Knowtek DSE6120 Auto Start/Mains Failure Generator Controller User Manual

1. Introduction

The Knowtek DSE6120 is an advanced Auto Start Control Module and Auto Mains (Utility) Failure (AMF) Control Module designed for a wide range of single gen-set applications. This controller provides comprehensive monitoring and control functionalities, ensuring reliable operation of your generator system. It is suitable for both electronic (CAN) and non-electronic (magnetic pick-up/alternator sensing) engine types.

Key Features:

• Automatic transfer between mains (utility) and generator power (DSE6120 only).
• Monitors speed, frequency, voltage, current, oil pressure, coolant temperature, and fuel level.
• Displays warnings, shutdown status, and engine information on a back-lit LCD screen and illuminated LEDs.
• Configurable using DSE Configuration Suite PC software or via front panel editing.
• Compatible with a wide range of CAN engines and offers Tier 4 engine support.
• IP65 rating (with optional gasket) for increased resistance to water ingress.
• Multi-language support including English, Spanish, Portuguese, French, German, Russian, Thai, Arabic, and Chinese.

2. Product Overview

The DSE6120 controller features an intuitive front panel for easy interaction and monitoring. The display provides real-time data and status updates, while the buttons allow for navigation and control.

Figure 2.1: Front panel of the DSE6120 controller, showing the LCD screen, navigation buttons, and status indicators.

The front panel includes a liquid crystal display (LCD) for detailed information, along with illuminated LED indicators for quick status checks. Navigation buttons allow users to scroll through menus and acknowledge alarms. Dedicated buttons are provided for functions such as Stop/Reset, Manual Start, Auto Mode, and Test.

3. Installation and Wiring

Proper installation and wiring are crucial for the safe and correct operation of the DSE6120 controller. Refer to the wiring diagram on the back of the unit and the detailed instructions in the full installation guide for specific connections.

Figure 3.1: Rear view of the DSE6120 controller, illustrating the terminal blocks for power, inputs, outputs, and communication, including a USB port for configuration.

Wiring Considerations:

• DC Supply: Connect the controller to a stable 12V DC power source. Ensure correct polarity.
• Engine Inputs: Connect sensors for oil pressure, coolant temperature, fuel level, and engine speed (magnetic pick-up or CAN bus).
• Generator Inputs: Connect voltage and current transformers for generator monitoring.
• Mains (Utility) Inputs: For AMF functionality, connect mains voltage sensing inputs.
• Outputs: Connect to engine start/stop solenoids, fuel solenoids, and other control relays. The controller provides flexible outputs for various applications.
• USB Port: Used for connecting to a PC for configuration via the DSE Configuration Suite software.

Always ensure all wiring is performed by qualified personnel and complies with local electrical codes and safety standards. Disconnect all power sources before performing any wiring or maintenance.

4. Configuration

The DSE6120 controller can be configured to suit specific application requirements using two primary methods:

• DSE Configuration Suite PC Software: This software provides a comprehensive and user-friendly interface for setting up all parameters of the controller. Connect the controller to a PC via the USB port. The software allows for detailed customization of inputs, outputs, engine parameters, alarm thresholds, and operational logic.
• Front Panel Editing: Selected parameters can be adjusted directly from the controller's front panel using the navigation buttons and LCD display. This method is suitable for minor adjustments or quick changes in the field. Refer to the detailed programming manual for specific front panel navigation and editing procedures.

It is recommended to use the DSE Configuration Suite PC software for initial setup and complex configurations to ensure all settings are correctly applied.

5. Operation

The DSE6120 controller offers various operational modes to manage your generator and mains power.

Operational Modes:

• STOP/RESET Mode: Press the Stop/Reset button (red circle) to stop the engine or clear any active alarms.
• MANUAL Mode: Press the Manual button (hand icon) to start the engine manually. The engine will run until manually stopped or a shutdown alarm occurs.
• AUTO Mode: Press the Auto button (AUTO icon) to enable automatic operation. In this mode, the controller will monitor the mains (utility) supply and automatically start the generator if the mains fail, and stop it when mains power is restored.
• TEST Mode: Press the Test button to initiate a test run of the generator. The behavior in test mode can be configured (e.g., with or without load).

Monitoring and Display:

The LCD screen continuously displays critical engine and generator parameters, including:

• Engine speed (RPM)
• Generator frequency (Hz)
• Generator voltage (V) and current (A)
• Oil pressure
• Coolant temperature
• Fuel level
• Battery voltage
• Engine hours run

The controller will activate visual warnings (LEDs and LCD messages) and audible alarms in case of abnormal conditions or faults, providing immediate notification of issues.

6. Maintenance

Regular maintenance ensures the longevity and reliable performance of your DSE6120 controller and the connected generator system.

General Maintenance Guidelines:

• Visual Inspection: Periodically inspect the controller for any signs of physical damage, loose connections, or corrosion.
• Cleaning: Keep the controller's front panel clean using a soft, dry cloth. Avoid using abrasive cleaners or solvents.
• Firmware Updates: Check the manufacturer's website for any available firmware updates to ensure optimal performance and access to new features.
• Battery Check: Ensure the generator's battery, which powers the controller, is in good condition and properly charged.
• Hours Counter: Utilize the built-in hours counter to track engine run time, which is essential for scheduling routine generator maintenance (e.g., oil changes, filter replacements).
• Environmental Protection: Ensure the controller's environment is within specified operating temperatures and humidity levels. If installed in an exposed location, ensure the optional IP65 gasket is properly fitted to protect against water ingress.

Always disconnect power before performing any maintenance that involves opening the controller or accessing wiring terminals.

7. Troubleshooting

The DSE6120 controller is designed to provide clear indications of operational issues. When a fault occurs, the controller will display a warning or shutdown message on the LCD screen and illuminate relevant LEDs.

Common Troubleshooting Steps:

• Identify the Alarm: Read the message on the LCD screen and note any illuminated LEDs. This will indicate the nature of the fault (e.g., Low Oil Pressure, High Engine Temperature, Overspeed, Undervoltage).
• Acknowledge and Reset: Press the Stop/Reset button to acknowledge the alarm and attempt to reset the controller. For shutdown alarms, the engine will not restart until the fault condition is resolved.
• Check Connections: Verify all wiring connections are secure and free from corrosion, especially for the sensor related to the alarm.
• Inspect Sensors: If an alarm persists, inspect the relevant sensor for damage or malfunction.
• Review Configuration: Ensure that the controller's configuration settings (e.g., alarm thresholds) are appropriate for your generator and application. Incorrect settings can lead to false alarms.
• Power Supply: Confirm that the DC power supply to the controller is stable and within the specified voltage range.

For persistent or complex issues, consult the comprehensive DSE6120 technical manual or contact Knowtek technical support.

8. Technical Specifications

Below are the technical specifications for the Knowtek DSE6120 Auto Start/Mains Failure Generator Controller:

9. Warranty and Support

Warranty Information:

The Knowtek DSE6120 controller comes with a 1-year warranty from the date of purchase. This warranty covers defects in materials and workmanship under normal use. It does not cover damage caused by improper installation, misuse, accidents, unauthorized repairs, or acts of nature. Please retain your proof of purchase for warranty claims.

Technical Support:

For technical assistance, troubleshooting guidance, or warranty inquiries, please contact Knowtek customer support. Refer to the contact information provided with your product packaging or visit the official Knowtek website for support resources.

When contacting support, please have your product model (DSE6120) and purchase details readily available to facilitate a quicker resolution.