Datakom D-500 MK2 User manual

D-500 MK2 User Manual Firmware V-6.3
D-500 MK2
ADVANCED
GENSET
CONTROLLER
D-500 MK2 is a next generation genset controller
combining multi-functionality and wide communication
capabilities together with a reliable and low-cost
design.
The same controller provides synchronization, load
share, AMF, ATS, Remote Start, Engine Control and
Remote Display Panel 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, 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. The Rainbow Scada web monitoring service
allows monitoring and control of an unlimited number
of gensets through any web browser.
Multi genset synchronizer and load share *
Multi genset mains synchronizer *
Single genset parallel with mains *
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
*Optional with plug-in module
•Ethernet port (100Mbps) *
•GSM-GPRS *
•Embedded web server *
•Web monitoring *
•Web programming *
•Central Monitoring through internet *
•SMS message sending *
•E-mail sending *
•Central monitoring *
•Modbus RTU through RS-485 *
•Modbus TCP/IP *
•SNMP *
•USB Host *
•CANBUS-2 for inter- module comm. *
•USB Device
•PC software: Rainbow Plus
•J1939-CANBUS for electronic engines
*Optional with plug-in module
3 phases 4 wires, star
3 phases 4 wires, delta
3 phases 3 wires, delta, 3 CTs
3 phases 3 wires, delta, 2 CTs (L1-L2)
3 phases 3 wires, delta,2 CTs (L1-L3)
2 phases 3 wires, L1-L2
2 phases 3 wires, L1-L3
1 phase 2 wires
FUNCTIONALITIES
COMMUNICATIONS
TOPOLOGIES
DESCRIPTION

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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-500 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-DYNdns account setting
Dynamic DNS Account Setting
500-Ethernet Configuration
Ethernet Configuration Guide
500-GSM Configuration
GSM Configuration Guide
500-Firmware Update
Firmware Update Guide
500-MODBUS
Modbus Application Manual
500-snmp_E_34076
MIB file for SNMP Application
500-Rainbow Scada Installation
Rainbow Scada Installation Guide
500-Rainbow Scada Usage
Rainbow Scada Usage Guide
QUERRIES
RELATED DOCUMENTS
ABOUT THIS DOCUMENT
COPYRIGHT NOTICE

D-500 MK2 User Manual Firmware V-6.3
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REVISION
DATE
AUTHOR
DESCRIPTION
01
24.09.2019
MH
First release, 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-500 family units are available in various options and peripheral features. Please use below
information for ordering the correct version:
D-500 MK2
-S
-E
-M
-C
-G
-T
-00
Screw type bracket
Stock Code=J10P01 (per unit)
Self-Retaining type bracket
Stock Code=K16P01 (per unit)
Sealing Gasket, Stock Code= K20P01
SPARE PARTS
ORDERING CODES
Family Code
GSM-GPRS
Modem slot
USB-Host,
RS-485,
Ethernet slot
With Sealing
gasket
With Conformal
Coating
Variant
00: standard unit
01...99: customer
specific products
Synchronization
slot
I/O Extension
slot

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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 of fast type with a maximum rating of 6A must be
connected to supply and AC voltage inputs of the controller.
▪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. DIGITAL OUTPUTS
3.9. MAINS CONTACTOR OUTPUT
3.10. GENERATOR CONTACTOR OUTPUT
3.11. INPUT/OUTPUT EXTENSION
3.12. J1939-CANBUS PORT
3.13. USB DEVICE PORT
4. PLUG-IN MODULES
4.1. MODEM PLUG-IN
4.1.1. GSM MODEM SLOT
4.1.2. Wi-Fi SLOT
4.1.3. ETHERNET SLOT
4.1.4. RS-485 SLOT
4.2. SYNCHRONIZATION PLUG-IN
4.2.1. ANALOG AVR CONTROL OUTPUT
4.2.2. ANALOG GOVERNOR CONTROL OUTPUT
4.2.3. DATALINK-CANBUS PORT
4.2.4. ANALOG LOAD SHARE SIGNAL
4.3. ANALOG PLUG-IN
4.3.1. ANALOG I/O EXTENSION SLOT
4.3.2. 3 X MAINS CT INPUTS SLOT
4.4. COMMUNICATION SLOT
4.4.1. ETHERNET PORT
4.4.2. USB HOST PORT
4.4.3. RS-485 PORT
TABLE OF CONTENTS

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5. TOPOLOGIES
5.1. SELECTING THE TOPOLOGY
5.2. 3 PHASE, 4 WIRE, STAR
5.3. 3 PHASE, 3 WIRE, DELTA
5.4. 3 PHASE, 4 WIRE, DELTA
5.5. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L2)
5.6. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L3)
5.7. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L2)
5.8. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L3)
5.9. 1 PHASE, 2 WIRE
6. FUNCTIONALITIES
6.1. CT LOCATION SELECTION
6.2. SYNCHRONIZATION FUNCTIONALITY
6.3. MAINS SYNCHRONIZATION FUNCTIONALITY
6.4. SINGLE GENSET PARALLEL WITH MAINS
6.5. AMF FUNCTIONALITY
6.6. ATS FUNCTIONALITY
6.7. REMOTE START FUNCTIONALITY
6.8. ENGINE CONTROLLER FUNCTIONALITY
6.9. REMOTE DISPLAY UNIT FUNCTIONALITY
6.10. 400HZ OPERATION
7. CONNECTION DIAGRAMS
7.1. GENSET SYNCHRONIZATION FUNCTIONALITY
7.2. MAINS SYNCHRONIZATION FUNCTIONALITY
7.3. SINGLE GENSET PARALLEL WITH MAINS FUNCTIONALITY
7.4. AMF FUNCTIONALITY
7.5. ATS FUNCTIONALITY
7.6. REMOTE START FUNCTIONALITY
7.7. ENGINE CONTROL FUNCTIONALITY
7.8. REMOTE DISPLAY PANEL FUNCTIONALITY
8. TERMINAL DESCRIPTION
9. TECHNICAL SPECIFICATIONS
10. DESCRIPTION OF CONTROLS
10.1. FRONT PANEL FUNCTIONALITY
10.2. PUSHBUTTON FUNCTIONS
10.3. DISPLAY SCREEN ORGANIZATION
10.4. AUTOMATIC DISPLAY SCROLL
10.5. MEASURED PARAMETERS
10.6. LED LAMPS
11. WAVEFORM DISPLAY & HARMONIC ANALYSIS
12. DISPLAYING EVENT LOGS

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13. STATISTICAL COUNTERS
13.1. FUEL FILLING COUNTER
13.2. FUEL CONSUMPTION MONITORING
14. OPERATION OF THE UNIT
14.1. QUICK START GUIDE
14.2. STOP MODE
14.3. AUTO MODE
14.4. RUN MODE, MANUAL CONTROL
14.5. TEST MODE
15. PROTECTIONS AND ALARMS
15.1. DISABLING ALL PROTECTIONS
15.2. SERVICE REQUEST ALARM
15.3. SHUTDOWN ALARMS
15.4. LOADDUMP ALARMS
15.5. WARNINGS
15.6. NON-VISUAL WARNINGS
16. PROGRAMMING
16.1. RESETTING TO FACTORY DEFAULTS
16.2. ENTERING THE PROGRAMMING MODE
16.3. NAVIGATING BETWEEN MENUS
16.4. MODIFYING PARAMETER VALUE
16.5. PROGRAMMING MODE EXIT
17. PROGRAM PARAMETER LIST
17.1. CONTROLLER CONFIGURATION GROUP
17.2. ELECTRICAL PARAMETERS GROUP
17.3. ENGINE PARAMETERS GROUP
17.4. ADJUST DATE AND TIME
17.5. WEEKLY OPERATION SCHEDULE
17.6. EXERCISER SCHEDULE
17.7. SENDER CONFIGURATION
17.8. DIGITAL INPUT CONFIGURATION
17.9. OUTPUT CONFIGURATION
17.10. SITE ID STRING
17.11. ENGINE SERIAL NUMBER
17.12. MODEM1-2/SMS1-2-3-4 TELEPHONE NUMBERS
17.13. GSM MODEM PARAMETERS
17.14. ETHERNET PARAMETERS
17.15. SNTP PARAMETERS
17.15. Wi-Fi PARAMETERS
17.17. SYNCHRONIZATION PARAMETERS

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18. ETHERNET CONFIGURATION
19. Wi-Fi CONFIGURATION
20. GSM CONFIGURATION
21. CRANK CUTTING
22. OVERCURRENT PROTECTION (IDMT)
23. MOTORIZED CIRCUIT BREAKER CONTROL
24. AUTO LEARNING
25. SPEED & VOLTAGE UP/DOWN RELAY OUTPUTS
25.1. SPEED UP/DOWN CONTROL
25.2. VOLTAGE UP/DOWN CONTROL
26. J1939 CANBUS ENGINE SUPPORT
27. GPS SUPPORT
28. SMS COMMANDS
29. LOAD TRANSFER MODES
29.1. TRANSFER WITH INTERRUPTION
29.2. UNINTERRUPTED TRANSFER
29.3. SOFT TRANSFER
30. LOAD SHARING
30.1. DIGITAL LOAD SHARING (DATALINK)
30.2. ANALOG LOAD SHARING
30.3. DROOP MODE OPERATION
31. PARALLELING WITH MAINS OPERATION
31.1. PEAK LOPPING
31.2. POWER EXPORT TO MAINS
31.3. DISTRIBUTED POWER EXPORT TO MAINS
31.4. PEAK LOPPING WITH GENSET PRIORITY
32. PROTECTION FUNCTIONS PARALLELING WITH MAINS
32.1. ROCOF FUNCTION (rate of change of frequency)
32.2. VECTOR SHIFT FUNCTION
32.3. OVER/UNDER FREQUENCY FUNCTION
32.4. OVER/UNDER VOLTAGE FUNCTION
32.5. MAINS REVERSE POWER FUNCTION
32.6. NO FREQUENCY FUNCTION
33. DATA RECORDING
33.1. DATA RECORDING MEDIA
33.2. DIRECTORY STRUCTURE
33.3. UNDERSTANDING THE CSV FORMAT
33.4. RECORDED DATA LIST, RECORD PERIOD

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34. SOFTWARE FEATURES
34.1. LOAD SHEDDING / DUMMY LOAD
34.2. LOAD ADD / SUBSTRACT
34.3. FIVE STEP LOAD MANAGEMENT
34.4. REMOTE START OPERATION
34.5. DISABLE AUTO START, SIMULATE MAINS
34.6. BATTERY CHARGING OPERATION, DELAYED SIMULATE MAINS
34.7. DUAL GENSET MUTUAL STANDBY OPERATION
34.8. MULTIPLE VOLTAGE AND FREQUENCY
34.9. SINGLE PHASE OPERATION
34.10. EXTERNAL CONTROL OF THE UNIT
34.11. AUTOMATIC EXERCISER
34.12. WEEKLY OPERATION SCHEDULER
34.13. ENGINE HEATING OPERATION
34.14. ENGİNE IDLE SPEED OPERATİON
34.15. ENGINE BLOCK HEATER
34.16. FUEL PUMP CONTROL
34.17. GAS ENGINE FUEL SOLENOID CONTROL
34.18. PRE-TRANSFER SIGNAL
34.19. CHARGING THE ENGINE BATTERY
34.20. EXTERNALLY CONTROLLED DIGITAL OUTPUTS
34.21. COMBAT MODE
34.22. RESETTING THE CONTROLLER
34.23. AUTOMATIC CONNECTION TOPOLOGY DETERMINATION
34.24. ZERO POWER AT REST
35. MODBUS COMMUNICATIONS
35.1. PARAMETERS REQUIRED FOR RS-485 MODBUS OPERATION
35.2. PARAMETERS REQUIRED FOR MODBUS-TCP/IP VIA ETHERNET
35.3. DATA FORMATS
36. SNMP COMMUNICATIONS
36.1. PARAMETERS REQUIRED FOR SNMP VIA ETHERNET
36.2. SNMP TRAP MESSAGES
37. DECLARATION OF CONFORMITY
38. MAINTENANCE
39. DISPOSAL OF THE UNIT
40. ROHS COMPLIANCE
41. 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 break 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: 211x162x42mm
Panel Cutout: 176x121mm minimum
Weight: 500g (approx..)
2.1. DIMENSIONS
2. MOUNTING

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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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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
Module
Panel

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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 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:
9 to 36VDC
Cranking dropouts:
Survives 0VDC during 100ms. The voltage before surge should be
9VDC minimum
Overvoltage protection:
Withstands 150VDC continuously.
Reverse voltage:
-36VDC continuous
Maximum operating
current:
600mA @ 12VDC. (All options included, digital outputs open.)
300mA @ 24VDC. (All options included, digital outputs open.)
Typical operating current:
300mA @ 12VDC. (all options passive, digital outputs open)
150mA @ 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:
0 to 300 VAC
Minimum voltage for
frequency detection:
15 VAC (Ph-N)
Supported topologies:
3 ph 4 wires star
3 ph 4 wires delta
3 ph 3 wires delta
3 ph 3 wires delta L1-L2
3 ph 3 wires delta L2-L3
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)
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 4 wires star, 3 ph 4 wires delta,
3 ph 3 wires delta
3 ph 3 wires delta L1-L2
3 ph 3 wires delta L2-L3
2ph 3 wires L1-L2
2ph 3 wires L1-L3
1 ph 2 wires
CT secondary rating:
5A
Measurement range:
5/5 to 5000/5A minimum
Input impedance:
15 milliohm
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.
It is advised CT rating to be selected following
this table for the best measurement accuracy.
3.3. AC CURRENT INPUTS

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