Datakom DK-70 User manual

DK-70
INTERNET BASED
COMPRESSOR
CONTROLLER
DK-70 is a next generation compressor controller
providing control of a screw or piston type air compressor
driven by electric motor.
DK-70 offers wide internet-based communication
capabilities satisfying tomorrow’s needs. It allows remote
monitoring and control over internet. A mobile phone app
is also available for ease of use.
The unit incorporates all functions needed in a
compressor control panel, eliminating the need for extra
modules in the panel and lowering panel cost.
The early start function analyzes the air consumption
trend and starts the compressor before the pressure falls
below the low set limit.
Using the Weekly Schedule Program and Pressure
Calendar functions, the compressor can be programmed
to start on given hours and days of the week with user
defined set pressure values.
The unit is supplied from the utility. Fault contacts and
senders are internally supplied, eliminating the need for a
supply transformer in the panel.
The 2.9”, 128x64 pixel LCD screen displays values in
bigger size with graphic support.
The controller is designed to conform to highest industrial
standards in safety, vibration, EMC and environmental
conditions.
Firmware updates can be done easily via the USB port.
The device can be monitored and programmed via USB,
RS-485, Ethernet, WIFI and GPRS using the Windows
based free PC software.
Rainbow Scada web service enables central remote
monitoring and control of an unlimited number of
compressors.
Ethernet (optional)
GSM-2G-3G-4G-NB/IOT-SMS (optional)
Wi-Fi connection (optional)
Embedded Web server
Monitoring & programming & control
Canbus multi-compressor operation (opt.)
Modbus RS-485 (optional)
RS-232 (optional)
Modbus TCP/IP - SNMP
USB Flash Drive socket (optional)
USB GPS support
USB Device Port
Equal aging, multiple compressor control
Weekly schedule and pressure calendar
5 independent service counters
Star / Delta starting
0-10V and 4-20mA frequency inverter control
8 programmable relay outputs
8 programmable digital inputs
3 pressure sender inputs
4 temperature sender inputs
Adjustable sender curves
Current, voltage, power, and phase sequence
protections
V & I harmonic analysis and oscilloscope
Fully closed front panel (IP65 with gasket)
3 phase 4 wire, star
3 phase 4 wire, delta
3 phase 3 wire, 2 CTs (L1-L2)
3 phase 3 wire, 2 CTs (L1-L3)
2 phase 3 wire, L1-L2
1 phase 2 wire
FUNCTIONS
FEATURES
CONNECTIONS
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 the minimum requirements and necessary steps for the successful installation
of the DK-70 family compressors.
Follow carefully the advice given in the document. These are often good practices for the installation of
compressor controllers which reduce future issues.
For all technical queries, please contact Datakom at the e-mail address below:
[e-mail]
If additional information to this manual is required, please contact the manufacturer directly at:
[e-mail]
Please provide the following information in order to receive answers to any question:
- Device model name (see back panel),
- Device serial number (see back panel),
- Firmware version (read from display screen),
- Measuring circuit voltage and power supply voltage,
- Precise description of the query.
FILE NAME
DESCRIPTION
Rainbow Installation
Rainbow Plus Installation Manual
Rainbow Use
Rainbow Plus User Manual
Rainbow Scada Use
Rainbow Scada User Manual
RELATED DOCUMENTS
ABOUT THIS DOCUMENT
COPYRIGHT NOTICE
QUERIES

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REVISION
DATE
AUTHOR
DESCRIPTION
01
26.03.2019
OK
First Edition
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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Screw type bracket
Stock Code=J10P01 (per unit)
Self-retaining type bracket
Stock Code=K16P01 (per unit)
Sealing Gasket, Stock Code= L057P01
SPARE PARTS

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▪Electrical equipment should be installed only by a qualified
specialist. No responsibility is assured by the manufacturer or
any of its subsidiaries for any consequences resulting from non-
compliance to these instructions.
▪Check the controller for cracks and damages due to
transportation. Do not install damaged equipment.
▪Do not open the controller. There are no serviceable parts inside.
▪Fuses must be connected to the power supply and phase voltage
inputs in close proximity to the controller.
▪Fuses must be of fast type (FF) with a maximum rating of 6A.
▪Disconnect all power before working on the equipment.
▪Do not touch the terminals when the controller is connected to
the network.
▪Short circuit terminals of unused current transformers.
▪Any electrical parameter applied to the device must be within the
range specified in the user manual. Although the controller is
designed with a wide safety margin, over-range parameters may
reduce lifetime, alter operational precision or even damage the
controller.
▪Do not try to clean the device with solvent or the like. Only clean
with a damp cloth.
▪Verify correct terminal connections before applying power.
▪Only for panel mounting.
SAFETY NOTICE
Failure to follow the following instructions may 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. POWER SUPPLY INPUT
3.2. AC VOLTAGE INPUTS
3.3. AC CURRENT INPUTS
3.4. DIGITAL INPUTS
3.5. PT100 TEMPERATURE SENDER INPUT
3.6. ANALOG TEMPERATURE SENDER INPUTS
3.7. PRESSURE SENDER INPUTS
3.8. 0-10V ANALOG OUTPUT
3.9. 4-20 mA ANALOG OUTPUTS
3.10. RELAY OUTPUTS
3.11. INPUT/OUTPUT EXPANSION
3.12. RS-485 PORT (OPTIONAL)
3.13. ETHERNET PORT (OPTIONAL)
3.14. USB DEVICE PORT
3.15. USB HOST PORT (OPTIONAL)
3.16. RS-232 PORT (OPTIONAL)
3.17. GSM MODEM (OPTIONAL)
3.18. WIFI COMMUNICATION (OPTIONAL)
4. TOPOLOGIES
4.1. 3 PHASE, 4 WIRE, STAR
4.2. 3 PHASE, 4 WIRE, DELTA
4.3. 3 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L2)
4.4. 3 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L3)
4.5. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L2)
4.6. 1 PHASE, 2 WIRE
5. CONNECTION DIAGRAM
6. TECHNICAL SPECIFICATIONS
7. DESCRIPTION OF CONTROLS
7.1. FRONT PANEL FUNCTIONALITY
7.2. PUSHBUTTON FUNCTIONS
7.3. DISPLAY SCREEN ORGANIZATION
7.4. MEASURED PARAMETERS
7.5. LED LAMPS
8. WAVEFORM DISPLAY & HARMONIC ANALYSIS
9. MINIMUM, MAXIMUM & DEMAND VALUES
TABLE OF CONTENTS

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10. EVENT RECORDS
11. STATISTICAL COUNTERS
12. OPERATION OF THE UNIT
12.1. SELECTION OF OPERATION MODE
12.2. STOPPING METHOD
12.3. STARTING THE COMPRESSOR
12.4. UNLOADING AND RELOADING THE COMPRESSOR
13.5. STOPPING AND RESTARTING FOLLOWING OUTPUT PRESSURE
13. ALARMS AND WARNINGS
13.1. SERVICE COUNTER WARNINGS
13.2. ALARMS
13.3. WARNINGS
14. PROGRAMMING
14.1. RESETTING TO FACTORY DEFAULTS
14.2. ENTERING PROGRAMMING MODE
14.3. NAVIGATING BETWEEN MENUS
14.4. MODIFYING PARAMETER VALUE
14.5. EXITING PROGRAMMING MODE
15. PROGRAM PARAMETER LIST
15.1. CONTROLLER CONFIGURATION GROUP
15.2. ELECTRICAL PARAMETERS GROUP
15.3. COMPRESSOR PARAMETERS GROUP
15.4. ADJUST DATE AND TIME
15.5. WEEKLY OPERATION SCHEDULE
15.6. PRESSURE CALENDAR
15.7. SENDER CONFIGURATION
15.8. INPUT CONFIGURATION
15.9. DIGITAL OUTPUT (RELAY) CONFIGURATION
15.10. SITE ID STRING
15.11. ENGINE SERIAL NUMBER
15.12. SMS1-2-3-4 PHONE NUMBERS
15.13. GSM MODEM PARAMETERS
15.14. ETHERNET PARAMETERS
15.15. SNTP PARAMETER
15.16. USER INPUT STRINGS
16. ETHERNET CONFIGURATION
17. GSM CONFIGURATION
18. Wi-Fi CONFIGURATION
19. SMS COMMANDS

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20. DATA RECORDING
20.1. DATA RECORDING MEDIA
20.2. DIRECTORY STRUCTURE
20.3. CSV FORMAT
20.4. RECORDED DATA LIST, RECORD PERIOD
21. SOFTWARE FEATURES
21.1. REMOTE START
21.2. SINGLE PHASE OPERATION
21.3. EXTERNALLY CONTROLLED DIGITAL OUTPUTS
21.4. RESETTING THE CONTROLLER
21.5. VARIABLE SERVICE TIMER SELECTION
21.6. PREVENTING PRESSURE LOSS
21.7. VARIABLE UNLOADED OPERATION TIMER
21.8. PID CONTROL AND ANALOG OUTPUT (PWM)
21.9. PID CONTROLLD FAN DRIVE
21.10. MOTOR PTC INPUT
21.11. MULTIPLE COMPRESSOR OPERATION
22. MODBUS COMMUNICATION
22.1. PARAMETERS FOR RS-485 MODBUS OPERATION
22.2. PARAMETERS FOR ETHERNET MODBUS-TCP/IP
22.3. DATA FORMATS
22.4. COMMANDS
22.5. EVENT RECORDS MEMORY STRUCTURE
22.6. REAL TIME CLOCK
23. SNMP COMMUNICATION
23.1. PARAMETERS FOR ETHERNET SNMP
23.2. SNMP TRAP MESSAGES
24. DECLARATION OF CONFORMITY
25. MAINTENANCE
26. DISPOSAL OF THE UNIT
27. ROHS COMPLIANCE

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Before installation:
▪Read the user manual carefully; determine the correct connection diagram.
▪Remove all connectors and mounting brackets from the controller, then pass the controller
through the mounting opening.
▪Place the 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 into 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 the specified range.
▪Voltage at digital inputs beyond the specified range.
▪Current through measuring terminals beyond the specified range.
▪Overload or short circuit at relay outputs.
▪Connecting or disconnecting data terminals while the device is powered on.
▪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.
▪Incorrect phase order of voltage inputs.
▪Current transformers not matching relevant phases.
▪Incorrect current transformer polarity.
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 through the mounting opening.
Place and tighten the 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 compressor 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 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 to the unit.
▪Fuses must be of fast type 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 or 1A output.
▪For current transformer inputs, use at least 1.5mm2section (AWG15) cable.
▪The current transformer cable length should not exceed 1.5 meters. If a
longer cable is used, increase the cable section proportionally.
2.3. ELECTRICAL INSTALLATION
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, switch-mode power supplies and the like.

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Supply voltage:
85-300 VAC or 88-400VDC
Polarity:
Indifferent
Maximum power:
7W @ 230VAC. (All features active, relay outputs empty)
Typical operating power:
2W @ 230VAC. (All features passive, relay outputs empty)
Isolation:
2000 VAC (between voltage inputs and supply inputs)
Measurement method:
True RMS
Sampling rate:
8000 Hz
Harmonic analysis:
Up to 31st harmonic
Input voltage range:
0 - 300 VAC phase-neutral, 0-520V phase-phase.
Minimum voltage for
frequency detection:
15 VAC (Ph-N)
Supported topologies:
3 phase 4 wire star
3 phase 3 wire delta
3 phase 4 wire delta
2 phase 3 wire L1-L2
1 phase 2 wire
Measuring range:
0 … 300VAC Ph-N (0 … 520VAC Ph-Ph)
Input impedance:
4.5M-ohm
Display resolution:
1V-DC
Accuracy:
0.5% + 1 digit @ 230V-AC Ph-N (±2VAC Ph-N)
0.5% + 1 digit @ 400V-AC Ph-Ph (±3VAC Ph-Ph)
Frequency range:
DC - 500Hz
Frequency display
resolution:
0.1 Hz
Frequency accuracy:
0.2% + 1 digit (±0.1 Hz @ 50Hz)
3.2. AC VOLTAGE INPUTS
3.1. POWER SUPPLY INPUT
3. TERMINAL DESCRIPTIONS

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Measurement method:
True RMS
Sampling rate:
8000 Hz
Harmonic analysis:
Up to 31st harmonic
Supported topologies:
3 Phase 3 CT
3 Phase 2 CT L1-L2
2 Phase 2 CT L1-L2
1 Phase 1 CT
CT secondary:
5A or 1A
Measuring range:
5/5 - 5000/5A minimum
Input impedance:
15 milli-ohm
Burden:
0.375W
Maximum continuous
current:
6A
Measuring range:
0.1 - 7.5A
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 to a
minimum in order to minimize the 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 be selected from
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 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 to connect each CT to the relevant phase input with the correct polarity. Mixing CTs between
phases will cause faulty power and pf readings.
Many combinations of incorrect CT connections are possible, so check both the order of the CTs and
their polarities. Reactive power measurement is affected by incorrect CT connections in a similar way as
active power measurement.
CORRECT CT CONNECTIONS
Let’s suppose that the compressor 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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EFFECT OF POLARITY REVERSAL
The compressor 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 polarity. The result is that total compressor 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 compressor is still loaded with 100 kW in 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 compressor power displayed by the controller will be 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

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Number of inputs:
8 inputs, all configurable
Structure:
Serial diode, with 113k-ohm resistor to the GND terminal
Function selection:
From list
Contact type:
Normally open or normally closed (programmable)
Switching:
Active under positive-DC or AC voltage, passive when left open
Low level threshold:
1.0V-DC/AC
High level threshold:
6.0V-DC/AC
Maximum input voltage:
150V-DC/AC
Reverse input voltage:
-500V-DC maximum
Noise filtering:
Yes
Number of inputs:
1 input, additional sender ground input
Structure:
PT100 measuring Wheatstone bridge and instrumentation op-amp
Measurement:
Analog resistance measurement.
Function:
The measured resistance value is converted to temperature via the
preprogrammed PT100 sender curve.
Analog measurement
range:
75 –240-Ohm
Accuracy:
1°Celsius
Noise filtering:
Yes
Number of inputs:
4 inputs
Measurement:
Analog resistance measurement.
Function:
The measured resistance value is converted to temperature via the
programmable sender curve.
Open circuit voltage:
3.3VDC
Short circuit current:
330 μA-DC
Measurement range:
1k-ohm to 100k-ohm
Open circuit threshold:
100k-ohm
Resolution:
12-bit
Accuracy:
% 0.3
Noise filtering:
Yes
3.6. ANALOG TEMPERATURE SENDER INPUTS
3.5. PT100 TEMPERATURE SENDER INPUT
3.4. DIGITAL INPUTS

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Number of inputs:
3 inputs, additional +12V (PRES+) sender supply
Structure:
50-ohm resistance to ground
Measurement:
Analog DC current measurement
Function:
The measured current value is converted to pressure via the
programmed sender curve.
Nominal input current:
4-20mA-DC
Current measurement
range:
0-30mA-DC
Breakdown limit:
70mA-DC
Resolution:
12-bit
Accuracy:
%0.5
Noise filtering:
Yes
Number of outputs:
0-10V analog output
Structure:
Op-amp output though 1k-ohm serial resistor
Function:
Controls the variable rpm inverter via PID control loop.
Resolution:
16-bit
Accuracy:
%0.5
Cutoff frequency:
16Hz
3.7. PRESSURE SENDER INPUTS
3.8. 0-10V ANALOG OUTPUT