Datakom D-200 MK2 User manual

D-200 MK2 User Manual Firmware V-6.3
D-200 MK2
ADVANCED
GENSET
CONTROLLER
The D-200-MK2 is a next generation genset control unit
combining multi-functionality and wide communication
possibilities together with a reliable and low cost design.
The same controller provides AMF, ATS, Remote Start,
Engine Control functionalities.
The module comes ready for remote monitoring over
GSM or Ethernet with plug-in communication modules.
Various plug-in modules provide unlimited expansion
capabilities allowing to meet any special requirement.
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, serial and GPRS.
The Rainbow Scada central monitoring service allows
monitoring and control of an unlimited number of
gensets from a single central location.
AMF unit
ATS unit
Remote start controller
Manual start controller
Engine controller
Waveform display of V & I
Harmonic analysis of V & I
CTs at genset or load side
• GSM Modem (2G-3G-4G) *
• Ethernet 100Mbps *
• Wi-Fi *
•RS-485 isolated (2400-57600baud) *
• RS-232 isolated (2400-57600baud) *
• USB Device
• J1939 CANBUS (optional)
• Web monitoring *
• Web programming *
• Central Monitoring through internet *
• SMS message sending *
• E-mail sending *
• PC software: Rainbow Plus
• Central monitoring *
• Modbus RTU through RS-485 *
• Modbus TCP/IP *
*Optional with plug-in module
3 phases 4 wires, star & delta
3 phases 3 wires, 3 CTs
3 phases 3 wires, 2 CTs
2 phases 3 wires
1 phase 2 wires
FUNCTIONALITIES
COMMUNICATIONS
TOPOLOGIES
DESCRIPTION

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L058D01-EN - 2 -
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.
This document describes minimum requirements and necessary steps for the successful installation of
the D-200 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:
[e-mail]
If additional information to this manual is required, please contact the manufacturer directly at below e-
mail address: [e-mail]
Please provide following information in order to get answers to any question:
- Device model name (see the back panel of the unit),
- Complete serial number (see the back panel of the unit),
- Firmware version (read from the display screen),
- Measuring-circuit voltage and power supply voltage,
- Precise description of the query.
FILENAME
DESCRIPTION
500-Rainbow Installation
Rainbow Plus Installation Guide
500-Rainbow Usage
Rainbow Plus Usage Guide
500-GSM Configuration
GSM Configuration Guide for D-series
200-Firmware Update
Firmware Update Guide for D-200 D-300 and D-500-LITE
500-MODBUS
Modbus Application Manual for D-series
500-Rainbow Scada Usage
Rainbow Scada Usage Guide
QUERRIES
RELATED DOCUMENTS
ABOUT THIS DOCUMENT
COPYRIGHT NOTICE

D-200 MK2 User Manual Firmware V-6.3
L058D01-EN - 3 -
REVISION
DATE
AUTHOR
DESCRIPTION
01
10.09.2019
MH
First edition, firmware version 6.3
CAUTION: Potential risk of injury or death.
WARNING: Potential risk of malfunction or material damage.
ATTENTION: Useful hints for the understanding of device operation.
REVISION HISTORY
TERMINOLOGY

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The D-xxx family units are available in various options and peripheral features. Please use below
information for ordering the correct version:
D200
-M2
-J
-G
-T
-00
Screw type bracket
Stock Code=J10P01 (per unit)
Self Retaining type bracket
Stock Code=K16P01 (per unit)
Sealing Gasket
SPARE PARTS
ORDERING CODES
Family Code
PLUG-IN MODULE
M2: 2G-GSM Modem
M3: 3G-GSM Modem
M4: 4G-GSM Modem
W: WiFi module
E: Ethernet module
R4: RS-485 module
R2: RS-232 module
With Conformal
Coating
Variant
00: standard unit
01...99: customer
specific products
With Sealing
Gasket
With CANBUS
J1939 port

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▪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
non-compliance 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.
SAFETY NOTICE
Failure to follow below instructions
will result in death or serious injury
Current Transformers must be used for current measurement.
No direct connection allowed.

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1. INSTALLATION INSTRUCTIONS
2. MOUNTING
2.1 DIMENSIONS
2.2 SEALING, GASKET
2.3 ELECTRICAL INSTALLATION
3. TERMINAL DESCRIPTIONS
3.1. BATTERY VOLTAGE INPUT
3.2. AC VOLTAGE INPUTS
3.3. AC CURRENT INPUTS
3.4. DIGITAL INPUTS
3.5. ANALOG SENDER INPUTS AND SENDER GROUND
3.6. CHARGE INPUT TERMINAL
3.7. MAGNETIC PICKUP INPUT
3.8. MAINS CONTACTOR OUTPUT
3.9. GENERATOR CONTACTOR OUTPUT
3.10. DIGITAL OUTPUTS
3.11. -
3.12. RS-485 PORT (PLUG-IN MODULE)
3.13. J1939-CANBUS PORT (OPTIONAL)
3.14. USB DEVICE PORT
3.15. GSM MODEM (PLUG-IN MODULE)
3.16. ETHERNET PORT (PLUG-IN MODULE)
3.17. WI-FI (PLUG-IN MODULE)
4. TOPOLOGIES
4.1. SELECTING THE TOPOLOGY
4.2. 3 PHASE, 4 WIRE, STAR
4.3. 3 PHASE, 3 WIRE, DELTA
4.4. 3 PHASE, 4 WIRE, DELTA
4.5. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L2)
4.6. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L3)
4.7. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L2)
4.8. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L3)
4.9. 1 PHASE, 2 WIRE
TABLE OF CONTENTS

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5. FUNCTIONALITIES
5.1. CT LOCATION SELECTION
5.2. AMF FUNCTIONALITY
5.3. ATS FUNCTIONALITY
5.4. REMOTE START FUNCTIONALITY
5.5. ENGINE CONTROLLER FUNCTIONALITY
5.6. -
5.7. 400HZ OPERATION
6. CONNECTION DIAGRAMS
6.1. AMF FUNCTIONALITY, CTs AT LOAD SIDE
6.2. AMF FUNCTIONALITY, CTs AT ALTERNATOR SIDE
6.3. ATS FUNCTIONALITY
6.4. REMOTE START FUNCTIONALITY
6.5. ENGINE CONTROL FUNCTIONALITY
6.6. -
7. TERMINAL DESCRIPTION
8. TECHNICAL SPECIFICATIONS
9. DESCRIPTION OF CONTROLS
9.1. FRONT PANEL FUNCTIONALITY
9.2. PUSHBUTTON FUNCTIONS
9.3. DISPLAY SCREEN ORGANIZATION
9.4. AUTOMATIC DISPLAY SCROLL
9.5. MEASURED PARAMETERS
9.6. LED LAMPS
10. WAVEFORM DISPLAY & HARMONIC ANALYSIS
11. DISPLAYING EVENT LOGS
12. STATISTICAL COUNTERS
12.1. FUEL FILLING COUNTER
12.2. FUEL CONSUMPTION MONITORING
13. OPERATION OF THE UNIT
13.1. QUICK START GUIDE
13.2. STOP MODE
13.3. AUTO MODE
13.4. RUN MODE
13.5. TEST MODE

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14. PROTECTIONS AND ALARMS
14.1. DISABLING ALL PROTECTIONS
14.2. SERVICE REQUEST ALARM
14.3. SHUTDOWN ALARMS
14.4. LOADDUMP ALARMS
14.5. WARNINGS
14.6. NON-VISUAL WARNINGS
15. PROGRAMMING
15.1. RESETTING TO FACTORY DEFAULTS
15.2. ENTERING THE PROGRAMMING MODE
15.3. NAVIGATING BETWEEN MENUS
15.4. MODIFYING PARAMETER VALUE
15.5. PROGRAMMING MODE EXIT
16. PROGRAM PARAMETER LIST
16.1. CONTROLLER CONFIGURATION GROUP
16.2. ELECTRICAL PARAMETERS GROUP
16.3. ENGINE PARAMETERS GROUP
16.4. ADJUST DATE AND TIME
16.5. WEEKLY OPERATION SCHEDULE
16.6. EXERCISER SCHEDULE
16.7. SENDER CONFIGURATION
16.8. DIGITAL INPUT CONFIGURATION
16.9. OUTPUT CONFIGURATION
16.10. SITE ID STRING
16.11. ENGINE SERIAL NUMBER
16.12. MODEM1-2/SMS1-2-3-4 TELEPHONE NUMBERS
16.13. GSM MODEM PARAMETERS
16.14. TCP/IP PARAMETERS
16.15. Wi-Fi PARAMETERS
17. ETHERNET CONFIGURATION
18. Wi-Fi CONFIGURATION
19. GSM CONFIGURATION
20. CRANK CUTTING
21. OVERCURRENT PROTECTION (IDMT)
22. MOTORIZED CIRCUIT BREAKER CONTROL
23. J1939 CANBUS ENGINE SUPPORT (OPTIONAL)
24. SMS COMMANDS

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25. SOFTWARE FEATURES
25.1. LOAD SHEDDING / DUMMY LOAD
25.2. LOAD ADD / SUBSTRACT
25.3. FIVE STEP LOAD MANAGEMENT
25.4. REMOTE START OPERATION
25.5. DISABLE AUTO START, SIMULATE MAINS
25.6. BATTERY CHARGING OPERATION, DELAYED SIMULATE MAINS
25.7. DUAL GENSET MUTUAL STANDBY OPERATION
25.8. MULTIPLE VOLTAGE AND FREQUENCY
25.9. SINGLE PHASE OPERATION
25.10. EXTERNAL CONTROL OF THE UNIT
25.11. AUTOMATIC EXERCISER
25.12. WEEKLY OPERATION SCHEDULER
25.13. ENGINE HEATING OPERATION
25.14. ENGİNE IDLE SPEED OPERATİON
25.15. ENGINE BLOCK HEATER
25.16. FUEL PUMP CONTROL
25.17. GAS ENGINE FUEL SOLENOID CONTROL
25.18. PRE-TRANSFER SIGNAL
25.19. CHARGING THE ENGINE BATTERY
25.20. EXTERNALLY CONTROLLED DIGITAL OUTPUTS
25.21. COMBAT MODE
25.22. RESETTING THE CONTROLLER
25.23. -
25.24. ZERO POWER AT REST
26. MODBUS COMMUNICATIONS
27.1. PARAMETERS REQUIRED FOR RS-485 MODBUS OPERATION
27.2. DATA FORMATS
27. DECLARATION OF CONFORMITY
28. MAINTENANCE
29. DISPOSAL OF THE UNIT
30. ROHS COMPLIANCE
31. TROUBLESHOOTING GUIDE

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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 brake 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.
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.
Current Transformers must be used for current
measurement.
No direct connection allowed.
1. INSTALLATION INSTRUCTIONS

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Dimensions: 133x107x46mm (5.25”x4.2”x1.9”)
Panel Cutout: 117x87mm minimum (4.6”x3.43”)
Weight: 250g (0.55 lb)
2.1. DIMENSIONS
2. MOUNTING

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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.
87mm
117mm
Panel Cutout
WALL
40mmmin 60mm
Required Panel Depth
The unit is designed for panel mounting. The user
should not be able to access parts of the unit other
than the front panel.

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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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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
2.2. SEALING, GASKET
Gasket
Panel
Module

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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 1A or 5A output.
▪For current transformer inputs, use at least 1.5mm2section (AWG15) cable.
▪The current transformer cable length should not exceed 1.5 meters. If
longer cable is used, increase the cable section proportionally.
For the correct operation of the exerciser and
weekly schedule programs, adjust the real time
clock of the unit through programming menu.
The engine body must be grounded. Otherwise faulty
voltage and frequency measurements may occur.
Current Transformers must be used for current
measurement.
No direct connection allowed.
Do not install the unit close to high electromagnetic
noise emitting devices like contactors, high current
busbars, switchmode power supplies and the like.
2.3. ELECTRICAL INSTALLATION

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Supply voltage:
8 to 36VDC
Cranking dropouts:
Survives 0VDC during 100ms. The voltage before surge should be
8VDC minimum
Overvoltage protection:
Withstands 150VDC continuously.
Reverse voltage:
-150VDC 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
3.1. BATTERY VOLTAGE INPUT
3. TERMINAL DESCRIPTIONS

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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 650Hz
Frequency display
resolution:
0.1 Hz
Frequency accuracy:
0.2% + 1 digit (±0.1 Hz @ 50Hz)
3.2. AC VOLTAGE INPUTS

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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 or 1A
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 30VAC 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.
3.3. AC CURRENT INPUTS

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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
▪Current Transformers must be used for current
measurement. No direct connection allowed.
▪No common terminals or grounding allowed.

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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
Total
0.0
0.0
300
0.0