Datakom D Series User manual

D-500L Firmware V-5.8
D 500
WARNING
SERVICE
REQU EST
ALARM
PGM
AUTO STOPTEST RUN
MAINS
GENSET
LOAD
A
STATUS
D-500L
ADVANCED
GENSET
CONTROLLER
The D-xxx series are next generation genset control
units 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, serial and GPRS.
The PC based Rainbow Scada software allows
monitoring and control of an unlimited number of
gensets from a single central location.
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
GSM-GPRS
Internal GPRS modem (optional)
GSM-SMS
e-mail
Modbus
USB Device
RS-485
RS-232
J1939-CANBUS
3 phases 4 wires, star
3 phases 3 wires, 3 CTs
3 phases 3 wires, 2 CTs (L1-L2)
3 phases 3 wires, 2 CTs (L1-L3)
2 phases 3 wires, L1-L2
2 phases 3 wires, L1-L3
3 phases 4 wires, delta
1 phase 2 wires
FUNCTIONALITIES
COMMUNICATIONS
TOPOLOGIES
DESCRIPTION

D-500L Firmware V-5.8
K35D03-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-xxx 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].tr
If additional information to this manual is required, please contact the manufacturer directly at below e-
mail address: [email protected].tr
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 D-500 D-700 Installation Guide
500-Rainbow Usage
Rainbow Plus D-500 D-700 Usage Guide
500-GSM Configuration
GSM Configuration Guide for D-500 D-700
500-Firmware Update
Firmware Update Guide for D-500 D-700
500-MODBUS
Modbus Application Manual for D-500 D-700
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-500L Firmware V-5.8
K35D03-EN - 3 -
REVISION
DATE
AUTHOR
DESCRIPTION
01
19.06.2015
MH
First edition, firmware version 5.4
02
06.05.2016
MH
Revised for firmware version 5.7
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

D-500L Firmware V-5.8
K35D03-EN - 4 -
The D-500 family units are available in various options and peripheral features. Please use below
information for ordering the correct version:
Dxxx
-M
-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
With Internal
GSM-GPRS
Modem
With CANBUS-
J1939 port
With Sealing
gasket
With Conformal
Coating
Variant
00: standard unit
01...99: customer
specific products

D-500L Firmware V-5.8
K35D03-EN - 5 -
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.

D-500L Firmware V-5.8
K35D03-EN - 6 -
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. INPUT/OUTPUT EXTENSION
3.12. RS-485 PORT
3.13. RS-232 PORT
3.14. J1939-CANBUS PORT
3.15. USB DEVICE PORT
3.16. GSM MODEM (OPTIONAL)
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

D-500L Firmware V-5.8
K35D03-EN - 7 -
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. REMOTE DISPLAY UNIT FUNCTIONALITY
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. REMOTE DISPLAY PANEL FUNCTIONALITY
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, MANUAL CONTROL
13.5. TEST MODE
14. PROTECTIONS AND ALARMS
14.1. DISABLING ALL PROTECTIONS
14.2. SERVICE REQUEST ALARM
14.3. SHUTDOWN ALARMS
14.4. LOADDUMP ALARMS

D-500L Firmware V-5.8
K35D03-EN - 8 -
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. ETHERNET PARAMETERS
17. CRANK CUTTING
18. OVERCURRENT PROTECTION (IDMT)
19. MOTORIZED CIRCUIT BREAKER CONTROL
20. J1939 CANBUS ENGINE SUPPORT
21. GPS SUPPORT
22. GSM CONFIGURATION
23. CENTRAL MONITORING OF GENSETS
24. E-MAIL SENDING
25. SMS COMMANDS

D-500L Firmware V-5.8
K35D03-EN - 9 -
26. SOFTWARE FEATURES
26.1. LOAD SHEDDING / DUMMY LOAD
26.2. LOAD ADD / SUBSTRACT
26.3. FIVE STEP LOAD MANAGEMENT
26.4. REMOTE START OPERATION
26.5. DISABLE AUTO START, SIMULATE MAINS
26.6. BATTERY CHARGING OPERATION, DELAYED SIMULATE MAINS
26.7. DUAL GENSET MUTUAL STANDBY OPERATION
26.8. MULTIPLE VOLTAGE AND FREQUENCY
26.9. SINGLE PHASE OPERATION
26.10. EXTERNAL CONTROL OF THE UNIT
26.11. AUTOMATIC EXERCISER
26.12. WEEKLY OPERATION SCHEDULER
26.13. ENGINE HEATING OPERATION
26.14. ENGİNE IDLE SPEED OPERATİON
26.15. ENGINE BLOCK HEATER
26.16. FUEL PUMP CONTROL
26.17. GAS ENGINE FUEL SOLENOID CONTROL
26.18. PRE-TRANSFER SIGNAL
26.19. CHARGING THE ENGINE BATTERY
26.20. EXTERNALLY CONTROLLED DIGITAL OUTPUTS
26.21. COMBAT MODE
26.22. RESETTING THE CONTROLLER
26.23. AUTOMATIC CONNECTION TOPOLOGY DETERMINATION
26.24. ZERO POWER AT REST
27. MODBUS COMMUNICATIONS
27.1. PARAMETERS REQUIRED FOR RS-485 MODBUS OPERATION
27.2. DATA FORMATS
28. DECLARATION OF CONFORMITY
29. MAINTENANCE
30. DISPOSAL OF THE UNIT
31. ROHS COMPLIANCE
32. TROUBLESHOOTING GUIDE

D-500L Firmware V-5.8
K35D03-EN - 10 -
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

D-500L Firmware V-5.8
K35D03-EN - 11 -
Dimensions: 200x148x47mm (7.9”x5.8”x1.9”)
Panel Cutout: 176x121mm minimum (7.0”x4.8”)
Weight: 450g (1 lb)
64 63 67 65 66 68 69 70 71 72
3+ 3-
I I
MN-N
MN-L3
MN-L2
MN-L1
MN-C
RS-232
51 52 53 54 55 56 57 58 62 61 60 59
2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
G-N
G-L3
G-L2
G-L1
G-C
I1+
1- 2+ 2-
I I I
BAT +
BAT - OUT 1 OUT 2 OUT 3 OUT 4 CHG IN 1
IN 2 IN 3
IN 4 IN 5 IN 6 IN 7 IN 8 SGND SND 1 SND 2 SND 3 PGND 485-B 485-A MPU+ MPU- / PGND CANH CANL
SIM
CARD
GSM
ANTENNA USB-DEVICE
I/O
EXTENSION
8 to 36Vdc, 500mAmax
!300Vac, 0-600 Hz
0.2 to 6.0Aac
2.1. DIMENSIONS
2. MOUNTING

D-500L Firmware V-5.8
K35D03-EN - 12 -
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
The unit is designed for panel mounting. The user
should not be able to access parts of the unit other
than the front panel.

D-500L Firmware V-5.8
K35D03-EN - 13 -
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.

D-500L Firmware V-5.8
K35D03-EN - 14 -
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

D-500L Firmware V-5.8
K35D03-EN - 15 -
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

D-500L Firmware V-5.8
K35D03-EN - 16 -
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:
-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
3.1. BATTERY VOLTAGE INPUT
3. TERMINAL DESCRIPTIONS

D-500L Firmware V-5.8
K35D03-EN - 17 -
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)
3.2. AC VOLTAGE INPUTS

D-500L Firmware V-5.8
K35D03-EN - 18 -
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.
3.3. AC CURRENT INPUTS

D-500L Firmware V-5.8
K35D03-EN - 19 -
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.

D-500L Firmware V-5.8
K35D03-EN - 20 -
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