Datakom D-500 MK3 User Manual
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Datakom D-500 MK3 User Manual

Advanced genset controller
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D-500 MK3 User Manual
DESCRIPTION
D-500 MK3 is a next generation genset controller
combining multi-functionality and wide communication
capabilities together with a reliable and low-cost
design.
The same controller provides synchronization, load
share, AMF, DC Genset, ATS, Remote Start, Engine
Control and Remote Display Panel functionalities.
The module comes ready for remote monitoring over
GSM or Ethernet with plug-in communication modules.
Various plug-in modules provide unlimited expansion
capabilities allowing to meet any special requirement.
The unit complies and mostly exceeds world's tightest
safety, vibration and environmental standards for the
industrial category.
Software features are complete with easy firmware
upgrade process through USB port.
The Windows based PC software allows monitoring
and programming through USB, RS-485, Ethernet and
GPRS. The Rainbow Scada web monitoring service
allows monitoring and control of an unlimited number
of gensets through any web browser.
FUNCTIONALITIES
Multi genset synchronizer and load share *
Multi genset mains synchronizer *
Single genset parallel with mains *
DC genset controller
AMF unit with uninterrupted transfer
ATS unit with uninterrupted transfer
Remote start controller
Manual start controller
Engine controller
Remote display & control unit
Waveform display of V & I
Harmonic analysis of V & I
*Optional with plug-in module
Firmware V-14.2
D-500 MK3
ADVANCED
GENSET
CONTROLLER
COMMUNICATIONS
•
Ethernet port (100Mbps) *
• GSM-GPRS *
• Embedded web server *
• Web monitoring *
• Web programming *
• Central Monitoring through internet *
• SMS message sending *
• E-mail sending *
• Central monitoring *
• Modbus RTU through RS-485 *
• Modbus TCP/IP *
• SNMP *
• USB Host *
• CANBUS-2 for inter- module comm. *
• USB Device
• PC software: Rainbow Plus
• J1939-CANBUS for electronic engines
*Optional with plug-in module
TOPOLOGIES
3 phases 4 wires, star
3 phases 4 wires, delta
3 phases 3 wires, delta, 3 CTs
3 phases 3 wires, delta, 2 CTs (L1-L2)
3 phases 3 wires, delta,2 CTs (L1-L3)
2 phases 3 wires, L1-L2
2 phases 3 wires, L1-L3
1 phase 2 wires

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  • Page 1 ADVANCED GENSET CONTROLLER DESCRIPTION COMMUNICATIONS • D-500 MK3 is a next generation genset controller Ethernet port (100Mbps) * • GSM-GPRS * combining multi-functionality and wide communication • Embedded web server * capabilities together with a reliable and low-cost • Web monitoring * design.
  • Page 2 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: technical.support@datakom.com.tr QUERRIES...
  • Page 3 D-500 MK3 User Manual Firmware V-14.2 REVISION HISTORY REVISION DATE AUTHOR DESCRIPTION 24.05.2021 First release, firmware version 6.3 09.11.2022 Revised for firmware version 14.2 - Analog outputs functionality added - SNMP v2c and v3 functionality added - DC genset functionality added...
  • Page 4 Firmware V-14.2 ORDERING CODES The D-500 family units are available in various options and peripheral features. Please use below information for ordering the correct version: D-500 MK3 -S -E -M -C -G -T -00 Family Code Variant 00: standard unit 01...99: customer...
  • Page 5 D-500 MK3 User Manual Firmware V-14.2 SAFETY NOTICE Failure to follow below instructions will result in death or serious injury ▪ Electrical equipment should be installed only by qualified specialist. No responsibility is assured by the manufacturer or any of its subsidiaries for any consequences resulting from the non-compliance to these instructions.

  • Page 6: Table Of Contents

    D-500 MK3 User Manual Firmware V-14.2 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.
  • Page 7 D-500 MK3 User Manual Firmware V-14.2 5. TOPOLOGIES 5.1. SELECTING THE TOPOLOGY 5.2. 3 PHASE, 4 WIRE, STAR 5.3. 3 PHASE, 3 WIRE, DELTA 5.4. 3 PHASE, 4 WIRE, DELTA 5.5. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L2) 5.6. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L3) 5.7.
  • Page 8 D-500 MK3 User Manual Firmware V-14.2 11. WAVEFORM DISPLAY & HARMONIC ANALYSIS 12. DISPLAYING EVENT LOGS 13. STATISTICAL COUNTERS 13.1. FUEL FILLING COUNTER 13.2. FUEL CONSUMPTION MONITORING 14. OPERATION OF THE UNIT 14.1. QUICK START GUIDE 14.2. STOP MODE 14.3. AUTO MODE 14.4.
  • Page 9 D-500 MK3 User Manual Firmware V-14.2 17.17. SYNCHRONIZATION PARAMETERS 17.18. DC GENSET PARAMETERS 17.19. SNMP PARAMETERS 18. ETHERNET CONFIGURATION 19. Wi-Fi CONFIGURATION 20. GSM CONFIGURATION 21. CRANK CUTTING 22. OVERCURRENT PROTECTION (IDMT) 23. MOTORIZED CIRCUIT BREAKER CONTROL 24. AUTO LEARNING 25.
  • Page 10 D-500 MK3 User Manual Firmware V-14.2 35. DATA RECORDING 35.1. DATA RECORDING MEDIA 35.2. DIRECTORY STRUCTURE 35.3. UNDERSTANDING THE CSV FORMAT 35.4. RECORDED DATA LIST, RECORD PERIOD 36. SOFTWARE FEATURES 36.1. LOAD SHEDDING / DUMMY LOAD 36.2. LOAD ADD / SUBSTRACT 36.3.
  • Page 11 D-500 MK3 User Manual Firmware V-14.2 39. DECLARATION OF CONFORMITY 40. MAINTENANCE 41. DISPOSAL OF THE UNIT 42. ROHS COMPLIANCE 43. TROUBLESHOOTING GUIDE - 11 -...

  • Page 12: Installation Instructions

    D-500 MK3 User Manual Firmware V-14.2 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.

  • Page 13: Mounting

    D-500 MK3 User Manual Firmware V-14.2 2. MOUNTING 2.1. DIMENSIONS Dimensions: 211x162x42mm Panel Cutout: 176x121mm minimum Weight: 500g (approx..) - 13 -...
  • Page 14 D-500 MK3 User Manual Firmware V-14.2 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.
  • Page 15 D-500 MK3 User Manual Firmware V-14.2 Two different types of brackets are provided: Self retaining type bracket Screw type bracket Installation of screw type bracket Installation of self-retaining type bracket Do not tighten too much, this may break the unit.

  • Page 16: Sealing, Gasket

    D-500 MK3 User Manual Firmware V-14.2 2.2. SEALING, GASKET Panel Gasket Module The rubber gasket provides a watertight means of mounting the module to the genset panel. Together with the gasket, 60529-IP65 protection can be reached from the front panel. A short definition of IP protection levels is given below.

  • Page 17: Electrical Installation

    D-500 MK3 User Manual Firmware V-14.2 2.3. 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.

  • Page 18: Terminal Descriptions

    D-500 MK3 User Manual Firmware V-14.2 3. TERMINAL DESCRIPTIONS 3.1. BATTERY VOLTAGE INPUT Supply voltage: 9 to 36VDC Cranking dropouts: Survives 0VDC during 100ms. The voltage before surge should be 9VDC minimum Overvoltage protection: Withstands 150VDC continuously. Reverse voltage: -36VDC continuous Maximum operating 600mA @ 12VDC.

  • Page 19: Ac Voltage Inputs

    D-500 MK3 User Manual Firmware V-14.2 3.2. AC VOLTAGE INPUTS Measurement method: True RMS Sampling rate: 8000 Hz Harmonic analysis: up to 31th harmonic Input voltage range: 0 to 300 VAC Minimum voltage for 15 VAC (Ph-N) frequency detection: Supported topologies:...

  • Page 20: Ac Current Inputs

    D-500 MK3 User Manual Firmware V-14.2 3.3. AC CURRENT INPUTS Measurement method: True RMS Sampling rate: 8000 Hz Harmonic analysis: up to 31th harmonic Supported topologies: 3 ph 4 wires star, 3 ph 4 wires delta, 3 ph 3 wires delta...
  • Page 21 D-500 MK3 User Manual Firmware V-14.2 SELECTING THE CT ACCURACY CLASS: The CT accuracy class should be selected in accordance with the required measurement precision. The accuracy class of controller is 0.5%. Thus 0.5% class CTs are advised for the best result.
  • Page 22 D-500 MK3 User Manual Firmware V-14.2 EFFECT OF POLARITY REVERSAL The generator is still loaded with 100 kW on each phase. The load Power Factor (PF) is 1. PF in phase L2 will show -1.00 due to reverse CT polarity. The result is that total generator power displayed by the controller is 100 kW.

  • Page 23: Digital Inputs

    D-500 MK3 User Manual Firmware V-14.2 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.

  • Page 24: Charge Input Terminal

    D-500 MK3 User Manual Firmware V-14.2 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.

  • Page 25: Digital Outputs

    D-500 MK3 User Manual Firmware V-14.2 3.8. DIGITAL OUTPUTS The unit offers 6 digital outputs with programmable function, selectable from list. Structure: Negative pulling protected semiconductor output. One terminal is connected to battery negative. Max continuous current: 1.0 ADC Max switching voltage:...

  • Page 26: Input/Output Expansion

    D-500 MK3 User Manual Firmware V-14.2 3.11. INPUT/OUTPUT EXPANSION The module provides resources for 32 additional digital inputs and 32 additional digital outputs. Digital inputs can be extended using DKG-188 Digital Input Expansion 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.

  • Page 27: J1939-Canbus Port

    The RainbowPlus software can be downloaded from Datakom 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.

  • Page 28: Plug-In Modules

    D-500 MK3 User Manual Firmware V-14.2 4. PLUG-IN MODULES PLUG-IN MODULES MODEM PLUG-IN -2G Modem Slot, -3G Modem Slot, -4G Modem Slot, -Wi-Fi Slot, -Ethernet Slot, -RS-485 Slot SYNCHRONIZATION PLUG-IN -Synchronization Slot ANALOG PLUG-IN -Analog I/O Expansion Slot, -3xMains CT Inputs Slot...

  • Page 29: Modem Plug-In

    D-500 MK3 User Manual Firmware V-14.2 4.1. MODEM PLUG-IN 4.1.1. GSM MODEM SLOT The optional 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.

  • Page 30: Wi-Fi Slot

    D-500 MK3 User Manual Firmware V-14.2 LOCATION DETERMINATION VIA GSM The unit determines automatically the geographical position through the GSM network. No settings are necessary for this. This feature is especially useful for the remote monitoring where the controller will appear automatically at its geo-position or for mobile gensets.

  • Page 31: Ethernet Slot

    D-500 MK3 User Manual Firmware V-14.2 4.1.3. ETHERNET SLOT Link Established Data Flow Ethernet Slot STANDARD ETHERNET CABLE Description: IEEE802.3 compliant, 100 Base-TX RJ45 ethernet port with indicating leds Data rate: 100 Mbps, auto detecting Connector: RJ45 Cable type: CAT5 or CAT6...

  • Page 32: Slot

    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.

  • Page 33: Synchronization Plug-In

    D-500 MK3 User Manual Firmware V-14.2 4.2. SYNCHRONIZATION PLUG-IN Synchronization Slot 4.2.1. ANALOG AVR CONTROL OUTPUT Isolated analog output, ±3 VDC Structure: Connection: 2 wires Output Impedance: 270 ohms Isolation Voltage: 1000 VAC, 1 minute Precision: 12 bits Rest point:...

  • Page 34: Datalink-Canbus Port

    D-500 MK3 User Manual Firmware V-14.2 4.2.3. DATALINK-CANBUS PORT Structure: CANBUS, isolated. Connection: 4 wires (DATALINK-H, DATALINK-L, GND, TERMINATION). Data rate: 250 kbps standard (adjustable between 50 and 500 kbps) Termination: 120 ohms resistor internally connected to DATALINK-H. The TERMINATION is to be connected to DATALINK-L in order to terminate the Datalink bus.

  • Page 35: Analog Load Share Signal

    D-500 MK3 User Manual Firmware V-14.2 4.2.4. ANALOG LOAD SHARE SIGNAL Structure: Non-isolated analog input & output, 0-10 VDC Reference: Battery negative Output Impedance: 1000 ohms Precision: 12 bits Rest point: Adjustable through program parameter Sweep Range: Adjustable through program parameter 4.3.

  • Page 36: Mains Ct Inputs Slot

    D-500 MK3 User Manual Firmware V-14.2 Analog module provides 2 x 4-20mA analog outputs. The measurement to output from each channel is selectable from below list. Available functions; -Genset average voltage -Genset average current -Genset total active power -Genset total reactive power -Engine speed, rpm 4.3.2.

  • Page 37: Dc Voltage & Current Slot

    D-500 MK3 User Manual Firmware V-14.2 4.3.3. DC VOLTAGE & CURRENT SLOT Voltage inputs: Measurement method: Isolated DC voltage measurement Sampling rate: 100K s/s Input voltage range: 0 to 70 VDC Measurement range: 0 to 70 VDC Input impedance: 215 K-ohms Display resolution: 0.1VDC...

  • Page 38: Communication Slot

    D-500 MK3 User Manual Firmware V-14.2 4.4. COMMUNICATION SLOT 4.4.1. ETHERNET PORT Description: IEEE802.3 compliant, 100 Base-TX RJ45 ethernet port with indicating leds Data rate: 100 Mbits/s, auto detecting Connector: RJ45 Cable type: CAT5 or CAT6 Isolation: 1500 VAC, 1 minute...

  • Page 39: Usb Host Port

    D-500 MK3 User Manual Firmware V-14.2 4.4.2. USB HOST PORT USB HOST Port USB FLASH MEMORY The USB-Host port is available in units with COMM option. Description: USB 2.0, not isolated Power Supply 5V, 300mA max Output: Data rate: Full Speed 1.5/12 Mbits/s, auto detecting...

  • Page 40: Port

    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.

  • Page 41: Topologies

    D-500 MK3 User Manual Firmware V-14.2 5. 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.

  • Page 42: Phase, 4 Wire, Star

    D-500 MK3 User Manual Firmware V-14.2 5.2. 3 PHASE, 4 WIRE, STAR 5.3. 3 PHASE, 3 WIRE, DELTA - 42 -...

  • Page 43: Phase, 4 Wire, Delta

    D-500 MK3 User Manual Firmware V-14.2 5.4. 3 PHASE, 4 WIRE, DELTA 5.5. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L2) - 43 -...

  • Page 44: Phase, 3 Wire, Delta, 2 Ct (L1-L3)

    D-500 MK3 User Manual Firmware V-14.2 5.6. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L3) 5.7. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L2) - 44 -...

  • Page 45: Phase, 3 Wire, Delta, 2 Cts (L1-L3)

    D-500 MK3 User Manual Firmware V-14.2 5.8. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L3) 5.9. 1 PHASE, 2 WIRE - 45 -...

  • Page 46: Functionalities

    D-500 MK3 User Manual Firmware V-14.2 6. FUNCTIONALITIES The same unit provides different functionalities through parameter setting. Thus, a single stock item will fulfill various duties, minimizing stock cost. The selection of the functionality is done through Controller Parameter, as shown in below picture.

  • Page 47: Synchronization Functionality

    D-500 MK3 User Manual Firmware V-14.2 6.2 SYNCHRONIZATION FUNCTIONALITY The synchronization functionality is used to parallel 2 or more gensets on the same busbar, in order to increase the total genset power rating or in order to have redundancy/reserve power for a more reliable operation.

  • Page 48: Mains Synchronization Functionality

    D-500 MK3 User Manual Firmware V-14.2 6.3 MAINS SYNCHRONIZATION FUNCTIONALITY The mains synchronization functionality is used to synchronize a genset group to the power grid. Gensets are put in parallel on the same busbar. A maximum number of 16 mains synchronizing controllers may coexist on the same Datalink bus.

  • Page 49: Single Genset Parallel With Mains

    D-500 MK3 User Manual Firmware V-14.2 6.4 SINGLE GENSET PARALLEL WITH MAINS A single controller is able to provide all the functionality required in order to control a genset running in parallel with the grid. Parallel operation with the grid may be required for various purposes:...

  • Page 50: Amf Functionality

    D-500 MK3 User Manual Firmware V-14.2 6.6. AMF FUNCTIONALITY When AMF functionality is selected, the unit will monitor mains voltages, provide mains 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.

  • Page 51: Remote Start Functionality

    D-500 MK3 User Manual Firmware V-14.2 6.8. 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.

  • Page 52: Engine Controller Functionality

    D-500 MK3 User Manual Firmware V-14.2 6.9. 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 not display genset AC parameters (volts, amps, kW and pf).

  • Page 53: Remote Display Unit Functionality

    D-500 MK3 User Manual Firmware V-14.2 6.10. REMOTE DISPLAY UNIT FUNCTIONALITY The unit is able to become the remote display and control panel of another identical module. Remote Control Unit Display Unit 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.

  • Page 54: 400Hz Operation

    D-500 MK3 User Manual Firmware V-14.2 6.11. 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.

  • Page 55: Connection Diagrams

    D-500 MK3 User Manual Firmware V-14.2 7. CONNECTION DIAGRAMS 7.1. GENSET SYNCHRONIZATION FUNCTIONALITY - 55 -...

  • Page 56: Mains Synchronization Functionality

    D-500 MK3 User Manual Firmware V-14.2 7.2. MAINS SYNCHRONIZATION FUNCTIONALITY - 56 -...
  • Page 57 D-500 MK3 User Manual Firmware V-14.2 7.3. SINGLE GENSET PARALLEL WITH MAINS FUNCT. - 57 -...

  • Page 58: Dc Genset Functionality

    D-500 MK3 User Manual Firmware V-14.2 7.4. DC GENSET FUNCTIONALITY - 58 -...

  • Page 59: Amf Functionality

    D-500 MK3 User Manual Firmware V-14.2 7.5. AMF FUNCTIONALITY - 59 -...

  • Page 60: Ats Functionality

    D-500 MK3 User Manual Firmware V-14.2 7.6. ATS FUNCTIONALITY - 60 -...

  • Page 61: Remote Start Functionality

    D-500 MK3 User Manual Firmware V-14.2 7.7. REMOTE START FUNCTIONALITY - 61 -...

  • Page 62: Engine Control Functionality

    D-500 MK3 User Manual Firmware V-14.2 7.8. ENGINE CONTROL FUNCTIONALITY - 62 -...

  • Page 63: Remote Display Panel Functionality

    D-500 MK3 User Manual Firmware V-14.2 7.9. REMOTE DISPLAY PANEL FUNCTIONALITY - 63 -...

  • Page 64: Terminal Description

    D-500 MK3 User Manual Firmware V-14.2 8. TERMINAL DESCRIPTION Term Function Technical data Description BATTERY POSITIVE +12 or 24VDC The positive terminal of the DC Supply. BATTERY NEGATIVE O VDC Power supply negative connection. DIGITAL OUTPUT 1 Protected This relay...
  • Page 65 D-500 MK3 User Manual Firmware V-14.2 Term Function Technical data Description SENDER GROUND Input Ground potential for analog senders. Connect to the engine body, close to senders. Connect to the oil pressure sender. Do not connect the sender to other devices.
  • Page 66 D-500 MK3 User Manual Firmware V-14.2 Term Function Technical data Description Connect the generator current transformer GEN I1+ Generator current terminals to these inputs. transformer inputs, connect same current 5A-AC GEN I1- transformer to other instruments otherwise this may damage the unit.
  • Page 67 D-500 MK3 User Manual Firmware V-14.2 SYNCH PLUG-IN MODULE: Term Function Technical data Description DATA LINK TERMINATION 120 ohm resistor This terminal is used to enable the 120 RESISTOR ohms termination resistor of the Data Link. The Data Link bus should be terminated at 2 ends only.
  • Page 68 D-500 MK3 User Manual Firmware V-14.2 ANALOG I/O EXPANSION PLUG-IN MODULE: Term Function Technical data Description SND 6 Analog inputs, These inputs have programmable function. 0-5000 ohms 0 to 10 VDC SND 7 4 to 20 mA SND 8 A1 +...

  • Page 69: Technical Specifications

    D-500 MK3 User Manual Firmware V-14.2 9. TECHNICAL SPECIFICATIONS Alternator voltage: 0 to 300 V-AC (Ph-N) Alternator frequency: 0-600 Hz. Mains (Busbar) voltage: 0 to 300 V-AC (Ph-N) Mains (Busbar) frequency: 0-600 Hz. Topology: 1-2-3 phases, with or without neutral DC Supply Range: 8.0 to 36.0 V-DC.

  • Page 70: Description Of Controls

    D-500 MK3 User Manual Firmware V-14.2 10. DESCRIPTION OF CONTROLS 10.1. FRONT PANEL FUNCTIONALITY LCD screen Mains Contactor AUTO READY Mimic Diagram control in RUN indicator (sysem status) mode Genset Fault condition Contactor indicators control in RUN mode Programmable LED indicators...

  • Page 71: Pushbutton Functions

    D-500 MK3 User Manual Firmware V-14.2 10.2. PUSHBUTTON FUNCTIONS BUTTON FUNCTION Selects TEST mode. The genset runs and takes the load. Selects MANUAL mode. The RUN pushbutton is enabled. The genset will run when RUN mode is selected. It can be stopped anytime by depressing the OFF button.
  • Page 72 D-500 MK3 User Manual Firmware V-14.2 When held pressed for 5 seconds, switches to MANUAL ADJUST mode When held pressed for 1 seconds, switches to next PID ADJUST group in MANUAL ADJUST mode When held pressed for 5 seconds, exits the annunciator mode if enabled...

  • Page 73: Display Screen Organization

    D-500 MK3 User Manual Firmware V-14.2 10.3. 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 different groups are made with buttons.

  • Page 74: Automatic Display Scroll

    D-500 MK3 User Manual Firmware V-14.2 10.4. 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 > Screen options.
  • Page 75 D-500 MK3 User Manual Firmware V-14.2 - 75 -...

  • Page 76: Measured Parameters

    D-500 MK3 User Manual Firmware V-14.2 10.5. MEASURED PARAMETERS The unit performs a detailed set of AC measurements. 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...

  • Page 77: Led Lamps

    D-500 MK3 User Manual Firmware V-14.2 10.6. LED LAMPS AUTO READY indicator Mains available led Shutdown alarm indicator Mains Contactor Warning On led indicator Genset Contactor Service on led request indicator Genset Programmable available led LED indicators TEST mode AUTO mode...

  • Page 78: Waveform Display & Harmonic Analysis

    D-500 MK3 User Manual Firmware V-14.2 11. WAVEFORM DISPLAY & 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.
  • Page 79 D-500 MK3 User Manual Firmware V-14.2 The harmonic analyzer consists on a Fast Fourier Transform (FFT) algorithm which run twice a second on the selected channel. The sample memory is of 1024 samples length and 13 bits resolution with a sampling rate of 4096 s/s.

  • Page 80: Displaying Event Logs

    D-500 MK3 User Manual Firmware V-14.2 12. 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:...
  • Page 81 D-500 MK3 User Manual Firmware V-14.2 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 buttons for 5 seconds.

  • Page 82: Statistical Counters

    D-500 MK3 User Manual Firmware V-14.2 13. 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 genset export kWh...

  • Page 83: Fuel Consumption Monitoring

    D-500 MK3 User Manual Firmware V-14.2 13.2. FUEL CONSUMPTION MONITORING The unit is capable to display the actual fuel consumption of the engine by two different ways: ▪ Through J1939 fuel consumption information ▪ By counting fuel consumption pulses. If the engine is sending the fuel rate through J1939 messaging, then the unit will directly display the fuel consumption information coming from the ECU.

  • Page 84: Operation Of The Unit

    D-500 MK3 User Manual Firmware V-14.2 14. OPERATION OF THE UNIT 14.1. QUICK START GUIDE STOPPING THE ENGINE: Press STOP button STARTING THE ENGINE: Press MAN and then RUN button MANUAL LOAD TRANSFER: Use MAINS and GENSET buttons. LOAD TEST: Press TEST button.

  • Page 85: Auto Mode

    D-500 MK3 User Manual Firmware V-14.2 14.3. AUTO MODE The AUTO mode is entered by pressing the button. The AUTO mode is used for the automatic operation of the genset system. ▪ AMF Mode: The controller will constantly monitor the mains availability. It will run the engine and transfer the load when a mains failure occurs.

  • Page 86: Run Mode, Manual Control

    D-500 MK3 User Manual Firmware V-14.2 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.

  • Page 87: Test Mode

    D-500 MK3 User Manual Firmware V-14.2 14.5. 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 in the AUTO mode, regardless of the mains availability and the load will be transferred to the genset.

  • Page 88: Protections And Alarms

    D-500 MK3 User Manual Firmware V-14.2 15. 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,...

  • Page 89: Disabling All Protections

    D-500 MK3 User Manual Firmware V-14.2 15.1. 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 firefighting or other emergency cases.

  • Page 90: Shutdown Alarms

    D-500 MK3 User Manual Firmware V-14.2 15.3. SHUTDOWN ALARMS Digital input and analog sender alarms are fully programmable for the alarm name, sampling and action. Only internal alarms are explained in this section. GENSET LOW / HIGH Set if the generator frequency is outside programmed limits. These faults will FREQUENCY be monitored with Fault Holdoff Timer delay after the engine is running.

  • Page 91: Loaddump Alarms

    D-500 MK3 User Manual Firmware V-14.2 15.4. LOADDUMP ALARMS Digital input and analog sender alarms are fully programmable for the alarm name, sampling and action. Only 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.
  • Page 92 D-500 MK3 User Manual Firmware V-14.2 expiration of Synchronization Fail Timeout Busbar Voltage Fail Set if busbar voltages are not within limits and busbar voltage above Dead Bus Limit during 5 seconds, when the master requests the slave to close the genset contactor to the busbar.

  • Page 93: Warnings

    D-500 MK3 User Manual Firmware V-14.2 15.5. WARNINGS Digital input and analog sender alarms are fully programmable for the alarm name, sampling and action. Only internal alarms are explained in this section. All warnings can be made latching by enabling a single program parameter: Controller Configuration >Latch All Warnings...
  • Page 94 D-500 MK3 User Manual Firmware V-14.2 Set when an engine fault code is received from the ECU of the electronic J1939 ECU FAIL engine. This fault will not cause an engine stop. If necessary, the engine will be stopped by the ECU.

  • Page 95: Non-Visual Warnings

    D-500 MK3 User Manual Firmware V-14.2 15.6. NON-VISUAL WARNINGS These warnings are not announced at the device front panel, however they appear in event logs, transferred to the Scada and cause SMS and e-mail sending. Only internal alarms are explained in this section.

  • Page 96: Programming

    D-500 MK3 User Manual Firmware V-14.2 16. PROGRAMMING 16.1. 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 RIGHT ARROW button for 5 seconds -factory set values will be reprogrammed to the parameter memory.

  • Page 97: Entering The Programming Mode

    D-500 MK3 User Manual Firmware V-14.2 16.2. ENTERING THE PROGRAMMING MODE ◄ ► To enter the program mode, press together MENU and MENU buttons for 5 seconds. When the program mode is entered, below password entry screen will be displayed.

  • Page 98: Navigating Between Menus

    D-500 MK3 User Manual Firmware V-14.2 16.3. 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 ▼...

  • Page 99: Modifying Parameter Value

    D-500 MK3 User Manual Firmware V-14.2 16.4. MODIFYING PARAMETER VALUE Decrease Increase parameter parameter value value Previous parameter Next Long Press: parameter Return to the upper menu - 99 -...

  • Page 100: Programming Mode Exit

    D-500 MK3 User Manual Firmware V-14.2 16.5. 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. Press any mode button...

  • Page 101: Program Parameter List

    D-500 MK3 User Manual Firmware V-14.2 17. PROGRAM PARAMETER LIST 17.1. CONTROLLER CONFIGURATION GROUP Parameter Definition Unit Factory Description This parameter is used to set LCD LCD Contrast contrast. Adjust for the best viewing angle. The screen will scroll between different measurements with this interval.
  • Page 102 D-500 MK3 User Manual Firmware V-14.2 17.1. CONTROLLER CONFIGURATION GROUP (continued) Parameter Definition Unit Factory Description 0: no MODEM / no GPS 1: Internal MODEM, no GPS 2: External MODEM, no GPS Modem / GPS Selection 3: External generic MODEM, no GPS...
  • Page 103 D-500 MK3 User Manual Firmware V-14.2 17.1. CONTROLLER CONFIGURATION GROUP (continued) Factory Description Parameter Definition Unit This is the data rate of the RS-485 RS-485 Baud Rate 2400 115200 9600 Modbus port. 0: ethernet port disabled Ethernet Enable 1: ethernet port enabled...
  • Page 104 D-500 MK3 User Manual Firmware V-14.2 17.1. CONTROLLER CONFIGURATION GROUP (continued) Parameter Definition Unit Factory Description This parameter controls e-mail sending when IP address of GPRS or ethernet connection is changed. No warnings E-mail on IP Change generated. 0: no e-mail on IP change...
  • Page 105 D-500 MK3 User Manual Firmware V-14.2 17.1. CONTROLLER CONFIGURATION GROUP (continued) Factory Description Parameter Definition Unit 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 REMOTE START signal based on mains status.
  • Page 106 D-500 MK3 User Manual Firmware V-14.2 17.1. CONTROLLER CONFIGURATION GROUP (continued) Factory Description Parameter Definition Unit This is the number of pulses produced by the flowmeter for the unit volume. Fuel Pulses per Volume 65000 1000 This parameter is characteristic of the flowmeter used and should be set according to the flowmeter data.
  • Page 107 D-500 MK3 User Manual Firmware V-14.2 17.1. CONTROLLER CONFIGURATION GROUP (continued) Factory Description Parameter Definition Unit This is the parameter to enable modbus master/slave operation of controller Modbus Master Active through rs-485 terminal. 0: modbus slave controller 1: modbus master controller This parameter is functional for battery backup operation with DKG-359 device.

  • Page 108: Electrical Parameters Group

    D-500 MK3 User Manual Firmware V-14.2 17.2. ELECTRICAL PARAMETERS GROUP Parameter Definition Unit Factory Description This is the rated value of current transformers at the genset CT inputs. Genset Current 5000 All transformers must have the same Transformer Primary rating. The secondary of the transformer will be 5 Amps.
  • Page 109 D-500 MK3 User Manual Firmware V-14.2 17.2. ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition Unit Factory Description If the mains phase voltages are outside limits, but not more than this parameter (with reference to nominal voltage), then the genset will run without releasing the mains contactor.
  • Page 110 D-500 MK3 User Manual Firmware V-14.2 17.2. ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition Unit Factory Description If the genset frequency goes under this limit when feeding the load, this will Genset Low Frequency F-100 F+100 F-20% generate a GENSET LOW...
  • Page 111 D-500 MK3 User Manual Firmware V-14.2 17.2. ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition Unit Factory Description 0: no action Genset Current 1: shutdown alarm Unbalance Action 2: loaddump alarm 3: warning If the genset power is negative and goes above this limit then a REVERSE...
  • Page 112 D-500 MK3 User Manual Firmware V-14.2 17.2. ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition Unit Factory Description If the genset power goes below this limit then the load shedding relay will be Load Shedding Low Limit 50000 deactivated. Review chapter “Load Shedding”...
  • Page 113 D-500 MK3 User Manual Firmware V-14.2 17.2. ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition Unit Factory Description The mains MCB_open relay will be activated during this period. Mains MCB Open Pulse Review chapter “Motorized Circuit Breaker Control” for more details. The mains MCB_undervoltage coil is...
  • Page 114 D-500 MK3 User Manual Firmware V-14.2 17.2. ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition Unit Factory Description When a genset closes to the Busbar, if the mater genset controller does detect Busbar Fail Timer the Busbar voltage at the expiration of this period, a “BUSBAR FAIL”...
  • Page 115 D-500 MK3 User Manual Firmware V-14.2 17.2. ELECTRICAL PARAMETERS GROUP (continued) Parameter Definition Unit Factory Description 65000 If the total genset capacitive reactive Capacitive Overload Lim. kvar power goes over this limit when feeding the load, this will generate a genset over capacitive alarm.

  • Page 116: Engine Parameters Group

    D-500 MK3 User Manual Firmware V-14.2 17.3. ENGINE PARAMETERS GROUP Parameter Definition Unit Factory Description The nominal value of engine rpm. Low- Nominal RPM 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.
  • Page 117 D-500 MK3 User Manual Firmware V-14.2 17.3. ENGINE PARAMETERS GROUP (continued) Parameter Definition Unit Factory Description If the charge alternator voltage goes Charge Voltage Fail under limits during this timer, a charge Timer alternator voltage fault will occur. If it is requested that the engine runs...
  • Page 118 D-500 MK3 User Manual Firmware V-14.2 17.3. ENGINE PARAMETERS GROUP (continued) Parameter Definition Unit Factory Description When the engine runs, the Idle output relay function will be active during this Idle Speed (Run) Timer timer. While the IDLE output is active, low voltage, low frequency and low rpm checks are disabled.
  • Page 119 D-500 MK3 User Manual Firmware V-14.2 17.3. ENGINE PARAMETERS GROUP (continued) Parameter Definition Unit Factory Description If the coolant temp is above this limit then °C Coolant Cooler On the cooler relay function will become active. If the coolant temp is below this limit then °C...
  • Page 120 D-500 MK3 User Manual Firmware V-14.2 17.3. ENGINE PARAMETERS GROUP (continued) Parameter Definition Unit Factory Description The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last service. If the period Service-2 Engine Hours...
  • Page 121 D-500 MK3 User Manual Firmware V-14.2 17.3. ENGINE PARAMETERS GROUP (continued) Parameter Definition Unit Factory Description 0: GENERIC 1: CUMMINS 2: DETROIT DIESEL 3: DEUTZ 4: JOHN DEERE 5: PERKINS 6: VOLVO 7: CATERPILLAR J1939 Engine Brand 8: SCANIA 9: IVECO...
  • Page 122 D-500 MK3 User Manual Firmware V-14.2 17.3. ENGINE PARAMETERS GROUP (continued) GENERIC ENGINE BRAND 0: Generic CUMMINS ENGINE 0: CM850 1: CM570 2: GCS 3: CM2150 DETROIT DIESEL ENGINE 0: Generic DEUTZ ENGINE 0: Generic 1: EMR2 2: EMR3 JOHN DEERE ENGINE...
  • Page 123 D-500 MK3 User Manual Firmware V-14.2 17.3. ENGINE PARAMETERS GROUP (continued) Parameter Definition Unit Factory Description This parameter adjusts the speed of an J1939 Speed Adjust -100 +100 ECU controlled engine by +/- 8%. If the air inlet temperature measured...

  • Page 124: Adjust Date And Time

    D-500 MK3 User Manual Firmware V-14.2 17.4. ADJUST DATE AND TIME 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.

  • Page 125: Weekly Operation Schedule

    D-500 MK3 User Manual Firmware V-14.2 17.5. WEEKLY OPERATION SCHEDULE 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.

  • Page 126: Exerciser Schedule

    D-500 MK3 User Manual Firmware V-14.2 17.6. EXERCISER SCHEDULE The unit provides 7 independent automatic exerciser programs. Automatic exercise may be done in weekly or monthly basis. If monthly exercise is selected, the week, day and hour is adjustable for each exercise item.

  • Page 127: Sender Configuration

    D-500 MK3 User Manual Firmware V-14.2 17.7. 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.
  • Page 128 D-500 MK3 User Manual Firmware V-14.2 Factory Description Parameter Definition Unit Sender Curve-1 ohm ohms 5000 Point-1 ohm value Sender Curve-1 value 10000 Point-1 reading Sender Curve-2 ohm ohms 5000 Point-2 ohm value Sender Curve-2 value 10000 Point-2 reading Sender Curve-3 ohm...

  • Page 129: Digital Input Configuration

    D-500 MK3 User Manual Firmware V-14.2 17.8. DIGITAL INPUT CONFIGURATION The unit has 8 digital inputs. By using external input expansion modules, up to 40 inputs in total are available. Only parameters of one input are explained below. Other inputs have identical parameter set.
  • Page 130 D-500 MK3 User Manual Firmware V-14.2 INPUT FUNCTION LIST Description Description Description User Defined Function Over Resonance Low Oil Press. Switch Short-Circuit Alarm High Temp. Switch Reset Service 1 Alm Coolant Level Switch Reset Service 2 Alm Rectifier Fail Switch...

  • Page 131: Output Configuration

    D-500 MK3 User Manual Firmware V-14.2 17.9. OUTPUT CONFIGURATION The parameters below define the functions of relay outputs. The unit has 6 relay outputs. All relays have programmable functions, selected from a list. Relays may be extended up to 40 using Relay Expansion Modules.. Other relays are in the optional Expansion Modules.
  • Page 132 D-500 MK3 User Manual Firmware V-14.2 OUTPUT FUNCTION LIST Description Description Description Fuel Pgm Mode Active Remote Control Out 11 Horn Engine Running Remote Control Out 12 Crank Genset Voltage Ok Remote Control Out 13 Stop Solenoid Alarm Check Enable...

  • Page 133: Site Id String

    D-500 MK3 User Manual Firmware V-14.2 17.10. 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.

  • Page 134: Gsm Modem Parameters

    D-500 MK3 User Manual Firmware V-14.2 17.13. GSM MODEM PARAMETERS Parameter Definition Description The APN (access point name) username may be required by the GSM operator. However some GSM operators may allow access without APN User Name username. The exact information should be obtained from the GSM operator.

  • Page 135: Tcp/Ip Parameters

    D-500 MK3 User Manual Firmware V-14.2 17.14. TCP/IP PARAMETERS Parameter Definition Factory Set Description This is the IPv4 (internet protocol version 4) address that the unit will require from the DHCP (dynamic host control protocol) server. Network IP Address 0.0.0.0 If this parameter is set to 0.0.0.0 then the unit will...
  • Page 136 D-500 MK3 User Manual Firmware V-14.2 17.14. TCP/IP PARAMETERS (continued) Parameter Definition Factory Set Description This is the account name appearing in the “from” tab Mail Account Name d500_a of the e-mail recipient. (ex: D500@gmail.com) Mail Account d500_1234 This is the e-mail password of above e-mail account.

  • Page 137: Sntp Parameters

    D-500 MK3 User Manual Firmware V-14.2 17.15. SNTP PARAMETERS SNTP (simple network time protocol) communication allows the controller to querry high precision, atomic clock based date/time servers through the internet and to adjust its internal real time clock to these servers.

  • Page 138: Synchronization Parameters

    D-500 MK3 User Manual Firmware V-14.2 17.17. SYNCHRONIZATION PARAMETERS Factory Description Parameter Definition Unit Genset Active Power It defines genset active power rating. 65000 Rate Genset Reactive Power It defines genset reactive power rating. kVAr 65000 Rate Mains Active Power Rate...
  • Page 139 D-500 MK3 User Manual Firmware V-14.2 Factory Description Parameter Definition Unit The master keeps this amount of extra power available during whole operation System Reserve Power 65000 under load as a safety against a sudden load surge. Load Management 0: Equal Aging...
  • Page 140 D-500 MK3 User Manual Firmware V-14.2 Factory Description Parameter Definition Unit When synchronization is detected, both Synchronization 25.5 contactors will stay closed during this Contactor Timeout timer. This is the maximum difference between Max Frequency mains and genset frequencies to close Difference both contactors.
  • Page 141 D-500 MK3 User Manual Firmware V-14.2 Factory Description Parameter Definition Unit In case of a soft transfer, the load’s active Active Power Ramp 100.0 power (KW) will be transferred to the (kW/sec) mains with this rate vice versa. In case of a soft transfer, the load’s Reactive Power Ramp 100.0...
  • Page 142 D-500 MK3 User Manual Firmware V-14.2 Factory Description Parameter Definition Unit If the total active load is below this level Multi Genset Delayed during the period defined in Genset Start Stop Power parameter, the slave genset will stop. This is the time delay used for starting and stopping of the slave genset.
  • Page 143 D-500 MK3 User Manual Firmware V-14.2 Factory Description Parameter Definition Unit In peak lopping mode the multi genset system will start and enter in parallel with the mains only if the mains power exceeds this limit. However it will supply...
  • Page 144 D-500 MK3 User Manual Firmware V-14.2 Factory Description Parameter Definition Unit This parameter defines the maximum Voltage Up/Down pulse width in voltage pulse control mode. msec 2000 Pulse Maximum Duration If this parameter is set to zero then no maximum pulse width is used.

  • Page 145: Dc Genset Parameters

    D-500 MK3 User Manual Firmware V-14.2 17.18. DC GENSET PARAMETERS Factory Description Parameter Definition Unit 0: No communication with rectifier Enable DC Rectifier module Communication 1: Communication is enabled with rectifier module. 0: Optimal charging cycle is performed Uncontrolled Charge...
  • Page 146 D-500 MK3 User Manual Firmware V-14.2 Factory Description Parameter Definition Unit This is the max charging voltage Nominal Boost Voltage 60.0 28.8 allowed during the boost cycle. If this value is different from zero, when the charge current falls below this...

  • Page 147: Snmp Parameters

    D-500 MK3 User Manual Firmware V-14.2 17.19. SNMP PARAMETERS Parameter Definition Factory Set Description This is the parameter to enable authentication based V3 Security Level AuthPriv on SHA or MD5. V3 Authentication This is the parameter to define authentication method.

  • Page 148: Ethernet Configuration

    D-500 MK3 User Manual Firmware V-14.2 18. ETHERNET CONFIGURATION Related parameters are: Parameter Definition Factory Set Description This is the IPv4 (internet protocol version 4) address that the unit will require from the DHCP (dynamic host control protocol) server. Network IP Address 0.0.0.0...

  • Page 149: Wi-Fi Configuration

    D-500 MK3 User Manual Firmware V-14.2 19. Wi-Fi CONFIGURATION Related parameters are: Parameter Definition Factory Set Description This is the name of wireless network that you want to ………...…. SSID connect. This is the password of wireless network that you want ………...….

  • Page 150: Gsm Configuration

    D-500 MK3 User Manual Firmware V-14.2 20. GSM CONFIGURATION Related parameters are: Parameter Definition Factory Set Description 0: SMS messages disabled SMS Enable 1: SMS messages enabled GPRS Connection 0: GPRS disabled Enable 1: GPRS enabled This parameter controls SMS sending when mains SMS on Mains voltages status is changed.

  • Page 151: Crank Cutting

    D-500 MK3 User Manual Firmware V-14.2 21. 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 >...

  • Page 152: Overcurrent Protection (Idmt)

    D-500 MK3 User Manual Firmware V-14.2 22. OVERCURRENT PROTECTION (IDMT) The unit offers a programmable IDMT protection function in order to protect the 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.
  • Page 153 D-500 MK3 User Manual Firmware V-14.2 Below is a table showing the tripping delay in function of the percent load level (with TMS=36): 100% unlimited 170% 73s 240% 18s 110% 3600s 180% 56s 250% 16s 120% 900s 190% 44s 260% 14s...

  • Page 154: Motorized Circuit Breaker Control

    D-500 MK3 User Manual Firmware V-14.2 23. 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.
  • Page 155 D-500 MK3 User Manual Firmware V-14.2 MCB modules can be operated by 2 different ways. The unit supports both configurations. Below is the terminology used: M: gear motor PF: ready to close contact XF: close coil MX: open coil MN: undervoltage trip (release)

  • Page 156: Auto Learning

    D-500 MK3 User Manual Firmware V-14.2 24. AUTO LEARNING The controller offers the automatic learning feature for adjusting synchronization & load sharing set-points and PID coefficients. The AUTO LEARNING makes the synchronization commissioning and fine adjusting a simple straightforward operation.
  • Page 157 D-500 MK3 User Manual Firmware V-14.2 Stop the generator and enter programming > synchronization parameters. ▪ Enable Gov control enable parameter. ▪ Enable AVR control enable parameter. Next step will be auto learning. - 157 -...
  • Page 158 D-500 MK3 User Manual Firmware V-14.2 To activate Auto Learning, push MAN button and then hold pressed Up Arrow button The unit will ask for confirmation. Push button to start Auto Learning operation. Auto learning is completed successfully. The controller will force the genset to its nominal speed and voltage.

  • Page 159: Speed & Voltage Up/Down Relay Outputs

    D-500 MK3 User Manual Firmware V-14.2 25. SPEED & VOLTAGE UP/DOWN RELAY OUTPUTS These outputs will be available in firmware version 5.7 The unit is able to control motorized potentiometers through up/down output functions. In order to use up/down functions, corresponding digital output function parameter should be set properly.

  • Page 160: J1939 Canbus Engine Support

    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.
  • Page 161 D-500 MK3 User Manual Firmware V-14.2 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.
  • Page 162 D-500 MK3 User Manual Firmware V-14.2 DESCRIPTION Incorrect ECM software Engine magnetic speed sensor fault ECU internal +5V fail Preheating relay fault Injector power supply fault ECU hardware fail ECU memory fail Fuel injector valve fault Camshaft sensor Flywheel sensor ECU memory fail External speed comm.
  • Page 163 D-500 MK3 User Manual Firmware V-14.2 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 Value too high” Valid data, but above the normal working range “Value too low”...

  • Page 164: Dpf Regeneration Support

    D-500 MK3 User Manual Firmware V-14.2 27. DPF REGENERATION SUPPORT The unit offers DPF Regeneration functionality for diesel engines equipped with exhaust filter and SCR. This feature is enabled automatically once any of selected engine from ECU list supports the functionality.

  • Page 165: Dc Genset Operation

    D-500 MK3 User Manual Firmware V-14.2 28. DC GENSET OPERATION The unit is able to work as DC genset controller with optional plugin DC module. The genset starting is based on the precisely measured DC battery bank voltage. Once started, the controller will perform an optimal battery charging cycle and will stop the genset when batteries are fully charged.
  • Page 166 D-500 MK3 User Manual Firmware V-14.2 Step_A: The genset is at rest. The load consumes power from the battery bank. The battery bank voltage decreases slowly with discharge level. When the battery bank voltage falls below the start to charge voltage, after the charge voltage threshold timer, the controller detects that the battery bank is discharged and decides to run the genset.

  • Page 167: Uncontrolled Charging With Fixed Speed

    D-500 MK3 User Manual Firmware V-14.2 28.2. UNCONTROLLED CHARGING WITH FIXED SPEED It is strongly recommended to wire speed detection through MPU, charge alternator pulses or J1939- CANBUS and enter correct low and high rpm limit values in order to preserve engine speed protection.
  • Page 168 D-500 MK3 User Manual Firmware V-14.2 Step_D: The battery bank voltage increases slowly until reaching the nominal genset DC output voltage. Step_E: The genset keeps the output voltage constant at the nominal genset DC output voltage. The charge current decreases slowly.

  • Page 169: Gps Support

    D-500 MK3 User Manual Firmware V-14.2 29. GPS SUPPORT The unit supports external GPS module from USB-Host port. USB GPS modules can be procured from the free market. USB GPS MODULE Related parameters are: Factory Parameter Definition Unit Description 0: no modem...
  • Page 170 D-500 MK3 User Manual Firmware V-14.2 A minimum of 3 satellites are necessary to determine the location. A fourth satellite is used for verification. More satellites will mean more precision. The unit displays the number of effective satellites on its GPS screen.

  • Page 171: Sms Commands

    D-500 MK3 User Manual Firmware V-14.2 30. SMS COMMANDS SMS messages are accepted only from phone numbers recorded in the Communication>GSM>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.
  • Page 172 D-500 MK3 User Manual Firmware V-14.2 COMMAND DESCRIPTION ANSWER Puts the controller into STOP mode. Alarms MODE STOP Unit forced to STOP! are also cleared. Puts the controller into AUTO mode. Alarms MODE AUTO Unit forced to AUTO! are also cleared.

  • Page 173: Load Transfer Modes

    D-500 MK3 User Manual Firmware V-14.2 31. LOAD TRANSFER MODES The unit offers 3 ways of transferring the load from genset to mains and vice versa: -transfer with interruption, -no break transfer, (from genset to mains) -soft transfer 31.1. TRANSFER WITH INTERRUPTION This is the most conventional way of transferring the load between the genset and mains.

  • Page 174: Uninterrupted Transfer

    D-500 MK3 User Manual Firmware V-14.2 31.2. UNINTERRUPTED TRANSFER In this mode, the transfer will be made without power interruption from genset to mains. 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.

  • Page 175: Soft Transfer

    D-500 MK3 User Manual Firmware V-14.2 31.3. SOFT TRANSFER In this mode, the transfer will be made without interruption like the Uninterrupted Transfer mode. But the load will be gradually transferred under active and reactive power control. The Soft Transfer sequence starts like an Uninterrupted transfer. But when both contactors are activated, the unit starts transferring the kW and kVAr load to the mains with a predefined ramp (Active Power Ramp, Reactive Power Ramp).

  • Page 176: Load Sharing

    D-500 MK3 User Manual Firmware V-14.2 32. LOAD SHARING This chapter is only applicable to units operated in multi-genset SYNCHRONIZATION & LOAD SHARE mode. The load sharing functionality brings flexibility and economy to the genset system, where only the necessary number of gensets to supply the load run.

  • Page 177: Digital Load Sharing (Datalink)

    D-500 MK3 User Manual Firmware V-14.2 Load sharing may be performed in 3 different ways: • Digital load share, based on Datalink communication • Active power sharing based on the Analog Load Share Line • Uncontrolled load share, based on droop operation 32.1.

  • Page 178: Analog Load Sharing

    D-500 MK3 User Manual Firmware V-14.2 32.2. ANALOG LOAD SHARING Load sharing can be performed as well using the Analog Load Share line. The Analog Load Share facility is designed as an emergency backup to the digital load share for increased reliability.

  • Page 179: Droop Mode Operation

    D-500 MK3 User Manual Firmware V-14.2 32.3. DROOP MODE OPERATION Droop mode allows an uncontrolled load share for emergency cases where the Datalink and Analog Load Share are not available. This is the most primitive load sharing method, often used in old times.

  • Page 180: Peak Lopping

    D-500 MK3 User Manual Firmware V-14.2 33. PARALLEL OPERATION WITH MAINS 33.1. PEAK LOPPING The Peak Lopping feature consists on the use of the genset system as a backup to the mains, in cases where the mains power rating is insufficient to supply the load.

  • Page 181: Power Export To Mains

    D-500 MK3 User Manual Firmware V-14.2 33.2. POWER EXPORT TO MAINS GENSET MAINS LOAD The Export to Mains mode allows the multi genset system to supply the mains power grid under constant power factor. Thus the multi genset system will be part of the mains power supply system.

  • Page 182: Distributed Power Export To Mains

    D-500 MK3 User Manual Firmware V-14.2 33.3. DISTRIBUTED POWER EXPORT TO MAINS GENSET MAINS GENSET GENSET The Distributed Power Export to Mains mode allows an unlimited number of gensets to export power to the mains and share active and reactive loads without any communication between controllers.

  • Page 183: Peak Lopping With Genset Priority

    D-500 MK3 User Manual Firmware V-14.2 PARAMETERS TO ADJUST: The Distributed Power Export functionality is enabled by a digital input set to the “Distributed Power Export” function (function_56). When signal arrives to this input, then the Distributed Power Export operating mode is enabled.

  • Page 184: Protection Functions Paralleling With Mains

    D-500 MK3 User Manual Firmware V-14.2 34. PROTECTION FUNCTIONS PARALLELING WITH MAINS The D-500 includes a comprehensive set of protection functions to detect quickly a mains failure during parallel with mains operation. The protections are enabled after the timeout defined by the parameter Parallel Check Delay in order not to detect a mains failure during transients caused by the closing of the contactors.

  • Page 185: Over/Under Frequency Function

    D-500 MK3 User Manual Firmware V-14.2 34.3. OVER/UNDER FREQUENCY FUNCTION This protection function measures the frequency of the mains for each period. If the frequency is outside limits for 4 successive periods, it detects a mains failure. The response time of the mains frequency is approximately 4 cycles.

  • Page 186: Data Recording

    D-500 MK3 User Manual Firmware V-14.2 35. DATA RECORDING 35.1. DATA RECORDING MEDIA Data can be recorded in USB flash memory. As soon as a USB flash memory is inserted, the unit will start data recording and continue until the memory is removed.

  • Page 187: Directory Structure

    D-500 MK3 User Manual Firmware V-14.2 35.2. 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. Last day of SITE-ID Year 2012...

  • Page 188: Recorded Data List, Record Period

    D-500 MK3 User Manual Firmware V-14.2 35.4. RECORDED DATA LIST, RECORD PERIOD 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.

  • Page 189: Software Features

    D-500 MK3 User Manual Firmware V-14.2 36. SOFTWARE FEATURES 36.1. 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.

  • Page 190: Load Add / Substract

    D-500 MK3 User Manual Firmware V-14.2 36.2. LOAD ADD / SUBSTRACT The load add/subtract 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.

  • Page 191: Five Step Load Management

    D-500 MK3 User Manual Firmware V-14.2 36.3. 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.

  • Page 192: Remote Start Operation

    D-500 MK3 User Manual Firmware V-14.2 36.4. 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.

  • Page 193: Battery Charging Operation, Delayed Simulate Mains

    D-500 MK3 User Manual Firmware V-14.2 36.6. BATTERY CHARGING OPERATION, DELAYED SIMULATE MAINS The Delayed Mains Simulation feature is used in battery backed up telecom systems where batteries are able to supply the load during a certain period. The genset is requested to run only when battery voltage drops below the critical level.

  • Page 194: Dual Genset Mutual Standby Operation

    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. - 194 -...

  • Page 195: Multiple Voltage And Frequency

    D-500 MK3 User Manual Firmware V-14.2 36.8. MULTIPLE VOLTAGE AND FREQUENCY The unit offers 3 sets of voltage and frequency protection limit values. The user is allowed to switch between these 3 sets anytime. This feature is especially useful in multiple voltage or frequency gensets for easy switching between different operating conditions.

  • Page 196: Automatic Exerciser

    D-500 MK3 User Manual Firmware V-14.2 36.11. 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.

  • Page 197: Engine Heating Operation

    D-500 MK3 User Manual Firmware V-14.2 36.13. 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 suitable temperature. The unit offers 2 different ways of engine heating.

  • Page 198: Fuel Pump Control

    D-500 MK3 User Manual Firmware V-14.2 36.16. 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.

  • Page 199: Charging The Engine Battery

    D-500 MK3 User Manual Firmware V-14.2 36.19. 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 from total discharge when the genset has not run for a long time.

  • Page 200: Resetting The Controller

    D-500 MK3 User Manual Firmware V-14.2 36.22. RESETTING THE CONTROLLER When necessary, the controller may be manually reset by holding the STOP button pressed for 30 seconds. The manual reset will cause the hardware to be configured following new settings.

  • Page 201: Zero Power At Rest

    D-500 MK3 User Manual Firmware V-14.2 36.24. ZERO POWER AT REST In a manual genset, it is possible to reduce the current consumption of the unit down to true zero Amperes, in order to prevent the battery from discharging. For “zero power at rest operation”, an external relay and “wake-up” pushbutton is necessary.

  • Page 202: Modbus Communications

    D-500 MK3 User Manual Firmware V-14.2 37. MODBUS COMMUNICATIONS This chapter is a brief description of the Modbus properties of the controller. For a complete documentation please use “500 Modbus Application Manual” The unit offers the possibility of MODBUS communication through below carriers:...

  • Page 203: Parameters Required For Rs-485 Modbus Operation

    D-500 MK3 User Manual Firmware V-14.2 37.1. 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.
  • Page 204 D-500 MK3 User Manual Firmware V-14.2 Below is a shortlist of available Modbus registers. For complete register map please refer to 500 Modbus Application Manual. ADDRESS R / W DATA COEFF. DESCRIPTION (decimal) SIZE 8193 16bit Pushbutton simulation BIT 0.Simulate Stop button BIT 1.Simulate Manual button...
  • Page 205 D-500 MK3 User Manual Firmware V-14.2 ADDRESS R / W DATA COEFF. DESCRIPTION (decimal) SIZE 10504- 256bit Shutdown alarm bits. Bit definitions are given at the end of the 10519 document. 10520- 256bit Loaddump alarm bits. Bit definitions are given at the end of the 10535 document.

  • Page 206: Snmp Communications

    Genset Power Factor (L1, L2, L3, Total) Shutdown Alarm List Loaddump Alarm List Genset Phase Angle Warning Alarm List Genset Frequency Genset Operation Mode Remote Controlled Digital Outputs The SNMP MIB file is available at DATAKOM technical support. - 206 -...

  • Page 207: Parameters Required For Snmp Via Ethernet

    D-500 MK3 User Manual Firmware V-14.2 38.1. 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).
  • Page 208 D-500 MK3 User Manual Firmware V-14.2 39. DECLARATION OF CONFORMITY The unit conforms to the EU directives -2014/35/EC (low voltage) -2014/30/EC (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.
  • Page 209 D-500 MK3 User Manual Firmware V-14.2 43. 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.
  • Page 210 D-500 MK3 User Manual Firmware V-14.2 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.

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