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D-500

1. Parameter Definition Unit Min Max Factory Description Set 5 This parameter adjusts the speed of an J1939 Speed Adjust Jo 100 100 0 0 ECU controlled engine by 8 High Air Inlet If the air inlet temperature measured Temperature Warning C 0 200 0 through ECU is over this limit then a Limit high air inlet temperature warning will occur If the air inlet temperature measured High Air Inlet C 0 200 0 through ECU is over this limit then Temperature Alarm Limit high air inlet temperature shutdown loaddump alarm will occur High Air Inlet 0 shutdown alarm Temperature Alarm 0 1 1 loaddump alarm Action L w Coolant Level If the coolant level measured through 0 100 0 ECU is below this limit then a low Warning Limit coolant level warning will occur If the coolant level measured through Low Coolant Level Alarm o 0 100 0 ECU is below this limit then a low Limit coolant level shutdown loaddump alarm will occur Low Coolant Level Alarm _ 0 1 0 0 shutdown alarm Action 1 loaddump alarm If the battery voltage goes below this Battery Charge Run limit the engine will be automatically Voltage De 9 999 4 started in order to charge the battery using the charge alternator If the battery voltage goes below the Battery Charge Run Voltage limit the bud Charge R n min 0 1200 0 engine will be automatically run during this period in order to charge the battery using the charge alternator K35D03 EN
2. e 4 4 190 100 190 gt 2NBINN 19101 ss3ud 19101 3931430 SNIVIN aall uiv l135N39 G 190 1904 gt E 39IAH3S N 1N3HH 19 3unssaud N H3H10 SNIVIN 1JINI l35N39 i 1904 100 904 L 39IAH35 OL E11N3HHN2 34Nssatd LNO LYVLS 5 11N3gurno SAVG SNIVIN ogan SUH 3NI9N3 135339 L 39IAH3S OL 3unssaud JOVLIOA e11N3HHN SHH SNIVIN SSVOANVED 39uHVH9 l135N39 NOISH3A N E c L duna N c L dano N 2 b HHNO L141N3gHno 3unssaud JOVLIDA l3SN39 LASN39 13SN39 SNIVIN DIHLINOHVA 195339 ON 791935 N 2 L HHna3 N E c L HHna3 N E 2 L HHNO 39VH3AV 3unssaud JIOVHJAV 1 3NIDNA SNIVIA SNIVIA SNIVW SNIVIN Jana 135N39 1904 1904 100 i100 100 1007 100 00 al LIS e SLIOA 6 2 1 SLIOA 2 L SLIDA HEM 9 VMI 3unssaud diN3L 110 Henry 9 135N39 Hd Hd 145 39 Hd Hd 135 39 SNIVIN 4ANV1009 v4 d3aNas 13539 3WIL S aLva SNLVLS 9 ALA INHVTIV cL SLIOA cL SLIOA cL SLIOA Jd 9 MA Jd 9 NUI di NVM 3A393u awas N Hd LASN39 N Hd LASN39 135N39 SNIVIN 430N3S 4LASN39 0901 dl AVMALV9 H38ININ 2 b SLIOA 6 2 1 SLIOA 2 L SLIOA diN3L 9N3 SIN3HHNJ di LN3ITO SS3HQV dl IXIN Hd Hd SNIVIN Hd Hd SNIVIN Hd Hd SNIVIN HIQNIS 13S5N39 gt 100 00 00 100 100 00 100 1007 oo
3. L20 L2 T ITT ip i Lud e st O ON iD ONNA tida a 22144 59 E e 2 F gt gt Ini o gt 8 to 35Vdc 800mA max USB HOST SIM W 300Vac 0 100 Hz CARD mi F ETHER USB DEVICE n L LI ENSION GSM ANTENNA L E MICRO SD CARD 25 485 26 485 27 MPU 29 PGND 31 CANL E AAA AVE Force OFF Mode Temp Sender Oil Temp Sender Spare Input 1 Spare Input 2 Spare Input 3 BATTERY 12 24V To BMS 7 ECU Starter Motor Battery Negative must be grounded 4 Connect to the engine body close to the senders 2 Ground from one end only K35D03 EN 40 D 500 User Manual Rev_04 Firmware V 3 3 6 2 AMF FUNCTIONALITY CTs AT ALTERNATOR SIDE LOAD L1L2L3 N ALTERNATOR MAINS 110 H o L1 L 74 a 120 e 12 5 1 LP BONES 8 to 35Vdc 800mA max 300Vac 0 100 Hz RS 232 T E EXTENSION GSM ANTENNA USB DEVICE MICRO SD CARD mn AAA Starter Motor Spare Input 2 Force OFF Mode Temp Sender Spare Input 1 BATTERY 12 24V Battery Negative must be grounded 4 Connect to the engine body close to the senders 2 Ground from one end only K35D03 EN 41 D 500 User Manual Rev_04 Firmware V 3 3 6 3 ATS FUNCTIONALITY LOAD L1L2 L3 N ALTERNATOR MAINS aD 4 lt 116 AT NT o L1 L2
4. APASANBAAR HEEE 2 The module requires a GPRS enabled SIM card for full functionality Voice only type SIM cards will usually not function properly Please refer to GSM Modem Configuration Guide for more details K35D03 EN 30 D 500 User Manual Rev_04 Firmware V 3 3 SIM CARD EXTRACTION INSERTION SIM CARD PLACEMENT Description Quad band GSM GPRS 850 900 1800 1900MHz module GPRS multi slot class 10 8 GPRS mobile station class B Compliant to GSM phase 2 2 Class 4 2 W 850 900 MHz Class 1 1 W 1800 1900 2 Functionality Web Client SMTP Modbus TCP IP client SMS e mail Operating temp range 40 C to 85 C Data speed max 85 6 kbps download 42 8 kbps upload SIM card type external SIM 3V 1 8V GPRS enabled Antenna Quad band magnetic with 2m cable Module certificates CE FCC ROHS PTCRB GCF IC ICASA REACH K35D03 EN 31 D 500 User Manual Rev_04 Firmware V 3 3 4 TOPOLOGIES Various topologies are selectable through program parameter The topology is independently selectable for both genset and mains sections In following drawings the connections are shown for the alternator Current transformers are supposed connected to the alternator side Similar topologies re available for the mains side as well 4 1 SELECTING THE TOPOLOGY Rainbow Plus Beta Version 1 0 0 2 File Help Tools Topology Options
5. ENGINE RUNNING Set if the engine is running while the fuel output is not energized AUTO NOT READY Set if the genset is not in AUTO mode or a fault condition or the weekly schedule prevents the automatic starting of the genset K35D03 EN 71 D 500 User Manual Rev_04 Firmware V 3 3 15 PROGRAMMING 15 1 RESETTING TO FACTORY DEFAULTS In order to resume to the factory set parameter values hold pressed the OFF LAMP TEST and ALARM MUTE buttons for 5 seconds RETURN TO FACTORY SET will be displayed immediately press and hold pressed the ALARM MUTE button for 5 seconds factory set values will be reprogrammed to the parameter memory Hold pressed OFF LAMP TEST and ALARM MUTE Hold pressed ALARM MUTE K35D03 EN 72 D 500 User Manual Rev_04 Firmware V 3 3 The program mode is used to adjust timers operational limits and the configuration of the unit Although a free PC program is provided for programming every parameter may be modified through the front panel regardless of the operating mode When modified program parameters are automatically recorded into a non erasable memory and take effect immediately The program mode will not affect the operation of the unit Thus programs may be modified anytime even while the genset is running 15 2 ENTERING THE PROGRAMMING MODE To enter the program mode press together Q MENU and buttons for 5 seconds When the progra
6. Max common mode voltage 5VDC Frequency range 10Hz to 10 kHz Resolution 1 rpm Accuracy 0 2 1 rpm 3rpm 1500 rpm Flywheel teeth range 1 to 500 Do not share MPU with other devices K35D03 EN 21 Firmware V 3 3 D 500 User Manual Rev_04 Firmware V 3 3 3 8 MAINS CONTACTOR OUTPUT Structure Relay output normally closed contact One terminal is internally connected to mains phase L1 input Max switching current 12A 250VAC Max switching voltage 440VAC Max switching power 3000VA 3 9 GENERATOR CONTACTOR OUTPUT Structure Relay output normally open contact One terminal is internally connected to genset phase L1 input Max switching current 16A 250VAC Max switching voltage 440VAC Max switching power 4000VA 3 10 DIGITAL OUTPUTS The unit offers 6 digital outputs with programmable function selectable from list protection Structure Negative pulling protected semiconductor output One terminal is connected to battery negative Max continuous current 1 0 ADC Max switching voltage 33 VDC Overvoltage protection 40 VDC Short circuit protection gt 1 7 ADC Reverse voltage 500 VDC K35D03 EN 22 D 500 User Manual Rev_04 Firmware V 3 3 3 11 INPUT OUTPUT EXTENSION The module provides resources for 32 additional digital inputs and 32 additional digital ou
7. If the coolant temp is below this limit then the cooler relay function will become inactive Coolant Heater On C 250 50 If the coolant temp is below this limit then the heater relay function will become active Coolant Heater Off C 250 60 If the coolant temp is above this limit then the heater relay function will become inactive Fan Overrun Timer sec 240 The cooler relay will stay active during this timer after the coolant temp is below Coolant Cooler Off limit Canopy Fan Turn On C 250 90 If the canopy temp is above this limit then the canopy fan relay function will become active Canopy Fan Turn Off C 250 80 If the canopy temp is below this limit then the canopy fan relay function will become inactive Ambient Fan Turn On C 250 90 If the ambient temp is above this limit then the ambient fan relay function will become active Ambient Fan Turn Off C 250 80 If the ambient temp is below this limit then the ambient fan relay function will become inactive Service 1 Engine Hours hours 5000 250 The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last service If the period is set to 0 no SERVICE REQUEST will be generated depending on service 1 engine hours Service 1 Period month 24 The SERVICE REQUEST led indicator will turn on after this
8. USB HOST RS 232 MICRO SD 100 Hz 0 x lt e B gt e 2 300Vac N N39 GSM ANTENNA TN39 o G 9 ES VrYN39 O N39 EXTENSION CARD TNO TN ORK Jepueg dwt IIO Jopues LX Jepues 1 A X 2 5594 Lx pus PON 440 99104 induj eueds Z indu yndu eueds ju8J002 dois dwar t esuszq eeN Starter Motor 4 Connect to the engine body close to the senders 2 Ground from one end only Battery Negative must be grounded 44 K35D03 EN Firmware V 3 3 D 500 User Manual Rev 04 6 6 REMOTE DISPLAY PANEL FUNCTIONALITY MI LJ USB HOST r 8 to 35Vdc 800mA max 300Vac 0 100 Hz N N39 TN39 cro E VrN39 O N39 USB DEVICE E J GSM ANTENNA EXTENSION MICRO SD CARD v TN ORM 0 52 Eu G 9po N 440 99104 9 induj eueds G 1ndu eueds y 1nduj eueds jnduy eueds dois oueBjeui3 Indu ejeds 13 osnj AH3 LIVS 2 Ground from one end only Battery Negative must be grounded 45 K35D03 EN D 500 User Manual Rev_04 Firmware V 3 3 7 TERMINAL DESCRIPTION Term Function Technical data Descrip
9. 0 normal operation 1 the unit becomes an annunciator of the remote unit Engine genset control functions are disabled CT Location Gen Load Gen 0 CTs are at the genset side Mains currents are not measured 1 CTs are at load side Both mains and genset currents are monitored following contactor status Reverse CT Direction K35D03 EN 79 This parameter is useful to invert all CT polarities at the same time 0 normal CT polarity assumed 1 reverse CT polarity assumed D 500 User Manual Rev_04 Firmware V 3 3 16 1 CONTROLLER CONFIGURATION GROUP continued Parameter Definition Unit Min Factory Max Set Description Buzzer Enable Internal buzzer control not functional in D 500 0 buzzer disabled 1 buzzer enabled Unit Functionality 3 AMF 0 AMF functionality The unit controls both engine and load transfer The genset starts based on mains status 1 ATS functionality The unit controls the load transfer and issues genset start signal based on mains status 2 REMOTE START functionality The unit controls engine and alternator The genset starts with external signal 3 RESERVED Not used Data Logging Period sec 3600 2 This parameter adjusts the data logging frequency to micro SD or USB Flash memories Frequent recording will require more memory capacity With a period of 2 seconds 4GB per year of memory is neces
10. 30 2 UNINTERRUPTED TRANSFER In this mode the transfer will be made without power interruption This implies that both of the mains and generator contactors will be active during transfer The maximum duration that both contactors will be active is programmable However this process may be quicker with the use of one auxiliary feedback contact from each contactor Thus the changeover will be quite instantaneous preventing any excess or reverse power condition To prevent a phase to phase short circuit below criteria must be met The mains and generator voltages must be equal The mains and generator voltages must have the same phase The mains and generator voltages must have the same phase sequence order The unit will allow an Uninterrupted Transfer only if all of the below conditions are fulfilled Mains phase voltages within the programmed limits Mains frequency within the programmed limits Genset phase voltages within the programmed limits Genset frequency within the programmed limits Mains phase order correct or phase order check must be disabled Genset phase order correct or phase order check must be disabled The difference between mains and genset frequencies not more than programmed limit The voltage difference mains L1 and genset L1 not more than programmed limit The phase angle between mains L1 and genset L1 not more than programmed limit When an uninterrupted transfer cycle is started the unit
11. 4 Relay 34 1 Relay extension module 4 Relay 35 1 Relay extension module 4 Relay 36 1 Relay extension module 4 Relay 37 1 Relay extension module 4 Relay 38 1 Relay extension module 4 Relay 39 1 Relay extension module 4 Relay 40 1 Relay extension module 4 K35D03 EN 101 D 500 User Manual Rev_04 Firmware V 3 3 A Below is a short list for reference purposes Please use the RainbowPlus program for complete selection list OUTPUT FUNCTION LIST No Description No Description No Description 1 Fuel 41 Genset Ph Order Fail 81 Remote Control Out 1 2 Horn 42 Auto Ready 82 Remote Control Out 2 3 Crank 43 Weekly Schedule On 83 Remote Control Out 4 Stop Solenoid 44 Exerciser On 84 Remote Control Out 4 5 Genset Contactor 45 Mains Fail 85 Remote Control Out 5 6 Mains Contactor 46 Pgm Mode Active 86 Remote Control Out 6 7 Idle Speed 47 Engine Running 87 Remote Control Out 7 8 Preheat 48 Genset Voltage Ok 88 Remote Control Out 8 9 Alternate Crank 49 Alarm Check Enable 89 Remote Control Out 9 10 Fuel Main Winding 50 Oil Pressure Ok 90 Remote Control Out 10 11 Genset Close Pulse 51 Shutdown Alarm 91 Remote Control Out 11 12 Genset Open Pulse 52 Loaddump Alarm 92 Remote Control Out 12 13 Genset UV Coil 53 Warning
12. Factory Terminal Description set number Relay 01 3 4 Factory set as Crank Relay output Relay 02 1 5 Factory set as Fuel Relay output Relay 03 2 6 Factory set as Horn Relay output Relay 04 8 7 Factory set as Preheat Relay output Relay 05 4 8 Factory set as Stop Relay output Relay 06 7 9 Factory set as Idle Speed Relay output Relay 07 6 72 Factory set as Mains Contactor Relay output Relay 08 5 51 Factory set as Genset Contactor Relay output Relay 09 1 Relay extension module 1 Relay 10 1 Relay extension module 1 Relay 11 1 Relay extension module 1 Relay 12 1 Relay extension module 1 Relay 13 1 Relay extension module 1 Relay 14 1 Relay extension module 1 Relay 15 1 Relay extension module 1 Relay 16 1 Relay extension module 1 Relay 17 1 Relay extension module 2 Relay 18 1 Relay extension module 2 Relay 19 1 Relay extension module 2 Relay 20 1 Relay extension module 2 Relay 21 1 Relay extension module 2 Relay 22 1 Relay extension module 2 Relay 23 1 Relay extension module 2 Relay 24 1 Relay extension module 2 Relay 25 1 Relay extension module 3 Relay 26 1 Relay extension module 3 Relay 27 1 Relay extension module 3 Relay 28 1 Relay extension module 3 Relay 29 1 Relay extension module 3 Relay 30 1 Relay extension module 3 Relay 31 1 Relay extension module 3 Relay 32 1 Relay extension module 3 Relay 33 1 Relay extension module
13. action taken at fault condition is programmable OVERCURRENT Set if at least one of the genset phase currents goes over the Overcurrent Limit for the period allowed by the IDMT curve setting The allowed timer is dependent of the overcurrent level If currents go below the limit before expiration of the timer then no alarm will be set Please check chapter Overcurrent Protection IDMT for more details The action taken at fault condition is programmable OVERLOAD Set if the genset power kW supplied to the load goes over the Overload Load Dump limit for Overload Timer If the power goes below the limit before expiration of the timer then no alarm will be set REVERSE POWER Set if the genset power kW is negative and goes over the Reverse Power limit for Reverse Power Timer If the power goes below the limit before expiration of the timer then no alarm will be set REVERSE POWER Set if the genset power kW is negative and goes over the Reverse Power limit for Reverse Power Timer If the power goes below the limit before expiration of the timer then no alarm will be set GENSET PHASE ORDER FAIL Set if the fault is enabled and the genset phase order is reverse MAINS CB FAIL TO OPEN Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor Open Close Fail Timer GENSET CB FAIL TO CLOSE Set if the feedback input is defin
14. fuse protecting the generator phases may be failed A misconnection may be occurred If everything is OK turn all the fuses off and then turn all the fuses on starting from the DC supply fuse Then test the unit again The unit is late to remove engine cranking The generator voltage rises lately Also the generator remnant voltage is below 15 volts The unit removes starting with the generator frequency and needs at least 15 volts to measure the frequency The unit is also able to cut cranking from charge alternator voltage and oil pressure input Please read chapter CRANK CUTTING The unit is inoperative Measure the DC supply voltage between terminals BAT and BAT at the rear of the unit If OK turn all fuses off then turn all the fuses on starting from the DC supply fuse Then test the unit again Programming mode can not be entered The program lock input disables programming mode entry Disconnect the program lock input from battery negative before modification Do not forget to make this connection again to prevent unauthorized program modifications Some program parameters are skipped These parameters are reserved for factory setting and cannot be modified AUTO led flashes and the genset does not run when mains fail The unit is in Weekly Schedule OFF time Please check date and time setting of the unit Please check also Weekly Schedule program parameters The genset runs but does not take the load Check
15. thus Load_Add_2 becomes active l4 the load goes above the Multi Load Substract Power Level 15 after Multi Load Substract Start Delay the load is still above Multi Load Substract Power Level thus the Load_Add_2 becomes inactive and the Load_Substract_2 becomes active for 3 seconds fixed delay te the load goes above the Multi Load Substract Power Level t7 after Multi Load Substract Start Delay the load is still above Multi Load Substract Power Level thus the Load_Add_2 becomes inactive and the Load_Substract_1 becomes active for 3 seconds fixed delay K35D03 EN 125 D 500 User Manual Rev_04 Firmware V 3 3 32 4 REMOTE START OPERATION The unit offers the possibility of Remote Start mode of operation Any digital input may be assigned as Remote Start Input using Input Function Select program parameters The Remote Start signal may be a NO or NC contact switching to either battery positive or battery negative These selections are made using programming menu It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarm from this input When a Remote Start input is defined the mains phases are not monitored When the Remote Start signal is present then the mains will be supposed to fail inversely when the Remote Start signal is absent then mains voltages will be supposed to be present The front panels mimic diagram s mains LEDs will always reflect the status of t
16. value Increase parameter Previous parameter Long Press Return to the upper menu parameter 15 5 PROGRAMMING MODE EXIT To exit the program mode press one of the mode selection keys If no button is pressed during 2 minutes the program mode will be cancelled automatically STATUS i BIN i sies am KDISFLAM EVENT LOGG mm CONTROLLER COHFIG ELECTRICAL FARAHS REQUEST Press any mode button K35D03 EN 75 Firmware V 3 3 D 500 User Manual Rev_04 16 PROGRAM PARAMETER LIST 16 1 CONTROLLER CONFIGURATION GROUP Parameter Definition Unit Min Max Factory Set Description LCD Contrast 30 50 39 This parameter is used to set LCD contrast Adjust for the best viewing angle Screen Scroll Timer sec 250 The screen will scroll between different measurements with this interval If set to zero the screen scroll will be disabled Language 0 English language selected 1 Local language selected This language may depend on the country where the unit is intended to be used Genset Default Display This parameter selects the screen which is displayed during genset on load operation genset voltages table genset currents and freq table genset kW and pf table genset kVA and kVAr table genset average measurements Status Prompt Window Enable Status prompts disabled Status prompts e
17. 0 ethernet modbus gateway function disabled Ethernet to RS 485 _ 0 1 0 1 ethernet modbus gateway function Modbus Gateway Enable enabled The unit will redirect Modbus requests from ethernet to the RS 485 port 0 gprs modbus gateway function disabled GPRS to RS 485 _ 0 1 0 1 gprs modbus gateway function Modbus Gateway Enable enabled The unit will redirect Modbus requests from GPRS to the RS 485 port K35D03 EN s D 500 User Manual Rev_04 Firmware V 3 3 16 1 CONTROLLER CONFIGURATION GROUP continued Factory Description Parameter Definition Unit Min Max Set 0 RS 485 port disabled l l L 1 RS 485 port enabled Modbus Address _ 0 240 1 This is the modbus controller identity used in Modbus communication RS 485 Baud Rate bps 2400 115200860 TMS 5 the data rate of the Mo 485 Modbus port 0 ethernet port disabled i 0 L 1 ethernet port enabled 0 crank cut is performed through oil Oil Pressure Switch pressure switch and oil pressure sender 0 1 0 reading Priory 1 crank cut is performed only through oil pressure switch Delayed Simulate Mains Operation max genset running time after Simulate Flashing Relay ON Timer min 0 1200 0 Mains signal disappears Dual Genset Systems flashing relay ON state duration timer Flashing Relay OFF Dual Genset Systems flashing relay Timer G 9 TOM 9 OFF state duration This parameter trims precisely the real ti
18. 15 value X 0 10000 Point 15 reading Sender Curve 16 ohm ohms 0 5000 Point 16 ohm value Sender Curve 16 value X 0 10000 Point 16 reading If the sender type parameter is set to Sender l zero not used this string is used as sender name while displaying the sender reading If the sender type parameter is set to Sender Low Fault String _ _ zero not used this string is used as sender low value fault in the alarm display If the sender type parameter is set to zero not used this string is used as Sender Hight Fault Sting l 2 high Als fault in the alarm display K35D03 EN 98 D 500 User Manual Rev_04 Firmware V 3 3 16 8 DIGITAL INPUT CONFIGURATION The unit has 8 digital inputs By using external input extension modules up to 40 inputs in total are available Only parameters of one input are explained below Other inputs have identical parameter set The input name is freely programmable thus the input can be adapted to any functionality through programming input name entry is made through RainbowPlus program only Each sender has below programmable parameters Parameter Definition Unit Min Factory Description Set Selects between predefined input functions Selected input name is Input Function 0 99 displayed in the line below If this parameter is set to 0 then the input name string can be freely entered shutdown alarm loaddump alarm warn
19. 3 ELECTRICAL INSTALLATION Do not install the unit close to high electromagnetic noise emitting devices like contactors high current busbars switchmode power supplies and the like 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 75mm AWG18 Follow national rules for electrical installation Current transformers must have 5A output For current transformer inputs use at least 1 5mm section AWG15 cable The current transformer cable length should not exceed 1 5 meters If longer cable is used increase the cable section proportionally Current Transformers must be used for current measurement No direct connection allowed The engine body must be grounded Otherwise faulty voltage and frequency measurements may occur For the correct operation of the exerciser and weekly schedule programs adjust the real time clock of the unit through programming menu K35D03 EN 14 D 500 User Manual Rev_04 Firmware V 3 3 3 TERMINAL DESCRIPTIONS 3 1 BATTERY VO
20. 4 Scopemeter 2202 V 10 9 8 7 6 5 4 3 2 1 1 0 1 1 millisecond Harmonic Channel Selection Mains Voltage L1 N 4 RainbowPlus Scada section Harmonic Analysis Waveform Display K35D03 EN 58 D 500 User Manual Rev_04 Firmware V 3 3 11 DISPLAYING EVENT LOGS The unit features more than 400 event logs with date time stamp and full snapshot of measured values at the moment that the event has occurred Stored values in an event record are listed below event number event type fault definition see below for various event sources date and time operation mode operation status on load on mains cranking etc engine hours run mains phase voltages L1 L2 L3 mains frequency genset phase voltages L1 L2 L3 genset phase currents L1 L2 L3 genset frequency genset total active power kW genset total power factor oil pressure engine temperature fuel level oil temperature canopy temperature ambient temperature engine rom battery voltage charge voltage Possible event sources are various Every source can be individually enabled or disabled Rainbow Plus Version 2 4 File Tools Help Configuration Scada Functionality Screen Options Timers Exercise Scheduler Time Data Logging amp Module Functionality Miscellaneous Warning Before Start v Delayed Simulate Mains Second
21. 94 D 500 User Manual Rev_04 Firmware V 3 3 16 4 ADJUST DATE AND TIME 1 114 TUE NN PROGRAMI bAdjust Date ADJUST DATE Adzust Mon Adrust Adjust These parameters allow adjusting the battery backup real time clock of the module Once set the clock will continue to run even if DC power is removed from the unit Parameter Definition Unit Min Max Description Date 01 31 Current day of the month Month 01 12 Current month Year 00 99 Last two digits of the current year Hours 00 23 Current hour of the day Minutes 00 59 Current minute of the hour Seconds 00 59 second of the minute 16 5 WEEKLY OPERATION SCHEDULE i 1 LUGPIHPITTING PHONDAY WEEKLY SCHEDULE TUESDAY MONDAY HEDNESDR E In AUTO mode it is possible to define the periods where automatic operation is desired It may be required that the genset does not start at night or weekends Weekly schedule programs allow an hourly setting of automatic operation of the unit during one week There are 7days x 24hours 144 parameters Each hour of the week can be independently defined as AUTO or OFF period exerciser the AUTO led will flash A If automatic operation is disabled by the weekly K35D03 EN 95 D 500 User Manual Rev_04 Firmware V 3 3 16 6 EXERCISER SCHEDULE PM PROGHHIIMING L PROGRAMMING WEEKLY SCHEDULE bEXerciser Schedule 1 PEXERCISER
22. Auxiliary 51 Lamp Test 91 12 Mains Cont Auxiliary 52 Combat Mode 92 13 Force AUTO Mode 53 93 14 Force OFF Mode 54 94 15 Force TEST Mode 55 95 16 Over Load Switch 56 96 17 Manual Fuel Fill 57 97 18 Priority 58 98 19 Remote Start 59 99 20 Disable Auto Start 60 100 Input not in Use 21 Force to Start 61 22 Fault Reset 62 23 Alarm Mute 63 24 Panel Lock 64 25 Fuel Pump Switch 65 26 Secondary Volt amp Freq 66 27 Disable Protections 67 28 Auto Restore Inhibit 68 29 GensetLoadinglnhibit 69 30 Air Flap Fault 70 31 Canopy Door Open 71 32 Station Door Open 72 33 Station Over Heat Sw 73 34 Weather Cloudy 74 35 Weather Rainy 75 36 Lightning 76 37 Cooler Fan Fault 77 38 Heater Fan Fault 78 39 Canopy Fan Fault 79 40 Station Fan Fault 80 D 500 User Manual Rev_04 Firmware V 3 3 16 9 OUTPUT CONFIGURATION The parameters below define the functions of relay outputs The unit has 8 relay outputs All relays have programmable functions selected from a list Relays may be extended up to 40 using Relay Extension Modules Other relays are in the optional Extension Modules Parameter Definition
23. Description Sender Curve 1 ohm ohms 0 5000 Point 1 ohm value Sender Curve 1 value X 0 10000 Point 1 reading Sender Curve 2 ohm ohms 0 5000 Point 2 ohm value Sender Curve 2 value X 0 10000 Point 2 reading Sender Curve 3 ohm ohms 0 5000 Point 3 ohm value Sender Curve 3 value X 0 10000 Point 3 reading Sender Curve 4 ohm ohms 0 5000 Point 4 ohm value Sender Curve 4 value X 0 10000 Point 4 reading Sender Curve 5 ohm ohms 0 5000 Point 5 ohm value Sender Curve 5 value X 0 10000 Point 5 reading Sender Curve 6 ohm ohms 0 5000 Point 6 ohm value Sender Curve 6 value X 0 10000 Point 6 reading Sender Curve 7 ohm ohms 0 5000 Point 7 ohm value Sender Curve 7 value X 0 10000 Point 7 reading Sender Curve 8 ohm ohms 0 5000 Point 8 ohm value Sender Curve 8 value X 0 10000 Point 8 reading Sender Curve 9 ohm ohms 0 5000 Point 9 ohm value Sender Curve 9 value X 0 10000 Point 9 reading Sender Curve 10 ohm ohms 0 5000 Point 10 ohm value Sender Curve 10 value X 0 10000 Point 10 reading Sender Curve 11 ohm ohms 0 5000 Point 11 ohm value Sender Curve 11 value X 0 10000 Point 11 reading Sender Curve 12 ohm ohms 0 5000 Point 12 ohm value Sender Curve 12 value X 0 10000 Point 12 reading Sender Curve 13 ohm ohms 0 5000 Point 13 ohm value Sender Curve 13 value X 0 10000 Point 13 reading Sender Curve 14 ohm ohms 0 5000 Point 14 ohm value Sender Curve 14 value X 0 10000 Point 14 reading Sender Curve 15 ohm ohms 0 5000 Point 15 ohm value Sender Curve
24. Display Timers Voltage Frequency Configuration Topology Selection File Tools Help Configuration Selection K35D03 EN Rainbow Plus Beta Version 1 0 0 2 Topology Timers Voltage Frequency Topology Module Generator Connection Type Mains B Engine Generator Phase Order Check LI H Analog Input i Dadia Parameters 3 Phase 4 Wire Star v 33 Dini 2 Phase 3 Wire L1 L2 s deiode ann 2 Phase 3 Wire L1 L3 Communication 3 Phase 3 Wire 3 Phase 3 Wire L1 L2 CT 3 Phase 3 Wire L1 L3 CT 3 Phase 4 Wire Star 3 Phase 4 Wire Delta Single Phase 2 Wire 13 L2 Module Generator Connection Type TE man Phase Order Check Engine Mains Parameters 3 Phase 4 Wire Star v LX mE Communication 3 phe 3 Wire 3 Phase 3 Wire L1 L2 CT 3 Phase 3 Wire L1 L3 CT 3 Phase 4 Wire Star 3 Phase 4 Wire Delta Single Phase 2 Wire 32 D 500 User Manual Rev_04 Firmware V 3 3 4 2 3 PHASE 4 WIRE STAR ALTERNATOR L1 TO oW oO x o0 ON Morand 0 0 0 00 10 N Oo O a 23 mom 5 5 529 i 27 29 ES amp 5 22 Fa gt O 6 o 9 gt gt 4 3 3 PHASE 3 WIRE DELTA ALTERNATOR L1 K35D03 EN 33 D 500 User Manual Rev_04 Firmware V 3
25. K35D03 EN 46 Firmware V 3 3 D 500 User Manual Rev_04 Term Function Technical data Description 13 DIGITAL INPUT 3 The input has programmable function Factory set as EMERGENCY STOP 14 DIGITAL INPUT 4 The input has programmable function Factory set as LOW COOLANT LEVEL SWITCH 15 DIGITAL INPUT 5 The input has programmable function Factory set as SPARE INPUT 1 16 DIGITAL INPUT 6 The input has programmable function Factory set as SPARE INPUT 2 17 DIGITAL INPUT 7 The input has programmable function Factory set as SPARE INPUT 3 18 DIGITAL INPUT 8 The input has programmable function Factory set as FORCE OFF MODE 19 SENDER GROUND Ground potential for analog senders Connect to the engine body close to senders 20 ANALOG SENDER 1 Connect to the oil pressure sender OIL PRESSURE SENDER Do not connect the sender to other devices 21 ANALOG SENDER 2 Connect to the coolant temperature COOLANT TEMP SENDER sender Do not connect the sender to other devices 22 ANALOG SENDER 3 Connect to the fuel level sender FUEL LEVEL SENDER Do not connect the sender to other devices 23 ANALOG SENDER 4 Connect to the oil temperature sender OIL TEMP SENDER Do not connect the sender to other devices Term Function Technical data Description 24 PROTECTION GROUND Output OVdc Connect the protecti
26. K35D03 EN 17 D 500 User Manual Rev_04 Firmware V 3 3 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 MAINS or ALTERNATOR CONTROLLER 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 K35D03 EN 18 D 500 User Manual Rev_04 Firmware V 3 3 EFFECT OF POLARITY REVERSAL MAINS or ALTERNATOR CONTROLLER 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 MAINS or ALTERNATOR CONTROLLER The generator is still load
27. Load Add Wait This is the minimum period between Delay PERUI d two load addt operations K35D03 EN 87 D 500 User Manual Rev_04 Firmware V 3 3 16 3 ENGINE PARAMETERS GROUP Parameter Definition Unit Min Factory Description Set The nominal value of engine rpm Low Nominal RPM rpm 0 50000 1500 high rpm limits are defined by reference to this value When secondary frequency is selected this is the nominal value of engine rpm hominal REM J 20900 TRUY Low high rpm limits are defined by reference to this value If the engine rpm goes under this limit Low RPM Warning Limit 96 R 100 R 100 R 10 when feeding the load this will generate a GENSET LOW RPM warning If the engine rpm goes under this limit Low RPM Shutdown 5 o When feeding the load this will generate Limit 7 R 100 R 100 R 15 3 GENSET LOW RPM shutdown alarm and the engine will stop If the engine rpm goes over this limit High RPM Warning Limit R 100 R 100 R 10 when feeding the load this will generate a GENSET HIGH RPM warning If the engine rpm goes over this limit High RPM Shutdown o when feeding the load this will generate Limit R 100 R 100 R 15 GENSET HIGH RPM shutdown alarm and the engine will stop If the engine rpm goes outside of the RPM Fail Timer sec 0 10 3 limits during this timer an engine speed fault will occur If the engine rp
28. Mains current phase L3 Mains average current Mains kW phase L1 Mains kW phase L2 Mains kW phase L3 Mains total kW Mains kVA phase L1 Mains kVA phase L2 Mains kVA phase L3 Mains kVAr phase L1 Mains kVAr phase L2 Mains kVAr phase L3 Mains pf phase L1 Mains pf phase L2 Mains pf phase L3 Mains total pf Mains neutral current Below engine parameters are always measured Engine speed rpm Battery voltage Gen frequency Gen current phase L1 Gen current phase L2 Gen current phase L3 Gen average current Gen kW phase L1 Gen kW phase L2 Gen kW phase L3 Gen total kW Gen kVA phase L1 Gen kVA phase L2 Gen kVA phase L3 Gen kVAr phase L1 Gen kVAr phase L2 Gen kVAr phase L3 Gen pf phase L1 Gen pf phase L2 Gen pf phase L3 Gen total pf Gen Neutral current The unit features 4 analog senders fully configurable for the name and function Below is a typical list of analog senders capable of changing following configuration Coolant temperature Oil pressure bar kPa Fuel level 95 It Oil temperature C F Items in blue are measured only when current transformers are at the load side K35D03 EN 55 D 500 User Manual Rev_04 Firmware V 3 3 9 6 LED LAMPS AUTO READY indicator Mains DATAKOM available led Shutdown alarm indicator Warning indicator Genset Contactor on led Service request indicator Genset available led T
29. 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 J1939 CANBUS PORT 3 14 ETHERNET PORT 3 15 USB DEVICE PORT 3 16 USB HOST PORT OPTIONAL 3 17 RS 232 PORT OPTIONAL 3 18 MICRO SD MEMORY CARD SLOT OPTIONAL 3 19 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 K35D03 EN 5 D 500 User Manual Rev_04 Firmware V 3 3 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 PARAMETE
30. THE ENGINE Press RUN MANUAL LOAD TRANSFER Use MAINS and buttons LOAD TEST Press TEST The genset will run and take the load AUTOMATIC OPERATION Press AUTO Q o Check that AUTO READY led is illuminated Mode can be changed anytime without negative effect Changing the operation mode while the genset is running will result into a behavior suitable for the new operating mode 13 2 STOP MODE The STOP mode is entered by pressing the button In this mode the genset will be in a rest state When STOP mode is selected if the genset is running under load then it will be immediately unloaded The engine will continue to run during Cooldown Timer and will stop afterwards If the STOP button is pressed again then the engine will immediately stop If the engine fails to stop after the expiration of Stop Timer then a Fail to Stop warning will occur In this mode the mains contactor will be energized only if mains phase voltages and frequency are within the programmed limits If enabled the mains phase order is also checked If a Remote Start or Force to Start signal arrives in STOP mode the genset will not start until AUTO mode is selected K35D03 EN 62 D 500 User Manual Rev_04 Firmware V 3 3 13 3 AUTO MODE The AUTO mode is entered by pressing the button The AUTO mode is used for the automatic transfer between genset and mains The controller will constantly monitor the mains availab
31. The action of the tripping may be selected as a Loaddump stop after cooldown or shutdown alarm immediate stop Current Limit Over Current 1 J 100 OverCurent2 M 200 Y Over Current IDMT Multiplier 2 36 g Over Current Action Load Dump Screenshot from RainbowPlus configuration program Generator gt Current section K35D03 EN 109 D 500 User Manual Rev_04 Below is a table showing the 100 110 120 130 140 150 160 ing dela unlimited 170 3600s 180 900s 190 400s 200 225s 210 144s 220 100s 230 Firmware V 3 3 in function of the percent load level with TMS 36 735 565 445 36s 30s 25s 21s 240 250 260 270 280 290 300 18s 16s 14s 12s 11s 10s 9s Below is the tripping delay curve in function of the load level with TMS 36 tripping delay in seconds 100000 overload level times x setpoint 1 T T T T T T 11 1 2 1 3 14 15 1 6 17 18 19 2 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 3 K35D03 EN 110 D 500 User Manual Rev_04 Firmware V 3 3 19 MOTORIZED CIRCUIT BREAKER CONTROL The unit offers full control for any brand and model of motorized circuit breakers MCB The MCB control is performed through 3 digital output functions namely Open Close and Undervoltage coil controls Only 2 of these outputs are used in a single application Any digital output can be assigned to MCB control signals through programming
32. address claim or set to a value in order to claim a defined address Ethernet Gateway IP Should be set in accordance with your local switch configuration Ethernet Subnet Mask Should be set in accordance with your local switch configuration The complete Ethernet port specifications are found in the D 500 700 User Manual Please rewiev the document Ethernet Configuration Guide for D 500 700 for more details about the ethernet port setup 38 3 DATA FORMATS 16bit variables These variables are stored in a single register Bit 0 denotes the LSB and bit 15 denotes the MSB 32 bit variables These variables are stored in 2 consecutive registers The high order 16 bits are in the first register and the low order 16 bits are in the second register Bit arrays Arrays larger than 16 bits are stored in multiple registers The LSB of the first register is bit 0 The MSB of the first register is bit 15 The LSB of the second register is bit 16 The MSB of the second register is bit 31 and so on K35D03 EN 135 D 500 User Manual Rev_04 Firmware V 3 3 Below is a shortlist of available Modbus registers For complete register map please refer to D 500 700 Modbus Application Manual ADDRESS R W DATA COEFF DESCRIPTION decimal SIZE 8193 W 16bit x10 Pushbutton simulation BIT 0 Simulate Stop button BIT 1 Simulate Man
33. alternator against excessive currents The IDMT Inverse Definite Minimum Time protection function has such tripping characteristics that the tripping time varies inversely with the value of current Beyond a certain current limit the tripping time becomes constant definite and causes tripping in minimum time The tripping formula is defined as below TMS 2 i1 Iset Where TMS is the IDMT time multiplier setting This is also the tripping time at 100 overload lis the current of the most loaded phase Iset IS the programmed overcurrent limit tis the tripping time in seconds Currents below the overcurrent limit are allowed to flow for unlimited time Currents above the limit will cause the IDMT protection to trigger with a delay depending on the strength of the overcurrent Higher the current faster the protection will trip When non tripping overcurrent condition occurs the unit will keep trace of it In case of a consecutive overcurrent the controller will take into account the residual heat caused by the previous overcurrent and will trip faster than usual The IDMT multiplier adjusts the sensitivity of the IDMT detector When the multiplier is low then tripping will be faster for the same current The unit provides separate Overcurrent limits for primary and secondary volt speed amp settings Switching from primary volt freq amps to secondary values will also switch the IDMT detector to the secondary setting
34. amount of time from the last service If the period is set to 0 no SERVICE REQUEST will be indicated depending on Service 1 Period Service 1 Alarm Level 0 no action 1 shutdown alarm 2 loaddump alarm 3 warning K35D03 EN 91 D 500 User Manual Rev_04 Firmware V 3 3 16 3 ENGINE PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Description Set The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last service If the period is set to 0 no SERVICE REQUEST will be generated depending on service 2 engine hours Service 2 Engine Hours hours 0 5000 250 The SERVICE REQUEST led indicator will turn on after this amount of time from the last service If the period is set menti SB at 6 to 0 no SERVICE REQUEST will be indicated depending on Service 2 Period 0 no action Service 2 Alarm Level 0 3 0 1 shutdown alarm 2 loaddump alarm 3 warning The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last service If the period is set to 0 no SERVICE REQUEST will be generated depending on service 3 engine hours Service 3 Engine Hours hours 0 5000 250 The SERVICE REQUEST led indicator will turn on after this amount of time from the last service If the period is set Sense Pengu DE BA 6 to 0 no SERVICE REQUEST will be indic
35. in the AUTO mode regardless of the mains availability and the load will be transferred to the genset The genset will feed the load indefinitely unless another mode is selected K35D03 EN 65 D 500 User Manual Rev_04 Firmware V 3 3 14 PROTECTIONS AND ALARMS The unit provides 3 different protection levels being warnings loaddumps and shutdown alarms 1 SHUTDOWN ALARMS These are the most important fault conditions and cause The ALARM led to turn on steadily genset contactor to be released immediately The engine to be stopped immediately The Alarm digital output to operate 2 LOAD_DUMPS These fault conditions come from electrical trips and cause ALARM led to turn on steadily genset contactor to be released immediately engine to be stopped after Cooldown period The Alarm digital output to operate 3 WARNINGS These conditions cause The WARNING led to turn on steadily The Alarm digital output to operate If a fault condition occurs the display will automatically switch to the ALARM LIST page Alarms operate in a first occurring basis If a shutdown alarm is present following shutdown alarms loaddumps and warnings will not be accepted If a loaddump is present following loaddumps and warnings will not be accepted If a warning is present following warnings will not be accepted If the ALARM MUTE button is pressed the Alarm output will be deactivated h
36. is deenergized when the charge alternator voltage reaches this limit Crank Cut with Oil Pressure 0 no crank cut with oil pressure 1 cranking is cut when oil pressure switch is open or the oil pressure measured is above shutdown limit Crank Cut with Oil Pressure Delay sec 30 If crank cutting with oil pressure is enabled cranking is cut after this delay when oil pressure switch is open or the oil pressure measured is above shutdown limit Charge Input Connected 0 Crank cutting with charge input disabled 1 Crank cutting with charge input enabled Fuel Tank Capacity Lt 65000 The full capacity of the fuel tank If this parameter is zero the fuel quantity in the tank is not displayed Fuel Consumption per Hour 100 0 0 This parameter is the threshold for sending FUEL THEFT and FUELLING sms messages If this parameter is set to 0 then no Fuel Theft and Fuelling sms messages will be sent If SMS is required set this parameter to a value above the hourly fuel consumption of the genset K35D03 EN 90 D 500 User Manual Rev_04 Firmware V 3 3 16 3 ENGINE PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Set Description Coolant Cooler On C 250 90 If the coolant temp is above this limit then the cooler relay function will become active Coolant Cooler Off C 250 80
37. menu MCB CLOSE MCB OPEN SEQUENCE SEQUENCE The MCB CLOSE sequence is below Activate UV output wait for undervoltage coil timer tiv Activate CLOSE output wait for close pulse timer ta Deactivate CLOSE output The MCB OPEN sequence is below Deactivate UV output Activate OPEN output wait for open pulse timer top Deactivate OPEN output Open Pulse Close Pulse and Undervoltage Coil timers are adjusted through programming menu If MCB feedback input is defined and the MCB fails to change position after the expiration of MCB Fail timer then a fault condition will occur K35D03 EN 111 D 500 User Manual Rev_04 Firmware V 3 3 MCB modules can be operated by 2 different ways The unit supports both configurations Below is the terminology used M gear motor ready to close contact XE close coil MX open coil MN undervoltage trip release AUX auxiliary contacts MCB WITH OPEN CLOSE COILS MCB WITH CLOSE UV COILS CONTROLLER OUTx OUTy CONTROLLER OUTx OUTy BAT BAT In the diagram at left relay function assignments should be as below OUTx Mains or Genset Close Pulse OUTy Mains or Genset Open Pulse In the diagram at right relay function assignments should be as below OUTx Mains or Genset Close Pulse OUTy Mains or Genset Undervoltage Coil K35D03 EN 112 D 500 User Manual Rev_04 Firmware V 3 3 20 1939 CANBUS ENGINE SUPPORT The unit offers a speci
38. second set of limit values can be done in 2 ways by setting the program parameter Secondary Volt Freq to 1 with digital input signal Thus the user has full flexibility for manual or external switching If switching is done with digital input signal one of digital inputs has to be defined as i Volt Freq Select using INPUT FUNCTION SELECT program group Below parameters are available for second voltage frequency selection Nominal Voltage Nominal Frequency Nominal RPM Genset Overcurrent Limit 37 9 SINGLE PHASE OPERATION If the unit is used in a single phase electrical network it is advised to select the topology as Single Phase 2 Wires When the topology is set to Single Phase 2 Wires then the unit will measure electrical parameters only on phases L1 of genset and mains Voltage and overcurrent checks will be performed on phases L1 only Phases L2 and L3 parameters as well as phase to phase voltages are removed from display screens 37 10 EXTERNAL CONTROL OF THE UNIT The unit offers total external control through programmable digital inputs Any digital input may be programmed for below functions Force STOP mode Force AUTO mode Force TEST mode Disable Auto Start Force to Start Fault Reset Alarm Mute Panel Lock External mode select signals have priority on mode buttons of the unit If the mode is selected by external signal it is impossible to change this mode with front panel pushbu
39. total power factor 10338 R 16bit x100 Mains frequency 10339 R 16bit x100 Genset frequency 10341 R 16bit x100 Battery voltage 10361 R 16bit x10 Oil pressure in bars multiply by 14 50 to for psi 10362 R 16bit x10 Engine temp in C multiply by 1 8 then add 32 for F 10363 R 16bit x10 Fuel level in 10364 R 16bit x10 Oil temp in C multiply by 1 8 then add 32 for F 10365 R 16bit x10 Canopy temp in C multiply by 1 8 then add 32 for F 10366 R 16bit x10 Ambient temp in C multiply by 1 8 then add 32 for F 10376 R 16bit 1 K35D03 EN 136 D 500 User Manual Rev_04 Firmware V 3 3 ADDRESS R W DATA COEFF DESCRIPTION decimal SIZE 10504 R 256bit Shutdown alarm bits Bit definitions are given at the end of the 10519 document 10520 R 256bit Loaddump alarm bits Bit definitions are given at the end of the 10535 document 10536 R 256bit Warning alarm bits Bit definitions are given at the end of the 10551 document 10604 R 16bit Unit operation status 0 genset at rest 1 wait before fuel 2 engine preheat 3 wait oil flash off 4 crank rest 5 cranking 6 engine run idle speed 7 engine heating 8 running off load 9 synchronizing to mains 10 load transfer to genset 11 gen cb activation 12 genset cb timer 13 master genset on load 14 peak lopping 15 power exporting 16 slave genset on load 17 sy
40. voltage is below the programmed limit This fault will be monitored with Fault Holdoff Timer delay after the engine is running K35D03 EN 70 D 500 User Manual Rev_04 Firmware V 3 3 J1939 ECU FAIL Set when an engine fault code is received from the ECU of the electronic engine This fault will not cause an engine stop If necessary the engine will be stopped by the ECU VOLTAGE UNBALANCE Set if any of the generator phase voltages differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running CURRENT UNBALANCE Set if any of the generator phase currents differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running The action taken at fault condition is programmable OVERCURRENT Set if at least one of the genset phase currents goes over the Overcurrent Limit for the period allowed by the IDMT curve setting The allowed timer is dependent of the overcurrent level If currents go below the limit before expiration of the timer then no alarm will be set Please check chapter Overcurrent Protection IDMT for more details The action taken at fault condition is programmable OVERCURRENT Set if at least one of the genset phase currents goes over the Overcurrent Limit REVERSE
41. 0 Rainbow Scada Usage Rainbow Scada Usage Guide REVISION HISTORY REVISION DATE AUTHOR DESCRIPTION 02 15 08 2012 MH Remote Monitoring and SNMP functionality added 03 01 10 2012 MH Revised for firmware version 3 2 03 01 10 2012 MH Revised for firmware version 3 3 A A CAUTION Potential risk of injurv or death WARNING Potential risk of malfunction or material damage ATTENTION Useful hints for the understanding of device operation K35D03 EN D 500 User Manual Rev_04 Firmware V 3 3 ORDERING CODES The D 500 family units are available in various options and peripheral features Please use below information for ordering the correct version D500 M l G l G T 00 Variant 00 standard unit 01 99 customer specific products Family Code With Conformal Coating With Internal GSM GPRS With USB Host RS 232 micro SD card SPARE PARTS With Sealing gasket Screw type bracket Self Retaining type bracket Stock Code J10P01 per unit Stock Code K16P01 per unit Sealing Gasket Stock Code K35P01 K35D03 EN 3 D 500 User Manual Rev_04 Firmware V 3 3 p 00 OF K35D03 EN SAFETY NOTICE Failure to follow below instructions will result in death or serious iniurv Electrical equipment should be installed only by qualified specialist No responsibility is assured by the ma
42. 0 Tr LILI L30 TO nN T dn UH Tc st OR 1 10 0 ONNA A E 2 15 5 23 4 2 ox e gt zz 25 E 9 gt o 8 to 35Vdc 800mA max L J w 300Vac 0 100 Hz 1 0 EXTENSION e GSM ANTENNA L 20 SND 1 21 5 0 2 22 SND 3 26 485 31 Force OFF Mode Spare Input 1 Spare Input 2 Spare Input 3 Spare Input 4 Spare Input 5 Spare Input 6 Emergency Stop E at of x A a e j oO S aq al al o t m b u 2 BMS lt a Battery Negative must be grounded 2 Ground from one end only K35D03 EN 42 Firmware V 3 3 D 500 User Manual Rev 04 6 4 REMOTE START FUNCTIONALITY LOAD ALTERNATOR L2 L3 N L MICRO S 11 MI LJ USB HOST RS 232 9 8 to 35Vdc 800mA max 300Vac 0 100 Hz N N39 GSM ANTENNA TN39 o G ero E p VrN39 O N39 1 0 EXTENSION 2 O D CARD e Queste v sb n 1 661 6 61 give c WIE Starter Motor 4 Connect to the engine body close to the senders 2 Ground from one end only Battery Negative must be grounded 43 K35D03 EN Firmware V 3 3 D 500 User Manual Rev 04 6 5 ENGINE CONTROL FUNCTIONALITY
43. 0 ohms a fault case is generated This parameter defines the action taken upon fault case 0 no alarm 1 shutdown alarm 2 loaddump alarm 3 warning The low alarm may be selected as shutdown or loaddump with alarm Low Alarm Check Enable 0 0 1 level parameter 0 low value alarm disabled 1 low value alarm enabled Low Warning Check 0 low value warning disabled Enable 1 low value warning enabled The high alarm may be selected as High Alarm Check shutdown or loaddump with alarm Enable 0 0 1 level parameter 0 high value alarm disabled 1 high value alarm enabled High Warning Check 0 high value warning disabled Enable 1 high value warning enabled If enabled defines the low alarm limit The low alarm may be selected as shutdown or loaddump with alarm level parameter Low Warning Level X 0 10000 If defined defines the low warning If enabled defines the high alarm limit The high alarm may be selected as Alarm Handling 0 3 Sender Open Alarm 0 3 Low Alarm Level x 0 10000 9 on shutdown or loaddump with alarm level parameter High Warning Level X 0 10000 If defined defines the high warning K35D03 EN 97 D 500 User Manual Rev_04 Firmware V 3 3 Parameter Definition Unit Min Max ee
44. 00mA max Output Data rate Full Speed 1 5 12 Mbits s auto detecting Connector USB A PC type connector Cable length Max 1 5m Functionality USB memory FAT32 data recording Memory capacity all USB flash memories The USB Host port is designed for detailed data recording The period of recording is adjustable through program parameter As soon as a USB flash memory is inserted the unit will start data recording and continue until the memory is removed For more details about data recording please review chapter Data Recording Micro SD memory card has priority for data recording If both micro SD and USB Flash memories are inserted data will be recorded on micro SD memory If USB Device is plugged then USB Host port will not function K35D03 EN 2f D 500 User Manual Rev_04 Firmware V 3 3 3 17 RS 232 PORT OPTIONAL Description RS 232 non isolated Functionality External GSM modem external PSTN modem Connector DB 9 9 pins male Connection 5 wires Rx Tx DTR CxD GND Full duplex Baud rate 2400 115200 bauds selectable Data type 8 bit data no parity 1 bit stop Max distance 15m Cable type Standard modem cable Terminal description 1 CxD input 6 NC 2 Rx input 7 NC 3 Tx output 8 NC 4 DTR output 9 NC 5 GND K35D03 EN 28 D 500 User Manual Rev_04 Firmware V 3 3 3 18 MICRO SD MEMORY CARD SLOT OPTIONAL
45. 04 108 electro magnetic compatibility Norms of reference EN 61010 safety requirements EN 61326 EMC requirements The CE mark indicates that this product complies with the European requirements for safety health environmental and customer protection UL CSA Conformity certification teting in progress UL 508 Edition 17 UL 2200 1st Edition UL 840 Edition 3 CSA C22 2 NO 14 Edition 10 41 MAINTENANCE DO NOT OPEN THE UNIT There are NO serviceable parts inside the unit Wipe the unit if necessary with a soft damp cloth Do not use chemical agents 42 DISPOSAL OF THE UNIT Following DIRECTIVE 2002 96 EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 27 January 2003 on waste electrical and electronic equipment WEEE this unit should be stored and disposed separately from the usual waste 43 ROHS COMPLIANCE The european ROHS directive restricts and prohibits the use of some chemical materials in electronic devices Following the DIRECTIVE 2011 65 EU OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 8 June 2011 on the restriction of the use of certain hazardous substances in electrical and electronic equipment this product is listed in annex under category Monitoring and control instruments including industrial monitoring and control instruments and exempted from ROHS directive However Datakom is not using any ROHS uncompliant electronic components in the production Only the solder cont
46. 3 4 4 3 PHASE 4 WIRE DELTA ALTERNATOR L1 e 4 5 3 PHASE WIRE DELTA 2 11 12 ALTERNATOR L1 Lo Ie 9 z z o 9 K35D03 EN 34 D 500 User Manual Rev_04 Firmware V 3 3 4 6 3 PHASE 3 WIRE DELTA 2 CT L1 L3 ALTERNATOR L1 GEN C 51 4 7 2 PHASE 3 WIRE DELTA 2 CTs 11 12 ALTERNATOR L1 K35D03 EN xd Firmware V 3 3 D 500 User Manual Rev 04 4 8 2 PHASE 3 WIRE DELTA 2 CTs L1 L3 ALTERNATOR L1 4 9 1 PHASE 2 WIRE ALTERNATOR L1 36 K35D03 EN D 500 User Manual Rev_04 Firmware V 3 3 5 FUNCTIONALITIES The same unit provides different functionalities through parameter setting Thus a single stock item will fulfill various duties minimizing stock cost 5 1 CT LOCATION SELECTION CTs may be placed at alternator or load busbars The CT location selection is configured with Controller Configuration gt CT Location parameter When CTs are located at the alternator side them mains current and power parameters will not be displayed When CTs are located at load side then both mains and genset currents and power parameters will be displayed based on contactor positions Please review AMF functionality connection diagrams for CT connection details 5 2 AMF FUNCTIONALITY When AMF functionality is selected the unit will monitor mains voltages provide m
47. Alarm 93 Remote Control Out 13 14 Mains Close Pulse 54 Shutdown or Loaddump 94 Remote Control Out 14 15 Mains Open Pulse 55 Shut or LDD or Warn 95 Remote Control Out 15 16 Mains UV Coil 56 Test Mode 96 Remote Control Out 16 17 Flashing Relay 57 Auto Mode 97 Multi Load Add Out 1 18 Gas Solenoid 58 Manual Mode 98 Multi Load Subst Out 1 19 Fuel Pump Control 59 Off Mode 99 Multi Load Add Out 2 20 Choke 60 Not In Auto 100 Multi Load Subst Out 2 21 Block Heater 61 Genset At Rest 101 Multi Load Add Out 3 22 Coolant Cooler 62 Waiting Before Fuel 102 Multi Load Subst Out 3 23 Coolant Heater 63 Preheating 103 Multi Load Add Out 4 24 Fan Control 64 Waiting Cil Flash Off 104 Multi Load Subst Out 4 25 Air Flap Control 65 Engine Heating 105 Multi Load Add Out 5 26 Canopy Fan Control 66 Synchronizing 106 Multi Load Subst Out 5 27 Ambient Fan Control 67 Cooling Down 107 Heavy Duty Active 28 Remote Start Output 68 Stopping 108 ECU Power On 29 Genset Ready 69 Protections Disabled 109 Battery Charge Run 30 Bus Bar Contactor 70 Remote Start Input 110 Fire Circuit PS Active 31 Bus Bar Close Pulse 71 Disable Auto Start 111 Pre transfer Delay 32 Bus Bar Open Pulse 72 Force to Start 112 Secondary Volt Freq 33 Bus Bar UV Coil 73 Auto Restore Inhibited 113 Lamp Test Active 34 Load Shedding 74 Gen Loading Inhibited 114 Alarm Mute Active 35
48. Crank Cutting for more details The engine will run at idle speed during Idle Speed Timer engine will run unloaded until another mode is selected The RUN mode allows also manual contactor control through MC and GC buttons When acontactor button is pressed the related contactor will change position Thus if it was on then it will turn off If it was off then it will turn on If the other contactor was on then it will turn off the controller will wait for the related contactor timer and the contactor will turn on This will prevent manual closure of both contactors If uninterrupted transfers are allowed then the unit will check the synchronization If synchronization is complete then it will make an uninterrupted transfer where both contactors will be on for a short while If Emergency Backup mode is enabled and if the mains are off then the mains contactor will be deactivated and the generator contactor will be activated When the mains are on again a reverse changeover to the mains will be performed but the engine will be kept running unless another mode is selected In order to stop the engine press button or select another mode of operation K35D03 EN 64 D 500 User Manual Rev_04 Firmware V 3 3 13 5 TEST MODE The TEST mode is entered by pressing the button The TEST mode is used in order to test the genset under load Once this mode is selected the engine will run as described
49. D 500 User Manual Rev_04 Firmware V 3 3 DATAKOM DATAKOM STATUS i sr MAINS 22 9 ADVANCED ALARM l WARNING Li SERVICE be 1 AS wall gari GENSE I LOAD 1 CONTROLLER DESCRIPTION COMMUNICATIONS The D 500 is a next generation genset control unit Ethernet combining multi functionality and wide GSM GPRS communication possibilities together with a reliable Internal GPRS modem optional and low cost design Embedded web server The unit complies and mostly exceeds world s Web monitoring tightest safety EMC vibration and environmental Web programming standards for the industrial category GSM SMS Software features are complete with easy firmware EE RS 485 upgrade process through USB port Modbus TCP IP The Windows based PC software allows monitoring SNMP and programming through USB RS 485 Ethernet USB Host optional and GPRS USB Device The PC based Rainbow Scada software allows RS 485 monitoring and control of an unlimited number of RS 232 optional gensets from a single central location Micro SD card slot optional J1939 CANBUS FUNCTIONALITIES TOPOLOGIES AMF unit with uninterrupted transfer 2 phases 3 wires L1 L2 ATS unit with uninterrupted transfer 2 phases 3 wires L1 L3 Remote start controller 3 phases 3 wires 3 CTs Manual start controller 3 phases 3 wires 2 CTs L1 L2 Engine controller 3 phases 3 wires 2 CTs L1 L3 Remote display amp control unit 3 ph
50. D 500 User Manual Rev_04 Firmware V 3 3 39 SNMP COMMUNICATIONS The unit offers the possibility of SNMP communication through its Ethernet port 10 100Mb The supported version of the SNMP is V1 0 Below parameters may be set to the Genset Operation Status controller Charge Input Voltage Control Buttons 5 22 Remote Controlled Digital Outputs Coolant Temperature Fuel Level Oil Temperature Below parameters may be read from the Canopy Temperature controller MEM Ambient Temperature Mains voltages L1 L2 L3 L12 L23 L31 Engine RPM Mains Currents I1 I2 I3 IN Total Genset Cranks Counter Mains Active Power L1 L2 L3 Total Total Genset Runs Counter Mains Reactive Power L1 L2 L3 Total Engine Run Hours Counter Mains Apparent Power L1 L2 L3 Total Total kW h counter Mains Power Factor L1 L2 L3 Total Total KVAR h inductive Counter Mains Phase Angle Total kVAR h capacitive Counter Mains Frequency Engine Hours to Service 1 Counter Genset voltages L1 L2 L3 L12 L23 131 Days to Service 1 Counter Genset Currents 11 12 IN Engine Hours to Service 2 Counter Genset Active Power L1 L2 L3 Total Days to Service 2 Counter Genset Reactive Power L1 L2 L3 Total Engine Hours to Service 3 Counter Genset Apparent Power L1 L2 L3 Total Days to Service 3 Counter Genset Power Factor L1 L2 L3 Total Shutdown Alarm List Genset Phase Angle Loaddump Alarm List Genset Frequency Warni
51. ENTRAL MONITORING OF GENSETS E MAIL SENDING ETHERNET GPRS MODBUS GATEWAY OPERATION SMS COMMANDS LOAD TRANSFER MODES 30 1 TRANSFER WITH INTERRUPTION 30 2 UNINTERRUPTED TRANSFER K35D03 EN EL D 500 User Manual Rev_04 Firmware V 3 3 31 DATA RECORDING 31 1 DATA RECORDING MEDIA 31 2 DIRECTORY STRUCTURE 31 3 UNDERSTANDING THE CSV FORMAT 31 4 RECORDED DATA LIST RECORD PERIOD 32 SOFTWARE FEATURES 32 1 LOAD SHEDDING DUMMY LOAD 32 2 LOAD ADD SUBSTRACT 32 3 FIVE STEP LOAD MANAGEMENT 32 4 REMOTE START OPERATION 32 5 DISABLE AUTO START SIMULATE MAINS 32 6 BATTERY CHARGING OPERATION DELAYED SIMULATE MAINS 32 7 DUAL GENSET MUTUAL STANDBY OPERATION 32 8 DUAL VOLTAGE AND FREQUENCY 37 9 SINGLE PHASE OPERATION 37 10 EXTERNAL CONTROL OF THE UNIT 37 11 AUTOMATIC EXERCISER 37 12 WEEKLY OPERATION SCHEDULER 37 13 ENGINE HEATING OPERATION 37 14 ENGINE IDLE SPEED OPERATION 37 15 ENGINE BLOCK HEATER 37 16 FUEL PUMP CONTROL 37 17 GAS ENGINE FUEL SOLENOID CONTROL 37 18 PRE TRANSFER SIGNAL 37 19 CHARGING THE ENGINE BATTERY 37 20 EXTERNALLY CONTROLLED DIGITAL OUTPUTS 37 21 COMBAT MODE 38 MODBUS COMMUNICATIONS 38 1 PARAMETERS REQUIRED FOR RS 485 MODBUS OPERATION 38 2 PARAMETERS REQUIRED FOR MODBUS TCP IP VIA ETHERNET 38 3 DATA FORMATS 39 SNMP COMMUNICATIONS 39 1 PARAMETERS REQUIRED FOR SNMP THROUGH ETHERNET PORT 40 DECLARATION OF CONFORMITY 41 MAINTENANCE 42 DISPOSAL OF THE UNIT 43 ROHS COMPLIANCE 44 TR
52. EST mode indicator RUN mode indicator AUTO mode indicator STOP mode indicator STATUS LEDS AUTO READY Turns on when the AUTO mode is selected and there is no condition preventing engine start ALARM Turns on when a shutdown alarm or loaddump condition exists WARNING Turns on when a warning condition exists SERVICE REQUEST Turns on when at least one of the service counters has expired MODE LEDS Each led turns on when the related mode is selected either locally or remotely MIMIC DIAGRAM LEDS MAINS AVAILABLE This led turns on when all mains phase voltages and the mains frequency are within limits If enabled the mains phase rotation order must be also right When any digital input is defined as Remote Start this led will reflect the status of the input When a Simulate Mains signal is present then mains status will become available When a Force to Start signal is present then the mains status will become not available MAINS CONTACTOR ON Turns on when the mains contactor is activated GENSET CONTACTOR ON Turns on when the genset contactor is activated GENSET AVAILABLE This led turns on when all genset phase voltages and the genset frequency are within limits If enabled the genset phase rotation order must be also right If a Remote Start input is defined then the Mains led will reflect the input status Simulate Mains and Force to Start signals will also affect this led K35D03 E
53. HNICAL SPECIFICATIONS DC Supply Range 9 0 to 33 0 V DC DC power consumption 250 mA DC typical 12V DC 125 mA DC typical 24V DC 500 mA DC max 12V DC 250 mA DC max 24V DC Alternator voltage 0 to 330 V AC Ph N 0 to 570V Ph Ph Alternator frequency 0 500 Hz Mains voltage 0 to 330 V AC Ph N 0 to 570V Ph Ph Mains frequency 0 500 Hz Current Inputs from current transformers 5A CT Range 5 5A to 5000 5A VT Range 0 1 1 to 6500 1 kW Range 0 1kW to 65000 kW Accuracy Voltage 0 5 1 digit Current 0 5 1 digit Frequency 0 5 1 digit Power kW kVAr 1 0 2digit Power factor 0 5 1 digit Digital inputs input voltage 0 to 36 V DC Analog input range 0 5000 ohms Mains and genset contactor outputs 16Amps 250V DC Outputs Protected mosfet semiconductor outputs rated 1Amp 28V DC Cranking dropouts survives OV for 100ms Magnetic pickup voltage 0 5 to 30V RMS Magnetic pickup frequency 10 to 10000 Hz Charge Alternator Excitation 160mA 12VDC 80mA 24VDC Ethernet Port 10 100 Mbits USB Device USB 2 0 Full speed USB Host USB 2 0 Full speed RS 485 Port selectable baud rate RS 232 Port selectable baud rate Operating temperature 20 C to 70 C 4 to 158 F Storage temperature 40 C to 80 C 40 to 176 F Maximum humidity 95 non condensing IP Protection 54 from front panel IP30 from the rear Dimensions 200 x 148 x 46mm WxHxD Panel Cut out Dimensions 176 x 121 mm minimum Weight 450
54. Hz resolution Frequency accuracy 0 2 1 digit 0 1 Hz 50Hz K35D03 EN 16 D 500 User Manual Rev_04 Firmware V 3 3 3 3 AC CURRENT INPUTS 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 ph1 CT CT secondary rating 5A Measurement range 5 5 to 5000 5A minimum Input impedance 15 mili ohms Burden 0 375W Maximum continuous 6A current 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 B 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 40 shift in a CT will cause erroneous power and power factor readings although amp 95 readings are correct Datakom advises CT rating to be selected following this table for the best measurement accuracy N CT RATING VA 5 10 15 20 25 30 35 40 45 50 CABLE LENGHT TO CT m 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
55. IOD The recording period is adjustable between 2 seconds and 18 hours by program parameter A short period will give better resolution but it will generate more data in the memory card One data record is typically 250 bytes long thus with a minimum period of 2 seconds the unit will store 10 8 MB of data per day 250x30x60x24 A typical memory of 4GB will store data during 370 days more than 1 year With a recording period of 1 minute 4GB memory card will store data during 30 years Below parameters are recorded Date and time of recording Operating mode Mains voltage phase L1 to neutral Mains voltage phase 12 to neutral Mains voltage phase L3 to neutral Mains voltage phase L1 L2 Mains voltage phase L2 L3 Mains voltage phase L3 L1 Mains frequency Mains current phase L1 Mains current phase L2 Mains current phase L3 Mains average current Mains frequency Mains kW phase L1 Mains kW phase L2 Mains kW phase L3 Mains total kW Mains kVA phase L1 Mains kVA phase L2 Mains kVA phase L3 Mains kVAr phase L1 Mains kVAr phase L2 Mains kVAr phase L3 Mains pf phase L1 Mains pf phase L2 Mains pf phase L3 Mains total pf Mains neutral current K35D03 EN Gen voltage phase L1 to neutral Gen voltage phase L2 to neutral Gen voltage phase L3 to neutral Gen average voltage phase to neutral Gen voltage phase L1 L2 Gen voltage phase L2 L3 Gen voltage phase L3 L1 Gen current phase L1 Gen current phase L2 Ge
56. Injector cylinder 8 fault 678 X ECU internal power supply fail 723 X Secondary engine speed sensor fail 1108 X Critical override enabled 1111 X Check configuration parameters 2000 X ECU failure K35D03 EN 114 D 500 User Manual Rev_04 Firmware V 3 3 Below is a basic list of FMI codes Please be aware that these codes may differ slightly depending on the engine brand and model DESCRIPTION 0 Value too high Valid data but above the normal working range 1 Value too low Valid data but below the normal working range 2 Faulty data Intermittent or faulty data or Short circuit to battery voltage injector high voltage side 3 Electrical fault Abnormally high voltage or short circuit to battery voltage injector low voltage side 4 Electrical fault Abnormally low voltage or short circuit to battery negative injector low voltage or high voltage side 5 Electrical fault Abnormally low current or open circuit 6 Electrical fault Abnormally high current or short circuit to battery negative 7 Mechanical fault Faulty response from mechanical system 8 Mechanical or electrical fault Abnormal frequency 9 Communication fault Abnormal updating rate or Open circuit in injector circuit 10 Mechanical or electrical fault Abnormally large variations 11 Unknown fault Unidentified fault 12 Component fault Faulty unit or component 13 Faulty calibration Cali
57. It is advised to set these slave addresses to the default setting which is 1 K35D03 EN 134 D 500 User Manual Rev_04 Firmware V 3 3 38 1 PARAMETERS REQUIRED FOR RS 485 MODBUS OPERATION Modbus Slave Address may be set between 1 and 240 RS 485 Enable must be set to 1 or checkbox enabled RS 485 Baud Rate selectable between 2400 and 115200 bauds All devices in the same network must use the same Baud Rate The complete RS 485 port specifications are found in the D 500 700 User Manual Selecting a higher baud rate will allow faster communication but will reduce the communication distance Selecting a lower baud rate will increase the communication distance but will cause slower response times Typically 9600 bauds will allow 1200m distance with special balanced 120 ohms cable 38 2 PARAMETERS REQUIRED FOR MODBUS TCP IP VIA ETHERNET Modbus Slave Address may be set between 1 and 240 If only one unit is available in the same IP address it is advised to keep the default address 1 Ethernet Enable This parameter should be set to 1 or checked in order to enable the ethernet port Modbus TCP IP Port The usual setting is 502 However the unit is able to work on any port address User IP Mask There are 3 mask registers available The use of the registers are emphasized in the D 500 700 User Manual Please set the first mask as 255 255 255 0 for the proper operation Ethernet Network IP May be left as 0 0 0 0 for automatic
58. LTAGE INPUT Supply voltage 9 to 33VDC Cranking dropouts Survives OVDC during 100ms The voltage before surge should be 9VDC minimum Overvoltage protection Withstands 150VDC continuously Reverse voltage 33VDC continuous Maximum operating 500mA 12VDC All options included digital outputs open current 250mA 24VDC All options included digital outputs open Typical operating current 250mA 9 12VDC all options passive digital outputs open 125mA 9 24VDC all options passive digital outputs open Measurement range 0 to 36VDC Display resolution 0 1VDC Accuracy 0 5 1 digit B 24VDC K35D03 EN 15 D 500 User Manual Rev_04 Firmware V 3 3 3 2 AC VOLTAGE INPUTS 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 0 1
59. Load Add 75 Inp Expansioni Mounted 115 Combat mode 36 Load Substract 76 Inp Expansion2Mounted 116 37 Service 1 Request 77 Out Expansion1Mounted 117 38 Service 2 Request 78 Out Expansion2Mounted 118 39 Service 3 Request 79 Master Unit 119 40 Mains Ph Order Fail 80 Multi Gen Remote Start 120 K35D03 EN 102 D 500 User Manual Rev_04 Firmware V 3 3 16 10 SITE ID STRING The site identity string is designed to identify the current controller This is the site Id string sent at the beginning of SMS messages e mails and web page headers for the identification of the genset sending the message Any 20 character long string may be entered 16 11 ENGINE SERIAL NUMBER The engine serial number string is designed to identify the current controller Ths string is added to GSM SMS messages e mails web page headers etc 16 12 MODEM1 2 SMS1 2 3 4 TELEPHONE NUMBERS These telephone number buffers accept up to 16 digits including the wait character in order to enable dialing through a pabx If Modem Selection External PSTN Modem First 2 numbers are used for modem calls Other selections all numbers are used for SMS sending A Enter numbers starting from first character Do not leave blank characters at the beginning K35D03 EN 103 D 500 User Manual Rev_04 Firmware V 3 3 16 13 GSM MODEM PARAMETERS Parameter Definition Descriptio
60. MICRO SD Card Slot 13N83HL13 MICRO SD MEMORV CARD The micro SD card slot is available in units with COMM option The slot is of push in push out tvpe When pushed in the card is firmly held by its connector Description micro SD card reader Data rate serial 10Mb s Functionality Flash memory FAT32 data recording Memory capacity micro SD card any capacity The micro SD card slot is designed for detailed data recording The period of recording is adjustable through program parameter As soon as a micro SD memory card is inserted the unit will start data recording and continue until the memory card is removed For more details about data recording please review chapter Data Recording Micro SD memory card has priority for data recording If both micro SD and USB Flash memories are inserted data will be recorded on micro SD memory K35D03 EN 29 D 500 User Manual Rev_04 Firmware V 3 3 3 19 GSM MODEM OPTIONAL The optional internal GSM modem offers the advantage of being internally powered and is fully compatible with the unit It does not require any special setup The 1800 1900 MHz magnetic antenna together with its 2 meter cable is supplied with the internal modem option The antenna is intended to be placed outside of the genset panel for the best signal reception 0500 AMF Ure 3X m KO oA ma v NE vw Antenna connector Du n CE
61. N 56 D 500 User Manual Rev_04 Firmware V 3 3 10 WAVEFORM DISPLAY amp HARMONIC ANALYSIS The unit features waveform display together with a precision harmonic analyzer for both mains and genset voltages and currents Both phase to neutral and phase to phase voltages are available for analysis thus 18 channels in total are possible A In order to enable display and analysis of mains currents current transformers must be placed at load side Available channels are Mains volts V1 V2 V3 U12 U23 U31 Mains currents 11 12 Genset volts V1 V2 V3 012 U23 031 Genset currents 11 12 MAINS Ui SCOPEMETER Scopemeter Display The waveform display memory is of 100 samples length and 13 bit resolution with a sampling rate of 4096 s s Thus one cycle of a 50Hz signal is represented with 82 points The vertical scale is automatically adjusted in order to avoid clipping of the signal The waveform is displayed on the device screen and with more resolution on PC screen through the RainbowPlus program The display memory is also available in the Modbus register area for third party applications For more details please check chapter MODBUS Communications The waveform display is updated twice a second All channels may be scrolled using buttons K35D03 EN 57 D 500 User Manual Rev_04 Firmware V 3 3 The harmonic analyzer consists on a Fast Fourier Transform FFT algorithm which is run
62. OUBLESHOOTING GUIDE K35D03 EN 8 D 500 User Manual Rev_04 Firmware V 3 3 1 INSTALLATION INSTRUCTIONS 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 mounting brackets and tighten Do not tighten too much this can brake the enclosure electrical connections with plugs removed from sockets then place plugs to their sockets sure that adequate cooling is provided 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 Current Transformers must be used for current measurement No direct connection allowed Below conditions may cause abnormal operation Power supply voltage below minimum acceptable level Power suppl
63. P addresses etc Status amp Counters Groups This group includes various parameters like genset status service counters date time firmware version etc K35D03 EN 52 D 500 User Manual Rev_04 Firmware V 3 3 9 4 AUTOMATIC DISPLAY SCROLL The unit will automatically scroll all Mains Genset and Engine measurements with programmable interval The scroll period setting can be performed using the RainbowPlus program through Module gt Screen options Rainbow Plus Beta Version 1 0 0 6 File Tools Help Scada Functionality Screen Options Timers Exercise Scheduler Time Module Functionality Screen Screen _ Options LCD Contrast 2 39 Timers Screen Scroll Timer 14 2 sec Exercise v Scheduler Time Screen Generator Mains Genset Default Display Volts v Status Prompts Enable Configuration Engine Analog Inputs Language G EX Digital Inputs j Digital Outputs ee eee Eventually the same parameter can be modified through the front panel programming menu The related parameter is Controller Configuration gt Screen Scroll Timer If the Screen Scroll Timer is set to zero then scrolling will be disabled When a front panel button is pressed the scrolling is suspended during 2 minutes If a fault condition occurs the display will automatically switch to the ALARM LIST page K35D03 EN 53
64. POWER Set if the genset power kW is negative and goes over the Reverse Power limit for Reverse Power Timer If the power goes below the limit before expiration of the timer then no alarm will be set MAINS PHASE ORDER FAIL Set if the mains phase order checking is enabled mains phases are present and mains phase order is reversed This fault prevents the Mains Contactor to close GENSET CB FAIL TO CLOSE OPEN Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor Open Close Fail Timer MAINS CB FAIL TO CLOSE Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor Open Close Fail Timer SYNCHRONIZATION FAIL Set if the uninterrupted transfer is enabled and voltage frequency and phase matching is not found before the expiration of the Synchronization Fail Timer PICKUP SIGNAL LOST Set if the rom measured from the magnetic pickup input falls below the Crank Cut RPM level during Loss of Speed Signal Timer The action of signal loss is programmable SERVICE REQUEST Set if at least one of the service counters has expired In order to reset the service counters please hold pressed both with buttons during 5 seconds The screen will display Completed EEPROM WRITE FAULT Set if the internal non volatile memory cannot be written
65. Period IP Confirmation Address checkip dyndns org This internet address is regularly accessed in order to read the IPv4 address of the unit Rainbow Address 1 Rainbow Address 2 K35D03 EN These parameters accept both internet addresses like http datakom com tr and IPv4 addresses like 78 192 238 116 Information for remote monitoring is sent to these addresses The port information of these addresses are found in Controller Configuration group 105 D 500 User Manual Rev_04 Firmware V 3 3 16 14 ETHERNET PARAMETERS continued Parameter Definition Factory Set Description This is the account name appearing in the from tab Nama of the e mail recipient ex datakom d500 gmail com Mail Accoun d500_1234 This is the e mail password of above e mail account Password Mail Server Address smtp mail yahoo com This is the Outgoing Mail Server Address of the above e mail account ex smtp gmail com E mail Address 1 E mail Address 2 E mail Address 3 These are e mail recipient addresses where the unit is intended to send e mail messages Up to 3 e mails can be sent at once A Below ETHERNET related parameters are found in the Controller Configuration group Parameter Definition Unit Min Max Doseription Web Programming l 0 1 0 0 Web programming disabled Enable 1 Web progr
66. RS 9 6 LED LAMPS 10 WAVEFORM DISPLAY amp HARMONIC ANALYSIS 11 DISPLAYING EVENT LOGS 12 STATISTICAL COUNTERS 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 14 5 WARNINGS K35D03 EN 6 D 500 User Manual Rev_04 Firmware V 3 3 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 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 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 16 15 SYNCHRONIZATION PARAMETERS CRANK CUTTING OVERCURRENT PROTECTION IDMT MOTORIZED CIRCUIT BREAKER CONTROL J1939 CANBUS ENGINE SUPPORT ETHERNET CONFIGURATION GSM CONFIGURATION DYNAMIC DNS FEATURE ACCESSING THE EMBEDDED WEB SERVER WEB MONITORING AND CONTROL OF GENSETS C
67. RVICE REQUEST led is designed to help the periodic maintenance of the genset to be made consistently The periodic maintenance is basically carried out after a given engine hours for example 200 hours but even if this amount of engine hours is not fulfilled it is performed after a given time limit for example 12 months The unit offers 3 independent service counter sets in order to enable different service periods with different priorities The fault level created upon expiration of service timers may be set as Warning Loaddump or Shutdown Thus different levels of fault conditions may be generated at different overrun levels Each service counter set has both programmable engine hours and maintenance time limit If any of the programmed values is zero this means that the parameter will not be used For example a maintenance period of 0 months indicates that the unit will request maintenance only based on engine hours there will be no time limit If the engine hours is also selected as 0 hours this will mean that this service counter set is not operative When the engine hours OR the time limit is over the SERVICE REQUEST led red will start to flash and the service request output function will be active The service request can also create a fault condition of any level following parameter setting The service request output function may be assigned to any digital output using Relay Definition program parameters Also relays on an ext
68. SCHEDULE Exerciser Schedule zZ SENDER CONFIGURATION Exerciser Scheduls C PROGRAMMING Exerciser schedule 1 WEE ORY Mea A aa ae ath acm The unit provides 7 independent automatic exerciser programs Automatic exercise be done weekly or monthly basis If monthly exercise is selected the week day and hour is adjustable for each exercise item If weekly exercise is selected the day and hour is adjustable for each exercise item Exercise can be done with or without load Thus the genset can be instructed to run automatically in given days and times of a week and take the load K35D03 EN 96 D 500 User Manual Rev_04 Firmware V 3 3 16 7 SENDER CONFIGURATION The unit has 4 analog sender inputs Only parameters of one sender are explained below Other senders have identical parameter set Each sender has 16 step programmable curves The sender name and reading unit is freely programmable thus the sender can be adapted to any type through programming Each sender has below programmable parameters Parameter Definition Unit Min Factory Description Set Selects between predefined sender 15 functions If this parameter is set to 13 14 15 then the sender name string can be freely entered 0 shutdown alarm 1 loaddump alarm 0 always 1 2 Sender Type 0 Alarm Level 0 1 on engine running after hold off timer reserved If sender resistor is above 500
69. SIM card will not operate 0000 9999 0 SMS Enable 0 SMS messages disabled 1 SMS messages enabled GPRS Connection Enable 0 GPRS disabled 1 GPRS enabled SMS on Mains Change This parameter controls SMS sending when mains voltages status is changed No warnings generated 0 1 0 0 no SMS on mains failed or restored 1 SMS sent on mains failed or restored SMS on IP Change This parameter controls SMS sending when IP address of GPRS connection is changed No warnings generated 0 no SMS on IP change 1 SMS sent on IP change K35D03 EN 104 D 500 User Manual Rev_04 Firmware V 3 3 16 14 ETHERNET PARAMETERS Parameter Definition Factory Set Description Network IP Address 0 0 0 0 This is the IPv4 internet protocol version 4 address that the unit will require from the DHCP dynamic host control protocol server If this parameter is set to 0 0 0 0 then the unit will require any IPv4 address from the DHCP server If you are not an IP professional please leave this address as 0 0 0 0 Gateway IP Address 0 0 0 0 This is the router IPv4 address If the Network IP address and Gateway IP Address are set to 0 0 0 0 then the unit will get the gateway address automatically If you are not an IP professional please leave this address as 0 0 0 0 Subnet Mask 255 255 255 0 Reserved for IP professionals If you are not a
70. acket Do not tighten too much this may break the unit K35D03 EN 12 D 500 User Manual Rev_04 Firmware V 3 3 2 2 SEALING GASKET 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 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 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 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 K35D03 EN 13 D 500 User Manual Rev_04 Firmware V 3 3 2
71. actor period and the generator contactor will be energized When mains are evaluated as available again then an engine stop sequence begins The engine will continue to run for the mains waiting period to allow mains voltages to stabilize Then the generator contactor is deactivated and the mains contactor will be energized after mains contactor timer If a cooldown period is given the generator will continue to run during the cooldown period Before the end of cooldown the unit will reduce the engine speed to idle speed At the end of cooldown the fuel solenoid will be de energized the stop solenoid will be energized for Stop Solenoid timer and the diesel will stop The unit will be ready for the next mains failure If the operation of the genset is disabled by the weekly schedule then the AUTO led will flash and the operation of the genset will be as in the OFF mode K35D03 EN 63 D 500 User Manual Rev_04 Firmware V 3 3 13 4 RUN MODE MANUAL CONTROL The RUN mode is entered by pressing the qp button When the RUN mode is selected the engine will be started regardless of the mains availability The starting sequence is as described below The unit turns on the fuel and preheat glow plugs if any and waits for preheat timer engine will be cranked for programmed times during crank timer When the engine fires the crank relay will be immediately deactivated See section
72. age Guide 27 E MAIL SENDING Please see related document Ethernet Configuration Guide for D 500 D 700 28 ETHERNET GPRS MODBUS GATEWAY OPERATION This feature is not available yet K35D03 EN 116 D 500 User Manual Rev_04 29 SMS COMMANDS Firmware V 3 3 SMS messages are accepted only from phone numbers recorded in the Communication gt GSM gt Message Numbers tab Answers to SMS messages will be sent to all phone numbers in the list SMS messages must be written exactly as below without any preceding blanks Only UPPERCASE characters are permitted COMMAND DESCRIPTION ANSWER GET IP If GPRS connection is active the controller will reply by an SMS message IP 188 41 10 244 indicating the IP address of the GSM modem GPRS 1 Activates the GPRS connection GPRS enabled GPRS 0 Stops the GPRS connection GPRS disabled RESET Clears alarms of the controller The operating ALARMS mode is not modified Alarms cleared REBOOT Performs a hard reset on the controller no answer MODE STOP Puts the controller into STOP mode Alarms p are aleo cleared Unit forced to STOP MODE AUTO Puts the controller into AUTO mode Alarms are also cleared Unit forced to AUTO MODE MANUAL Puts the controller into MANUAL RUN mode Alarms are also cleared Unit forced to RUN MODE TEST Puts the controller into TEST mode Alarms also cleared Unit forced to TEST OUT1 ON Sets
73. ains and genset contactor control run the engine and provide engine and alternator instrumentation and fault monitoring The unit features both MPU and J1939 CANBUS inputs Thus both mechanical and electronic engines are supported The unit provides control outputs for both contactors and motorized circuit breakers 5 3 ATS FUNCTIONALITY When ATS functionality is selected the unit will monitor mains voltages provide mains and genset contactor control and issue a Remote Start signal to the engine controller It will provide alternator instrumentation and fault monitoring Engine instrumentation and protection will be insured by the engine controller 5 4 REMOTE START FUNCTIONALITY When the Remote Start functionality is selected the unit will wait for a Remote Start signal from external controller Upon reception of this signal it will run the engine and provide engine and alternator instrumentation and fault monitoring The genset contactor MCB control functionality will be available The unit features both MPU and J1939 CANBUS inputs Thus both mechanical and electronic engines are supported K35D03 EN 37 D 500 User Manual Rev_04 Firmware V 3 3 5 5 ENGINE CONTROLLER FUNCTIONALITY When the Engine Controller functionality is selected genset electrical measurements and protections will be disabled The unit is supposed to control an engine without alternator When the Engine Control Mode is activated the unit will no
74. ains lead The switching to unleaded solderin is in progress K35D03 EN 140 D 500 User Manual Rev_04 Firmware V 3 3 44 TROUBLESHOOTING GUIDE Below is a basic list of most often encountered troubles More detailed investigation may be required in some cases The genset operates while AC mains are OK or continues to operate after AC mains are OK Check engine body grounding AC mains voltages may be outside programmed limits measure the phase voltages Check the AC voltage readings on the screen Upper and lower limits of the mains voltages may be too tight Check the parameters Mains Voltage Low Limit and Mains Voltage High Limit Standard values are 170 270 volts The hysteresis voltage may be given to excessive The standard value is 8 volts AC voltages or frequency displayed on the unit are not correct Check engine body grounding it is necessary The error margin of the unit is 2 volts If there are faulty measurements only when the engine is running there may be a faulty charging alternator or voltage regulator on the engine Disconnect the charging alternator connection of the engine and check if the error is removed If there are faulty measurements only when mains are present then the battery charger may be failed Turn off the rectifier fuse and check again KW and cos readings are faulty although the Amp readings are correct Current transformers are not connected to the correct inputs or som
75. al J1939 port in order to communicate with electronic engines controlled by an ECU electronic control unit The J1939 port consists of 2 terminals which are J1939 and J1939 The connection between the unit and the engine should be made with an appropriate balanced 120 ohms low capacitance coaxial cable The external conductor should be grounded at one end only A 120 ohms termination resistor is installed inside the unit Please do not connect external resistor The J1939 port is activated by setting the program parameter J1939 Enable to 1 The J1939 Engine Type parameter should be set accordingly The list of available engines is given at the programming section Please contact DATAKOM for the most current list of engines If the J1939 port is enabled then the oil pressure coolant temperature and the engine rpm information are picked up from the ECU unit If connected the MPU unit and related analog senders are discarded The controller is able to read and display all below parameters under condition that the engine sends these information Most engines send only some of them If the engine does not send a parameter the unit will simply skip it Thus only available information are displayed The complete list of J1939 display parameters is below Engine Brand ECU Type J1939 SW version Engine Coolant Level Engine Oil Level Engine Coolant Pressure Engine Fuel Delivery Pressure Barometric Pressure Engine Crankcase Press
76. ameters The dual genset intermittent operation uses also the Disable Auto Start feature Please review related chapter for a detailed explanation of this feature Priority In Dual Genset Mutual Standby Operation It may be required that the dual genset system starts the same genset at every mains failure This is achieved using the PRIORITY input Any digital input may be assigned as Priority using Input Function Select program parameters It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarms generated from this input The Priority signal may be a NO or NC contact switching to either battery positive or battery negative These selections are made using the programming menu If a Priority input is defined then the system will work in priority mode If the priority signal is applied the unit will become master after each mains failure If the priority signal is not applied then the unit will become the slave one and the other genset will start Please contact DATAKOM for a complete application manual K35D03 EN 128 D 500 User Manual Rev_04 Firmware V 3 3 32 8 DUAL VOLTAGE AND FREQUENCY The unit offers 2 sets of voltage and frequency protection limit values The user is allowed to switch between these 2 sets anytime This feature is especially useful in dual voltage or frequency gensets for easy switching between 2 operating conditions The switching to the
77. amming enabled 0 Web control disabled Web Control Enable 0 1 0 4 Web control enabled The unit will refresh the web page with Web Refresh Rate sec 0 240 5 this interval The unit will check the availability of the PII renee 4 internet connection with this interval The unit will update the distant MAMAS ee 0 9 monitoring terminal with this rate This is the port number of the first Rainbow Address 1 Port 0 65535 0 monitoring terminal address This is the port number of the second Rainbow Address 2 Port 0 65535 0 monitoring terminal address This is the port number of the internal Web Server Port 0 65535 80 web server The unit will answer queries to this port only This is the port number of the internal Modbus TCP IP terminal The unit will Modbus TCP Port l 0 89545 Sue answer Modbus requests to this port only This is the port number used for e mail SMTP Port 0 65535 587 sending 0 ethernet port disabled Ethernet Enable li 0 1 1 ethernet port enabled This parameter controls e mail sending when IP address of GPRS or ethernet _ connection is changed No warnings E mail on IP Change 0 1 0 generated 0 no e mail on IP change 1 e mail sent on IP change K35D03 EN 106 D 500 User Manual Rev_04 Firmware V 3 3 16 15 SYNCHRONIZATION PARAMETERS Factory Description Parameter Definition Unit Min Max Set No Break Transfer l 0 1 0 0 only interrupted transfe
78. arameters will not be displayed Synchronization Display A graphical synchroscope is displayed The synchroscope display is updated 10 times a second in order to have smooth sweep Scopemeter Display This group display waveforms of voltages and currents as an oscilloscope All Ph N and Ph Ph voltages as well as phase currents are available This feature is especially useful to investigate waveform distortions and harmonic loads Graphical Harmonic Analysis Results This group displays harmonic composition of voltages and currents All Ph N and Ph Ph voltages as well as phase currents are available This feature is especially useful to investigate the harmonic caused by complex loads Only harmonics above 2 are represented in the graphics because of the display resolution In order to see all harmonic levels please use the Alphanumerical Harmonic Analysis Results Alphanumerical Harmonic Analysis Results This group displays harmonic composition of voltages and currents with 0 1 resolution All Ph N and Ph Ph voltages as well as phase currents are available This feature is especially useful to investigate the harmonic caused by complex loads Alarm Display This group displays all existing alarms one screen per alarm When there is no more alarm to display it will show END OF ALARM LIST GSM Modem Parameters Signal strength counters communication status IP addresses etc Ethernet Parameters Ethernet connection status counters I
79. ary Volt Freq Timers Latch AllWamings Pressure Switch Priority C Buzzer Enable Exercise Scheduler Open With Last Mode v Check Auto Not Ready Check Unit Not Tested v Time Data Logaing Generator Event Logs Enable Mains po FL PGM Entrance Periodic Mode Change C Event enable Shut Down v Load Dump v Warning v selection tab Mains Fail Engine Started Genset On Load Mains Restore Engine Stopped Genset Off Load C Synchronization Program mode entrance event recorded with the password level when program mode is entered Periodic event recorded every 30 minutes when the engine is running and every 60 minutes anyway Mode change event recorded when the operation mode is changed Shutdown loaddump warning events recorded when the related fault condition occurs Mains fail restore events recorded when mains status is changed Engine started stopped events recorded when engine status is changed Genset on load off load events recorded when the genset loading status is changed K35D03 EN 59 D 500 User Manual Rev_04 Firmware V 3 3 Event logs are displayed within the program mode menu This is designed in order to reduce the interference of event logs with other measurement screens To enter the event display press together o buttons for 5 seconds When the program mode is entered below password entry screen will be displayed GEH PHASE VOLTAGES Pre
80. ases 4 wires star Waveform display of V amp I 3 phases 4 wires delta Harmonic analysis of V amp I 1 phase 2 wires CTs at genset or load side 4 D 500 User Manual Rev_04 Firmware V 3 3 COPYRIGHT NOTICE 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 ABOUT THIS DOCUMENT 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 datakom datakom com tr RELATED DOCUMENTS 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 DYNdns account setting Dynamic DNS Account Setting for D 500 D 700 500 Ethernet Configuration Ethernet Configuration Guide for D 500 D 700 500 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 snmp E 34076 D500 MIB file for SNMP Application of D 500 D 700 500 Rainbow Scada Installation Rainbow Scada Installation Guide 50
81. assigned to these signals When the load is above the Load Shedding High Limit the controller will activate the Load Shedding output When the load is below the Load Shedding Low Limit the controller will release the Load Shedding output The parameters used in Load Shedding feature are in the Electrical Parameters Group Load Shedding Low Limit If the genset power goes below this limit then the load shedding relay will be deactivated Load Shedding High Limit If the genset power goes above this limit then the load shedding relay will be activated HIGH LIMIT LOW LIMIT TIME LOAD LEVEL 1805 LOAD SHEDDING OUTPUT mu lo S o t t2 t t1 the load goes below the Load Shedding Low Limit thus the Load Shedding output becomes inactive 12 the load goes above the Load Shedding High Limit thus the Load Shedding output becomes active t3 the load goes below the Load Shedding Low Limit thus the Load Shedding output becomes inactive K35D03 EN 123 D 500 User Manual Rev_04 Firmware V 3 3 32 2 LOAD ADD SUBSTRACT The load add substract output functions are designed to provide control signals for an external multi step load adding substracting system This external system will add either linearly or by small steps a dummy load that will prevent the genset from running below the minimum required load level The same function may be used in order to supply loads of different priority levels following
82. ated depending on Service 3 Period 0 no action Service 3 Alarm Level 0 3 0 ann 2 loaddump alarm 3 warning K35D03 EN 92 D 500 User Manual Rev_04 Firmware V 3 3 16 3 ENGINE PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Description Set 0 The J1939 port is inoperative 1 The analog measurements oil temp J1939 Enable 0 1 0 rpm picked up from the ECU If the ECU communication is lost then the engine will be stopped 0 GENERIC 1 CUMMINS DETROIT DIESEL DEUTZ JOHN DEERE PERKINS VOLVO CATERPILLAR SCANIA IVECO 10 MTU MDEC 11 BOSCH Other values Reserved Do not use J1939 Engine Brand 0 15 0 GENERIC ENGINE BRAND 0 Generic CUMMINS ENGINE 0 CM850 1 CM570 DETROIT DIESEL ENGINE 0 Generic DEUTZ ENGINE 0 Generic 1 EMR2 2 EMR3 JOHN DEERE ENGINE 0 Generic PERKINS ENGINE 0 Generic 1 ADEM3 2 ADEM 1 3 VOLVO ENGINE 0 Generic J1939 ECU Type 0 7 0 1 without CIU unit 2 EDC4 CATERPILLAR ENGINE 0 Generic SCANIA ENGINE 0 Generic 1 Single Speed 2 All Speed IVECO ENGINE 0 Generic MTU MDEC ENGINE 0 MDEC 302 1 MDEC 201 2 MDEC 303 3 MDEC 304 4 MDEC 506 BOSCH INJECTION SYSTEM 0 Generic 1 EDC 731 2 EDC 9 3 K35D03 EN 93 D 500 User Manual Rev_04 Firmware V 3 3 16 3 ENGINE PARAMETERS GROUP continued
83. bration values outside the limits 14 Unknown fault Special instructions 15 Data valid but above normal operating range least severe level 16 Data valid but above normal operating range moderately severe level 17 Data valid but below normal operating range least severe level 18 Data valid but below normal operating range moderately severe level 19 Received network data in error 20 not used reserved 21 not used reserved 22 not used reserved 23 not used reserved 24 not used reserved 25 not used reserved 26 not used reserved 27 not used reserved 28 not used reserved 29 not used reserved 30 not used reserved 31 Condition exist K35D03 EN 115 D 500 User Manual Rev_04 Firmware V 3 3 21 ETHERNET CONFIGURATION Please see related document Ethernet Configuration Guide for D 500 D 700 22 GSM CONFIGURATION Please see related document GSM Configuration Guide for D 500 D 700 23 DYNAMIC DNS FEATURE Please see related document Dynamic DNS Account Setting for D 500 D 700 24 ACCESSING THE EMBEDDED WEB SERVER Please see related document Ethernet Configuration Guide for D 500 D 700 25 WEB MONITORING AND CONTROL OF GENSETS Please see related document Ethernet Configuration Guide for D 500 D 700 26 CENTRAL MONITORING OF GENSETS Please see related document Rainbow Scada Us
84. der to exit from the group to the main list please press lt MENU button STATUS 5 007150 li inside tne Eef POISPLAY EVENT LOGG group then MM NT main CONTROLLER CONFIG PGA menu ELECTRICAL PARAMS Enter inside the group Next group Previous group Navigation inside a group is made also with Wand A buttons A list of available parameters will be displayed Selected parameter is shown in reverse video blue on white In order display change the value of this parameter please press MENUP button Parameter value may be increased and decreased with Wand buttons If these keys are hold pressed the program value will be increased decreased by steps of 10 When a program parameter is modified it is automatically saved in memory If MENU DP button is pressed next parameter will be displayed If 4MENU button is pressed then the list of parameters in this group will be displayed Edit parameter Return to the main menu kLCD Contras Screen Scroll Timer Lansuase Selection LOAD pom C 1 j KAT GENSET Next Previous parameter inside the parameter same group inside the same group K35D03 EN 74 D 500 User Manual Rev_04 Firmware V 3 3 15 4 MODIFYING PARAMETER VALUE STATUS e PROGRAMING o READY CONTROLLER COHFIG LED Contrast Decrease parameter
85. dump alarm If this parameter is set to 0 then overload fault is not monitored Genset Overload Fail Timer sec 120 If the genset active power is over the limit during this timer an overload fault will occur Load Shedding Low Limit kW 50000 If the genset power goes below this limit then the load shedding relay will be deactivated Review chapter Load Shedding for more details Load Shedding High Limit kW 50000 If the genset power goes above this limit then the load shedding relay will be activated Review chapter Load Shedding for more details K35D03 EN 84 Firmware V 3 3 D 500 User Manual Rev_04 16 2 ELECTRICAL PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Set Description Load Add Delay sec 240 0 This is the minimum delay between 2 load_add pulses Review chapter Load Shedding for more details Load Subtract Add Delay min 120 0 This is the minimum delay required for a load_add pulse after a load_substract pulse Review chapter Load Shedding for more details Mains Waiting Timer sec 50000 30 This is the time between the mains voltages and frequency entered within the limits and the generator contactor is deactivated Mains Connection Topology This is the connection topology of mains voltages and CTs Detailed explanations are given in the chap
86. e a digital output in order to drive the block heater resistor The temperature reference is the coolant temperature measured from the analog sender input The block heater output function may be assigned to any digital output using Relay Definition program parameters The engine body temperature limit is adjusted using the parameter Engine Heating Temperature The same parameter is used for engine heating operation The relay will become active if the body temperature falls to 4 degrees below the limit set by Engine Heating Temperature It turns off when the body temperature exceeds Engine Heating Temperature K35D03 EN 131 D 500 User Manual Rev_04 Firmware V 3 3 37 16 FUEL PUMP CONTROL The unit is able to provide a digital output function in order to drive the fuel pump motor The fuel pump is used to transfer fuel from the large capacity main tank if exists to the genset daily tank which is generally integrated in the chassis and has a limited capacity The fuel level reference is measured through the analog fuel level sender When the measured fuel level falls below Fuel Pump Low Limit parameter the fuel pump output function will become active When the fuel level reaches Fuel Pump High Limit parameter the output function will become passive Thus the chassis fuel tank level will be always kept between Fuel Pump Low Limit and Fuel Pump High Limit parameters If the Fuel Pump High Limit is not reached within Fuel Filling Tim
87. e of the CTs are connected with reverse polarity Determine the correct connections of each individual CT in order to obtain correct KW and cos for the related phase and then connect all CTs Please review chapter AC CURRENT INPUTS A Short circuit outputs of unused Current Transformers When the AC mains fails the unit energizes the fuel solenoid but does not start and OIL PRESSURE EXISTS message is displayed The unit is not supplied with battery voltage at the oil pressure input Oil pressure switch not connected Oil pressure switch connection wire cut Oil pressure switch faulty Oil pressure switch closes too lately If oil pressure switch closes the unit will start Optionally oil pressure switch may be replaced K35D03 EN 141 D 500 User Manual Rev_04 Firmware V 3 3 The engine does not run after the first start attempt then the unit does not start again and OIL PRESSURE EXISTS message is displayed The oil pressure switch closes very lately As the unit senses an oil pressure it does not start When oil pressure switch closes the unit will start Optionally the oil pressure switch may be replaced When the AC mains fails the engine starts to run but the unit gives START FAIL alarm and then the engine stops The generator phase voltages are not connected to the unit Measure the AC voltage between terminals GEN L1 L2 L3 and Generator Neutral at the rear of the unit while the engine is running A
88. ed and the related contactor block feedback signal is not detected after the expiration of Contactor Open Close Fail Timer PICKUP SIGNAL LOST Set if the rom measured from the magnetic pickup input falls below the Crank Cut RPM level during Loss of Speed Signal Timer The action of signal loss is programmable SERVICE REQUEST Set if at least one of the service counters has expired In order to reset the service counters please hold pressed both with and 5 seconds The screen will display Completed buttons during UNIT LOCKED Set if the controller is remotely locked K35D03 EN 69 D 500 User Manual Rev_04 Firmware V 3 3 14 5 WARNINGS Digital input and analog sender alarms are fully programmable for the alarm name sampling and action Onlv internal alarms are explained in this section All warnings can be made latching by enabling a single program parameter Controller Configuration gt Latch All Warnings gt Rainbow Plus Beta Version 1 0 0 6 File Tools Configuration Scada B Module Functionality Screen Options Timers Exercise Scheduler Time Generator Mains Engine Analog Inputs Digital Inputs Digital Outputs 4 a a a Functionality Screen Options Timers Exercise Scheduler Time Miscellaneous Warning Before Start Delayed Simulate Mains Secondary Volt Freq Latch All Wamings Pressure Switch P
89. ed 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 K35D03 EN 19 D 500 User Manual Rev_04 Firmware V 3 3 3 4 DIGITAL INPUTS Number of inputs 8 inputs all configurable Function selection from list Contact type Normally open or normally closed programmable Switching Battery negative or battery positive programmable Structure 47 k ohms resistor to battery positive 110k ohms to battery negative Measurement Analog voltage measurement Open circuit voltage 70 of battery voltage Low level threshold 35 of battery voltage High level threshold 85 of battery voltage Maximum input voltage 100VDC with respect to battery negative Minimum input voltage 70VDC with respect to battery negative Noise filtering yes 3 5 ANALOG SENDER INPUTS AND SENDER GROUND Number of inputs 4 inputs all configurable additional sender ground input Function selection from list Structure 667 ohms resistor polarizing to 3 3VDC Mea
90. eneric modem 4 external PSTN land modem abe Modem Baud bps 2400 115200 115200 This is the data rate for accessing the ate external modem If the GSM SIM card uses pin number i enter the pin number here If incorrect GSM Sim Card Pin l QUUD 54993 pin number is entered then the SIM card will not operate 0 SMS messages disabled SMS Enable l 4 1 1 SMS messages enabled GPRS Connection l 0 1 0 0 GPRS disabled Enable 1 GPRS enabled Web Programming l 0 1 0 0 Web programming disabled Enable 1 Web programming enabled 0 Web control disabled Web Control Enable 0 1 0 1 Web control enabled The unit will refresh the web page with Web Refresh Rate sec 0 240 5 this interval The unit will check the availability of the Ping Peniga 52 90 a09 Ten internet connection with this interval Rainbow Scada Refresh The unit will update the distant Rate E 9 ies monitoring with this rate Rainbow Scada l 0 65535 0 This is the port number of the first Address 1 Port monitoring terminal address Rainbow Scada l 0 65535 0 This is the port number of the second Address 2 Port monitoring terminal address This is the port number of the internal Web Server Port 0 65535 80 web server The unit will answer queries to this port only Internal Modbus TCP IP server s port Modbus TCP IP Port 0 65535 502 number The unit answers Modbus requests to this port only SMTP Port l 0 65535 587 This is the port number used for e mail sending
91. enset phase L1 AC voltage reaches Engine Parameters gt Crank Cut Voltage then cranking is immediately stopped Genset frequency over threshold If the genset phase L1 frequency reaches Engine Parameters gt Crank Cut Frequency then cranking is immediately stopped Genset rpm over threshold If the genset rpm reaches Engine Parameters gt Crank Cut RPM then cranking is immediately stopped Charge alternator voltage over threshold Following setting is necessary Engine Parameters gt Charge Input Connected 1 If the charge alternator voltage reaches Engine Parameters gt Crank Cut Charge Voltage then cranking is immediately stopped Oil pressure above threshold Following setting is necessary Engine Parameters gt Crank Cut with Oil Pressure 1 The crank cutting with oil pressure offers a programmable delay through Engine Parameters gt Crank Cut with Oil Pressure Delay The parameter is factory set to 2 seconds Both low oil pressure switch and oil pressure sender readings may be used for crank cutting The oil pressure switch is always used The sender may be disabled through Controller Configuration gt Oil Pressure Switch Priority parameter If enabled when oil pressure is detected cranking is stopped after adjustable timer delay K35D03 EN 108 D 500 User Manual Rev_04 Firmware V 3 3 18 OVERCURRENT PROTECTION IDMT The unit offers a programmable IDMT protection function in order to protect the
92. ension module may be assigned to this function To turn off the SERVICE REQUEST led and reset the service period press together the ALARM MUTE and LAMP TEST keys for 5 seconds The remaining engine hours and the remaining time limits are kept stored in a non volatile memory and are not affected from power supply failures The time and engine hours to service are displayed in the GENSET STATUS menu group K35D03 EN 67 D 500 User Manual Rev_04 Firmware V 3 3 14 3 SHUTDOWN ALARMS Digital input and analog sender alarms are fully programmable for the alarm name sampling and action Onlv internal alarms are explained in this section GENSET LOW HIGH FREQUENCY Set if the generator frequency is outside programmed limits These faults will be monitored with Fault Holdoff Timer delay after the engine is running Low and high limits are separately programmable The detection delay is also programmable Another high frequency shutdown limit which is 12 above the high limit is always monitored and stops the engine immediately GENSET LOW HIGH RPM Set if the generator rpm is outside programmed limits These faults will be monitored with Fault Holdoff Timer delay after the engine is running Low and high limits are separately programmable The detection delay is also programmable The high rpm overshoot limit is always monitored and stops the engine immediately GENSET LOW HIGH VOLTAGE Set if any of t
93. er duration then the fuel pump will stop for safety The fuel pump relay function may be assigned to any digital output using Relay Definition program parameters 37 17 GAS ENGINE FUEL SOLENOID CONTROL The unit provides a special function for the fuel solenoid control of a gas engine The fuel solenoid of a gas engine is different from a diesel engine It should be opened after the cranking has been started and should be closed between crank cycles The delay between the crank start and solenoid opening is adjusted using the Gas Solenoid Delay program parameter The gas engine fuel solenoid relay function may be assigned to any digital output using Relay Definition program parameters 37 18 PRE TRANSFER SIGNAL The controller is able to provide a pre transfer digital output function This function is designed for elevator systems in order to bring the cabin to a floor and open cabin doors before transfer The duration where this output is active is adjusted with the Pre Transfer Delay parameter If the Pre transfer Delay parameter is not zero this will delay transfers by the same amount K35D03 EN 132 D 500 User Manual Rev_04 Firmware V 3 3 37 19 CHARGING THE ENGINE BATTERY The controller offers an automatic charge cycle for the engine battery When the engine battery weakens the genset will run automatically during programmed period in an unloaded state in order to charge the engine battery protecting it fr
94. erent groups are made with e buttons Each depression of the e button will cause the display to switch to the next group of parameters After the last group the display will switch to the first group Each depression of the button will cause the display to switch to the previous group of parameters After the first group the display will switch to the last group Navigation inside a groups is made with buttons Each depression of the e button will cause the display to switch to the next parameter in the same group After the last parameter the display will switch to the first parameter Each depression of the button will cause the display to switch to the previous parameter the same group After the first parameter the display will switch to the last parameter Below is a basic list of parameter groups Genset Parameters Genset voltages currents kW kVA kVAr pf etc Engine Parameters Analog sender readings rpm battery voltage engine hours etc J1939 Parameters Opens only if the J1939 port is enabled The unit is able to display a long list of parameters under the condition that the engine sends this information A complete list of available readings is found at chapter J1939 CANBUS ENGINE SUPPORT Mains Parameters Mains voltages currents kW kVA kVAr pf etc Mains currents and power parameters are displayed only when CT Selection is made as LOAD SIDE Otherwise mains current and power related p
95. g approx Case Material High Temperature non flammable ROHS compliant ABS PC Mounting Flush mounted with rear retaining plastic brackets EU Directives Conformity 2006 95 EC low voltage 2004 108 electro magnetic compatibility Norms of reference EN 61010 safety requirements EN 61326 EMC requirements UL Compatibility UL 508 Industrial Control Equipment CSA Compatibility CAN CSA C22 2 No 14 2005 Industrial Control Equipment K35D03 EN 49 D 500 User Manual Rev_04 Firmware V 3 3 9 DESCRIPTION OF CONTROLS 9 1 FRONT PANEL FUNCTIONALITY Graphic LCD screen Mimic Diagram sysem status AUTO READY indicator DATAKOM Mains Contactor control in RUN Next display Fault condition indicators Genset Next screen in the same group LAMP TEST if held pressed Previous screen in the same group ALARM Mute Previous display group AUTO mode button STOP mode button TEST mode button button When the engine hours OR the time limit is over the SERVICE REQUEST led red will start to flash and the service request output function will be active The service request can also create a fault condition of any level following parameter setting The service request output function may be assigned to any digital output using Relay Definition program parameters Also relays on an extension m
96. he Remote Start input 32 5 DISABLE AUTO START SIMULATE MAINS The unit offers an optional Disable Auto Start signal input Any digital input may be assigned as Disable Auto Start using Input Function Select program parameters It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarms generated from this input The Disable Auto Start signal may be a NO or NC contact switching to either battery positive or battery negative These selections are made using the programming menu If the Disable Auto Start input is defined and the input signal is active the mains phases not monitored and supposed to be inside limits This will prevent the genset from starting even in case of a mains failure If the genset is running when the signal is applied then usual Mains Waiting and Cooldown cycles will be performed before engine stop When the Disable Auto Start signal is present the front panels mimic diagram s mains LEDs will reflect the mains voltages as present When the signal is passive the unit will revert to normal operation and monitor the mains voltage status The REMOTE START operation overrides DISABLE AUTO START and FORCE TO START operations K35D03 EN 126 D 500 User Manual Rev_04 Firmware V 3 3 32 6 BATTERY CHARGING OPERATION DELAYED SIMULATE MAINS The Delayed Mains Simulation feature is used in battery backed up telecom systems where batteries are able to
97. he generator phase voltages goes outside programmed limits for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running LOW HIGH BATTERY VOLTAGE Set if the genset battery voltage is outside programmed limits Low and high limits are separately programmable The detection delay is also programmable FAIL TO START Set if the engine is not running after programmed number of start attempts LOW CHARGE VOLTAGE Set if the charge alternator voltage is below the programmed limit This fault will be monitored with Fault Holdoff Timer delay after the engine is running J1939 ECU FAIL Set if no information has been received during 3 seconds from the ECU of the electronic engine This fault condition is only controlled when fuel is on VOLTAGE UNBALANCE Set if any of the generator phase voltages differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running CURRENT UNBALANCE Set if any of the generator phase currents differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running The action taken at fault condition is programmable OVERCURRENT Set if at least one of the genset phase currents goes over the Overcurrent Limit for the period all
98. his is the time between the mains fails and the fuel solenoid turns on before starting the genset It prevents unwanted genset operation in battery backed up loads Preheat Timer sec 30 This is the time after the fuel solenoid is energized and before the genset is started During this period the PREHEAT relay output is energized if assigned by Relay Definitions Crank Timer sec This is the maximum start period Starting will be automatically cancelled if the genset fires before the timer Wait Between Starts sec 240 10 This is the waiting period between two start attempts Engine Heating Timer sec 240 This is the period used for engine heating before load transfer Engine Heating Method The genset will not take the load before engine heating is completed 0 engine is heated during Engine Heating Timer 1 engine is heated until the coolant temperature reaches the Engine Heating Temperature and at least during the Engine Heating Timer Cooldown Timer sec 600 120 This is the period that the generator runs for cooling purpose after the load is transferred to mains Stop Solenoid Timer sec 90 10 This is the maximum time duration for the engine to stop During this period the STOP relay output is energized if assigned by Relay Definitions If the genset has not stopped after this period a FAIL TO STOP warning occurs Number of Starts N
99. ic list of fault conditions x denotes any Firmware V 3 3 SPN FMI DESCRIPTION 94 X Fuel filter restriction Fuel pressure sensor fail 98 X Low oil level High oil level Oil level sensor fail 100 X Low oil pressure Oil pressure sensor fail 102 X High boost pressure Turbo outlet pressure sensor fail 105 X Intake manifold temp high Intake manifold temp sensor fail 107 X Air filter restriction Air filter sensor fail 108 X Athmospheric pressure sensor fail 110 X High coolant temperature Coolant temperature sensor fail 111 X Low coolant level Coolant level sensor fail 164 X High injector activation pressure Injector activation pressure sensor fail 168 X Battery voltage failure 172 X High inlet air temperature High inlet manifold air temperature Inlet manifold air temperature sensor fail 174 X High fuel temperature Fuel temperature sensor fail 175 X High oil temperature Oil temperature sensor fail 190 x Overspeed Speed sensor loss of signal Speed sensor mechanical failure 228 X Timing calibration required 234 X Incorrect ecm software 620 X ECU internal 5V fail 629 X ECU hardware fail 651 X Injector cylinder 1 fault 652 X Injector cylinder 2 fault 653 X Injector cylinder 3 fault 654 X Injector cylinder 4 fault 655 X Injector cylinder 5 fault 656 X Injector cylinder 6 fault 657 X Injector cylinder 7 fault 657 X
100. igure the site id parameter accordingly to the genset installation place Thus the same memory module may be used for recording in different controllers Inside the lt SITE ID gt directory the unit will open a separate directory for each year of recording The directory will be simply named by the year like 2012 2013 etc Inside the year directory the controller will record data in a different file for each day of recording The record file will be named YYYYMMDD like 20120331 representing March 31 2012 Thus alphabetical listing will produce a sorted list by date of recording The recorded file is of CSV comma separated values type This is a text file which can be directly opened with Microsoft Excel program without any loss of information It can be also opened with any text editor like Notepad program Inside the file each record consists of a line including a large set of measured parameters The recorded parameters list is not adjustable The controller records all practically necessary parameters 31 3 UNDERSTANDING THE CSV FORMAT The csv file is basically a text file format Thanks to this it can be opened by any text editor in any operating system When opened with the Microsoft Excel program the values will appear in tabulated form enabling application of formulas graphs and other features of Excel program K35D03 EN 121 D 500 User Manual Rev_04 Firmware V 3 3 31 4 RECORDED DATA LIST RECORD PER
101. ility It will run the engine and transfer the load when a mains failure occurs If a panel lock input is defined and signal is applied then mode change will not occur However display navigation buttons are still enabled and parameters may be visualized The mains availability evaluation sequence is below If at least one of the mains phase voltages or the mains frequency is outside limits the mains will be supposed failing Otherwise mains is available Ifa Simulate Mains signal is present then mains are made available Ifa Force to Start signal is present then mains are unavailable Ifa Remote Start input is defined then this signal decides of mains availability When mains are evaluated as unavailable then an engine start sequence begins The unit waits during Engine Start Delay for skipping short mains failures If the mains is restored before the end of this timer the genset will not start The unit turns on the fuel and preheat glow plugs if any and waits for preheat timer The engine will be cranked for programmed times during crank timer When the engine fires the crank relay will be immediately deactivated See section Crank Cutting for more details The engine will run at idle speed during Idle Speed Timer The engine will run unloaded during engine heating timer If alternator phase voltages frequency and phase order are correct the unit will wait for the generator cont
102. ing no fault condition from this input always on engine running after hold off timer reserved non latching The fault disappears when cause is removed Latching 0 1 1 latching The fault persists even if th cause is removed Requires manual reset Normally open Normally closed Battery negative Battery positive No delay Delayed 1sec Delayed 5sec Delayed 10sec Action 0 3 Sampling 0 3 NM a Contact type 0 1 Switching 0 1 Response delay 0 3 Oo K35D03 EN 99 D 500 User Manual Rev_04 INPUT FUNCTION LIST Firmware V 3 3 K35D03 EN 100 No Description No Description No Description 1 User Defined Function 41 Over Resonance 81 2 Low Oil Press Switch 42 Short Circuit Alarm 82 3 High Temp Switch 43 Reset Service 1 Alm 83 l 4 Coolant Level Switch 44 Reset Service 2 Alm 84 5 Rectifier Fail Switch 45 Reset Service 3 Alm 85 6 Emergency Stop 46 Heavy Duty 86 7 Alternator High Temp 47 Synchro Genset Run 87 8 Excitation Loss Sw 48 Synch Genset on Load 88 9 Low Fuel Switch 49 Program Lock 89 10 Earthquake Detector 50 Fire Circuit Press Sw 90 11 Gen Cont
103. ing when mains voltages status is changed No warnings generated 0 no SMS on mains failed or restored 1 SMS sent on mains failed or restored SMS on IP Change This parameter controls SMS sending when IP address of GPRS connection is changed No warnings generated 0 no SMS on IP change 1 SMS sent on IP change E mail on IP Change This parameter controls e mail sending when IP address of GPRS or ethernet connection is changed No warnings generated 0 no e mail on IP change 1 e mail sent on IP change Fuel Pump Low Limit 100 20 If the fuel level measured from the sender input falls below this level then the FUEL PUMP function will become active Fuel Pump High Limit 100 80 If the fuel level measured from the sender input goes above this level then the FUEL PUMP function will become passive Warning Before Start This parameter controls the activation of the ALARM output during Engine Start Delay timer before engine run 0 no warning before start 1 warning before start Latch all Warnings 0 warnings are latching non latching on parameter control 1 all warnings are latched Even if the fault source is removed warnings will persist until manually reset Remote Control Enable This parameter controls remote control of the unit through Rainbow Modbus and Modbus TCP IP 0 remote control disabled 1 remote control enabled Annunciator Mode
104. ing Low Limit thus the Load Add output becomes inactive 1 the load goes above the Load Shedding High Limit thus the Load Substract output becomes active 14 the load goes below the Load Shedding High Limit thus the Load Substract output becomes inactive ts the load goes below the Load Shedding Low Limit but the Load Substract Add delay is not expired The controller waits until expiration of the timer ts the timer is expired and the load is still below the Load Shedding Low Limit the Load Add output becomes active t7 the load goes above the Load Shedding Low Limit thus the Load Add output becomes inactive K35D03 EN 124 D 500 User Manual Rev_04 Firmware V 3 3 32 3 FIVE STEP LOAD MANAGEMENT The controller is able to manage the supply of up to 5 prioritized loads The loads are supplied starting from the number 1 highest priority and unloaded from the highest number lowest priority available Protection timers help to stabilizing the decision algorithm and preventing unwanted multiple operations When the load is below the Multi Load Add Power Level during Multi Load Add Start Delay then 1 step of load is added The minimum wait period between two load_adds is Multi Load Add Wait Delay When the load is above the Multi Load Substract Power Level during Multi Load Substract Start Delay then 1 step of load is unloaded The minimum wait period between two load_substracts is Multi Load Substract Wait Delay The
105. ing Relay On Timer program parameter After this usual Mains Waiting and Cooldown cycles will be performed before engine stop When the SIMULATE MAINS signal is present the front panels mimic diagram s mains LEDs will reflect the mains voltages as present When the signal is passive the unit will revert to normal operation and monitor the mains voltage status The REMOTE START operation overrides Disable Auto Start operation When both Remote Start Operation and Delayed Simulate Mains are enabled then REMOTE START operation mode is performed K35D03 EN 127 D 500 User Manual Rev_04 Firmware V 3 3 32 7 DUAL GENSET MUTUAL STANDBY OPERATION Dual genset intermittent operation consists of regular switching of the load between 2 gensets The use of 2 gensets instead of one is due either to safety purposes in case of a genset failure or to a continuous operation requesting service stops The running period for each genset is adjustable using Flashing Relay On Timer and Flashing Relay Off Timer program parameters If the time is adjusted as 0 hours it will be actually set to 2 minutes for faster testing purposes A flashing relay output function is provided based on the parameter Flashing Relay On Off Timers Each time the period programmed using Flashing Relay Timer elapses the relay output will change position The flashing relay function may be assigned to any digital output using Output Configuration program par
106. ion will be enabled for 10 seconds K35D03 EN 133 D 500 User Manual Rev_04 Firmware V 3 3 38 MODBUS COMMUNICATIONS This chapter is a brief description of the Modbus properties of the controller For a complete documentation please use D 500 D 700 Modbus Application Manual The unit offers the possibility of MODBUS communication through below carriers RS485 serial port with adjustable baud rate between 2400 and 115200 bauds MODBUS TCP IP through Ethernet port 10 100Mb MODBUS TCP IP through GPRS 85 42kb client mode through Rainbow Scada only The MODBUS properties of the unit are Data transfer mode RTU Serial data selectable baud rate 8 bit data no parity 1 bit stop Modbus TCP IP Ethernet 10 100Mb or GPRS Class 10 Supported functions Function 3 Read multiple registers Function 6 Write single register Function 16 Write multiple registers Each register consists of 2 bytes 16 bits A larger data structure will contain multiple registers The Modbus communications requires a slave address to be assigned to each device in the Modbus network This address ranges between 1 and 240 and allows the addressing of different slave devices in the same network Each device in the same RS 485 serial network must be assigned a different slave address Otherwise the Modbus communications will not be performed Devices using Modbus TCP IP with different IP or port addresses may use any slave address
107. ise will be immediately terminated Using the weekly exercise mode and with suitable parameter setting the unit may feed the load from the genset during predefined hours of each day This operation may be used in high tariff periods of the day 37 12 WEEKLY OPERATION SCHEDULER In most applications the genset is requested to operate only in working hours Thanks to the weekly program feature unwanted operation of the genset may be prohibited The scheduler is active only in AUTO mode When the scheduler prevents genset operation in AUTO mode the AUTO led will flash When the scheduler prevents genset operation in AUTO mode the AUTO led will flash The scheduler consists of 144 programmable parameters one for each hour in a week Thus every hour of the week may be independently selected as ON or OFF times These programmable parameters allow the genset to operate automatically only in allowed time limits The unit has a battery backed up precision real time clock circuit The real time clock circuit will continue its operation even in power failures The real time clock is precisely trimmed using the Real Time Clock Adjust program parameter For more details check the programming section K35D03 EN 130 D 500 User Manual Rev_04 Firmware V 3 3 37 13 ENGINE HEATING OPERATION Especially on engines without a body heater or with a failing one it may be desired that the genset should not take the load before reaching a su
108. it it means that the mains are off and starts the transfer to the genset in AUTO mode The value is defined with reference to Nominal Voltage Mains Voltage Fail Timer sec If at least one of the mains phase voltages goes outside of the limits during this timer it means that the mains are off and it starts the transfer to the genset in AUTO mode Instant Mains Dropout 50 If the mains phase voltages outside limits but not more than this parameter with reference to nominal voltage then the genset will run without releasing the mains contactor When the genset is ready to take the load the load will be transferred If this parameter is set to zero then the mains contactor is immediately released at mains failure K35D03 EN 81 D 500 User Manual Rev_04 Firmware V 3 3 16 2 ELECTRICAL PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Description Set If the mains frequency goes under this Mains Frequency Low limit it means that the mains are off and Limit F 100 F 100 F 10 starts the transfer to the gensetin AUTO mode The value is defined with reference to Nominal Frequency If the mains frequency goes over this Mains Frequency High limit it means that the mains are off and Limit 96 F 100 F 100 F 10 starts the transfer to the gensetin AUTO mode The value is defined w
109. itable temperature The unit offers 2 different ways of engine heating 1 Timer controlled heating This operation mode is selected when the Engine Heating Method parameter is set to 0 In this mode the engine will run during parameter Engine Heating Timer and then the genset will take the load 2 Timer and temperature controlled heating This operation mode is selected when the Engine Heating Method parameter is set to 1 In this mode at first the engine will run during parameter Engine Heating Timer then it will continue to run until the measured coolant temperature reaches the limit defined in parameter Engine Heating Temperature When the requested temperature is reached the load will be transferred to the genset This operation mode may be used as a backup to the engine body heater If the engine body is warm the heating will be skipped 37 14 ENGINE IDLE SPEED OPERATION It may be required that the engine runs at the idle speed for a programmed duration for engine heating The idle operation duration is adjusted with the parameter Idle Speed Timer The idle speed will be set by the governor control unit of the engine Any digital output may be assigned as IDLE output using Relay Definition program parameters The Idle speed operation is performed both in engine start up and cool down sequences Low speed and low voltage protections are disabled during idle speed operation 37 15 ENGINE BLOCK HEATER The unit is able to provid
110. ith reference to Nominal Frequency If the mains frequency goes outside of Mains Frequency Fail 0 10 1 the limits during this timer it means that Timer the mains are off and starts the transfer to the genset in AUTO mode If one of the genset phase voltages goes Genset Low Voltage 5 under this limit when feeding the load Warning Limit V 100 V 100 V 15 this will generate GENSET LOW VOLTAGE warning If one of the genset phase voltages goes Genset Low Voltage under this limit when feeding the load Shutdown Limit 96 100 V 100 V 20 this will generate GENSET LOW VOLTAGE shutdown alarm and the engine will stop If one of the genset phase voltages goes Genset High Voltage 5 o over this limit when feeding the load this Warning Limit generate GENSET HIGH VOLTAGE warning If one of the genset phase voltages goes Genset High Voltage over this limit when feeding the load this Shutdown Limit 96 100 V 100 V 20 will generate a GENSET HIGH VOLTAGE shutdown alarm and the engine will stop If at least one of the genset phase Genset Voltage Fail S58 0 10 1 voltages goes outside of the limits Timer during this timer a genset voltage fault will occur If the genset frequency goes under this Genset Low Frequency 5 o limit when feeding the load this will Warning Limit reve generate a GENSET LOW FREQUENCY warning If the genset frequency goes under this Genset Low Fre
111. lt is not monitored Genset Reverse Power Loaddumpg Limit kW 50000 If the genset power is negative and goes above this limit then a REVERSE POWER loaddump will be generated Genset Reverse Power Fail Timer sec 120 If the genset power is negative and over limits during this timer a reverse power fault will occur Genset Overcurrent Limit Amp 50000 If one of the genset phase currents goes over this limit when feeding the load this will generate a genset overcurrent fault condition The action taken upon fault condition is programmable If this parameter is set to 0 then overcurrent fault is not monitored Genset Overcurrent Limit 2 Amp 50000 When secondary voltage is selected if one of the genset phase currents goes over this limit when feeding the load this will generate a genset overcurrent fault condition The action taken upon fault condition is programmable If this parameter is set to 0 then overcurrent fault is not monitored Genset Overcurrent Action 0 shutdown alarm 1 loaddump alarm Overcurrent Time Multiplier 64 This parameter defines the reaction speed of the overcurrent detector A higher number means higher sensitivity Detailed explanation is given at chapter Overcurrent Protection Genset Overload Limit kW 50000 If the total genset active power goes over this limit when feeding the load this will generate a genset overload load
112. m goes over the High RPM Shutdown Limit by this quantity jx a es this will generate immediately a GENSET HIGH RPM shutdown alarm and the engine will stop 0 speed signal existency not checked 1 If the speed signal is lost it will Loss of Signal Check 0 1 0 generate a Speed Signal Lost fault condition The action taken upon fault condition is programmable 0 shutdown alarm 41 speed signal 0 2 0 1 loaddump alarm 2 warning If the speed signal is lost during this 0 240 0 timer a Speed Signal Lost fault will imer occur If the charge alternator voltage goes Low Charge Voltage V DC 0 40 6 0 under this limit a charge alternator Warning Limit voltage warning will occur If the charge alternator voltage goes Low Charge Voltage under this limit a charge alternator Shutdown Limit VBL 0 an T9 voltage shutdown will occur and the engine will stop If the charge alternator voltage goes vokage Fal sec 0 120 1 under limits during this timer a charge imer alternator voltage fault will occur K35D03 EN 88 D 500 User Manual Rev_04 Firmware V 3 3 16 3 ENGINE PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Set Description Engine Heating Temperature C 80 If it is requested that the engine runs without load until reaching a certain temperature this parameter defines the temperature Engine Start Delay min 240 T
113. m mode is entered below password entry screen will be displayed GEH PHASE VOLTAGES Press 2 0 buttons 5 for 5 seconds ROGRAMMING Enter Tour Password CJ x CA A 4 digit password must be entered using V and MENU buttons The V A buttons modify the value of the current digit The MENU buttons navigate between digits The unit supports 3 password levels The level 1 is designed for field adjustable parameters The level 2 is designed for factory adjustable parameters The level 3 is reserved It allows recalibration of the unit The password level 1 is factory set to 1234 and the password level 2 is factory set to 9876 Passwords are not front panel adjustable If a wrong password is entered the unit will still allow access to the program parameters but in read only mode If password 0000 is entered only EVENT LOG file will be available K35D03 EN 73 D 500 User Manual Rev_04 Firmware V 3 3 15 3 NAVIGATING BETWEEN MENUS The program mode is driven with a two level menu system The top menu consists on program groups and each group consists on various program parameters When program mode is entered a list of available groups will be displayed Navigation between different groups are made with Wand Abuttons Selected group is shown in reverse video blue on white In order to enter inside a group please press MENU button In or
114. me clock circuit Values from 0 to 63 Real Time Clock Adjust 0 255 117 speed up the clock with 0 25sec day steps Values from 127 to 64 slow down the clock with 0 25sec day steps This parameter provides the mains and genset voltage limits with a hysteresis feature in order to prevent faulty decisions For example when the mains are present the mains voltage low limit will be used as the programmed low limit When the mains fail the low limit will be incremented by this value It is advised to set this value to 8 volts Hysteresis Voltage V AC 0 30 8 0 Genset control u L 0 1 Engine control no alternator This parameter is used for frquency to rpm conversion For a 1500 1800 rpm engine select 2 For a 3000 3600 rpm engine select 1 Alternator Pole Pairs 1 8 2 0 read rpm from the MPU input 0 1 1 1 convert frequency to rpm using Alternator Pole Pairs RPM from genset frequency This is the number of pulses generated Crank Teeth Count 1 244 30 by the magnetic pickup sensing unit in one turn of the flywheel 0 Use primary volt frequency limits Secondary Volt Freq l i l k 1 Use secondarv volt frequencv limits K35D03 EN 78 D 500 User Manual Rev_04 Firmware V 3 3 16 1 CONTROLLER CONFIGURATION GROUP continued Parameter Definition Unit Min Max Factory Set Description SMS on Mains Change This parameter controls SMS send
115. n APN User Name The APN access point name username may be required by the GSM operator However some GSM operators may allow access without username The exact information should be obtained from the GSM operator Please search the GSM operators website with APN string APN Password If the APN access point name username is required by the GSM operator most probably the APN password will also be required However some GSM operators may allow access without password The exact information should be obtained from the GSM operator Please search the GSM operator s website with APN string APN Name The APN access point name is always required by the GSM operator The exact information should be obtained from the GSM operator Please search the GSM operator s website with APN string SMS Service Center Number The SMS service center number may be required by the GSM operator However some GSM operators may allow SMS sending without SMS service center number The exact information should be obtained from the GSM operator Please search the GSM operators website with sms service center string A Below GSM modem related parameters are found in the Controller Configuration group Parameter Definition Factory Description Unit Min Max Set GSM Sim Card Pin If the GSM SIM card uses pin number enter the pin number here If incorrect pin number is entered then the
116. n IP professional please leave this address as 255 255 255 0 User IP Mask 1 2 3 255 255 255 255 0 0 0 0 0 0 0 0 These 3 registers control the IPv4 access to the unit The remote IPv4 address is logical AND ed with these IP addresses If the result gives the remote IP address then access is enabled Thus access may be limited to the same LAN members x x x 255 or strictly to predefined IPv4 addresses Domain Name d500 dyndns ip com This string is used in Dynamic DNS feature The unit will register itself to the dynamic DNS server under this name For more detailed information please review chapter on Dynamic DNS Feature and the document Dynamic DNS Account Setting Membership Address members dyndns org This string is used in Dynamic DNS feature This is the address used in registering to the dynamic DNS server For more detailed information please review chapter on Dynamic DNS Feature and the document Dynamic DNS Account Setting Username Password These strings are used in Dynamic DNS feature while registering to the dynamic DNS server For more detailed information please review chapter on Dynamic DNS Feature and the document Dynamic DNS Account Setting Ping Address www google com This internet address is regularly accessed in order to check the availability of internet access The access period is defined in parameter Controller Configuration gt Ping
117. n current phase L3 Gen average current Gen frequency Gen kW phase L1 Gen kW phase L2 Gen kW phase L3 Gen total kW Gen kVA phase L1 Gen kVA phase L2 Gen kVA phase L3 Gen kVAr phase L1 Gen kVAr phase L2 Gen kVAr phase L3 Gen pf phase L1 Gen pf phase L2 Gen pf phase L3 Gen total pf Neutral current Oil pressure bar amp psi Coolant temperature C amp F Fuel level Oil temperature C amp F Canopy temperature C amp F Engine speed rpm Battery voltage Charge input voltage Engine hours 122 D 500 User Manual Rev_04 Firmware V 3 3 32 SOFTWARE FEATURES 32 1 LOAD SHEDDING DUMMY LOAD The load shedding feature consists on the disconnection of the least crucial loads when the genset power approaches to its limits These loads will be supplied again when the genset power falls below the programmed limit The internal Load Shedding function is always active Any digital output may be used as the load shedding output The dummy load function consists on the connection of a dummy load if the total genset load is below a limit and to disconnection of the dummy load when the total power exceeds another limit The dummy load function is the inverse of the load shedding function thus the same output may be used for both purposes It is also possible to control more complex external systems with multiple steps using LOAD_ADD and LOAD_SUBSTRACT output functions Any digital output may be
118. nabled Fault Holdoff Timer sec 120 12 This parameter defines the delay after the engine runs and before the fault monitoring is enabled Alarm Relay Timer sec 120 60 This is the period during which the ALARM relay is active If the period is set to 0 this will mean that the period is unlimited Intermittent Alarm Relay 0 continuous 1 intermittent turns on and off every second Emergency Backup Operation 0 In RUN mode the load will not be transferred to the genset even if the mains fails 1 In RUN mode the load will be transferred to the genset if the mains fails Exerciser Enable 0 automatic exerciser disabled 1 automatic exerciser enabled Exercise Period 0 exercise once per week 1 exercise once per month The exact exerciser day and time is adjusted within the EXERCISE SCHEDULE section Exercise Off On Load 0 Exercise at RUN mode 1 Exercise at TEST mode K35D03 EN 76 D 500 User Manual Rev_04 Firmware V 3 3 16 1 CONTROLLER CONFIGURATION GROUP continued Parameter Definition Unit Min Max Factory Description Set 0 delayed simulate mains disabled Delayed Simulate Mains l l 0 1 simulate mains enabled 0 not used 1 Internal GSM modem Modem Selection 0 4 0 2 external GSM Datakom modem 3 external GSM g
119. nchronizing back to mains 18 load transfer to mains 19 mains cb activation 20 mains cb timer 21 stop with cooldown 22 cooling down 23 engine stop idle speed 24 immediate stop 25 engine stopping 10605 R 16bit Unit mode 0 STOP mode 1 AUTO mode 2 MANUAL mode 3 TEST mode 10606 R 16bit x1 Genset operation timer In various wait statuses the genset operation status will change at the expiration of this timer 10610 R 16bit Device hardware version information 10611 R 16bit Device software version information 10616 R 32bit x1 Counter number of genset runs 10618 H 32bit x1 Counter number of genset cranks 10620 R 32bit x1 Counter number of genset on load 10622 R 32bit x100 Counter engine hours run 10624 R 32bit x100 Counter engine hours since last service 10626 R 32bit x100 Counter engine days since last service 10628 R 32bit x10 Counter genset total active energy KWh 10630 H 32bit x10 Counter genset total inductive reactive energy kVArh ind 10632 R 32bit x10 Counter genset total capacitive reactive energy KVArh cap 10634 R 32bit x100 Counter remaining engine hours to service 1 10636 R 32bit x100 Counter remaining engine days to service 1 10638 H 32bit x100 Counter remaining engine hours to service 2 10640 H 32bit x100 Counter remaining engine days to service 2 10642 R 32bit x100 Counter remaining engine hours to service 3 10644 R 32bit x100 Counter remaining engine days to service 3 K35D03 EN 187
120. ng Alarm List Genset Operation Mode Remote Controlled Digital Outputs A The SNMP MIB file is available at Datakom Technical support K35D03 EN 138 D 500 User Manual Rev_04 Firmware V 3 3 39 1 PARAMETERS REQUIRED FOR SNMP VIA ETHERNET Modbus Slave Address may be set between 1 and 240 If only one unit is available in the same IP address it is advised to keep the default address 1 Ethernet Enable This parameter should be set to 1 or checked in order to enable the ethernet port Modbus TCP IP Port The usual setting is 502 However the unit is able to work on any port address User IP Mask There are 3 mask registers available The use of the registers are emphasized in the D 500 700 User Manual Please set the first mask as 255 255 255 0 for the proper operation Ethernet Network IP May be left as 0 0 0 0 for automatic address claim or set to a value in order to claim a defined address Ethernet Gateway IP Should be set in accordance with your local switch configuration Ethernet Subnet Mask Should be set in accordance with your local switch configuration The complete Ethernet port specifications are found in the D 500 700 User Manual Please rewiev the document Ethernet Configuration Guide for D 500 700 for more details about the ethernet port setup K35D03 EN 139 D 500 User Manual Rev_04 Firmware V 3 3 40 DECLARATION OF CONFORMITY The unit conforms to the EU directives 2006 95 EC low voltage 20
121. nufacturer 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 Current Transformers must be used for current measurement No direct connection allowed D 500 User Manual Rev_04 Firmware V 3 3 TABLE OF CONTENTS 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
122. odule may be assigned to this function To turn off the SERVICE REQUEST led and reset the service period press together the ALARM MUTE and LAMP TEST keys for 5 seconds K35D03 EN 50 D 500 User Manual Rev_04 Firmware V 3 3 9 2 PUSHBUTTON FUNCTIONS FUNCTION Selects TEST mode The genset runs and takes the load Selects RUN mode The genset runs off load Selects AUTO mode The genset runs when necessary and takes the load Selects OFF mode The genset stops Selects next display screen in the same display group LAMP TEST when held pressed Selects previous display group Selects next display group Selects previous display screen in the same display group Resets the ALARM RELAY Manual MAINS CONTACTOR control in RUN mode Manual GENSET CONTACTOR control in RUN mode 00000000000 When held pressed for 5 seconds enters PROGRAMMING mode 000 Makes factory reset Please review chapter RESETTING TO FACTORY DEGAULTS for more details When held pressed for 5 seconds resets service request counters Please review chapter SERVICE REQUEST ALARM for more details K35D03 EN 51 D 500 User Manual Rev_04 Firmware V 3 3 9 3 DISPLAY SCREEN ORGANIZATION The unit measures a large number of electrical and engine parameters The display of the parameters is organized as PARAMETER GROUPS and items in a group Navigation between diff
123. om total discharge when the genset has not run for a long time Related parameters Battery Charge Run Voltage If this parameter is different from zero and the engine battery voltage falls below this limit then the controller will run the engine unloaded in order to charge engine battery The running duration is determined by the Battery Charge Run Timer parameter Battery Charge Run Timer This parameter determines the engine battery charge running duration The minimum run time is 2 minutes 37 20 EXTERNALLY CONTROLLED DIGITAL OUTPUTS The controller offers 16 externally controllable digital output functions These output functions have no effect in the operation of the unit however they can be redirected to any digital output allowing remote control of functions or external devices The remote control of these outputs are enabled through Modbus Modbus TCP IP and Rainbow Scada remote control functions The outputs are in 16 bits of the same Modbus register placed at address 11559d Output statuses are kept in a non volatile memory and are not affected by power failures Please review the Modbus manual for more details 37 21 COMBAT MODE The controller offers a combat mode input function When a digital input is defined as Combat Mode and signal applied to this input the controller will turn off all led lamps and the backlight illumination 10 seconds after any key is pressed When a button is pressed the illuminat
124. or more details Mains MCB Undervoltage Coil Timer sec 0 5 The mains MCB_undervoltage coil is energized during this period before the mains MCB close relay is activated Review chapter Motorized Circuit Breaker Control for more details Mains MCB Fail Timer sec 2 0 If a mains MCB feedback input is defined and if the mains MCB fails to change position before the expiration of this timer then a fault condition occurs Mains Phase Order Check Enable 0 mains phase order checking disabled 1 if mains phase order is faulty then a warning is given and mains contactor deenergized Genset Contactor Timer sec 600 0 5 This is the period after the mainscontactor has been deactivated and before the genset contactor has been activated Genset MCB Close Pulse sec 0 5 After the genset MCB_undervoltage coil is energised and genset MCB_undervoltage coil timer is elapsed the genset MCB close relay will be activated during this period Review chapter Motorized Circuit Breaker Control for more details Genset MCB Open Pulse sec 0 5 The genset open relay will be activated during this period Review chapter Motorized Circuit Breaker Control for more details Genset MCB Undervoltage Coil Timer sec 0 5 The genset MCB_undervoltage coil is energised during this period before the genset MCB close relay is activated Review chapter Motorized Circ
125. owed by the IDMT curve setting The allowed timer is dependent of the overcurrent level If currents go below the limit before expiration of the timer then no alarm will be set Please check chapter Overcurrent Protection IDMT for more details The action taken at fault condition is programmable PICKUP SIGNAL LOST Set if the rom measured from the magnetic pickup input falls below the Crank Cut RPM level during Loss of Speed Signal Timer The action of signal loss is programmable SERVICE REQUEST Set if at least one of the service counters has expired In order to reset the service counters please hold pressed both with and seconds The screen will display Completed buttons during 5 K35D03 EN 68 D 500 User Manual Rev_04 Firmware V 3 3 14 4 LOADDUMP ALARMS Digital input and analog sender alarms are fully programmable for the alarm name sampling and action Onlv internal alarms are explained in this section VOLTAGE UNBALANCE Set if any of the generator phase voltages differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running CURRENT UNBALANCE Set if any of the generator phase currents differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running The
126. owever the existing alarms will persist and disable the operation of the genset Alarms may be of LATCHING type following programming For latching alarms even if the alarm condition is removed the alarms will stay on and disable the operation of the genset Existing alarms may be canceled by pressing one of the operating mode buttons 006 Most of the alarms have programmable trip levels See the programming chapter for adjustable alarm limits K35D03 EN 66 D 500 User Manual Rev_04 Firmware V 3 3 14 1 DISABLING ALL PROTECTIONS The unit allows any digital input to be configured as Disable Protections This input configuration is used in cases where the engine is required to run until destruction This may be the case under critical conditions like fire fighting or other emergency cases This input should be configured as a Warning Thus when protections are disabled a warning message will immediately appear on the screen When protections are disabled all shutdown alarms and loaddumps will become warnings They will appear on the screen but will not affect genset operation The input may be constantly activated or preferably it may be activated by an external key activated switch in order to prevent unauthorized activation Disabling protections will allow the genset run until destruction Place written warnings about this situation in the genset room 14 2 SERVICE REQUEST ALARM The SE
127. parameters used in Load Shedding feature are in the Electrical Parameters Group Multi Load Substract Power Level When the genset active power goes over this limit the controller will start substracting load as described in chapter Five Step Load Management Multi Load Add Power Level When the genset active power goes below this limit the controller will start adding load as described in chapter Five Step Load Management Multi Load Subsiract Start Delay If the load stays over the Multi Load Substract Power Level parameter during this timer then 1 step of load is substracted Multi Load Substract Wait Delay This is the minimum period between two load subtract operations Multi Load Add Start Delay If the load stays below the Multi Load Add Power Level parameter during this timer then 1 step of load is added Multi Load Add Wait Delay This is the minimum period between two load addt operations SUBSTRACT LIMIT ADD LIMIT we LOAD LEVEL TIME OUTPUT tian tap tisp LOAD SUBSTRACT_1 OUTPU OUTPUT zz OR ta ts LOAD SUBSTRACT_2 IIL 3 sec OUTPU ti te 4 t1 the load goes below the Multi Load Add Power Level 12 after Multi Load Add Start Delay the load is still below Multi Load Add Power Level the Load_Add_1 becomes active 1 after Multi Load Add Start Delay and Multi Load Add Wait Delay the load is still below Multi Load Add Power Level
128. quency limit when feeding the load this will Shutdown Limit 100 F 100 F 20 generate GENSET LOW FREQUENCY shutdown alarm and the engine will stop K35D03 EN 82 D 500 User Manual Rev_04 Firmware V 3 3 16 2 ELECTRICAL PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Description Set If the genset frequency goes over this Genset High Frequency A o limit when feeding the load this will Warning Limit 7 F 100 F 100 F 15 Jenerate a GENSET HIGH FREQUENCY warning If the genset frequency goes over this Genset High Frequency limit when feeding the load this will Shutdown Limit F 100 F 100 F 20 generate a GENSET HIGH FREQUENCY shutdown alarm and the engine will stop If the genset frequency goes outside of a Frequency Fan Sec 0 10 1 the limits during this timer a genset frequency fault will occur Low Battery Voltage If the battery voltage falls below this Warning Limit V DC 5 0 35 0 12 0 limit this will generate a LOW BATTERY warning If the battery voltage falls below this Low Battery Voltage limit this will generate a LOW Shutdown Limit wpe 28 52 90 BATTERY shutdown alarm and the engine will stop f the battery voltage goes over this limit Piga Sanary volage 50 350 29 0 this will crete a HIGH BATTERY Warning Limit warning If the battery voltage goes over this High Battery Voltage limi
129. r 00 a snivis SH31NnOO9 S TATI 1VN9SIS SIOA 5 2 1 SIOA 6 2 1 SLIDA S39V I110A NOISH3A MS SSatid S39V I10A 135339 SS3HQQV dl SNLVLS NSD N Hd 5 N Hd 5 SNIVIN 39095 9 SNIVIN 3dAL 3NION3 L d3aN3s l135N39 4 SIN3LI nN3IA HS c 2 6 Sualaiwvuvd SH3LJAVHVd SH3LJAVHVd e 2 SH3L1Nno3 SHualdiVvuvd AV IdSIa Sualaivuvd SualaiWvuvd LLI o SNLYLS I3NH3H13 SISATVNV SISATVNV IWNHOJJAVM JNIZINOHHIS 7219199719 5 ANION 121919913 JINOWHVH JINOINHVH SNIVIAN 13SN39 1 2 4 e e 9 4 SINSLI NNW NIVIN m D 500 User Manual Rev_04 Firmware V 3 3 9 5 MEASURED PARAMETERS The unit performs a detailed set of AC measurements Mains currents and power parameters listed in blue color are measured and displayed only if CTs are placed at load side please see connection diagrams section for more details The list of measured AC parameters is below Mains voltage phase L1 to neutral Gen voltage phase L1 to neutral Mains voltage phase L2 to neutral Gen voltage phase L2 to neutral Mains voltage phase L3 to neutral Gen voltage phase L3 to neutral Mains average voltage phase to neutral Gen average voltage phase to neutral Mains voltage phase L1 L2 Gen voltage phase L1 L2 Mains voltage phase L2 L3 Gen voltage phase L2 L3 Mains voltage phase L3 L1 Gen voltage phase L3 L1 Mains frequency Mains current phase L1 Mains current phase L2
130. r enabled Enable 1 no break transfer enabled If the phase and voltage synchronization is not successful before Synchronization Fail 0 240 30 the expiration of this timer then Timeout Synchronization Fail warning is given and the transfer will be performed with interruption When synchronization is detected both sec 0 25 0 5 contactors will stay closed during this timer Synchronization Contactor Timeout This is the maximum difference Max Freq Difference Hz 0 1 2 0 0 5 between mains and genset frequencies to close both contactors This is the maximum difference between the mains phase L1 and the genset phase L1 voltages to close both contactors If voltage transformer is used this quantity is multiplied with voltage transformer ratio Max Volt Difference VAC 0 20 5 This is the maximum phase angle between the mains phase L1 and the genset phase L1 voltages to close both contactors Max Phase Difference deg 0 20 10 K35D03 EN 107 D 500 User Manual Rev_04 Firmware V 3 3 17 CRANK CUTTING In order to insure fast and reliable crank cutting the unit uses various resources for engine running condition detection Cranking is stopped when at least one of below conditions is met Crank timer expired The crank timer is adjusted through Engine Parameters gt Crank Timer The maximum allowed timer is 15 seconds Genset AC voltage over threshold If the g
131. remote controlled output 1 to active state OUT 1 ON OUT1 OFF Sets remote controlled output 1 to passive state OUT 1 OFF OUTxx ON Sets remote controlled output xx to active state xx denotes any number OUT xx ON between 1 and 16 OUTxx OFF Sets remote controlled output xx to passive state xx denotes any number between 1 and 16 OUT xx z OFF K35D03 EN de D 500 User Manual Rev_04 Firmware V 3 3 30 LOAD TRANSFER MODES The unit offers 2 ways of transferring the load from genset to mains and vice versa transfer with interruption no break transfer with or without synchronization 30 1 TRANSFER WITH INTERRUPTION This is the most conventional way of transferring the load between the genset and mains There will be a power interruption period during the transfer Note that the program parameters Mains Contactor Timer and Genset Contactor Timer define the power interruption period interlock between the two contactors to prevent an accidental phase to phase short circuit A If this transfer method is used it is advised to make an electrical Transfer from genset to mains The generator contactor releases The unit waits for Mains Contactor Timer The mains contactor is energized Transfer from mains to genset The mains contactor releases The unit waits for Generator Contactor Timer The generator contactor is energized K35D03 EN 118 D 500 User Manual Rev_04 Firmware V 3 3
132. req Difference This is the maximum phase angle between the mains phase L1 and the genset phase L1 voltages to close both contactors K35D03 EN 119 D 500 User Manual Rev_04 Firmware V 3 3 31 DATA RECORDING 31 1 DATA RECORDING MEDIA Data can be recorded in USB flash memory or MICRO SD memory card Both options are available As soon as a USB flash memory or a MICRO SD card is inserted the unit will start data recording and continue until the memory is removed eal USB HOST USB FLASH MEMORY MICRO SD Card Slot The USB Host port and MICRO SD card slot are available with COMM option Micro SD memory card has priority for data recording If both micro SD and USB Flash memories are inserted data will be recorded on micro SD memory If USB Device is plugged then USB Host port will not function K35D03 EN 120 D 500 User Manual Rev_04 Firmware V 3 3 31 2 DIRECTORY STRUCTURE The unit will record data in either an USB Flash memory or a micro SD flash memory card The record structure is the same in both cases GENSET 01 2012 i 2011 20121231 csv 20121230 5 Last day of the vear 20120101 csv 20111231 First day of the year 20120101 csv The unit will record data in a directory named with the first 11 characters of its site id parameter In order to avoid confusion between records it is highly recommended to conf
133. riority Buzzer Enable Event Logs Enable Periodic ore Warming v Mode Change Latch All Warnings Entrance v Mains Fail E GENSET LOW HIGH FREQUENCY Set if the generator frequency is outside programmed limits These faults will be monitored with Fault Holdoff Timer delay after the engine is running Low and high limits are separately programmable The detection delay is also programmable Another high frequency shutdown limit which is 1296 above the high limit is always monitored and stops the engine immediately GENSET LOW HIGH RPM Set if the generator rpm is outside programmed limits These faults will be monitored with Fault Holdoff Timer delay after the engine is running Low and high limits are separately programmable The detection delay is also programmable The high rpm overshoot limit is always monitored and stops the engine immediately GENSET LOW HIGH VOLTAGE Set if any of the generator phase voltages goes outside programmed limits for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running LOW HIGH BATTERY VOLTAGE Set if the genset battery voltage is outside programmed limits Low and high limits are separately programmable The detection delay is also programmable FAIL TO STOP Set if the engine has not stopped before the expiration of the Stop Timer LOW CHARGE VOLTAGE Set if the charge alternator
134. ription Current Transformer Primary Amp 5000 500 This is the rated value of current transformers All transformers must have the same rating The secondary of the transformer will be 5 Amps Voltage Transformer Ratio 5000 1 0 This is the voltage transformer ratio This value will multiply all voltage and power readings If transformers are not used the ratio should be set to 1 0 Nominal Voltage V AC 300 230 The nominal value of genset and mains voltages Voltage limits are defined by reference to this value Nominal Frequency Hz 500 50 The nominal value of genset and mains frequency Frequency limits are defined by reference to this value Nominal Voltage 2 V AC 300 120 When secondary voltage is selected this is the nominal value of genset and mains voltages Voltage limits are defined by reference to this value Nominal Frequency 2 Hz 500 60 When secondary frequency is selected this is nominal value of genset and mains frequency Frequency limits are defined by reference to this value Mains Voltage Low Limit 96 V 100 V 100 V 20 If one of the mains phases goes under this limit it means that the mains are off and starts the transfer to the genset in AUTO mode The value is defined with reference to Nominal Voltage Mains Voltage High Limit V 100 V 100 V 20 If one of the mains phases goes over this lim
135. s balanced cable The RS 485 port features MODBUS RTU protocol Multiple modules up to 128 can be paralleled on the same RS 485 bus for data transfer to automation or building management systems The Modbus register list is available at Datakom technical support The RS 485 port provides also a good solution for distant PC connection where RainbowPlus program will enable programming control and monitoring For more details about programming control and monitoring through RS 485 port please refer to RainbowPlus user manual 3 13 J1939 CANBUS PORT Structure CANBUS non isolated Connection 3 wires CANH CANL GND Data rate 250 kbps Termination Internal 120 ohms provided Common mode voltage 0 5 VDC to 15 VDC internally clamped by transient suppressors Max distance 200m with 120 ohm balanced cable K35D03 EN 24 D 500 User Manual Rev_04 Firmware V 3 3 3 14 ETHERNET PORT Description IEEE802 3 compliant 10 100 Base TX RJ45 ethernet port with indicating leds Data rate 10 100 Mbits s auto detecting Ethernet Connector RJ45 Connector Cable type 5 or 6 Isolation 1500 VAC 1 minute Max distance 30m Functionality Embedded TCP IP Web Server Web Client SMTP e mail SNMP Modbus Data Flow TPAR led STANDARD ETHERNET CABLE Link Established led LED FUNCTIONS GREEN This led t
136. sary With a period of 1 minute 133MB is consumed per year LCD Backlight Dimming Delay min 1440 60 If no button is pressed during thiss period then the unit will reduce the LCD screen backlight intensity in for economy Fuel Filling Timer sec 36000 0 After activation of the fuel pump function if the Fuel Pump High Limit level is not reached then the fuel pump will stop for safety If this parameter is set to zero then the timer is unlimited SMS Commands Enabled 0 SMS commands not accepted 1 SMS commands are accepted but from listed telephone numbers only Open with Last Mode 0 The unit powers up in STOP mode 1 The unit powers up in the Isame operating mode before power down Pre Transfer Delay sec 60 0 If this parameter is not zero the unit will activate the Wait Before Transfer output function during this timer before initiating a load transfer This function is designed for elevator systems in order to bring the cabin to a floor and open doors before transfer E mail on mains change 0 No e mail at mains status changes 1 E mails sent at mains status change Enable Auto not Ready Warning 0 Auto not Ready Warning disabled 1 Auto not Ready Warning enabled K35D03 EN 80 D 500 User Manual Rev_04 Firmware V 3 3 16 2 ELECTRICAL PARAMETERS GROUP Parameter Definition Unit Min Max Factory Set Desc
137. ss 2 buttons for 5 seconds Enter Stour Password glI 1I 1Ix Skip the password entry screen by pressing the o button 4 times The screen below left will come Press again the o button The last stored event will open as in the below right picture The first page will display the event number event type fault type and date time information POISPLAY EVENT LOGG ENGINE SHUTDOWN Fail To Start 12 03 2012 19 55 14 When displaying event logs button will display the next information in the same event button will display the previous information the same event button will display the same information of the previous event e button will display the same information of the next event K35D03 EN 60 D 500 User Manual Rev_04 Firmware V 3 3 12 STATISTICAL COUNTERS The unit provides a set of non resettable incremental counters for statistical purposes The counters consist on total genset kWh total genset kVArh inductive total genset kVArh capacitive total engine hours total engine starts engine hours to service 1 time to service 1 engine hours to service 2 time to service 2 engine hours to service 3 time to service 3 These counters are kept in a non volatile memory and are not affected from power failures K35D03 EN 61 D 500 User Manual Rev_04 Firmware V 3 3 13 OPERATION OF THE UNIT 13 1 QUICK START GUIDE STOPPING THE ENGINE Press STOP STARTING
138. supply the load during a certain period The genset is requested to run only when battery voltage drops below the critical level Once the engine runs the rectifier system starts charging the batteries and the battery voltage goes up immediately Thus the engine should continue to run a programmed period for effective charging The critical battery voltage level will be detected by an external unit which provides the digital Disable Auto Start signal for the genset control unit The unit offers an optional Disable Auto Start signal input Any digital input be assigned as Simulate Mains using Input Function Select program parameters It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any alarms generated from this input The Disable Auto Start signal may be a NO or NC contact switching to either battery positive or battery negative These selections are made using the programming menu If the Delayed Simulate Mains program parameter is set to 1 and the input signal is active when the genset is not feeding the load the mains phases are not monitored and supposed to be inside limits This will prevent the genset from starting when the simulate mains signal is present batteries charged The genset will start when mains voltages are out of limits and the simulate mains signal not present If the genset is running when the signal is applied then MAINS SIMULATION will be prevented during Flash
139. surement Analog resistor measurement Open circuit voltage 3 3VDC Short circuit current 5mA Measurement range 0 to 5000 ohms Open circuit threshold 5000 ohms Resolution 1 ohms 300 ohms or lower Accuracy 2 1 ohm 7 ohms 2300 ohms Common mode voltage 3VDC range Noise filtering yes K35D03 EN 20 D 500 User Manual Rev_04 3 6 CHARGE INPUT TERMINAL The Charge terminal is both an input and output When the engine is ready to run this terminal supplies the excitation current to the charge alternator The excitation circuit is equivalent to a 2W lamp The threshold voltages for warning and shutdown alarm are adjustable through program parameter Structure battery voltage output through 20 ohm voltage measurement input resolution Output current 160mA 12VDC 80mA 24VDC Voltage measurement 0 1VDC Voltage measurement accuracy 2 0 1V 0 9V 30VDC Alarm Threshold Charge Fail Warning adjustable Threshold Charge Fail Shutdown adjustable Open circuit voltage battery positive Overvoltage protection gt 500VDC continuous with respect to battery negative Reverse voltage protection 30VDC with respect to battery negative 3 7 MAGNETIC PICKUP INPUT Structure Differential frequency measurement input Input impedance 50 k ohms Input voltage 0 5VAC RMS to 30VAC RMS
140. t this will generate a HIGH Shutdown Limit Re 30 52 BATTERY shutdown alarm the engine will stop If the battery voltage goes outside of the voltage Fail sec 0 10 3 limits during this timer a battery voltage fault will occur If any genset phase voltage differs from the average more than this limit it will Genset Voltage generate a Voltage Unbalance fault Unbalance Limit 0 100 0 0 condition The action taken upon fault condition is programmable If this parameter is set to 0 0 then voltage unbalance is not monitored 0 no action Genset Voltage l 0 3 0 1 shutdown alarm Unbalance Action 2 loaddump alarm 3 warning If any genset phase current differs from the average more than this limit it will Current generate a Current Unbalance fault Limit 0 100 0 0 condition The action taken upon fault condition is programmable If this parameter is set to 0 0 then voltage unbalance is not monitored 0 no action Genset Current _ 0 3 0 1 shutdown alarm Unbalance Action 2 loaddump alarm 3 warning K35D03 EN 83 D 500 User Manual Rev_04 Firmware V 3 3 16 2 ELECTRICAL PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Set Description Genset Reverse Power Warning Limit kW 50000 If the genset power is negative and goes above this limit then a REVERSE POWER warning will be generated If this parameter is set to 0 then reverse power fau
141. t display genset AC parameters volts amps kW and pf genset voltage and frequency protections are disabled However engine rpm protections will be active Note that the engine controller functionality is compatible with both AMF and Remote Start modes When AMF and Engine controller modes are selected the unit will monitor the mains and will run the engine upon mains failure This functionality is useful for the backup electric motor driven systems during mains failures like fire pump or irrigation systems When Remote Start and Engine controller modes are selected the unit will start and stop the engine with external signal only The unit features both MPU and J1939 CANBUS inputs Thus both mechanical and electronic engines are supported It is strongly recommended to wire speed detection through MPU or J1939 CANBUS and enter correct low and high rpm limit values in order to preserve engine speed protection K35D03 EN 38 D 500 User Manual Rev_04 Firmware V 3 3 5 6 REMOTE DISPLAY UNIT FUNCTIONALITY The unit is able to become the remote display and control panel of another identical module The connection between two modules is done through RS 485 ports For the best results a 120 ohms balanced low capacitance cable should be used The data rate between modules is selectable between 2400 and 115200 bauds A high data rate offers better synchronization between modules but the distance will be limited Typicall
142. ter TOPOLOGIES 2 phase 3 wire L1 L2 1 2 phase 3 wire L1 L3 2 3 phase 3 wire 3 3 phase 3 wire 2CTs L1 L2 4 3 phase 3 wire 2CTs L1 L3 5 6 e 3 phase 4 wire star 3 phase 4 wire delta single phase 2 wire J Genset Connection Topology This is the connection topology of genset voltages and CTs Detailed explanations are given in the chapter TOPOLOGIES 0 2 phase 3 wire L1 L2 1 2 phase 3 wire L1 L3 2 3 phase 3 wire 3 3 phase 3 wire 2CTs L1 L2 4 3 phase 3 wire 2CTs L1 L3 5 3 phase 4 wire star 6 3 phase 4 wire delta single phase 2 wire J Mains Contactor Timer sec 600 0 5 This is the period after the generator contactor has been deactivated and before the mains contactor has been activated K35D03 EN 85 D 500 User Manual Rev_04 Firmware V 3 3 16 2 ELECTRICAL PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Set Description Mains MCB Close Pulse sec 0 5 After the mains MCB_undervoltage coil is energized and mains MCB_undervoltage coil timer is elapsed the mains MCB close relay will be activated during this period Review chapter Motorized Circuit Breaker Control for more details Mains MCB Open Pulse sec 10 0 5 The mains MCB open relay will be activated during this period Review chapter Motorized Circuit Breaker Control f
143. that the genset Yellow led is on steadily Adjust genset voltage and frequency limits if necessary Check that the digital output 8 is configured as Genset Contactor Check Genset Contactor Timer program parameter Check that a Genset Loading Inhibit input signal is not active Check input functions If an input is configured as Genset Loading Inhibit then check the signal is not present at this input K35D03 EN 142
144. the available genset capacity When the load is below the Load Shedding Low Limit the controller will activate the Load Add output The external system will increase the load until it goes over the low limit where the Load Add output will become inactive When the load is above the Load Shedding High Limit the controller will activate the Load Substract output The external system will decrease the load until it goes below the high limit where the Load Substract output will become inactive There are protection delays between two pulses The parameters used in Load Shedding feature are in the Electrical Parameters Group Load Shedding Low Limit If the genset power goes below this limit then the load shedding relay will be deactivated Load Shedding High Limit If the genset power goes above this limit then the load shedding relay will be activated Load Add Delay This is the minimum delay between 2 load_add pulses This is also the minimum delay between 2 load_substract pulses Load Subtract Add Delay This is the minimum delay between load_add and load_substract pulses HIGH LIMIT LOW LIMIT TIME LOAD LEVEL a Os LOAD ADD Load Add Delay OUTPUT a lt 2 LOAD SUBSTRACT Load Substrapt Add Delay OUTPUT l ti t2 ts ta ts ts t t1 the load goes below the Load Shedding Low Limit thus the Load Add output becomes active t2 the load goes above the Load Shedd
145. tion 1 POSITIVE 12 24VDC The positive terminal of the DC Supply 2 Do not connect this terminal 3 BATTERY NEGATIVE O VDC Power supply negative connection Function Technical data Description DIGITAL OUTPUT 1 DIGITAL OUTPUT 2 DIGITAL OUTPUT 3 DIGITAL OUTPUT 4 DIGITAL OUTPUT 5 DIGITAL OUTPUT 6 Protected Semiconductor Outputs 1A 28VDC This relay has programmable function selectable from a list Factory set as CRANK output This relay has programmable function selectable from a list Factory set as FUEL output This relay has programmable function selectable from a list Factory set as ALARM output This relay has programmable function selectable from a list Factory set as PREHEAT output This relay has programmable function selectable from a list Factory set as STOP output This relay has programmable function selectable from a list Factory set as IDLE SPEED output 10 CHARGE Input and output Connect the charge alternators D terminal to this terminal This terminal will supply the excitation current and measure the voltage of the charge alternator 11 DIGITAL INPUT 1 12 DIGITAL INPUT 2 Digital Inputs 0 30Vdc The input has programmable function Factory set as LOW OIL PRESSURE SWITCH The input has programmable function Factory set as HIGH TEMP SWITCH
146. tputs I O Extension Digital inputs be extended using DKG 188 Connector Digital Input Extension modules each one providing 8 inputs Digital inputs are programmable through the main controller The switching characteristic is not programmable and must be battery negative Any function can be assigned to digital inputs Digital outputs can be extended using DKG 186 Fet Extension modules each one providing 8 outputs Digital outputs have the same electrical characteristics as on board outputs They have programmable functions through the main controller Any function can be assigned to any output Input and output extension modules are connected to the main controller in a cascade structure in any order The connection cable is provided with each extension module TO OTHER INPUT OUTPUT EXTENSION MODULES ON 2 DHHBHHHBHE s s EIS DKG 188 INPUT DKG 186 OUTPUT EXTENSION MODULE EXTENSION MODULE K35D03 EN 23 D 500 User Manual Rev_04 Firmware V 3 3 3 12 RS 485 PORT Structure RS 485 non isolated Connection 3 wires A B GND Half duplex Baud rate 2400 115200 bauds selectable Data type 8 bit data no parity 1 bit stop Termination External 120 ohms required Common mode voltage 0 5 VDC to 7VDC internally clamped by transient suppressors Max distance 1200m 9600 bauds with 120 ohms balanced cable 200m 115200 bauds with 120 ohm
147. ttons However if the external mode select signal is removed the unit will revert to the last selected mode via pushbuttons It is also possible to lock the front panel completely for remote command K35D03 EN 129 D 500 User Manual Rev_04 Firmware V 3 3 37 11 AUTOMATIC EXERCISER The unit offers 7 independent automatic exercisers The exercise operation may be done on a weekly or monthly basis The start day and time of the exercise is programmable as well as its duration The exercise may be done with or without load following programming Program parameters related to the exerciser are Exercise start day and hour Exercise duration Exercise off_load on_load Please refer to the programming section for a more detailed description of the above parameters When the start day and hour of exercise has come the unit will automatically switch to either RUN or TEST mode The engine will run If the on_load exercise is selected then the load will be transferred to the genset If a mains failure occurs during the off load exercise the load will not be transferred to the genset unless the Emergency Backup Operation is allowed by setting the related program parameter to 1 Thus it is highly recommended that the Emergency Backup mode enabled with off load exerciser At the end of the exercise duration the unit will switch back to the initial mode of operation If any of the mode selection keys are pressed during exercise then the exerc
148. twice a second on the selected channel The sample memory is 1024 samples length and 13 bits resolution with a sampling rate of 4096 s s The theory says that a periodic signal may have only odd multiples of the main frequency Thus in a 50Hz network harmonics will be found only at 150 250 350 450 Hz etc The unit is able to analyze up to 1800Hz and up to 31th harmonic whichever is smaller Thus in a 50Hz system all 31 harmonics will be displayed but in a 60Hz system only 29 harmonics will come to the Screen In case of a 400Hz system only the 3 harmonic will be displayed Wi HBREHOHICS T esie m eel ow e ael et HIE HH T m DT Graphical Harmonic Table Alphanumeric Harmonics Table Harmonic are represented by 2 different ways on the device display The first one is a graphical representation allowing one sight perception of the harmonic structure Because of the display resolution only harmonics above 2 are displayed The second display is alphanumeric thus all harmonics are displayed with 0 1 resolution in order to provide more detailed information On RainbowPlus program harmonics and waveform are displayed on a single screen with more resolution Mains Generators Engine Digital Inputs Digital Outputs Analog Inputs Harmonics Alarms Counters Event Log User Page Harmonics THD 3
149. ual button BIT 2 Simulate Auto button BIT 3 Simulate Test button BIT 4 Simulate Run button BIT 5 Simulate GCB button BIT 7 Simulate Menu button BIT 8 Simulate Menu button BIT 9 Simulate Up button BIT10 Simulate Down button BIT14 Button Long pressed BIT15 Button Very Long Pressed 10240 R 32bit x10 Mains phase L1 voltage 10242 R 32bit x10 Mains phase L2 voltage 10244 R 32bit x10 Mains phase L3voltage 10246 R 32bit x10 Genset phase L1 voltage 10248 R 32bit x10 Genset phase L2 voltage 10250 R 32bit x10 Genset phase L3 voltage 10252 R 32bit x10 Mains phase L1 L2 voltage 10254 R 32bit x10 Mains phase L2 L3 voltage 10256 R 32bit x10 Mains phase 3 1 1voltage 10258 R 32bit x10 Genset phase L1 L2 voltage 10260 R 32bit x10 Genset phase L2 L3 voltage 10262 R 32bit x10 Genset phase L3 L1 voltage 10264 R 32bit x10 Mains phase L1 current 10266 R 32bit x10 Mains phase L2 current 10268 H 32bit x10 Mains phase L3 current 10270 R 32bit x10 Genset phase L1 current 10272 R 32bit x10 Genset phase L2 current 10274 R 32bit x10 Genset phase L3 current 10276 R 32bit x10 Mains neutral current 10278 R 32bit x10 Genset neutral current 10292 R 32bit x10 Mains total active power 10294 R 32bit x10 Genset total active power 10308 H 32bit x10 Mains total reactive power 10310 H 32bit x10 Genset total reactive power 10324 H 32bit x10 Mains total apparent power 10326 R 32bit x10 Genset total apparent power 10334 R 16bit x10 Mains total power factor 10335 R 16bit x10 Genset
150. uit Breaker Control for more details Genset MCB Fail Timer sec 2 0 If a genset MCB feedback input is defined and if the genset MCB fails to change position before the expiration of this timer then a fault condition occurs Genset Phase Order Check Enable 0 genset phase order checking disabled 1 if genset phase order is faulty then a genset phase order fail loaddump alarm is given K35D03 EN 86 D 500 User Manual Rev_04 Firmware V 3 3 16 2 ELECTRICAL PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Description Set When the genset active power goes Multi Load Substract over this limit the controller will start Power Level 0 63009 9 substracting load as described in chapter Five Step Load Management When the genset active power goes Multi Load Add Power below this limit the controller will start Level pu 9 3998 0 adding load as described in chapter Five Step Load Management If the load stays over the Multi Load Multi Load Substract Substract Power Level parameter Start Delay PES 0 SODA during this timer then 1 step of load is substracted Multi Load Substract This is the minimum period between Wait Delay udi 0 SPUY 9 two load subtract operations A If the load stays below the Multi Load ae Edad SH sec o 36000 Add Power Level parameter during this y timer then 1 step of load is added Multi
151. umber of Starts Choke Timer sec 240 This is the control delay of CHOKE output The choke output is activated together with the crank output It is released after this delay or when engine runs whichever occurs first K35D03 EN 89 D 500 User Manual Rev_04 Firmware V 3 3 16 3 ENGINE PARAMETERS GROUP continued Parameter Definition Unit Min Max Factory Set Description Idle Speed Timer sec 240 When the engine runs the Idle output relay function will be active during this timer While the IDLE output is active low voltage low frequency and low checks are disabled Idle Holdoff Timer sec 30 10 While the IDLE periode is over low voltage low frequency and low speed checks are enabled after the expiration of this timer Gas Solenoid Delay sec 240 The gas solenoid of the gas engine if assigned by Relay Definitions will be opened after this delay during cranking Crank Cut Voltage V AC 65000 100 The crank relay output is deenergized when the genset phase L1 voltage reaches this limit Crank Cut Frequency Hz 100 10 The crank relay output is deenergized when the genset frequency reaches this limit Crank Cut RPM rpm 65000 500 The crank relay output is deenergized when the engine rpm reaches this limit Crank Cut Charge Voltage V DC 40 The crank relay output
152. upper and lower limits are programmable 58 GENERATOR NEUTRAL Input 0 300V AC Neutral terminal for the generator phases Term Function Technical data Description 59 CURR_1 Current transformer Connect the generator current transformer inputs 5A AC terminals to these inputs 60 CURR 1 Do not connect the same current transformer to other instruments otherwise a unit fault will occur 81 CUBR 2 Connect each terminal of the transformer to the unit s related terminal 62 CURR_2 Do not use common terminals Do not use grounding 63 CURR_3 Correct polarity of connection is vital The rating of the transformers should be 64 CURR_3 identical for each of the 3 phases The secondary winding rating shall be 5 Amperes ex 200 5 Amps Term Function Technical data Description 65 MAINS NEUTRAL Input 0 300V AC Neutral terminal for the mains phases 67 MAINS L3 Mains phase inputs Connect the mains phases to these inputs 0 300V AC The mains voltages upper and lower limits are programmable 69 MAINS L2 71 MAINS L1 72 MAINS CONTACTOR Relay output 16A AC This output provides energy to the mains contactor If the mains phases do not have acceptable voltages the mains contactor will be de energized In order to provide extra security the normally closed contact of the generator contactor should be serially connected to this output K35D03 EN 48 D 500 User Manual Rev_04 Firmware V 3 3 8 TEC
153. ure Engine Turbocharger Boost Pressure Engine Air Inlet Pressure Engine Air Filter1 Differential Pressure Engine Fuel Temperature Ambient Air Temperature 13 Engine Air Inlet Temperature 14 Engine Intake Manifold1 Temperature 15 Engine Exhaust Gas Temperature 16 Engine Fuel Rate 17 Engine Instantaneous Fuel Economy 18 Engine Average Fuel Economy 19 Engine Total Fuel Used 20 Engine Total Hours 21 Engine Percent Load at Current Speed 22 Actual Engine Percentage Torque 23 Drivers Demand Engine Percentage Torque 24 Accelerator Pedal Position 24 Battery Potential Switched The J1939 measurements are also available for Modbus operation Please check chapter Modbus Communications for more details When the fuel output is active if no information is received from the ECU during last 3 seconds then the unit will give a ECU FAIL alarm and stop the engine This feature prevents uncontrolled engine operation The fault conditions of an electronic engine are considered by the unit as warnings and do not cause engine stop The engine is supposed protected by the ECU which will stop it when necessary The electronic engine fault codes are displayed in text within the alarm list table together with their SPN FMI codes The complete list of fault codes is given in the engine manufacturer s user manual K35D03 EN 113 D 500 User Manual Rev_04 Below is a bas
154. urns on when the ethernet link is established connector inserted YELLOW This led blinks when data transfer occurs inwards or outwards Periodic blinking will witness data flow K35D03 EN 25 D 500 User Manual Rev_04 Firmware V 3 3 3 15 USB DEVICE PORT USB Device Connector Description USB 2 0 not isolated HID mode Data rate Full Speed 1 5 12 Mbits s auto detecting Connector USB B printer connector Cable length Max 6m Functionality Modbus FAT32 for firmware upgrade boot loader mode only The USB Device port is designed to connect the module to a PC Using the RainbowPlus software programming control of the genset and monitoring of measured parameters are achieved The RainbowPlus software can be downloaded from www datakom com tr website The connector on the module is of USB B type Thus A to B type USB cable should be used This is the same cable used for USB printers For more details about programming control and monitoring please refer to RainbowPlus user manual A The battery voltage must be connected If USB Device is plugged then USB Host port will not function K35D03 EN 26 D 500 User Manual Rev_04 Firmware V 3 3 3 16 USB HOST PORT OPTIONAL use Host Port 3N33H13 USB FLASH MEMORY A The USB Host port is available in units with COMM option Description USB 2 0 not isolated Power Supply 5V 3
155. ve shield of the RS 485 cable to this terminal from one end only 25 5 485 Digital communication Connect the data lines of the RS 485 26 RS 485A port link to these terminals 27 Analog input 0 5 to Connect the MPU unit to these inputs 28 MPU 30V AC Use a twisted cable pair or coaxial cable for best results 29 PROTECTION GROUND Output OVdc Connect the protective shield of the MPU and CANBUS J1939 cables to this terminal from one end only 30 CANBUS H Digital communication Connect the J1939 port of an electronic 31 CANBUS L port engine to these terminals The 120 ohm terminating resistors are inside the unit Please do not connect external resistors Use a twisted cable pair or coaxial cable for best results K35D03 EN 47 D 500 User Manual Rev_04 Firmware V 3 3 Term Function Technical data Description 51 GENERATOR CONTACTOR Relay output 16A AC This output provides energy to the generator contactor If the generator phases do not have acceptable voltage or frequency values the generator contactor will be de energized In order to provide extra security the normally closed contact of the mains contactor should be serially connected to this output 52 GEN L1 Generator phase Connect the generator phases to these 54 GEN L2 inputs 0 300 inputs The generator phase voltages 56 GEN L3
156. will wait until the expiration of the Synchronization Fail Timer to find a matching frequency phase and voltage Usually with frequencies matching at 2Hz and voltages matching at 10 volts an Uninterrupted Transfer is expected to successful If matching is found before the expiration of the Synchronization Fail Timer then both contactors will be activated If contactor auxiliary contacts are used the other contactor will release immediately If contactor auxiliary contacts are not used the other contactor will release after contactor timeout The unit offers below parameters for the setup of the Uninterrupted transfer feature Parameter Definition Description No Break Transfer 0 only interrupted transfer enabled Enable 1 no break transfer enabled If the phase and voltage synchronization is not successful before the expiration of this timer then a Synchronization Fail warning is given and the Synchronization Fail transfer will be performed with interruption Synchronization When synchronization is detected both contactors will stay closed during this Contactor Timeout timer This is the maximum difference between mains and genset frequencies to close both contactors This is the maximum difference between the mains phase L1 and the genset Max Volt Difference phase L1 voltages to close both contactors If voltage transformer is used this quantity is multiplied with voltage transformer ratio Max F
157. y at 115200 bauds and with adequate cable the distance will be 200m maximum At 9600 bauds and adequate cable the distance can go up to 1200m Below settings are necessary PARAMETER MAIN UNIT REMOTE DISPLAY UNIT Annunciator Mode 0 1 RS 485 Enable 1 1 RS 485 Baud Rate any same as main unit Modbus Slave Address any same as main unit The remote display panel should be powered up with an isolated voltage source like a wall adapter Otherwise damages due to ground potential differences may occur 5 7 400HZ OPERATION The standard unit is also 400Hz enabled The nominal frequency setting accepts up to 500Hz Usual low and high limits will apply without any special setting The measurement system of the unit allows frequencies up to 1000Hz to be measured precisely However the display is limited to 650Hz Frequencies over 650Hz will be displayed as 650Hz The bandwidth of the harmonic analyzer is limited to 1800 2 Thus in case of a 400Hz system only the 3 harmonic will be displayed The waveform display of 400 2 signal will be represented with 10 points It will not be as accurate as 50 60 2 signals For more details please read chapter Waveform Display amp Harmonic Analysis K35D03 EN 39 D 500 User Manual Rev_04 Firmware V 3 3 6 CONNECTION DIAGRAMS 6 1 AMF FUNCTIONALITY CTs AT LOAD SIDE LOAD L1L2 L3 N ALTERNATOR MAINS INTIMI
158. y frequency out of specified limits Phase order of voltage inputs not correct Current transformers not matching related phases Current transformer polarity incorrect Missing grounding K35D03 EN 9 D 500 User Manual Rev_04 Firmware V 3 3 2 MOUNTING 2 1 DIMENSIONS Dimensions 200x148x47mm 7 9 x5 8 x1 9 Panel Cutout 176x121mm minimum 7 0 x4 8 Weight 450g 1 Ib DATAKOM STATUS READY ALARM AN wanninc H 2 service REQUEST 148mm 200mm 53 GEN L2 54 55 GEN L3 56 G C 51 G L1 52 q 9 8 to 35Vdc 800mA max Pw 300Vac 0 100 Hz 25 o 1 0 EXTENSION f BY GSM SG 2 31 CANL K35D03 EN 10 D 500 User Manual Rev_04 Firmware V 3 3 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 121mm 4 176mm 3 Panel Cutout min 60mm 40mm Required Panel Depth K35D03 EN 11 D 500 User Manual Rev_04 Firmware V 3 3 Two different types of brackets are provided Screw type bracket Self retaining type bracket instalation of soraw type Installation of self retaining type br

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