage Warning Limit

V-DC

0

40

6.0

Low Charge Voltage Shutdown Limit

V-DC

0

40

4.0

Charge Voltage Fail Timer

sec

0

120

1

RPM Fail Timer

K35D01-EN

— 88 —

Description The nominal value of engine rpm. Lowhigh rpm limits are defined by reference to this value. When secondary frequency is selected, this is the nominal value of engine rpm. Low-high rpm limits are defined by reference to this value. If the engine rpm goes under this limit when feeding the load, this will generate a GENSET LOW RPM warning. If the engine rpm goes under this limit when feeding the load, this will generate a GENSET LOW RPM shutdown alarm and the engine will stop. If the engine rpm goes over this limit when feeding the load, this will generate a GENSET HIGH RPM warning. If the engine rpm goes over this limit when feeding the load, this will generate a GENSET HIGH RPM shutdown alarm and the engine will stop. If the engine rpm goes outside of the limits during this timer, an engine speed fault will occur. If the engine rpm goes over the “High RPM Shutdown Limit” by this quantity, this will generate immediately a GENSET HIGH RPM shutdown alarm and the engine will stop. 0: speed signal existency not checked 1:If the speed signal is lost, it will generate a Speed Signal Lost fault condition. The action taken upon fault condition is programmable. 0: shutdown alarm 1: loaddump alarm 2: warning If the speed signal is lost during this timer, a Speed Signal Lost fault will occur. If the charge alternator voltage goes under this limit, a charge alternator voltage warning will occur. If the charge alternator voltage goes under this limit, a charge alternator voltage shutdown will occur and the engine will stop. If the charge alternator voltage goes under limits during this timer, a charge alternator voltage fault will occur.

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

ENGINE PARAMETERS GROUP (continued) Parameter Definition

Unit

Min

Max

Factory Set

Engine Heating Temperature

°C

0

80

0

Engine Start Delay

sec

0

240

1

Preheat Timer

sec

0

30

0

Crank Timer

sec

1

15

6

Wait Between Starts

sec

1

240

10

Engine Heating Timer

sec

0

240

4

—

0

1

0

Cooldown Timer

sec

0

600

120

Stop Solenoid Timer

sec

0

90

10

—

1

6

3

sec

0

240

5

Engine Heating Method

Number of Starts

Choke Timer

K35D01-EN

— 89 —

Description If it is requested that the engine runs without load until reaching a certain temperature, this parameter defines the temperature. This is the time between the mains fails and the fuel solenoid turns on before starting the genset. It prevents unwanted genset operation in battery backed-up loads. This is the time after the fuel solenoid is energized and before the genset is started. During this period the PREHEAT relay output is energized (if assigned by Relay Definitions) This is the maximum start period. Starting will be automatically cancelled if the genset fires before the timer. This is the waiting period between two start attempts. This is the period used for engine heating before load transfer. The genset will not take the load before engine heating is completed. 0: engine is heated during Engine Heating Timer. 1: engine is heated until the coolant temperature reaches the Engine Heating Temperature and at least during the Engine Heating Timer. This is the period that the generator runs for cooling purpose after the load is transferred to mains. This is the maximum time duration for the engine to stop. During this period the STOP relay output is energized (if assigned by Relay Definitions). If the genset has not stopped after this period, a FAIL TO STOP warning occurs. Number of Starts This is the control delay of CHOKE output. The choke output is activated together with the crank output. It is released after this delay or when engine runs (whichever occurs first).

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

ENGINE PARAMETERS GROUP (continued) Parameter Definition

Unit

Min

Max

Factory Set

Idle Speed Timer

sec

0

240

0

Idle Holdoff Timer

sec

0

30

10

Gas Solenoid Delay

sec

0

240

5

V-AC

0

65000

100

Crank Cut Frequency

Hz

0

100

10

Crank Cut RPM

rpm

0

65000

500

Crank Cut Charge Voltage

V-DC

0

40

6

Crank Cut with Oil Pressure

—

0

1

0

Crank Cut with Oil Pressure Delay

sec

0

30

2

Charge Input Connected

—

0

1

0

Fuel Tank Capacity

Lt

0

65000

0

Fuel Consumption per Hour

%

0

100

0.0

Crank Cut Voltage

K35D01-EN

— 90 —

Description When the engine runs, the Idle output relay function will be active during this timer. While the IDLE output is active, low voltage, low frequency and low rpm checks are disabled. While the IDLE periode is over, low voltage, low frequency and low speed checks are enabled after the expiration of this timer. The gas solenoid of the gas engine (if assigned by Relay Definitions) will be opened after this delay during cranking. The crank relay output is deenergized when the genset phase L1 voltage reaches this limit. The crank relay output is deenergized when the genset frequency reaches this limit. The crank relay output is deenergized when the engine rpm reaches this limit. The crank relay output is deenergized when the charge alternator voltage reaches this limit. 0: no crank cut with oil pressure 1: cranking is cut when oil pressure switch is open or the oil pressure measured is above shutdown limit. If crank cutting with oil pressure is enabled, cranking is cut after this delay when oil pressure switch is open or the oil pressure measured is above shutdown limit. 0: Crank cutting with charge input disabled 1: Crank cutting with charge input enabled The full capacity of the fuel tank. If this parameter is zero, the fuel quantity in the tank is not displayed. This parameter is the threshold for sending FUEL THEFT and FUELLING sms messages. If this parameter is set to 0, then no Fuel Theft and Fuelling sms messages will be sent. If SMS is required, set this parameter to a value above the hourly fuel consumption of the genset.

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

ENGINE PARAMETERS GROUP (continued) Parameter Definition

Unit

Min

Max

Factory Set

Coolant Cooler On

°C

0

250

90

Coolant Cooler Off

°C

0

250

80

Coolant Heater On

°C

0

250

50

Coolant Heater Off

°C

0

250

60

Fan Overrun Timer

sec

0

240

0

Canopy Fan Turn-On

°C

0

250

90

Canopy Fan Turn-Off

°C

0

250

80

Ambient Fan Turn-On

°C

0

250

90

Ambient Fan Turn-Off

°C

0

250

80

Service-1 Engine Hours

hours

0

5000

250

Service-1 Period

month

0

24

6

—

0

3

3

Service-1 Alarm Level

K35D01-EN

— 91 —

Description If the coolant temp is above this limit then the cooler relay function will become active. If the coolant temp is below this limit then the cooler relay function will become inactive. If the coolant temp is below this limit then the heater relay function will become active. If the coolant temp is above this limit then the heater relay function will become inactive. The cooler relay will stay active during this timer after the coolant temp is below “Coolant Cooler Off” limit. If the canopy temp is above this limit then the canopy fan relay function will become active. If the canopy temp is below this limit then the canopy fan relay function will become inactive. If the ambient temp is above this limit then the ambient fan relay function will become active. If the ambient temp is below this limit then the ambient fan relay function will become inactive. The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last service. If the period is set to ‘0’ no SERVICE REQUEST will be generated depending on service-1 engine hours. The SERVICE REQUEST led indicator will turn on after this amount of time from the last service. If the period is set to ‘0’ no SERVICE REQUEST will be indicated depending on Service-1 Period. 0: no action 1: shutdown alarm 2: loaddump alarm 3: warning

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

ENGINE PARAMETERS GROUP (continued) Parameter Definition

Unit

Min

Max

Factory Set

Service-2 Engine Hours

hours

0

5000

250

Service-2 Period

month

0

24

6

—

0

3

0

Service-3 Engine Hours

hours

0

5000

250

Service-3 Period

month

0

24

6

—

0

3

0

Service-2 Alarm Level

Service-3 Alarm Level

K35D01-EN

— 92 —

Description The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last service. If the period is set to ‘0’ no SERVICE REQUEST will be generated depending on service-2 engine hours. The SERVICE REQUEST led indicator will turn on after this amount of time from the last service. If the period is set to ‘0’ no SERVICE REQUEST will be indicated depending on Service-2 Period. 0: no action 1: shutdown alarm 2: loaddump alarm 3: warning The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last service. If the period is set to ‘0’ no SERVICE REQUEST will be generated depending on service-3 engine hours. The SERVICE REQUEST led indicator will turn on after this amount of time from the last service. If the period is set to ‘0’ no SERVICE REQUEST will be indicated depending on Service-3 Period. 0: no action 1: shutdown alarm 2: loaddump alarm 3: warning

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

ENGINE PARAMETERS GROUP (continued) Parameter Definition

Unit

Min

Max

Factory Set

J1939 Enable

—

0

1

0

J1939 Engine Brand

—

0

15

0

J1939 ECU Type

—

0

7

0

K35D01-EN

— 93 —

Description 0: The J1939 port is inoperative. 1: The analog measurements (oil, temp, rpm) are picked_up from the ECU. If the ECU communication is lost, then the engine will be stopped. 0: GENERIC 1: CUMMINS 2: DETROIT DIESEL 3: DEUTZ 4: JOHN DEERE 5: PERKINS 6: VOLVO 7: CATERPILLAR 8: SCANIA 9: IVECO 10: MTU-MDEC 11: BOSCH Other values: Reserved. Do not use. GENERIC ENGINE BRAND 0: Generic CUMMINS ENGINE 0: Generic DETROIT DIESEL ENGINE 0: Generic DEUTZ ENGINE 0: Generic 1: EMR2 2: EMR3 JOHN DEERE ENGINE 0: Generic PERKINS ENGINE 0: Generic 1: ADEM3 2: ADEM 1.3 VOLVO ENGINE 0: Generic 1: without CIU unit 2: EDC4 CATERPILLAR ENGINE 0: Generic SCANIA ENGINE 0: Generic 1: Single Speed 2: All Speed IVECO ENGINE 0: Generic MTU-MDEC ENGINE 0: MDEC 302 1: MDEC 201 2: MDEC 303 3: MDEC 304 4: MDEC 506 BOSCH INJECTION SYSTEM 0: Generic 1: EDC 731 2: EDC 9.3

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

ENGINE PARAMETERS GROUP (continued) Parameter Definition

Unit

Min

Max

Factory Set

J1939 Speed Adjust

%

-100

+100

0.0

High Air Inlet Temperature Warning Limit

°C

0

200

0

High Air Inlet Temperature Alarm Limit

°C

0

200

0

High Air Inlet Temperature Alarm Action

—

0

1

Low Coolant Level Warning Limit

%

0

100

0

Low Coolant Level Alarm Limit

%

0

100

0

Low Coolant Level Alarm Action

—

0

1

0

K35D01-EN

— 94 —

Description This parameter adjusts the speed of an ECU controlled engine by +/- 8%. If the air inlet temperature measured through ECU is over this limit, then a high air inlet temperature warning will occur. If the air inlet temperature measured through ECU is over this limit, then a high air inlet temperature shutdown/loaddump alarm will occur. 0: shutdown alarm 1: loaddump alarm If the coolant level measured through ECU is below this limit, then a low coolant level warning will occur. If the coolant level measured through ECU is below this limit, then a low coolant level shutdown/loaddump alarm will occur. 0: shutdown alarm 1: loaddump alarm

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

ADJUST DATE AND TIME

These parameters allow adjusting the battery backup real time clock of the module. Once set, the clock will continue to run even if DC power is removed from the unit. Parameter Definition Date Month Year Hours Minutes Seconds

Unit —

Min 01 01 00 00 00 00

Max 31 12 99 23 59 59

Description Current day of the month. Current month. Last two digits of the current year. Current hour of the day. Current minute of the hour. Current second of the minute.

WEEKLY OPERATION SCHEDULE

In AUTO mode, it is possible to define the periods where automatic operation is desired. It may be required that the genset does not start at night or weekends. Weekly schedule programs allow an hourly setting of automatic operation of the unit during one week. There are 7days x 24hours =144 parameters. Each hour of the week can be independently defined as AUTO or OFF period.

If automatic operation is disabled by the weekly exerciser, the AUTO led will flash.

K35D01-EN

— 95 —

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

EXERCISER SCHEDULE

The unit provides 7 independent automatic exerciser programs. Automatic exercise may be done in weekly or monthly basis. If monthly exercise is selected, the week, day and hour is adjustable for each exercise item. If weekly exercise is selected, the day and hour is adjustable for each exercise item. Exercise can be done with or without load. Thus the genset can be instructed to run automatically in given days and times of a week and take the load.

K35D01-EN

— 96 —

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

SENDER CONFIGURATION The unit has 4 analog sender inputs. Only parameters of one sender are explained below. Other senders have identical parameter set. Each sender has 16 step programmable curves. The sender name and reading unit is freely programmable, thus the sender can be adapted to any type through programming. Each sender has below programmable parameters: Parameter Definition

Unit

Min

Max

Sender Type

—

0

15

Alarm Level

—

0

1

Alarm Handling

—

0

3

Sender Open Alarm

—

0

3

Low Alarm Check Enable

0

0

1

Low Warning Check Enable

0

0

1

High Alarm Check Enable

0

0

1

High Warning Check Enable

0

0

1

Low Alarm Level

x

0

10000

Low Warning Level

x

0

10000

High Alarm Level

x

0

10000

High Warning Level

x

0

10000

K35D01-EN

Factory Set

— 97 —

Description Selects between predefined sender functions. If this parameter is set to 1314-15 then the sender name string can be freely entered. 0: shutdown alarm 1: loaddump alarm 0: always 1: on engine running 2: after hold-off timer 3: reserved If sender resistor is above 5000 ohms, a fault case is generated. This parameter defines the action taken upon fault case. 0: no alarm 1: shutdown alarm 2: loaddump alarm 3: warning The low alarm may be selected as shutdown or loaddump with “alarm level” parameter. 0: low value alarm disabled 1: low value alarm enabled 0: low value warning disabled 1: low value warning enabled The high alarm may be selected as shutdown or loaddump with “alarm level” parameter. 0: high value alarm disabled 1: high value alarm enabled 0: high value warning disabled 1: high value warning enabled If enabled, defines the low alarm limit. The low alarm may be selected as shutdown or loaddump with “alarm level” parameter. If defined, defines the low warning. If enabled, defines the high alarm limit. The high alarm may be selected as shutdown or loaddump with “alarm level” parameter. If defined, defines the high warning.

TJ-509T User Manual Rev_01

Parameter Definition

Unit

Sender Curve-1 ohm Sender Curve-1 value Sender Curve-2 ohm Sender Curve-2 value Sender Curve-3 ohm Sender Curve-3 value Sender Curve-4 ohm Sender Curve-4 value Sender Curve-5 ohm Sender Curve-5 value Sender Curve-6 ohm Sender Curve-6 value Sender Curve-7 ohm Sender Curve-7 value Sender Curve-8 ohm Sender Curve-8 value Sender Curve-9 ohm Sender Curve-9 value Sender Curve-10 ohm Sender Curve-10 value Sender Curve-11 ohm Sender Curve-11 value Sender Curve-12 ohm Sender Curve-12 value Sender Curve-13 ohm Sender Curve-13 value Sender Curve-14 ohm Sender Curve-14 value Sender Curve-15 ohm Sender Curve-15 value Sender Curve-16 ohm Sender Curve-16 value

PRELIMINARY VERSION

Min

Max

ohms x ohms x ohms x ohms x ohms x ohms x ohms x ohms x ohms x ohms x ohms x ohms x ohms x ohms x ohms x ohms x

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

5000 10000 5000 10000 5000 10000 5000 10000 5000 10000 5000 10000 5000 10000 5000 10000 5000 10000 5000 10000 5000 10000 5000 10000 5000 10000 5000 10000 5000 10000 5000 10000

Sender Name

—

—

—

Sender Low Fault String

—

—

—

Sender High Fault String

—

—

—

K35D01-EN

V-1.4

Factory Description Set Point-1 ohm value Point-1 reading Point-2 ohm value Point-2 reading Point-3 ohm value Point-3 reading Point-4 ohm value Point-4 reading Point-5 ohm value Point-5 reading Point-6 ohm value Point-6 reading Point-7 ohm value Point-7 reading Point-8 ohm value Point-8 reading Point-9 ohm value Point-9 reading Point-10 ohm value Point-10 reading Point-11 ohm value Point-11 reading Point-12 ohm value Point-12 reading Point-13 ohm value Point-13 reading Point-14 ohm value Point-14 reading Point-15 ohm value Point-15 reading Point-16 ohm value Point-16 reading If the sender type parameter is set to zero (not used), this string is used as sender name while displaying the sender reading. If the sender type parameter is set to zero (not used), this string is used as sender low value fault in the alarm display. If the sender type parameter is set to zero (not used), this string is used as sender high value fault in the alarm display.

— 98 —

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

DIGITAL INPUT CONFIGURATION

The unit has 8 digital inputs. By using external input extension modules, up to 40 inputs in total are available. Only parameters of one input are explained below. Other inputs have identical parameter set. The input name is freely programmable, thus the input can be adapted to any functionality through programming.

The input name entry is made through RainbowPlus program only.

Each sender has below programmable parameters: Parameter Definition

Unit

Min

Max

Input Function

—

0

99

Action

—

0

3

Sampling

—

0

3

Latching

—

0

1

Contact type

—

0

1

Switching

—

0

1

Response delay

—

0

3

K35D01-EN

Factory Set

— 99 —

Description Selects between predefined input functions. Selected input name is displayed in the line below. If this parameter is set to 0 then the input name string can be freely entered. 0: shutdown alarm 1: loaddump alarm 2: warning 3: no fault condition from this input. 0: always 1: on engine running 2: after hold-off timer 3: reserved 0: non-latching. The fault disappears when cause is removed. 1: latching. The fault persists even if the cause is removed. Requires manual reset. 0: Normally open 1: Normally closed 0: Battery negative 1: Battery positive 0: No delay 1: Delayed (1sec) 2: Delayed (5sec) 3: Delayed (10sec)

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

INPUT FUNCTION LIST No

Description

No

Description

No

Description

1

User Defined Function

41

Over Resonance

81

reserved for future use

2

Low Oil Press. Switch

42

Short-Circuit Alarm

82

reserved for future use

3

High Temp. Switch

43

Reset Service 1 Alm

83

reserved for future use

4

Coolant Level Switch

44

Reset Service 2 Alm

84

reserved for future use

5

Rectifier Fail Switch

45

Reset Service 3 Alm

85

reserved for future use

6

Emergency Stop

46

reserved for future use

86

reserved for future use

7

Alternator High Temp

47

reserved for future use

87

reserved for future use

8

Excitation Loss Sw.

48

reserved for future use

88

reserved for future use

9

Low Fuel Switch

49

reserved for future use

89

reserved for future use

10

Earthquake Detector

50

reserved for future use

90

reserved for future use

11

Gen Cont Auxiliary

51

reserved for future use

91

reserved for future use

12

Mains Cont Auxiliary

52

reserved for future use

92

reserved for future use

13

Force AUTO Mode

53

reserved for future use

93

reserved for future use

14

Force OFF Mode

54

reserved for future use

94

reserved for future use

15

Force TEST Mode

55

reserved for future use

95

reserved for future use

16

Over Load Switch

56

reserved for future use

96

reserved for future use

17

Manual Fuel Fill!

57

reserved for future use

97

reserved for future use

18

Priority

58

reserved for future use

98

reserved for future use

19

Remote Start

59

reserved for future use

99

reserved for future use

20

Disable Auto Start

60

reserved for future use

100

reserved for future use

21

Force to Start

61

reserved for future use

22

Fault Reset

62

reserved for future use

23

Alarm Mute

63

reserved for future use

24

Panel Lock

64

reserved for future use

25

Fuel Pump Switch

65

reserved for future use

26

Secondary Volt&Freq

66

reserved for future use

27

Disable Protections

67

reserved for future use

28

Auto Restore Inhibit

68

reserved for future use

29

GensetLoadingInhibit

69

reserved for future use

30

Air Flap Fault

70

reserved for future use

31

Canopy Door Open

71

reserved for future use

32

Station Door Open

72

reserved for future use

33

Station Over-Heat Sw

73

reserved for future use

34

Weather Cloudy

74

reserved for future use

35

Weather Rainy

75

reserved for future use

36

Lightning

76

reserved for future use

37

Cooler Fan Fault

77

reserved for future use

38

Heater Fan Fault

78

reserved for future use

39

Canopy Fan Fault

79

reserved for future use

40

Station Fan Fault

80

reserved for future use

K35D01-EN

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

OUTPUT CONFIGURATION The parameters below define the functions of relay outputs. The unit has 8 relay outputs. All relays have programmable functions, selected from a list. Relays may be extended up to 40 using Relay Extension Modules.. Other relays are in the optional Extension Modules. Parameter Definition Relay-01 Relay-02 Relay-03 Relay-04 Relay-05 Relay-06 Relay-07 Relay-08

Factory Terminal Description set number 3 4 Factory set as Crank Relay output 1 5 Factory set as Fuel Relay output 2 6 Factory set as Horn Relay output 8 7 Factory set as Preheat Relay output 4 8 Factory set as Stop Relay output 7 9 Factory set as Idle Speed Relay output 6 72 Factory set as Mains Contactor Relay output 5 51 Factory set as Genset Contactor Relay output

Relay-09 Relay-10 Relay-11 Relay-12 Relay-13 Relay-14 Relay-15 Relay-16

1 1 1 1 1 1 1 1

—

Relay extension module – 1 Relay extension module – 1 Relay extension module – 1 Relay extension module – 1 Relay extension module – 1 Relay extension module – 1 Relay extension module – 1 Relay extension module – 1

Relay-17 Relay-18 Relay-19 Relay-20 Relay-21 Relay-22 Relay-23 Relay-24

1 1 1 1 1 1 1 1

—

Relay extension module – 2 Relay extension module – 2 Relay extension module – 2 Relay extension module — 2 Relay extension module — 2 Relay extension module — 2 Relay extension module — 2 Relay extension module — 2

Relay-25 Relay-26 Relay-27 Relay-28 Relay-29 Relay-30 Relay-31 Relay-32

1 1 1 1 1 1 1 1

—

Relay extension module — 3 Relay extension module — 3 Relay extension module — 3 Relay extension module — 3 Relay extension module — 3 Relay extension module — 3 Relay extension module — 3 Relay extension module — 3

Relay-33 Relay-34 Relay-35 Relay-36 Relay-37 Relay-38 Relay-39 Relay-40

1 1 1 1 1 1 1 1

—

Relay extension module — 4 Relay extension module — 4 Relay extension module — 4 Relay extension module — 4 Relay extension module — 4 Relay extension module — 4 Relay extension module — 4 Relay extension module — 4

K35D01-EN

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

Below is a short list for reference purposes. Please use the RainbowPlus program for complete selection list. OUTPUT FUNCTION LIST No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Description Fuel Horn Crank Stop Solenoid Genset Contactor Mains Contactor Idle Speed Preheat Alternate Crank Fuel Main Winding Genset Close Pulse Genset Open Pulse Genset UV Coil Mains Close Pulse Mains Open Pulse Mains UV Coil Flashing Relay Gas Solenoid Fuel Pump Control Choke Block Heater Coolant Cooler Coolant Heater Fan Control Air Flap Control Canopy Fan Control Ambient Fan Control Remote Start Output Genset Ready Bus Bar Contactor Bus Bar Close Pulse Bus Bar Open Pulse Bus Bar UV Coil Load Shedding Load Add Load Substract Service 1 Request Service 2 Request Service 3 Request Mains Ph.Order Fail

K35D01-EN

No 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

Description Genset Ph.Order Fail Auto Ready Weekly Schedule On Exerciser On Mains Fail Pgm Mode Active Engine Running Genset Voltage Ok Alarm Check Enable Oil Pressure Ok! Shutdown Alarm Loaddump Alarm Warning Alarm Shutdown or Loaddump Secondary Volt & Freq Test Mode Auto Mode Manual Mode Off Mode Not In Auto Genset At Rest Waiting Before Fuel Preheating Waiting Oil Flash Off Engine Heating Synchronizing Cooling Down Stopping Protections Disabled Remote Start Input Disable Auto Start Force to Start Auto Restore Inhibited Gen.Loading Inhibited Inp.Expansion1Mounted Inp.Expansion2Mounted Out.Expansion1Mounted Out.Expansion2Mounted Master Unit —

— 102 —

No 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120

Description —

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

SITE ID STRING The site identity string is designed to identify the current controller. This is the site Id string sent at the beginning of SMS messages, e-mails and web page headers for the identification of the genset sending the message. Any 20 character long string may be entered.

ENGINE SERIAL NUMBER The engine serial number string is designed to identify the current controller. Th s string is added to GSM-SMS messages, e-mails, web page headers etc.

MODEM1-2/SMS1-2-3-4 TELEPHONE NUMBERS These telephone number buffers accept up to 16 digits, including the wait character (“,”) in order to enable dialing through a pabx. If Modem Selection= External PSTN Modem: First 2 numbers are used for modem calls. Other selections: all numbers are used for SMS sending.

Enter numbers starting from first character. Do not leave blank characters at the beginning.

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

GSM MODEM PARAMETERS Parameter Definition APN User Name

APN Password

APN Name

SMS Service Center Number

Description The APN (access point name) username may be required by the GSM operator. However some GSM operators may allow access without username. The exact information should be obtained from the GSM operator. Please search the GSM operator’s website with “APN” string. If the APN (access point name) username is required by the GSM operator, most probably the APN password will also be required. However some GSM operators may allow access without password. The exact information should be obtained from the GSM operator. Please search the GSM operator’s website with “APN” string. The APN (access point name) is always required by the GSM operator. The exact information should be obtained from the GSM operator. Please search the GSM operator’s website with “APN” string. The SMS service center number may be required by the GSM operator. However some GSM operators may allow SMS sending without SMS service center number. The exact information should be obtained from the GSM operator. Please search the GSM operator’s website with “sms service center” string.

Below GSM modem related parameters are found in the Controller Configuration group. Parameter Definition

Unit

Min

Max

GSM Sim Card Pin

—

0000

9999

SMS Enable

—

0

1

GPRS Connection Enable

—

0

1

SMS on Mains Change

—

0

1

SMS on IP Change

—

0

1

K35D01-EN

Factory Description Set If the GSM SIM card uses pin number, enter the pin number here. If incorrect 0 pin number is entered, then the SIM card will not operate. 0: SMS messages disabled 0 1: SMS messages enabled 0: GPRS disabled 0 1: GPRS enabled This parameter controls SMS sending when mains voltages status is changed. No warnings generated. 0 0: no SMS on mains failed or restored 1: SMS sent on mains failed or restored This parameter controls SMS sending when IP address of GPRS connection is changed. No warnings 0 generated. 0: no SMS on IP change 1: SMS sent on IP change

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

ETHERNET PARAMETERS Parameter Definition

Network IP Address

Gateway IP Address

Subnet Mask

User IP Mask 1 (2) (3)

Domain Name

Membership Address

Username/Password

Ping Address IP Confirmation Address Rainbow Address-1 Rainbow Address-2

K35D01-EN

Factory Set

Description This is the IPv4 (internet protocol version 4) address that the unit will require from the DHCP (dynamic host control protocol) server. 0.0.0.0 If this parameter is set to 0.0.0.0 then the unit will require any IPv4 address from the DHCP server. If you are not an IP professional please leave this address as “0.0.0.0”. This is the router IPv4 address, If the Network IP address and Gateway IP Address are set to “0.0.0.0” then the unit will get the gateway address 0.0.0.0 automatically. If you are not an IP professional please leave this address as “0.0.0.0”. Reserved for IP professionals. 255.255.255.0 If you are not an IP professional please leave this address as “255.255.255.0”. These 3 registers control the IPv4 access to the unit. The remote IPv4 address is logical AND’ed with these 255.255.255.255 IP addresses. If the result gives the remote IP address, 0.0.0.0 then access is enabled. 0.0.0.0 Thus access may be limited to the same LAN members (x.x.x.255) or strictly to predefined IPv4 addresses. This string is used in “Dynamic DNS” feature. The unit will register itself to the dynamic DNS server under this name. d500.dyndns-ip.com For more detailed information please review chapter on “Dynamic DNS Feature” and the document “Dynamic DNS Account Setting”. This string is used in “Dynamic DNS” feature. This is the address used in registering to the dynamic DNS server. members.dyndns.org For more detailed information please review chapter on “Dynamic DNS Feature” and the document “Dynamic DNS Account Setting”. These strings are used in “Dynamic DNS” feature while registering to the dynamic DNS server. For more detailed information please review chapter on “Dynamic DNS Feature” and the document “Dynamic DNS Account Setting”. This internet address is regularly accessed in order to check the availability of internet access. www.google.com The access period is defined in parameter Controller Configuration>Ping Period. This internet address is regularly accessed in order to checkip.dyndns.org read the IPv4 address of the unit. These parameters accept both internet addresses (like http://datakom.com.tr) and IPv4 addresses (like 78.192.238.116). Information for remote monitoring is sent to these addresses. The port information of these addresses are found in Controller Configuration group.

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

ETHERNET PARAMETERS (continued) Parameter Definition

Factory Set

Mail Account Name Mail Account Password

Description This is the account name appearing in the “from” tab of the e-mail recipient. (ex: [email protected])

d500_a d500_1234

Mail Server Address

This is the e-mail password of above e-mail account.

smtp.mail.yahoo.com

E-mail Address-1 E-mail Address-2 E-mail Address-3

—

This is the Outgoing Mail Server Address of the above e-mail account (ex: smtp.gmail.com) These are e-mail recipient addresses where the unit is intended to send e-mail messages. Up to 3 e-mails can be sent at once.

Below ETHERNET related parameters are found in the Controller Configuration group. Parameter Definition

Unit

Min

Max

Web Programming Enable

—

0

1

Web Control Enable

—

0

1

Web Refresh Rate

sec

0

240

Ping Period

min

0

240

Rainbow Refresh Rate

sec

0

65535

Rainbow Address-1 Port

—

0

65535

Rainbow Address-2 Port

—

0

65535

Web Server Port

—

0

65535

Modbus over IP Port

—

0

65535

SMTP Port

—

0

65535

Ethernet Enable

—

0

1

E-mail on IP Change

—

0

1

K35D01-EN

Factory Description Set 0: Web programming disabled 0 1: Web programming enabled 0: Web control disabled 0 1: Web control enabled The unit will refresh the web page with 5 this interval. The unit will check the availability of the 0 internet connection with this interval. The unit will update the distant 5 monitoring terminal with this rate. This is the port number of the first 0 monitoring terminal address. This is the port number of the second 0 monitoring terminal address. This is the port number of the internal 80 web server. The unit will answer queries to this port only. This is the port number of the internal Modbus over IP terminal. The unit will 502 answer Modbus requests to this port only. This is the port number used for e-mail 587 sending. 0: ethernet port disabled 1 1: ethernet port enabled This parameter controls e-mail sending when IP address of GPRS or ethernet connection is changed. No warnings 0 generated. 0: no e-mail on IP change 1: e-mail sent on IP change

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

SYNCHRONIZATION PARAMETERS Parameter Definition

Unit

Min

Max

—

0

1

Synchronization Fail Timeout

sec

0

240

Synchronization Contactor Timeout

sec

0

25

Max Freq Difference

Hz

0.1

2.0

Max Volt Difference

VAC

0

20

Max Phase Difference

deg.

0

20

No Break Transfer Enable

K35D01-EN

Factory Description Set 0: only interrupted transfer enabled 0 1: no break transfer enabled If the phase and voltage synchronization is not successful before the expiration of this timer, then a 30 Synchronization Fail warning is given and the transfer will be performed with interruption. When synchronization is detected, both 0.5 contactors will stay closed during this timer. This is the maximum difference 0.5 between mains and genset frequencies to close both contactors. This is the maximum difference between the mains phase-L1 and the genset phase-L1 voltages to close both 5 contactors. If voltage transformer is used, this quantity is multiplied with voltage transformer ratio. This is the maximum phase angle between the mains phase-L1 and the 10 genset phase-L1 voltages to close both contactors.

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

CRANK CUTTING In order to insure fast and reliable crank cutting, the unit uses various resources for engine running condition detection. Cranking is stopped when at least one of below conditions is met: — Crank timer expired: The crank timer is adjusted through Engine Parameters > Crank Timer. The maximum allowed timer is 15 seconds. — Genset AC voltage over threshold: If the genset phase L1 AC voltage reaches Engine Parameters > Crank Cut Voltage, then cranking is immediately stopped. — Genset frequency over threshold: If the genset phase L1 frequency reaches Engine Parameters > Crank Cut Frequency, then cranking is immediately stopped. — Genset rpm over threshold: If the genset rpm reaches Engine Parameters > Crank Cut RPM, then cranking is immediately stopped. — Charge alternator voltage over threshold Following setting is necessary: Engine Parameters > Charge Input Connected = 1 If the charge alternator voltage reaches Engine Parameters > Crank Cut Charge Voltage, then cranking is immediately stopped. — Oil pressure above threshold Following setting is necessary: Engine Parameters > Crank Cut with Oil Pressure = 1 The crank cutting with oil pressure offers a programmable delay through Engine Parameters > Crank Cut with Oil Pressure Delay. The parameter is factory set to 2 seconds. Both low oil pressure switch and oil pressure sender readings may be used for crank cutting. The oil pressure switch is always used. The sender may be disabled through Controller Configuration > Oil Pressure Switch Priority parameter. If enabled, when oil pressure is detected, cranking is stopped after adjustable timer delay.

K35D01-EN

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

OVERCURRENT PROTECTION (IDMT) The unit offers a programmable IDMT protection function in order to protect the alternator against excessive currents. The IDMT (Inverse Definite Minimum Time) protection function has such tripping characteristics that the tripping time varies inversely with the value of current. Beyond a certain current limit the tripping time becomes constant (definite) and causes tripping in minimum time. The tripping formula is defined as below:

Where: TMS is the IDMT time multiplier setting. This is also the tripping time at 100% overload. I is the current of the most loaded phase Iset is the programmed overcurrent limit t is the tripping time in seconds Currents below the overcurrent limit are allowed to flow for unlimited time. Currents above the limit will cause the IDMT protection to trigger with a delay depending on the strength of the overcurrent. Higher the current, faster the protection will trip. When a non-tripping overcurrent condition occurs, the unit will keep trace of it. In case of a consecutive overcurrent, the controller will take into account the residual heat caused by the previous overcurrent and will trip faster than usual. The IDMT multiplier adjusts the sensitivity of the IDMT detector. When the multiplier is low, then tripping will be faster for the same current. The unit provides separate Overcurrent limits for primary and secondary volt/speed/amp settings. Switching from primary volt/freq/amps to secondary values will also switch the IDMT detector to the secondary setting. The action of the tripping may be selected as a Loaddump (stop after cooldown) or shutdown alarm (immediate stop).

Screenshot from RainbowPlus configuration program, Generator>Current section

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

Below is a table showing the tripping delay in function of the percent load level (with TMS=36): 100% unlimited

170% 73s

240% 18s

110% 3600s

180% 56s

250% 16s

120% 900s

190% 44s

260% 14s

130% 400s

200% 36s

270% 12s

140% 225s

210% 30s

280% 11s

150% 144s

220% 25s

290% 10s

160% 100s

230% 21s

300% 9s

Below is the tripping delay curve in function of the load level (with TMS=36):

K35D01-EN

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

MOTORIZED CIRCUIT BREAKER CONTROL The unit offers full control for any brand and model of motorized circuit breakers (MCB). The MCB control is performed through 3 digital output functions, namely Open, Close and Undervoltage coil controls. Only 2 of these outputs are used in a single application. Any digital output can be assigned to MCB control signals through programming menu.

The MCB CLOSE sequence is below: Activate UV output, wait for undervoltage coil timer (tuv) Activate CLOSE output, wait for close pulse timer (tcl) Deactivate CLOSE output The MCB OPEN sequence is below: Deactivate UV output Activate OPEN output, wait for open pulse timer (top) Deactivate OPEN output

Open Pulse, Close Pulse and Undervoltage Coil timers are adjusted through programming menu.

If MCB feedback input is defined and the MCB fails to change position after the expiration of MCB Fail timer, then a fault condition will occur.

K35D01-EN

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

MCB modules can be operated by 2 different ways. The unit supports both configurations. Below is the terminology used: M: gear motor PF: ready to close contact XF: close coil MX: open coil MN: undervoltage trip (release) AUX: auxiliary contacts

MCB WITH OPEN-CLOSE COILS

MCB WITH CLOSE-UV COILS

In the diagram at left, relay function assignments should be as below: OUTx: Mains (or Genset) Close Pulse OUTy: Mains (or Genset) Open Pulse In the diagram at right, relay function assignments should be as below: OUTx: Mains (or Genset) Close Pulse OUTy: Mains (or Genset) Undervoltage Coil

K35D01-EN

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

J1939 CANBUS ENGINE SUPPORT The unit offers a special J1939 port in order to communicate with electronic engines controlled by an ECU (electronic control unit). The J1939 port consists of 2 terminals which are J1939+ and J1939-. The connection between the unit and the engine should be made with an appropriate balanced 120 ohms low capacitance coaxial cable. The external conductor should be grounded at one end only. A 120 ohms termination resistor is installed inside the unit. Please do not connect external resistor. The J1939 port is activated by setting the program parameter J1939 Enable to 1. The J1939 Engine Type parameter should be set accordingly. The list of available engines is given at the programming section. Please contact DATAKOM for the most current list of engines. If the J1939 port is enabled then the oil pressure, coolant temperature and the engine rpm information are picked up from the ECU unit. If connected, the MPU unit and related analog senders are discarded. The controller is able to read and display all below parameters, under condition that the engine sends these information. Most engines send only some of them. If the engine does not send a parameter, the unit will simply skip it. Thus only available information are displayed. The complete list of J1939 display parameters is below: 1. Engine Brand, ECU Type, J1939 SW version 2. Engine Coolant Level 3. Engine Oil Level 4. Engine Coolant Pressure 5. Engine Fuel Delivery Pressure 6. Barometric Pressure 7. Engine Crankcase Pressure 8. Engine Turbocharger Boost Pressure 9. Engine Air Inlet Pressure 10. Engine Air Filter1 Differential Pressure 11. Engine Fuel Temperature 12. Ambient Air Temperature 13. Engine Air Inlet Temperature 14. Engine Intake Manifold1 Temperature 15. Engine Exhaust Gas Temperature 16. Engine Fuel Rate 17. Engine Instantaneous Fuel Economy 18. Engine Average Fuel Economy 19. Engine Total Fuel Used 20. Engine Total Hours 21. Engine Percent Load at Current Speed 22. Actual Engine Percentage Torque 23. Drivers Demand Engine Percentage Torque 24. Accelerator Pedal Position 24. Battery Potential Switched The J1939 measurements are also available for Modbus operation. Please check chapter Modbus Communications for more details. When the fuel output is active, if no information is received from the ECU during last 3 seconds, then the unit will give a ECU FAIL alarm and stop the engine. This feature prevents uncontrolled engine operation. The fault conditions of an electronic engine are considered by the unit as warnings and do not cause engine stop. The engine is supposed protected by the ECU which will stop it when necessary. The electronic engine fault codes are displayed in text within the alarm list table, together with their SPN-FMI codes. The complete list of fault codes is given in the engine manufacturer’s user manual.

K35D01-EN

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

Below is a basic list of fault conditions (x denotes any FMI)

K35D01-EN

SPN 94

FMI x

98

x

100

x

102

x

105

x

107

x

108 110

x x

111

x

164

x

168 172

x x

174

x

175

x

190

x

228 234 620 629 651 652 653 654 655 656 657 657 678 723 1108 1111 2000

x x x x x x x x x x x x x x x x x

DESCRIPTION Fuel filter restriction Fuel pressure sensor fail Low oil level High oil level Oil level sensor fail Low oil pressure Oil pressure sensor fail High boost pressure Turbo outlet pressure sensor fail Intake manifold temp high Intake manifold temp sensor fail Air filter restriction Air filter sensor fail Athmospheric pressure sensor fail High coolant temperature Coolant temperature sensor fail Low coolant level Coolant level sensor fail High injector activation pressure Injector activation pressure sensor fail Battery voltage failure High inlet air temperature High inlet manifold air temperature Inlet manifold air temperature sensor fail High fuel temperature Fuel temperature sensor fail High oil temperature Oil temperature sensor fail Overspeed Speed sensor loss of signal Speed sensor mechanical failure Timing calibration required Incorrect ecm software ECU internal +5V fail ECU hardware fail Injector cylinder #1 fault Injector cylinder #2 fault Injector cylinder #3 fault Injector cylinder #4 fault Injector cylinder #5 fault Injector cylinder #6 fault Injector cylinder #7 fault Injector cylinder #8 fault ECU internal power supply fail Secondary engine speed sensor fail Critical override enabled Check configuration parameters ECU failure

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V-1.4

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

Below is a basic list of FMI codes. Please be aware that these codes may differ slightly depending on the engine brand and model. FMI 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

K35D01-EN

DESCRIPTION Value too high” Valid data, but above the normal working range “Value too low” Valid data, but below the normal working range “Faulty data” Intermittent or faulty data or Short circuit to battery voltage, injector high voltage side “Electrical fault” Abnormally high voltage or short circuit to battery voltage, injector low voltage side “Electrical fault” Abnormally low voltage or short circuit to battery negative, injector low voltage or high voltage side “Electrical fault” Abnormally low current or open circuit “Electrical fault” Abnormally high current or short circuit to battery negative “Mechanical fault” Faulty response from mechanical system “Mechanical or electrical fault” Abnormal frequency “Communication fault” Abnormal updating rate or Open circuit in injector circuit “Mechanical or electrical fault” Abnormally large variations “Unknown fault” Unidentified fault “Component fault” Faulty unit or component “Faulty calibration” Calibration values outside the limits “Unknown fault” Special instructions Data valid but above normal operating range — least severe level Data valid but above normal operating range — moderately severe level Data valid but below normal operating range — least severe level Data valid but below normal operating range — moderately severe level Received network data in error not used (reserved) not used (reserved) not used (reserved) not used (reserved) not used (reserved) not used (reserved) not used (reserved) not used (reserved) not used (reserved) not used (reserved) not used (reserved) Condition exist

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

ETHERNET CONFIGURATION Please see related document.

GSM CONFIGURATION Please see related document.

DYNAMIC DNS FEATURE Please see related document.

ACCESSING THE EMBEDDED WEB SERVER Please see related document.

CENTRAL MONITORING OF GENSETS Please see related document.

WEB MONITORING AND CONTROL OF GENSETS Please see related document.

E-MAIL SENDING Please see related document.

ETHERNET – MODBUS GATEWAY OPERATION This feature is not available yet.

GPRS – MODBUS GATEWAY OPERATION This feature is not available yet.

K35D01-EN

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V-1.4

TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

LOAD TRANSFER MODES The unit offers 2 ways of transferring the load from genset to mains and vice versa: -transfer with interruption, -no break transfer, (with or without synchronization)

TRANSFER WITH INTERRUPTION This is the most conventional way of transferring the load between the genset and mains. There will be a power interruption period during the transfer. Note that the program parameters Mains Contactor Timer and Genset Contactor Timer define the power interruption period.

If this transfer method is used, it is advised to make an electrical interlock between the two contactors to prevent an accidental phase to phase short circuit.

Transfer from genset to mains: -The generator contactor releases, -The unit waits for Mains Contactor Timer -The mains contactor is energized. Transfer from mains to genset: -The mains contactor releases, -The unit waits for Generator Contactor Timer -The generator contactor is energized.

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

UNINTERRUPTED TRANSFER In this mode, the transfer will be made without power interruption. This implies that both of the mains and generator contactors will be active during transfer. The maximum duration that both contactors will be active is programmable. However this process may be quicker with the use of one auxiliary feedback contact from each contactor. Thus the changeover will be quite instantaneous, preventing any excess or reverse power condition. To prevent a phase to phase short circuit below criteria must be met: -The mains and generator voltages must be equal, -The mains and generator voltages must have the same phase, -The mains and generator voltages must have the same phase sequence order. The unit will allow an Uninterrupted Transfer only if all of the below conditions are fulfilled: -Mains phase voltages within the programmed limits, -Mains frequency within the programmed limits, -Genset phase voltages within the programmed limits, -Genset frequency within the programmed limits, -Mains phase order correct (or phase order check must be disabled), -Genset phase order correct (or phase order check must be disabled), -The difference between mains and genset frequencies not more than programmed limit, -The voltage difference mains-L1 and genset-L1 not more than programmed limit, -The phase angle between mains-L1 and genset-L1 not more than programmed limit, When an uninterrupted transfer cycle is started, the unit will wait until the expiration of the Synchronization Fail Timer, to find a matching frequency, phase and voltage. Usually, with frequencies matching at +/- 2Hz and voltages matching at +/-10 volts an Uninterrupted Transfer is expected to successful. If matching is found before the expiration of the Synchronization Fail Timer, then both contactors will be activated. If contactor auxiliary contacts are used, the other contactor will release immediately. If contactor auxiliary contacts are not used, the other contactor will release after contactor timeout . The unit offers below parameters for the setup of the Uninterrupted transfer feature. Parameter Definition Description No Break Transfer Enable

0: only interrupted transfer enabled 1: no break transfer enabled

Synchronization Fail Timeout

If the phase and voltage synchronization is not successful before the expiration of this timer, then a Synchronization Fail warning is given and the transfer will be performed with interruption.

Synchronization Contactor Timeout

When synchronization is detected, both contactors will stay closed during this timer.

Max Freq Difference

This is the maximum difference between mains and genset frequencies to close both contactors.

Max Volt Difference

This is the maximum difference between the mains phase-L1 and the genset phase-L1 voltages to close both contactors. If voltage transformer is used, this quantity is multiplied with voltage transformer ratio.

Max Phase Difference

This is the maximum phase angle between the mains phase-L1 and the genset phase-L1 voltages to close both contactors.

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DATA RECORDING DATA RECORDING MEDIA Data can be recorded in USB flash memory. As soon as a USB flash memory is inserted, the unit will start data recording and continue until the memory is removed.

USB HOST Port

USB FLASH MEMORY

The USB-Host port is available with COMM option.

If USB-Device is plugged then USB-Host port will not function.

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DIRECTORY STRUCTURE The unit will record data in either an USB-Flash memory. The record structure is the same in both cases.

SITE-ID

Last day of the year

Year 2012 Year 2011

First day of the year

Previous years

The unit will record data in a directory named with the first 11 characters of its site-id parameter. In order to avoid confusion between records, it is highly recommended to configure the site-id parameter accordingly to the genset installation place. Thus the same memory module may be used for recording in different controllers, Inside the directory, the unit will open a separate directory for each year of recording. The directory will be simply named by the year, like 2012, 2013 etc… Inside the year directory, the controller will record data in a different file for each day of recording. The record file will be named YYYYMMDD like “20120331” representing March ’31, 2012. Thus alphabetical listing will produce a sorted list by date of recording. The recorded file is of CSV (comma separated values) type. This is a text file which can be directly opened with Microsoft Excel program without any loss of information. It can be also opened with any text editor (like Notepad program). Inside the file, each record consists of a line including a large set of measured parameters. The recorded parameters list is not adjustable. The controller records all practically necessary parameters.

UNDERSTANDING THE CSV FORMAT The “.csv” file is basically a text file format. Thanks to this, it can be opened by any text editor in any operating system. When opened with the Microsoft Excel program, the values will appear in tabulated form, enabling application of formulas, graphs and other features of Excel program.

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RECORDED DATA LIST, RECORD PERIOD The recording period is adjustable between 2 seconds and 18 hours by program parameter. A short period will give better resolution, but it will generate more data in the memory card. One data record is typically 250 bytes long, thus with a minimum period of 2 seconds, the unit will store 10.8 MB of data per day (250x30x60x24). A typical memory of 4GB will store data during 370 days, more than 1 year. With a recording period of 1 minute, 4GB memory card will store data during 30 years. Below parameters are recorded: Date and time of recording Operating mode Mains voltage phase L1 to neutral Mains voltage phase L2 to neutral Mains voltage phase L3 to neutral Mains voltage phase L1-L2 Mains voltage phase L2-L3 Mains voltage phase L3-L1 Mains frequency Mains current phase L1 Mains current phase L2 Mains current phase L3 Mains average current Mains frequency Mains kW phase L1 Mains kW phase L2 Mains kW phase L3 Mains total kW Mains kVA phase L1 Mains kVA phase L2 Mains kVA phase L3 Mains kVAr phase L1 Mains kVAr phase L2 Mains kVAr phase L3 Mains pf phase L1 Mains pf phase L2 Mains pf phase L3 Mains total pf Mains neutral current

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Gen voltage phase L1 to neutral Gen voltage phase L2 to neutral Gen voltage phase L3 to neutral Gen average voltage phase to neutral Gen voltage phase L1-L2 Gen voltage phase L2-L3 Gen voltage phase L3-L1 Gen current phase L1 Gen current phase L2 Gen current phase L3 Gen average current Gen frequency Gen kW phase L1 Gen kW phase L2 Gen kW phase L3 Gen total kW Gen kVA phase L1 Gen kVA phase L2 Gen kVA phase L3 Gen kVAr phase L1 Gen kVAr phase L2 Gen kVAr phase L3 Gen pf phase L1 Gen pf phase L2 Gen pf phase L3 Gen total pf Neutral current Oil pressure (bar & psi) Coolant temperature (°C & °F) Fuel level (%) Oil temperature (°C & °F) Canopy temperature (°C & °F) Engine speed (rpm) Battery voltage Engine hours

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SOFTWARE FEATURES

Load Shedding / Dummy Load The load shedding feature consists on the disconnection of the least crucial loads when the genset power approaches to its limits. These loads will be supplied again when the genset power falls below the programmed limit. The internal Load Shedding function is always active. Any digital output may be used as the load shedding output. The dummy load function consists on the connection of a dummy load if the total genset load is below a limit and to disconnection of the dummy load when the total power exceeds another limit. The dummy load function is the inverse of the load shedding function, thus the same output may be used for both purposes. It is also possible to control more complex external systems with multiple steps, using LOAD_ADD and LOAD_SUBSTRACT output functions. Any digital output may be assigned to these signals. When the load is below the Load Shedding Low Limit, the controller will activate the Load Add output. The external system will increase the load until it goes over the low limit, where the Load Add output will become inactive. When the load is above the Load Shedding High Limit, the controller will activate the Load Substract output. The external system will decrease the load until it goes below the high limit, where the Load Substract output will become inactive. There are protection delays between two pulses. The parameters used in Load Shedding feature are in the Electrical Parameters Group: Parameter Definition

Unit

Min

Factory Description Set

Max

Load Shedding Low Limit

kW

0

509T00

0

If the genset power goes below this limit then the load shedding relay will be deactivated.

Load Shedding High Limit

kW

0

509T00

0

If the genset power goes above this limit then the load shedding relay will be activated.

Load Add Delay

sec

0

240

0

This is the minimum delay between 2 load_add pulses. This is also the minimum delay between 2 load_substract pulses.

Load Subtract-Add Delay

min

0

120

0

This is the minimum delay between load_add and load_substract pulses.

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Remote Start Operation The unit offers the possibility of Remote Start mode of operation. Any digital input may be assigned as Remote Start Input using Input Function Select program parameters. The Remote Start signal may be a NO or NC contact, switching to either battery positive or battery negative. These selections are made using programming menu. It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarm from this input. When a Remote Start input is defined, the mains phases are not monitored. When the Remote Start signal is present then the mains will be supposed to fail, inversely when the Remote Start signal is absent then mains voltages will be supposed to be present. The front panels mimic diagram’s mains LEDs will always reflect the status of the Remote Start input.

Disable Auto Start, Simulate Mains The unit offers an optional Disable Auto Start signal input. Any digital input may be assigned as Disable Auto Start using Input Function Select program parameters. It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarms generated from this input. The Disable Auto Start signal may be a NO or NC contact, switching to either battery positive or battery negative. These selections are made using the programming menu. If the Disable Auto Start input is defined and the input signal is active, the mains phases are not monitored and supposed to be inside limits. This will prevent the genset from starting even in case of a mains failure. If the genset is running when the signal is applied, then usual Mains Waiting and Cooldown cycles will be performed before engine stop. When the Disable Auto Start signal is present, the front panels mimic diagram’s mains LEDs will reflect the mains voltages as present. When the signal is passive, the unit will revert to normal operation and monitor the mains voltage status.

The REMOTE START operation overrides DISABLE AUTO START and FORCE TO START operations.

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Battery Charging Operation, Delayed Simulate Mains The Delayed Mains Simulation feature is used in battery backed up telecom systems where batteries are able to supply the load during a certain period. The genset is requested to run only when battery voltage drops below the critical level. Once the engine runs, the rectifier system starts charging the batteries and the battery voltage goes up immediately. Thus the engine should continue to run a programmed period for effective charging. The critical battery voltage level will be detected by an external unit which provides the digital Disable Auto Start signal for the genset control unit. The unit offers an optional Disable Auto Start signal input. Any digital input may be assigned as Simulate Mains using Input Function Select program parameters. It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarms generated from this input. The Disable Auto Start signal may be a NO or NC contact, switching to either battery positive or battery negative. These selections are made using the programming menu. If the Delayed Simulate Mains program parameter is set to 1 and the input signal is active when the genset is not feeding the load, the mains phases are not monitored and supposed to be inside limits. This will prevent the genset from starting when the simulate mains signal is present (batteries charged). The genset will start when mains voltages are out of limits and the simulate mains signal not present. If the genset is running when the signal is applied, then MAINS SIMULATION will be prevented during Flashing Relay On Timer program parameter. After this, usual Mains Waiting and Cooldown cycles will be performed before engine stop. When the SIMULATE MAINS signal is present, the front panels mimic diagram’s mains LEDs will reflect the mains voltages as present. When the signal is passive, the unit will revert to normal operation and monitor the mains voltage status.

The REMOTE START operation overrides Disable Auto Start operation. When both “Remote Start Operation” and “Delayed Simulate Mains” are enabled then REMOTE START operation mode is performed.

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Dual Genset Mutual Standby Operation Dual genset intermittent operation consists of regular switching of the load between 2 gensets. The use of 2 gensets instead of one is due either to safety purposes in case of a genset failure or to a continuous operation requesting service stops. The running period for each genset is adjustable using Flashing Relay On Timer and Flashing Relay Off Timer program parameters. If the time is adjusted as 0 hours, it will be actually set to 2 minutes for faster testing purposes. A flashing relay output function is provided, based on the parameter Flashing Relay On/Off Timers. Each time the period programmed using Flashing Relay Timer elapses, the relay output will change position. The flashing relay function may be assigned to any digital output using Output Configuration program parameters. The dual genset intermittent operation uses also the Disable Auto Start feature. Please review related chapter for a detailed explanation of this feature.

Priority In Dual Genset Mutual Standby Operation: It may be required that the dual genset system starts the same genset at every mains failure. This is achieved using the PRIORITY input. Any digital input may be assigned as Priority using Input Function Select program parameters. It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarms generated from this input. The Priority signal may be a NO or NC contact, switching to either battery positive or battery negative. These selections are made using the programming menu. If a Priority input is defined, then the system will work in priority mode. If the priority signal is applied, the unit will become master after each mains failure. If the priority signal is not applied, then the unit will become the slave one and the other genset will start.

Please contact DATAKOM for a complete application manual.

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Dual Voltage and Frequency The unit offers 2 sets of voltage and frequency protection limit values. The user is allowed to switch between these 2 sets anytime. This feature is especially useful in dual voltage or frequency gensets for easy switching between 2 operating conditions. The switching to the second set of limit values can be done in 2 ways: -by setting the program parameter Secondary Volt/Freq to 1 -with digital input signal Thus the user has full flexibility for manual or external switching. If switching is done with digital input signal, one of digital inputs has to be defined as “2nd Volt-Freq Select” using “INPUT FUNCTION SELECT“program group. Below parameters are available for second voltage-frequency selection: Nominal Voltage Nominal Frequency Nominal RPM Genset Overcurrent Limit

Single Phase Operation If the unit is used in a single phase electrical network, it is advised to select the topology as Single Phase 2 Wires. When the topology is set to Single Phase 2 Wires, then the unit will measure electrical parameters only on phases L1 of genset and mains. Voltage and overcurrent checks will be performed on phases L1 only. Phases L2 and L3 parameters, as well as phase-to-phase voltages are removed from display screens.

External Control of the Unit The unit offers total external control through programmable digital inputs. Any digital input may be programmed for below functions: — Force STOP mode — Force AUTO mode — Force TEST mode — Disable Auto Start — Force to Start — Fault Reset — Alarm Mute — Panel Lock External mode select signals have priority on mode buttons of the unit. If the mode is selected by external signal, it is impossible to change this mode with front panel pushbuttons. However if the external mode select signal is removed, the unit will revert to the last selected mode via pushbuttons. It is also possible to lock the front panel completely for remote command.

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Automatic Exerciser The unit offers 7 independent automatic exercisers. The exercise operation may be done on a weekly or monthly basis. The start day and time of the exercise is programmable as well as its duration. The exercise may be done with or without load following programming. Program parameters related to the exerciser are: Exercise start day and hour Exercise duration Exercise off_load/on_load Please refer to the programming section for a more detailed description of the above parameters. When the start day and hour of exercise has come, the unit will automatically switch to either RUN or TEST mode. The engine will run. If the on_load exercise is selected then the load will be transferred to the genset. If a mains failure occurs during the off-load exercise, the load will not be transferred to the genset unless the Emergency Backup Operation is allowed by setting the related program parameter to 1. Thus it is highly recommended that the Emergency Backup mode enabled with off-load exerciser. At the end of the exercise duration, the unit will switch back to the initial mode of operation. If any of the mode selection keys are pressed during exercise, then the exercise will be immediately terminated. Using the weekly exercise mode and with suitable parameter setting, the unit may feed the load from the genset during predefined hours of each day. This operation may be used in high tariff periods of the day.

WEEKLY OPERATION SCHEDULER In most applications, the genset is requested to operate only in working hours. Thanks to the weekly program feature, unwanted operation of the genset may be prohibited. The scheduler is active only in AUTO mode. When the scheduler prevents genset operation in AUTO mode, the AUTO led will flash.

When the scheduler prevents genset operation in AUTO mode, the AUTO led will flash.

The scheduler consists of 144 programmable parameters, one for each hour in a week. Thus every hour of the week may be independently selected as ON or OFF times. These programmable parameters allow the genset to operate automatically only in allowed time limits. The unit has a battery backed-up precision real time clock circuit. The real time clock circuit will continue its operation even in power failures. The real time clock is precisely trimmed using the Real Time Clock Adjust program parameter. For more details check the programming section.

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Engine Heating Operation Especially on engines without a body heater, or with a failing one, it may be desired that the genset should not take the load before reaching a suitable temperature. The unit offers 2 different ways of engine heating. 1. Timer controlled heating: This operation mode is selected when the Engine Heating Method parameter is set to 0. In this mode, the engine will run during parameter Engine Heating Timer, and then the genset will take the load. 2. Timer and temperature controlled heating: This operation mode is selected when the Engine Heating Method parameter is set to 1. In this mode, at first the engine will run during parameter Engine Heating Timer, then it will continue to run until the measured coolant temperature reaches the limit defined in parameter Engine Heating Temperature. When the requested temperature is reached, the load will be transferred to the genset. This operation mode may be used as a backup to the engine body heater. If the engine body is warm the heating will be skipped.

Engine Idle Speed Operation It may be required that the engine runs at the idle speed for a programmed duration for engine heating. The idle operation duration is adjusted with the parameter Idle Speed Timer. The idle speed will be set by the governor control unit of the engine. Any digital output may be assigned as IDLE output using Relay Definition program parameters. The Idle speed operation is performed both in engine start-up and cool-down sequences. Low speed and low voltage protections are disabled during idle speed operation.

Engine Block Heater The unit is able to provide a digital output in order to drive the block heater resistor. The temperature reference is the coolant temperature measured from the analog sender input. The block heater output function may be assigned to any digital output using Relay Definition program parameters. The engine body temperature limit is adjusted using the parameter Engine Heating Temperature. The same parameter is used for engine heating operation. The relay will become active if the body temperature falls to 4 degrees below the limit set by Engine Heating Temperature. It turns off when the body temperature exceeds Engine Heating Temperature.

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Fuel Pump Control The unit is able to provide a digital output function in order to drive the fuel pump motor. The fuel pump is used in order to transfer fuel from the large capacity main tank (if exists), to the genset daily tank which is generally integrated in the chassis and has a limited capacity. The fuel level reference is measured through the analog fuel level sender. When the measured fuel level falls below Fuel Pump Low Limit parameter, the fuel pump output function will become active. When the fuel level reaches Fuel Pump High Limit parameter, the output function will become passive. Thus the chassis fuel tank level will be always kept between Fuel Pump Low Limit and Fuel Pump High Limit parameters. The fuel pump relay function may be assigned to any digital output using Relay Definition program parameters.

Gas Engine Fuel Solenoid Control The unit provides a special function for the fuel solenoid control of a gas engine. The fuel solenoid of a gas engine is different from a diesel engine. It should be opened after the cranking has been started and should be closed between crank cycles. The delay between the crank start and solenoid opening is adjusted using the Gas Solenoid Delay program parameter. The gas engine fuel solenoid relay function may be assigned to any digital output using Relay Definition program parameters.

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MODBUS COMMUNICATIONS

This chapter is a brief description of the Modbus properties of the controller. For a complete documentation please use “DKG-509T Modbus Application Manual”

The unit offers the possibility of MODBUS communication through below carriers: -RS485 serial port, with adjustable baud rate between 2400 and 115200 bauds -MODBUS-TCP/IP through Ethernet port (10/100Mb) -MODBUS-TCP/IP through GSM-GPRS modem. (84/42kb) The MODBUS properties of the unit are: -Data transfer mode: RTU -Serial data: selectable baud rate, 8 bit data, no parity, 1 bit stop -Modbus-TCP/IP: Ethernet 10/100Mb or GPRS Class 10. -Supported functions: -Function 3 (Read multiple registers) -Function 6 (Write single register) -Function 16 (Write multiple registers) Each register consists of 2 bytes (16 bits). A larger data structure will contain multiple registers. The Modbus communications requires a slave address to be assigned to each device in the Modbus network. This address ranges between 1 and 240 and allows the addressing of different slave devices in the same network.

Each device in the same RS-485 serial network must be assigned a different slave address. Otherwise the Modbus communications will not be performed.

Devices using Modbus-TCP/IP with different IP or port addresses may use any slave address. It is advised to set these slave addresses to the default setting which is 1.

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Parameters required for RS-485 Modbus operation Modbus Slave Address: may be set between 1 and 240 RS-485 Enable: must be set to 1 (or checkbox enabled) RS-485 Baud Rate: selectable between 2400 and 115200 bauds. All devices in the same network must use the same Baud Rate. The complete RS-485 port specifications are found in the D-500/700 User Manual. Selecting a higher baud rate will allow faster communication, but will reduce the communication distance. Selecting a lower baud rate will increase the communication distance, but will cause slower response times. Typically 9600 bauds will allow 1200m distance with special balanced 120 ohms cable.

Parameters required for Modbus-TCP/IP through Ethernet port Modbus Slave Address: may be set between 1 and 240. If only one unit is available in the same IP address, it is advised to keep the default address (1). Ethernet Enable: This parameter should be set to 1 (or checked) in order to enable the ethernet port. Modbus TCP/IP Port: The usual setting is 502. However the unit is able to work on any port address. User IP Mask: There are 3 mask registers available. The use of the registers are emphasized in the D500/700 User Manual. Please set the first mask as 255.255.255.0 for the proper operation. Ethernet Network IP: May be left as 0.0.0.0 for automatic address claim or set to a value in order to claim a defined address. Ethernet Gateway IP: Should be set in accordance with your local switch configuration. Ethernet Subnet Mask: Should be set in accordance with your local switch configuration. The complete Ethernet port specifications are found in the D-500/700 User Manual. Please rewiev the document Ethernet Configuration Guide for D-500/700 for more details about the ethernet port setup.

Parameters required for Modbus-TCP/IP through GSM_GPRS Modem Modbus Slave Address: may be set between 1 and 240. If only one unit is available in the same IP address, it is advised to keep the default address (1). Modem Selection: Internal or external following your configuration. Modem Baud Rate: Selectable only for external modem. 115200 bauds advised. Selecting a lower baud rate will slow down communication between the controller and the modem. GPRS Connection Enable: This parameter should be set to 1 (or checked). Modbus TCP/IP Port: Set this value to 80. User IP Mask: There are 3 mask registers available. The use of the registers are emphasized in the D500/700 User Manual. Please set the first mask as 255.255.255.0 for the proper operation.

Data Formats 16bit variables: These variables are stored in a single register. Bit_0 denotes the LSB and bit 15 denotes the MSB. 32 bit variables: These variables are stored in 2 consecutive registers. The high order 16 bits are in the first register and the low order 16 bits are in the second register Bit arrays: Arrays larger than 16 bits are stored in multiple registers. The LSB of the first register is bit_0. The MSB of the first register is bit_15. The LSB of the second register is bit_16. The MSB of the second register is bit_31, and so on.

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Below is a shortlist of available Modbus registers. For complete register map please refer to D-500/700 Modbus Application Manual. ADDRESS (decimal) 8193

R/W

10240 10242 10244 10246 10248 10250 10252 10254 10256 10258 10260 10262 10264 10266 10268 10270 10272 10274 10276 10278 10292 10294 10308 10310 10324 10326 10334 10335 10338 10339 10341 10361 10362 10363 10364 10365 10366 10376

K35D01-EN

COEFF.

W

DATA SIZE 16bit

R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R

32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 16bit 16bit 16bit 16bit 16bit 16bit 16bit 16bit 16bit 16bit 16bit 16bit

x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x10 x100 x100 x100 x10 x10 x10 x10 x10 x10 x1

x10

DESCRIPTION Pushbutton simulation BIT 0.Simulate Stop button BIT 1.Simulate Manual button BIT 2.Simulate Auto button BIT 3.Simulate Test button BIT 4.Simulate Run button BIT 5.Simulate GCB button BIT 7.Simulate Menu+ button BIT 8.Simulate Menu- button BIT 9.Simulate Up button BIT10.Simulate Down button BIT14.Button Long pressed BIT15.Button Very Long Pressed Mains phase L1 voltage Mains phase L2 voltage Mains phase L3voltage Genset phase L1 voltage Genset phase L2 voltage Genset phase L3 voltage Mains phase L1-L2 voltage Mains phase L2-L3 voltage Mains phase L3-L1voltage Genset phase L1-L2 voltage Genset phase L2-L3 voltage Genset phase L3-L1 voltage Mains phase L1 current Mains phase L2 current Mains phase L3 current Genset phase L1 current Genset phase L2 current Genset phase L3 current Mains neutral current Genset neutral current Mains total active power Genset total active power Mains total reactive power Genset total reactive power Mains total apparent power Genset total apparent power Mains total power factor Genset total power factor Mains frequency Genset frequency Battery voltage Oil pressure in bars (multiply by 14.50 to for psi) Engine temp in °C (multiply by 1.8 then add 32 for °F) Fuel level in % Oil temp in °C (multiply by 1.8 then add 32 for °F) Canopy temp in °C (multiply by 1.8 then add 32 for °F) Ambient temp in °C (multiply by 1.8 then add 32 for °F) Engine rpm

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TJ-509T User Manual Rev_01 ADDRESS (decimal) 1050410519 1052010535 1053610551 10604

R/W

COEFF.

R

DATA SIZE 256bit

R

256bit

—

R

256bit

—

R

16bit

—

10605

R

16bit

—

10606

R

16bit

x1

10610 10611 10616 10618 10620 10622 10624 10626 10628 10630 10632 10634 10636 10638 10640 10642 10644

R R R R R R R R R R R R R R R R R

16bit 16bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit 32bit

x1 x1 x1 x100 x100 x100 x10 x10 x10 x100 x100 x100 x100 x100 x100

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DESCRIPTION Shutdown alarm bits. Bit definitions are given at the end of the document. Loaddump alarm bits. Bit definitions are given at the end of the document. Warning alarm bits. Bit definitions are given at the end of the document. Unit operation status 0= genset at rest 1= wait before fuel 2= engine preheat 3= wait oil flash off 4=crank rest 5=cranking 6= engine run idle speed 7= engine heating 8= running off load 9= synchronizing to mains 10= load transfer to genset 11= gen cb activation 12= genset cb timer 13= master genset on load, 14= peak lopping 15= power exporting 16= slave genset on load 17= synchronizing back to mains 18= load transfer to mains 19= mains cb activation 20= mains cb timer 21= stop with cooldown 22= cooling down 23= engine stop idle speed 24= immediate stop 25= engine stopping Unit mode 0= STOP mode 1= AUTO mode 2= MANUAL mode 3= TEST mode Genset operation timer. In various wait statuses, the genset operation status will change at the expiration of this timer. Device hardware version information Device software version information Counter: number of genset runs Counter: number of genset cranks Counter: number of genset on load Counter: engine hours run Counter: engine hours since last service Counter: engine days since last service Counter: genset total active energy (kWh) Counter: genset total inductive reactive energy (kVArh-ind) Counter: genset total capacitive reactive energy (kVArh-cap) Counter: remaining engine hours to service-1 Counter: remaining engine days to service-1 Counter: remaining engine hours to service-2 Counter: remaining engine days to service-2 Counter: remaining engine hours to service-3 Counter: remaining engine days to service-3

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DECLARATION OF CONFORMITY The unit conforms to the EU directives -2006/95/EC (low voltage) -2004/108/EC (electro-magnetic compatibility) Norms of reference: EN 61010 (safety requirements) EN 61326 (EMC requirements) The CE mark indicates that this product complies with the European requirements for safety, health environmental and customer protection. UL / CSA Conformity: certification teting in progress UL 508, Edition 17 UL 2200, 1st Edition. UL 840 Edition 3 CSA C22.2 NO. 14 — Edition 10

MAINTENANCE

DO NOT OPEN THE UNIT ! There are NO serviceable parts inside the unit. Wipe the unit, if necessary with a soft damp cloth. Do not use chemical agents

DISPOSAL OF THE UNIT Following DIRECTIVE 2002/96/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 27 January 2003 on waste electrical and electronic equipment (WEEE), this unit should be stored and

disposed separately from the usual waste.

ROHS COMPLIANCE The european ROHS directive restricts and prohibits the use of some chemical materials in electronic devices. Following the “DIRECTIVE 2011/65/EU OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 8 June 2011 on the restriction of the use of certain hazardous substances in electrical and electronic equipment”, this product is listed in annex-I under category: “Monitoring and control instruments including industrial monitoring and control instruments” and exempted from ROHS directive. However Datakom is not using any ROHS uncompliant electronic components in the production. Only the solder contains lead. The switching to unleaded solderin is in progress.

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

TROUBLESHOOTING GUIDE

Below is a basic list of most often encountered troubles. More detailed investigation may be required in some cases.

The genset operates while AC mains are OK or continues to operate after AC mains are OK: -Check engine body grounding. -AC mains voltages may be outside programmed limits, measure the phase voltages. -Check the AC voltage readings on the screen. -Upper and lower limits of the mains voltages may be too tight. Check the parameters Mains Voltage Low Limit and Mains Voltage High Limit. Standard values are 170/270 volts. -The hysteresis voltage may be given to excessive. The standard value is 8 volts.

AC voltages or frequency displayed on the unit are not correct: -Check engine body grounding, it is necessary. -The error margin of the unit is +/- 2 volts. -If there are faulty measurements only when the engine is running, there may be a faulty charging alternator or voltage regulator on the engine. Disconnect the charging alternator connection of the engine and check if the error is removed. -If there are faulty measurements only when mains are present, then the battery charger may be failed. Turn off the rectifier fuse and check again. KW and cosΦ readings are faulty although the Amp readings are correct: -Current transformers are not connected to the correct inputs or some of the CTs are connected with reverse polarity. Determine the correct connections of each individual CT in order to obtain correct KW and cosΦ for the related phase, and then connect all CTs. Please review chapter “AC CURRENT INPUTS”

Short circuit outputs of unused Current Transformers.

When the AC mains fails the unit energizes the fuel solenoid, but does not start and OIL PRESSURE EXISTS ! message is displayed: The unit is not supplied with battery (-) voltage at the oil pressure input. -Oil pressure switch not connected. -Oil pressure switch connection wire cut. -Oil pressure switch faulty. -Oil pressure switch closes too lately. If oil pressure switch closes, the unit will start. Optionally oil pressure switch may be replaced.

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TJ-509T User Manual Rev_01

PRELIMINARY VERSION

V-1.4

The engine does not run after the first start attempt, then the unit does not start again and OIL PRESSURE EXISTS ! message is displayed: -The oil pressure switch closes very lately. As the unit senses an oil pressure, it does not start. When oil pressure switch closes the unit will start. Optionally the oil pressure switch may be replaced.

When the AC mains fails, the engine starts to run but the unit gives START FAIL alarm and then the engine stops: -The generator phase voltages are not connected to the unit. Measure the AC voltage between terminals GEN L1-L2-L3 and Generator Neutral at the rear of the unit while the engine is running. A fuse protecting the generator phases may be failed. A misconnection may be occurred. If everything is OK, turn all the fuses off, and then turn all the fuses on, starting from the DC supply fuse. Then test the unit again.

The unit is late to remove engine cranking: -The generator voltage rises lately. Also the generator remnant voltage is below 15 volts. The unit removes starting with the generator frequency, and needs at least 15 volts to measure the frequency. -The unit is also able to cut cranking from charge alternator voltage and oil pressure input. Please read chapter “CRANK CUTTING”

The unit is inoperative: Measure the DC-supply voltage between terminals BAT+ and BAT- at the rear of the unit. If OK, turn all fuses off, then turn all the fuses on, starting from the DC supply fuse. Then test the unit again.

Programming mode can not be entered: The program lock input disables programming mode entry. Disconnect the program lock input from battery negative before modification. Do not forget to make this connection again to prevent unauthorized program modifications.

Some program parameters are skipped: These parameters are reserved for factory setting and cannot be modified.

AUTO led flashes and the genset does not run when mains fail: The unit is in Weekly Schedule OFF time. Please check date and time setting of the unit. Please check also Weekly Schedule program parameters.

The genset runs but does not take the load: Check that the genset Yellow led is on steadily. Adjust genset voltage and frequency limits if necessary. Check that the digital output-8 is configured as “Genset Contactor” Check “Genset Contactor Timer” program parameter. Check that a Genset Loading Inhibit input signal is not active. Check input functions. If an input is configured as “Genset Loading Inhibit” then check the signal is not present at this input.

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