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D-100 MK2 User Manual Firmware V-6.3

D-100 MK2

ADVANCED

GENSET

CONTROLLER

The D-100 MK2 is a next generation genset control
units combining multi-functionality and wide
communication possibilities together with a reliable
and low cost design.

The unit co

mplies and mostly exceeds world’s

tightest safety, EMC, vibration and environmental
standards for the industrial category.

Software features are complete with easy firmware
upgrade process through USB port.

The Windows based PC software allows monitoring
and programming through USB, serial and GPRS.

The PC based Rainbow Scada software allows
monitoring and control of an unlimited number of
gensets from a single central location.

AMF unit with uninterrupted transfer
ATS unit with uninterrupted transfer
Remote start controller
Manual start controller
Engine controller
CTs at genset or load side

•

GSM Modem (2G-3G-4G) *

•

Ethernet 10/100Mbits *

•

Wi-Fi *

•

RS-485 isolated (2400-38400baud) *

•

RS-232 isolated (2400-38400baud) *

•

USB Device

•

J1939 CANBUS

•

Central Monitoring through internet *

•

SMS message sending *

•

PC software: Rainbow Plus

•

Central monitoring *

•

Modbus RTU through RS-485 *

•

Modbus TCP/IP *

*Optional with plug-in module

3 phases 4 wires, star
3 phases 3 wires, 3 CTs
3 phases 3 wires, 2 CTs (L1-L2)
3 phases 3 wires, 2 CTs (L1-L3)
2 phases 3 wires, L1-L2
2 phases 3 wires, L1-L3
3 phases 4 wires, delta
1 phase 2 wires

FUNCTIONALITIES

COMMUNICATIONS

TOPOLOGIES

DESCRIPTION

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Summary of Contents for D-100 MK2

Page 1: ...nitoring and control of an unlimited number of gensets from a single central location AMF unit with uninterrupted transfer ATS unit with uninterrupted transfer Remote start controller Manual start controller Engine controller CTs at genset or load side GSM Modem 2G 3G 4G Ethernet 10 100Mbits Wi Fi RS 485 isolated 2400 38400baud RS 232 isolated 2400 38400baud USB Device J1939 CANBUS Central Monitor...

Page 2: ... manufacturer directly at below e mail address technical support datakom com tr Please provide following information in order to get answers to any question Device model name see the back panel of the unit Complete serial number see the back panel of the unit Firmware version read from the display screen Measuring circuit voltage and power supply voltage Precise description of the query FILENAME D...

Page 3: ... AUTHOR DESCRIPTION 01 16 09 2019 MH First edition firmware version 6 3 CAUTION Potential risk of injury or death WARNING Potential risk of malfunction or material damage ATTENTION Useful hints for the understanding of device operation REVISION HISTORY TERMINOLOGY ...

Page 4: ...MK2 M2 G T 00 Screw type bracket Stock Code J10P01 per unit Self Retaining type bracket Stock Code K16P01 per unit Sealing Gasket SPARE PARTS ORDERING CODES Family Code PLUG IN MODULE M2 2G GSM Modem M3 3G GSM Modem M4 4G GSM Modem W WiFi module E Ethernet module R4 RS 485 module R2 RS 232 module With Conformal Coating Variant 00 standard unit 01 99 customer specific products With Sealing Gasket ...

Page 5: ...ng 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...

Page 6: ...E INPUT TERMINAL 3 7 3 8 3 9 3 10 DIGITAL OUTPUTS 3 11 3 12 RS 485 PORT PLUG IN MODULE 3 13 J1939 CANBUS PORT 3 14 USB DEVICE PORT 3 15 GSM MODEM PLUG IN MODULE 3 16 ETHERNET PORT PLUG IN MODULE 3 17 WI FI PLUG IN MODULE 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...

Page 7: ...R SIDE 6 3 ATS FUNCTIONALITY 6 4 REMOTE START FUNCTIONALITY 6 5 ENGINE CONTROL FUNCTIONALITY 6 6 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 9 5 MEASURED PARAMETERS 9 6 LED LAMPS 10 11 DISPLAYING EVENT LOGS 12 STATISTICAL COUNTERS 12 1 12 2 FUEL CONSUMPTION MONITORING 13 OPERA...

Page 8: ...GURATION 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 WIFI P...

Page 9: ...C EXERCISER 25 12 WEEKLY OPERATION SCHEDULER 25 13 ENGINE HEATING OPERATION 25 14 ENGİNE IDLE SPEED OPERATİON 25 15 ENGINE BLOCK HEATER 25 16 FUEL PUMP CONTROL 25 17 GAS ENGINE FUEL SOLENOID CONTROL 25 18 PRE TRANSFER SIGNAL 25 19 CHARGING THE ENGINE BATTERY 25 20 EXTERNALLY CONTROLLED DIGITAL OUTPUTS 25 21 COMBAT MODE 25 22 RESETTING THE CONTROLLER 25 23 AUTOMATIC CONNECTION TOPOLOGY DETERMINATIO...

Page 10: ...upply 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 Exces...

Page 11: ...D 100 MK2 User Manual Firmware V 6 3 K96D01 EN 11 Dimensions 133x107x46mm 5 25 x4 2 x1 9 Panel Cutout 117x87mm minimum 4 6 x3 43 Weight 250g 0 55 lb 2 1 DIMENSIONS 2 MOUNTING ...

Page 12: ...e mounting brackets and connectors from the unit then pass the unit through the mounting opening Place and tighten mounting brackets 87mm 117mm Panel Cutout WALL 40mm min 60mm Required Panel Depth The unit is designed for panel mounting The user should not be able to access parts of the unit other than the front panel ...

Page 13: ...6 3 K96D01 EN 13 Two different types of brackets are provided Screw type bracket Self retaining type bracket Installation of screw type bracket Installation of self retaining type bracket Do not tighten too much this may break the unit ...

Page 14: ...eign objects of 1 0 mm diameter and greater 5 Protected from the amount of dust that would interfere with normal operation 6 Dust tight 2nd Digit Description of Protection Level 0 Not protected 1 Protected against vertically falling water drops 2 Protected against vertically falling water drops when enclosure is tilted up to 15 3 Protected against water sprayed at an angle up to 60 on either side ...

Page 15: ...electrical installation Current transformers must have 5A output For current transformer inputs use at least 1 5mm2 section AWG15 cable The current transformer cable length should not exceed 1 5 meters If longer cable is used increase the cable section proportionally For the correct operation of the exerciser and weekly schedule programs adjust the real time clock of the unit through programming m...

Page 16: ...erse voltage 33VDC continuous Maximum operating current 500mA 12VDC All options included digital outputs open 250mA 24VDC All options included digital outputs open Typical operating current 250mA 12VDC all options passive digital outputs open 125mA 24VDC all options passive digital outputs open Measurement range 0 to 36VDC Display resolution 0 1VDC Accuracy 0 5 1 digit 24VDC 3 1 BATTERY VOLTAGE IN...

Page 17: ...es star 3 ph 3 wires delta 3ph 4 wires delta 2ph 3 wires L1 L2 2ph 3 wires L1 L3 1 ph 2 wires Measurement range 0 to 330VAC ph N 0 to 570VAC ph ph Common mode offset max 100V between neutral and BAT Input impedance 4 5M ohms Display resolution 1VDC Accuracy 0 5 1 digit 230VAC ph N 2VAC ph N 0 5 1 digit 400VAC ph ph 3VAC ph ph Frequency range DC to 500Hz Frequency display resolution 0 1 Hz Frequenc...

Page 18: ...l Display resolution 1A Accuracy 0 5 1 digit 5A 4 5A 5 500A full range SELECTING THE CT RATING AND CABLE SECTION The load on a CT should be kept minimum in order to minimize phase shift effect of the current transformer Phase shift in a CT will cause erroneous power and power factor readings although amp readings are correct Datakom advises CT rating to be selected following this table for the bes...

Page 19: ...rity Reactive power measurement is affected by incorrect CTs connection in similar way as active power measurement CORRECT CT CONNECTIONS Let s suppose that the genset is loaded with 100 kW on each phase The load Power Factor PF is 1 Measured values are as follows kW kVAr kVA pf Phase L1 100 0 0 0 100 1 00 Phase L2 100 0 0 0 100 1 00 Phase L3 100 0 0 0 100 1 00 Total 300 0 0 0 300 1 00 Current Tra...

Page 20: ...1 100 0 0 0 100 1 00 Phase L2 100 0 0 0 100 1 00 Phase L3 100 0 0 0 100 1 00 Total 100 0 0 0 300 0 33 EFFECT OF PHASE SWAPPING The generator is still loaded with 100 kW on each phase The load Power Factor PF is 1 PF in phases L2 and L3 will show 0 50 due to phase shift between voltages and currents which is caused by CT swapping The result is that total generator power displayed by controller is 0...

Page 21: ...old 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 Type of inputs all configurable additional sender ground input Function selection from list Structure 667 ohms resistor polarizing to 3 3VDC Measurement Analog resistor measurement Open circuit voltage 3 3VDC Short circuit current ...

Page 22: ...ion 0 1VDC Voltage measurement accuracy 2 0 1V 0 9V 30VDC Charge Fail Warning Threshold adjustable Charge Fail Shutdown Alarm Threshold adjustable Open circuit voltage battery positive Overvoltage protection 500VDC continuous with respect to battery negative Reverse voltage protection 30VDC with respect to battery negative Structure Negative pulling protected semiconductor output One terminal is c...

Page 23: ...20 ohms 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 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 monitorin...

Page 24: ...y 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 Th...

Page 25: ...Configuration Guide for more details 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 Although the controller supports also GPS location determination...

Page 26: ...able type CAT5 or CAT6 Isolation 1500 VAC 1 minute Max distance 100m with CAT5 or CAT6 cable Functionality Web Client Modbus TCP_IP LED FUNCTIONS GREEN This led turns 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 3 16 ETHERNET PORT PLUG IN MODULE Ethernet Slot Link Establishe...

Page 27: ...rmware V 6 3 K96D01 EN 27 Wi Fi protocols 802 11 b g n Frequency range 2 4 GHz 2 5 GHz 2400M 2483 5M Network Protocols IPv4 TCP UDP Security WPA WPA2 Functionality Web Client Modbus TCP_IP 3 17 Wi Fi PLUG IN MODULE Wi Fi Slot ...

Page 28: ...le 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 4 TOPOLOGIES Generator Parameters s Topology Selection Topology Selection Mains Parameters s ...

Page 29: ...D 100 MK2 User Manual Firmware V 6 3 K96D01 EN 29 4 3 3 PHASE 3 WIRE DELTA 4 2 3 PHASE 4 WIRE STAR ...

Page 30: ...D 100 MK2 User Manual Firmware V 6 3 K96D01 EN 30 4 5 3 PHASE 3 WIRE DELTA 2 CT L1 L2 4 4 3 PHASE 4 WIRE DELTA ...

Page 31: ...D 100 MK2 User Manual Firmware V 6 3 K96D01 EN 31 4 7 2 PHASE 3 WIRE DELTA 2 CTs L1 L2 4 6 3 PHASE 3 WIRE DELTA 2 CT L1 L3 ...

Page 32: ...D 100 MK2 User Manual Firmware V 6 3 K96D01 EN 32 4 9 1 PHASE 2 WIRE 4 8 2 PHASE 3 WIRE DELTA 2 CTs L1 L3 ...

Page 33: ...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 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 alterna...

Page 34: ...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 Thu...

Page 35: ...D 100 MK2 User Manual Firmware V 6 3 K96D01 EN 35 6 CONNECTION DIAGRAMS 6 1 AMF FUNCTIONALITY CTs AT LOAD SIDE ...

Page 36: ...D 100 MK2 User Manual Firmware V 6 3 K96D01 EN 36 6 2 AMF FUNCTIONALITY CTs AT ALTERNATOR SIDE ...

Page 37: ...D 100 MK2 User Manual Firmware V 6 3 K96D01 EN 37 6 3 ATS FUNCTIONALITY ...

Page 38: ...D 100 MK2 User Manual Firmware V 6 3 K96D01 EN 38 6 4 REMOTE START FUNCTIONALITY ...

Page 39: ...D 100 MK2 User Manual Firmware V 6 3 K96D01 EN 39 6 5 ENGINE CONTROL FUNCTIONALITY ...

Page 40: ...D 100 MK2 User Manual Firmware V 6 3 K96D01 EN 40 6 6 ...

Page 41: ...erially connected to this output 7 DIGITAL OUTPUT 5 This relay has programmable function selectable from a list Factory set as MAINS CONTACTOR output 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 8 CHARGE Input and outp...

Page 42: ...to these inputs The generator phase voltages upper and lower limits are programmable 54 GEN L2 56 GEN L3 58 GENERATOR NEUTRAL Input 0 300V AC Neutral terminal for the generator phases Term Function Technical data Description 59 CURR_1 Current transformer inputs 5A AC Connect the generator current transformer terminals to these inputs Do not connect the same current transformer to other instruments...

Page 43: ...ge 0 5000 ohms DC Outputs Protected mosfet semiconductor outputs rated 1Amp 28V DC Cranking dropouts survives 0V for 100ms Charge Alternator Excitation 100mA 12VDC 200mA 24VDC USB Device USB 2 0 Full speed 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 IP54 from front panel IP30 from the rear Dimensions 13...

Page 44: ... be assigned to any digital output using Relay Definition program parameters Also relays on an extension 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 9 1 FRONT PANEL FUNCTIONALITY 9 DESCRIPTION OF CONTROLS Fault condition indicators RUN mode button AUTO mode button STOP mode b...

Page 45: ...s the load Selects OFF mode The genset stops Selects next screen group LAMP TEST when held pressed Selects next display screen in the same group Resets the ALARM RELAY When held pressed for 5 seconds enters PROGRAMMING mode Makes factory reset Please review chapter RESETTING TO FACTORY DEFAULTS for more details When held pressed for 5 seconds resets service request counters Please review chapter S...

Page 46: ...arameter 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 ENG...

Page 47: ...e L2 L3 Gen voltage phase L3 L1 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 Below engine parameters ...

Page 48: ...ill 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 GENSET Turns on when the GENSET CONTACTOR is activated It flashes when all genset phase voltages and the genset frequency are within limits If enabled the genset phase rotation order must be also ...

Page 49: ...ges 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 rpm battery voltage charge voltage Possible event sources are various Every source can be individually enabled or disabled Program mode entrance event recorded with the password l...

Page 50: ...ine status is changed Genset on_load off_load events recorded when the genset loading status is changed Event logs are also displayed within the main screen Press button to find event record screen When displaying event logs button will display the next event Alarms are displayed with their numbers and engine hour on event log screen Press to navigate between screens ...

Page 51: ... 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 The unit is capable to display the actual fuel consumption of the engine through J1939 fuel consumption information If the engine is sending the fuel rate through J1939 messaging then the unit will directly display the fuel consumption i...

Page 52: ...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...

Page 53: ...e 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 contactor period and the generator contactor will be energized When mains are evaluated as available again then ...

Page 54: ...ther mode of operation The TEST mode is entered by holding pressed the button for 5 seconds 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 The genset will feed the load indefinitely unless another mode is selected 13 5 TEST M...

Page 55: ...e 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 Alarms may be of LATCHING type following programming For latching alarms even if the alarm condition is removed ...

Page 56: ...utdown 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 ...

Page 57: ...256 loaddump alarms and 256 warnings Thus a total of 768 different alarms may be displayed Warnings are displayed with e prefix Shutdowns and loaddumps are displayed with Xe prefix A sample Alarm e0569 High Engine Temperature Warning All warnings can be made latching by enabling a single program parameter Controller Configuration Latch All Warnings 14 3 LIST OF ALARMS Latch All Warnings ...

Page 58: ... be monitored Fault Holdoff Timer delay after the engine is running Shutdown and warning limits are independently programmable The detection delay is also programmable The high rpm overshoot limit is always monitored and stops the engine immediately 51 307 563 ENGINE HIGH RPM Set if the engine rpm is above programmed limits The faults will be monitored Fault Holdoff Timer delay after the engine is...

Page 59: ...mits are independently programmable 60 316 572 OIL SENDER OPEN Set if the resistor value read from the sender input is above 5000 ohms or if the terminal is left open 61 317 573 TEMPERATURE SENDER OPEN Set if the resistor value read from the sender input is above 5000 ohms or if the terminal is left open 62 318 574 FUEL LEVEL SENDER OPEN Set if the resistor value read from the sender input is abov...

Page 60: ...ion of the timer then no alarm will be set 72 328 584 GENSET PHASE ORDER FAIL Set if the fault is enabled and the genset phase order is reverse 73 329 585 MAINS PHASE ORDER FAIL Set if the fault is enabled and the mains phase order is reverse 74 330 586 GENSET CB FAIL TO CLOSE Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration ...

Page 61: ... or a fault condition or the weekly schedule prevents the automatic starting of the genset FUEL THEFT Engine is not running If the fuel level measured from the sender input falls by 20 or more in one hour then Fuel Theft warning occurs the detection delay is 10 sec not adjustable Engine is running If the fuel level measured from the sender input falls by 2x hourly fuel consumption percentage or mo...

Page 62: ... affect the operation of the unit Thus programs may be modified anytime even while the genset is running In order to resume to the factory set parameter values hold pressed the STOP LAMP TEST and ALARM MUTE buttons for 5 seconds RETURN TO FACTORY SET will be displayed immediately press and hold pressed LAMP TEST button for 5 seconds factory set values will be reprogrammed to the parameter memory C...

Page 63: ...ed below password entry screen will be displayed A 4 digit password must be entered using buttons The buttons modify the value of the current digit The 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 pa...

Page 64: ...button is pressed during 2 minutes the program mode will be cancelled automatically 15 4 MODIFYING PARAMETER VALUE 15 5 PROGRAMMING MODE EXIT Decrease parameter value Increase parameter value Previous parameter Long Press Return to the upper menu Next parameter Press STOP button to exit PROGRAM mode ...

Page 65: ...ode 008 Delayed Simulate Mains 0 1 0 0 delayed simulate mains disabled 1 delayed simulate mains enabled 009 SMS Enable 0 1 0 0 SMS messages disabled 1 SMS messages enabled 010 GPRS Connection Enable 0 1 0 0 GPRS disabled 1 GPRS enabled 011 Rainbow Scada Refresh Rate sec 0 65535 5 The unit will update the distant monitoring terminal with this rate 012 Rainbow Scada Address 1 Port 0 65535 0 This is ...

Page 66: ...s 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 023 Fuel Pump Low Limit 0 100 20 If the fuel level measured from the sender input falls below this level then the FUEL PUMP function will become active 024 Fuel Pump High Limit 0 100 80 If the fuel level measured from the sender input goes above this level then the FUEL P...

Page 67: ... 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 035 Open with Last Mode 0 1 0 0 The unit powers up in STOP mode 1 The unit powers up in the same operating mode before power down 036 Pre Transfer Delay sec 0 60 0 If this parameter is not zero the unit will activate the Wait Before Transfer output fun...

Page 68: ...ence to this value 049 Nominal Voltage 2 V AC 0 300 120 When secondary voltage is selected this is the nominal value of genset and mains voltages Voltage limits are defined by reference to this value 050 Nominal Frequency 2 Hz 0 500 60 When secondary frequency is selected this is nominal value of genset and mains frequency Frequency limits are defined by reference to this value 051 Nominal Voltage...

Page 69: ...de 060 Genset Low Voltage Warning Limit V 100 V 100 V 15 If one of the genset phase voltages goes under this limit when feeding the load this will generate a GENSET LOW VOLTAGE warning 061 Genset Low Voltage Shutdown Limit V 100 V 100 V 20 If one of the genset phase voltages goes under this limit when feeding the load this will generate a GENSET LOW VOLTAGE shutdown alarm and the engine will stop ...

Page 70: ...ltage Shutdown Limit V DC 5 0 35 0 30 0 If the battery voltage goes over this limit this will generate a HIGH BATTERY shutdown alarm and the engine will stop 074 Battery Voltage Fail Timer sec 0 10 3 If the battery voltage goes outside of the limits during this timer a battery voltage fault will occur 075 Genset Voltage Unbalance Limit 0 100 0 0 If any genset phase voltage differs from the average...

Page 71: ...ents 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 085 Genset Overcurrent Action 0 3 0 0 shutdown alarm 1 loaddump alarm 086 Overcurrent Time Multiplier 0 1 64 16 This parameter defines the reaction speed of the overcurrent...

Page 72: ...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 7 single phase 2 wire 096 Mains Contactor Timer sec 0 600 0 5 This is the period after the generator contactor has been deactivated and before the mains contactor has been activated 097 Mains MCB Clos...

Page 73: ...s activated Review chapter Motorized Circuit Breaker Control for more details 107 GCB Alarm Level 0 1 0 0 shutdown alarm 1 loaddump alarm 108 Genset MCB Fail Timer sec 0 600 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 109 Genset Phase Order Check Enable 0 1 0 0 genset phase order chec...

Page 74: ...M warning 123 High RPM Shutdown Limit R 100 R 100 R 15 If the engine rpm goes over this limit when feeding the load this will generate a GENSET HIGH RPM shutdown alarm and the engine will stop 124 RPM Fail Timer sec 0 10 3 If the engine rpm goes outside of the limits during this timer an engine speed fault will occur 125 Overspeed Overshoot Limit HRSL 100 HRSL 100 HRSL 10 If the engine rpm goes ov...

Page 75: ... Engine Heating Timer 137 Cooldown Timer sec 0 600 120 This is the period that the generator runs for cooling purpose after the load is transferred to mains 138 Stop Solenoid Timer sec 0 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 ...

Page 76: ...witch is open or the oil pressure measured is above shutdown limit 151 Charge Input Connected 0 1 0 0 Crank cutting with charge input disabled 1 Crank cutting with charge input enabled 152 Fuel Tank Capacity Lt 0 65000 0 The full capacity of the fuel tank If this parameter is zero the fuel quantity in the tank is not displayed 153 Fuel Consumption per Hour 0 100 0 0 This parameter is the threshold...

Page 77: ...ng on service 2 engine hours 163 Service 2 Period month 0 24 6 The SERVICE REQUEST led indicator will turn on after this amount of time from the last service If the period is set to 0 no SERVICE REQUEST will be indicated depending on Service 2 Period 164 Service 2 Alarm Level 0 3 0 0 no action 1 shutdown alarm 2 loaddump alarm 3 warning 165 Service 3 Engine Hours hours 0 5000 250 The SERVICE REQUE...

Page 78: ...eneric CUMMINS ENGINE 0 CM850 1 CM570 2 CM570_2 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 1 without CIU unit 2 EDC4 CATERPILLAR ENGINE 0 Generic SCANIA ENGINE 0 Generic 1 S6 Single Speed 2 S8 All Speed IVECO ENGINE 0 Generic 1 Vector 2 NEF CURSOR MTU MDEC ENGINE 0 MDEC 302 1 MD...

Page 79: ...is generated 176 Oil Pump Stop Pressure bars 0 20 0 The oil pump is activated prior to the crank cycle and stopped when this pressure level is reached If this value is set to zero then the oil pump is not activated 177 Disable ECU speed control 0 1 0 0 Engine speeed checking is performed with the RPM information coming from the engine ECU unit 1 the RPM information coming from the engine ECU unit ...

Page 80: ...e day Minutes 00 59 Current minute of the hour Seconds 00 59 Current second of the minute 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 o...

Page 81: ...thly 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 16 6 EXERCISER SCHEDULE ...

Page 82: ...action taken upon fault case 0 no alarm 1 shutdown alarm 2 loaddump alarm 3 warning Low Alarm Check Enable 0 0 1 The low alarm may be selected as shutdown or loaddump with alarm level parameter 0 low value alarm disabled 1 low value alarm enabled Low Warning Check Enable 0 0 1 0 low value warning disabled 1 low value warning enabled High Alarm Check Enable 0 0 1 The high alarm may be selected as s...

Page 83: ...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...

Page 84: ... line below If this parameter is set to 0 then the input name string can be freely entered Action 0 3 0 shutdown alarm 1 loaddump alarm 2 warning 3 no fault condition from this input Sampling 0 3 0 always 1 on engine running 2 after hold off timer 3 reserved Latching 0 1 0 non latching The fault disappears when cause is removed 1 latching The fault persists even if the cause is removed Requires ma...

Page 85: ...hibit 30 Air Flap Fault 31 Canopy Door Open 32 Station Door Open 33 Station Over Heat Sw 34 Weather Cloudy 35 Weather Rainy 36 Lightning 37 Cooler Fan Fault 38 Heater Fan Fault 39 Canopy Fan Fault 40 Station Fan Fault No Description 41 Over Resonance 42 Short Circuit Alarm 43 Reset Service 1 Alm 44 Reset Service 2 Alm 45 Reset Service 3 Alm 46 Heavy Duty 47 Synchro Genset Run 48 Synch Genset on Lo...

Page 86: ...nition Factory set Terminal number Description 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 Below is a short list for reference purposes Please use the RainbowPlus program for complete selection list 16 9 OUTPUT...

Page 87: ...d 70 Remote Start Input 71 Disable Auto Start 72 Force to Start 73 Auto Restore Inhibited 74 Gen Loading Inhibited 75 Inp Expansion1Mounted 76 Inp Expansion2Mounted 77 Out Expansion1Mounted 78 Out Expansion2Mounted 79 Master Unit 80 Multi Gen Remote Start 81 Remote Control Out 1 82 Remote Control Out 2 83 Remote Control Out 3 84 Remote Control Out 4 85 Remote Control Out 5 86 Remote Control Out 6 ...

Page 88: ...esigned to identify the current controller Th s string is added to GSM SMS messages web page headers etc 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 Enter numbers starting from first ch...

Page 89: ...rvice 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 operator s website with sms service center string Parameter Definition Unit Min Max Factory Set Description GSM Sim Card Pin 0000 9999 0 If the GSM SIM card uses pin number ent...

Page 90: ... 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 Rainbow Address 1 Rainbow Address 2 wss1 datakom com tr These parameters accept both internet addresses like htt...

Page 91: ... 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 an IP professional please leave this address as 255 255 255 0 ...

Page 92: ...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 an IP professional please leave this address as 255 255 255 0 The wifi connection status is monitored at ethernet screen page Connection Sta...

Page 93: ...ation read from GSM system 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 operator s website with APN string APN Password If the APN access point name username is required by the GSM operator most probably the APN pa...

Page 94: ...ngine Parameters Crank Cut RPM then cranking is immediately stopped Charge alternator voltage over threshold Following setting is necessary Engine Parameters Charge Input Connected 1 If the charge alternator voltage reaches Engine Parameters Crank Cut Charge Voltage then cranking is immediately stopped Oil pressure above threshold Following setting is necessary Engine Parameters Crank Cut with Oil...

Page 95: ...ill 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 a 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 m...

Page 96: ...nction 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 130 400s 200 36s 270 12s 140 225s 210 30s 280 11s 150 144s 220 25s 290 10s 160 100s 230 21s 300 9s Below is the tripping delay curve in function of the load level with TMS 36 ...

Page 97: ...rogramming menu The MCB CLOSE sequence is below Activate UV output wait for undervoltage coil timer tuv Activate CLOSE output wait for close pulse timer tcl Deactivate CLOSE output The MCB OPEN sequence is below Deactivate UV output Activate OPEN output wait for open pulse timer top Deactivate OPEN output If MCB feedback input is defined and the MCB fails to change position after the expiration of...

Page 98: ... XF close coil MX open coil MN undervoltage trip release AUX auxiliary contacts MCB WITH OPEN CLOSE COILS MCB WITH CLOSE UV COILS 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...

Page 99: ...ation PGN 65257 SPN 250 Engine Total Fuel Used PGN 65262 SPN 110 Engine Coolant Temperature SPN 174 Engine Fuel Temperature 1 SPN 175 Engine Oil Temperature 1 PGN 65263 SPN 100 Engine Oil Pressure SPN 94 Engine Fuel Delivery Pressure SPN 98 Engine Oil Level SPN 101 Engine Crankcase Pressure SPN 109 Engine Coolant Pressure SPN 111 Engine Coolant Level PGN 65266 SPN 183 Engine Fuel Rate SPN 184 Engi...

Page 100: ...el sensor fail 100 x Low oil pressure Oil pressure sensor fail 101 x Crankcase pressure fault 102 x Intake manifold 1 pressure fault 103 x Turbocharger 1 speed fault 105 x Intake manifold temp high Intake manifold temp sensor fail 106 x High boost pressure Turbo outlet pressure sensor fail 107 x Air filter restriction Air filter sensor fail 108 x Atmospheric pressure sensor fail 109 x Coolant pres...

Page 101: ...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 Injector cylinder 8 fault 677 x Start motor relay fail 723 x Secondary engine speed sensor fail 1075 x Electric lift pump circulation fault 1079 x ECU internal 5V fail 1111 x Check configuration p...

Page 102: ... 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 Calibration values outside the limits 14 Unk...

Page 103: ...T Puts the controller into TEST mode Alarms are also cleared Unit forced to TEST Unit forced to AUTO Unit forced to STOP SMS messages must be written exactly as below without any preceding blanks Only UPPERCASE characters are permitted 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...

Page 104: ...eps using LOAD_ADD and LOAD_SUBSTRACT output functions Any digital output may be 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...

Page 105: ... 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_add relay will be active Load Shedding High Limit If the genset power goes above this limit then the load_substract relay will be active Load Add Delay This is the minimum delay between 2 load_add pulses This is also the minimum delay betw...

Page 106: ...troller will start adding load Multi Load Subtract Start Delay tLSD If the load stays over the Multi Load Subtract Power Level parameter during this timer then 1 step of load is subtracted Multi Load Subtract Wait Delay tLSW This is the minimum period between two load subtract pulses Multi Load Add Start Delay tLAD If the load stays below the Multi Load Add Power Level parameter during this timer ...

Page 107: ...ut 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...

Page 108: ... 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 charg...

Page 109: ... 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 parameter...

Page 110: ...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 The unit offers total external c...

Page 111: ... mode of operation If any of the mode selection keys are pressed during exercise then the exercise 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 In most applications the genset is requested to operate only in...

Page 112: ...ped 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 st...

Page 113: ...el pump relay function may be assigned to any digital output using Relay Definition program parameters 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 o...

Page 114: ...gine battery charging run then the genset will take the load 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...

Page 115: ...ested to be one of below ones during holdoff timer period If below voltage conditions are met continuously during 3 seconds then the topology is considered to be determined If the topology cannot be determined during holdoff timer duration then an Unknown Topology loaddump is generated and the engine stops after cooldown This feature is especially useful for manual voltage adjustment after a new t...

Page 116: ...output may be assigned as zero power relay output Please refer to the relay function list for the setup CONTROLLER BAT OUTx SUPPLY The controller wakes up on applying the power through the wake up pushbutton Then it will immediately activate the zero power output which will cause the zero power relay to feed the controller If the engine is not run or if the engine stops a timer of 5 minutes will b...

Page 117: ...ion 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 Devices using Modbus TCP IP with different IP or port ad...

Page 118: ...e but will cause slower response times Typically 9600 bauds will allow 1200m distance with special balanced 120 ohms cable 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 ...

Page 119: ... 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 R 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...

Page 120: ... 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 R 32bit x1 Counter number of genset cranks 10620 R 32bit x1 C...

Page 121: ...arately from the usual waste 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 I under category Monitoring and c...

Page 122: ...e 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 cosΦ readings are faulty although the Amp readings are correct Current transformers are not connected to the correct inputs or some of the CTs are connected with reverse polarity Determine the correct connections of each individual CT in order to obtain co...

Page 123: ...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 disabl...

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