Datakom D-500 MK2 User Manual Download Page 6

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D-500 MK2 User Manual Firmware V-6.3

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1. INSTALLATION INSTRUCTIONS
2. MOUNTING

2.1 DIMENSIONS

2.2 SEALING, GASKET

2.3 ELECTRICAL INSTALLATION

3. TERMINAL DESCRIPTIONS

3.1. BATTERY VOLTAGE INPUT

3.2. AC VOLTAGE INPUTS

3.3. AC CURRENT INPUTS

3.4. DIGITAL INPUTS

3.5. ANALOG SENDER INPUTS AND SENDER GROUND

3.6. CHARGE INPUT TERMINAL

3.7. MAGNETIC PICKUP INPUT

3.8. DIGITAL OUTPUTS

3.9. MAINS CONTACTOR OUTPUT

3.10. GENERATOR CONTACTOR OUTPUT

3.11. INPUT/OUTPUT EXTENSION

3.12. J1939-CANBUS PORT

3.13. USB DEVICE PORT

4. PLUG-IN MODULES

4.1. MODEM PLUG-IN

4.1.1. GSM MODEM SLOT

4.1.2. Wi-Fi SLOT

4.1.3. ETHERNET SLOT

4.1.4. RS-485 SLOT

4.2. SYNCHRONIZATION PLUG-IN

4.2.1. ANALOG AVR CONTROL OUTPUT

4.2.2. ANALOG GOVERNOR CONTROL OUTPUT

4.2.3. DATALINK-CANBUS PORT

4.2.4. ANALOG LOAD SHARE SIGNAL

4.3. ANALOG PLUG-IN

4.3.1. ANALOG I/O EXTENSION SLOT

4.3.2. 3 X MAINS CT INPUTS SLOT

4.4. COMMUNICATION SLOT

4.4.1. ETHERNET PORT

4.4.2. USB HOST PORT

4.4.3. RS-485 PORT

TABLE OF CONTENTS

Summary of Contents for D-500 MK2

Page 1: ...inbow Scada web monitoring service allows monitoring and control of an unlimited number of gensets through any web browser Multi genset synchronizer and load share Multi genset mains synchronizer Single genset parallel with mains AMF unit with uninterrupted transfer ATS unit with uninterrupted transfer Remote start controller Manual start controller Engine controller Remote display control unit Wa...

Page 2: ...nical 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 DESCRIPTION 500 Rainbow Installation Rainbow Plus In...

Page 3: ...OR DESCRIPTION 01 24 09 2019 MH First release 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: ...00 MK2 S E M C G T 00 Screw type bracket Stock Code J10P01 per unit Self Retaining type bracket Stock Code K16P01 per unit Sealing Gasket Stock Code K20P01 SPARE PARTS ORDERING CODES Family Code GSM GPRS Modem slot USB Host RS 485 Ethernet slot With Sealing gasket With Conformal Coating Variant 00 standard unit 01 99 customer specific products Synchronization slot I O Extension slot ...

Page 5: ...wer before working on equipment When the unit is connected to the network do not touch terminals Short circuit terminals of unused current transformers Any electrical parameter applied to the device must be in the range specified in the user manual Although the unit is designed with a wide safety margin over range parameters may reduce lifetime alter operational precision or even damage the unit D...

Page 6: ...MAINS CONTACTOR OUTPUT 3 10 GENERATOR CONTACTOR OUTPUT 3 11 INPUT OUTPUT EXTENSION 3 12 J1939 CANBUS PORT 3 13 USB DEVICE PORT 4 PLUG IN MODULES 4 1 MODEM PLUG IN 4 1 1 GSM MODEM SLOT 4 1 2 Wi Fi SLOT 4 1 3 ETHERNET SLOT 4 1 4 RS 485 SLOT 4 2 SYNCHRONIZATION PLUG IN 4 2 1 ANALOG AVR CONTROL OUTPUT 4 2 2 ANALOG GOVERNOR CONTROL OUTPUT 4 2 3 DATALINK CANBUS PORT 4 2 4 ANALOG LOAD SHARE SIGNAL 4 3 AN...

Page 7: ...REMOTE START FUNCTIONALITY 6 8 ENGINE CONTROLLER FUNCTIONALITY 6 9 REMOTE DISPLAY UNIT FUNCTIONALITY 6 10 400HZ OPERATION 7 CONNECTION DIAGRAMS 7 1 GENSET SYNCHRONIZATION FUNCTIONALITY 7 2 MAINS SYNCHRONIZATION FUNCTIONALITY 7 3 SINGLE GENSET PARALLEL WITH MAINS FUNCTIONALITY 7 4 AMF FUNCTIONALITY 7 5 ATS FUNCTIONALITY 7 6 REMOTE START FUNCTIONALITY 7 7 ENGINE CONTROL FUNCTIONALITY 7 8 REMOTE DISP...

Page 8: ...ORY DEFAULTS 16 2 ENTERING THE PROGRAMMING MODE 16 3 NAVIGATING BETWEEN MENUS 16 4 MODIFYING PARAMETER VALUE 16 5 PROGRAMMING MODE EXIT 17 PROGRAM PARAMETER LIST 17 1 CONTROLLER CONFIGURATION GROUP 17 2 ELECTRICAL PARAMETERS GROUP 17 3 ENGINE PARAMETERS GROUP 17 4 ADJUST DATE AND TIME 17 5 WEEKLY OPERATION SCHEDULE 17 6 EXERCISER SCHEDULE 17 7 SENDER CONFIGURATION 17 8 DIGITAL INPUT CONFIGURATION ...

Page 9: ... TRANSFER 30 LOAD SHARING 30 1 DIGITAL LOAD SHARING DATALINK 30 2 ANALOG LOAD SHARING 30 3 DROOP MODE OPERATION 31 PARALLELING WITH MAINS OPERATION 31 1 PEAK LOPPING 31 2 POWER EXPORT TO MAINS 31 3 DISTRIBUTED POWER EXPORT TO MAINS 31 4 PEAK LOPPING WITH GENSET PRIORITY 32 PROTECTION FUNCTIONS PARALLELING WITH MAINS 32 1 ROCOF FUNCTION rate of change of frequency 32 2 VECTOR SHIFT FUNCTION 32 3 OV...

Page 10: ...4 ENGİNE IDLE SPEED OPERATİON 34 15 ENGINE BLOCK HEATER 34 16 FUEL PUMP CONTROL 34 17 GAS ENGINE FUEL SOLENOID CONTROL 34 18 PRE TRANSFER SIGNAL 34 19 CHARGING THE ENGINE BATTERY 34 20 EXTERNALLY CONTROLLED DIGITAL OUTPUTS 34 21 COMBAT MODE 34 22 RESETTING THE CONTROLLER 34 23 AUTOMATIC CONNECTION TOPOLOGY DETERMINATION 34 24 ZERO POWER AT REST 35 MODBUS COMMUNICATIONS 35 1 PARAMETERS REQUIRED FOR...

Page 11: ... voltage Voltage at measuring terminals beyond specified range Voltage applied to digital inputs over specified range Current at measuring terminals beyond specified range Overload or short circuit at relay outputs Connecting or removing data terminals when the unit is powered up High voltage applied to communication ports Ground potential differences at non isolated communication ports Excessive ...

Page 12: ...D 500 MK2 User Manual Firmware V 6 3 12 Dimensions 211x162x42mm Panel Cutout 176x121mm minimum Weight 500g approx 2 1 DIMENSIONS 2 MOUNTING ...

Page 13: ...ot be able to access parts of the unit other than the front panel Mount the unit on a flat vertical surface Before mounting remove the mounting brackets and connectors from the unit then pass the unit through the mounting opening Place and tighten mounting brackets Panel Cutout Required Panel Depth ...

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

Page 16: ...rical 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 menu T...

Page 17: ...voltage 36VDC continuous Maximum operating current 600mA 12VDC All options included digital outputs open 300mA 24VDC All options included digital outputs open Typical operating current 300mA 12VDC all options passive digital outputs open 150mA 24VDC all options passive digital outputs open Measurement range 0 to 36VDC Display resolution 0 1VDC Accuracy 0 5 1 digit 24VDC 3 1 BATTERY VOLTAGE INPUT 3...

Page 18: ... 3 wires delta 3 ph 3 wires delta L1 L2 3 ph 3 wires delta L2 L3 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 resolu...

Page 19: ...15 milliohm Burden 0 375W Maximum continuous current 6A Measurement range 0 1 to 7 5A Common mode offset Max 5VAC between BAT and any CT terminal Display resolution 1A Accuracy 0 5 1 digit 5A 4 5A 5 500A full range SELECTING THE CT RATING AND CABLE SECTION The load on a CT should be kept minimum in order to minimize phase shift effect of the current transformer Phase shift in a CT will cause erron...

Page 20: ...gs Many combinations of incorrect CTs connections are possible so check both order of CTs and their polarity Reactive power measurement is affected by incorrect CTs connection in similar way as active power measurement CORRECT CT CONNECTIONS Let s suppose that the genset is loaded with 100 kW on each phase The load Power Factor PF is 1 Measured values are as follows kW kVAr kVA pf Phase L1 100 0 0...

Page 21: ... 0 0 0 100 1 00 Phase L2 100 0 0 0 100 1 00 Phase L3 100 0 0 0 100 1 00 Total 100 0 0 0 300 0 33 EFFECT OF PHASE SWAPPING The generator is still loaded with 100 kW on each phase The load Power Factor PF is 1 PF in phases L2 and L3 will show 0 50 due to phase shift between voltages and currents which is caused by CT swapping The result is that total generator power displayed by controller is 0 kW M...

Page 22: ...ut voltage 100VDC with respect to battery negative Minimum input voltage 70VDC with respect to battery negative Noise filtering Yes both analog and digital filtering Number of inputs 4 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 ...

Page 23: ...resolution 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 Differential frequency measurement input Input impedance 5...

Page 24: ...it protection 1 7 ADC Reverse voltage protection 500 VDC Structure Relay output normally closed contact One terminal is internally connected to mains phase L1 input Max switching current 12A 250VAC Max switching voltage 440VAC Max switching power 3000VA Structure Relay output normally open contact One terminal is internally connected to genset phase L1 input Max switching current 16A 250VAC Max sw...

Page 25: ...e battery negative Any function can be assigned to digital inputs Digital outputs can be extended using DKG 186 Fet Extension modules each one providing 8 outputs Digital outputs have the same electrical characteristics as on board outputs They have programmable functions through the main controller Any function can be assigned to any output Input and output extension modules are connected to the ...

Page 26: ...32 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 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 us...

Page 27: ...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 Extension Slot 3xMains CT Inputs Slot DC Voltage and Current Inputs Slot Tilt Detector Slot COMMUNICATION PLUG IN Communication Slot 4 PLUG IN MODULES ...

Page 28: ...oice only type SIM cards will usually not function properly Please refer to GSM Modem Configuration Guide for more details Description Quad band GSM GPRS 850 900 1800 1900MHz module GPRS multi slot class 12 12 GPRS mobile station class B Compliant to GSM phase 2 2 Class 4 2 W 850 900 MHz Class 1 1 W 1800 1900MHz Functionality Web Client SMTP Modbus TCP IP client SMS e mail Operating temp range 40 ...

Page 29: ...ntroller supports also GPS location determination for more precise positioning the GSM based location is free of charge available everywhere even where GPS signal is not available 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 E mail Modbus TCP_IP 4 1 2 Wi Fi SLOT The location precision will depen...

Page 30: ...ype CAT5 or CAT6 Isolation 1500 VAC 1 minute Max distance 100m with CAT5 or CAT6 cable Functionality Web Client E mail 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 4 1 3 ETHERNET SLOT Ethernet Slot Link Established led Data Fl...

Page 31: ...ith 120 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 moni...

Page 32: ...hrough program parameter Sweep Range Adjustable through program parameter Structure Isolated analog 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 2 2 ANALOG GOVERNOR CONTROL OUTPUT 4 2 1 ANALOG AVR CONTROL OUTPUT 4 2 SYNCHRONIZATION PLUG IN Synchronization Sl...

Page 33: ...ION is to be connected to DATALINK L in order to terminate the Datalink bus Isolation voltage 1000 VAC 1 minute Common mode voltage 0 5 VDC to 15 VDC internally clamped by transient suppressors Max distance 200m with 120 ohm balanced cable Figure illustrating the Datalink termination from two ends The Datalink cable shield should be grounded from one end only The Datalink bus should be terminated ...

Page 34: ... extension plug in module with 3 analog inputs Each analog input can be switched by DIP switches for Resistive 4 to 20 mA 0 to 10 Vdc The main configuration of the inputs is done with DIP switches located on slot SND 8 cannot be switched to resistive input The configuration can be 4 20 mA or 0 10 VDC Analog outputs will be functional with further firmware version 4 3 1 ANALOG I O EXTENSION SLOT 4 ...

Page 35: ...res delta L1 L2 3 ph 3 wires delta L2 L3 2ph 3 wires L1 L2 2ph 3 wires L1 L3 1 ph 2 wires CT secondary rating 5A Measurement range 5 5 to 5000 5A minimum Input impedance 15 milliohm Burden 0 375W Maximum continuous current 6A Measurement range 0 1 to 7 5A Common mode offset Max 5VAC between BAT and any CT terminal Display resolution 1A Accuracy 0 5 1 digit 5A 4 5A 5 500A full range 4 3 2 3 X MAINS...

Page 36: ...minute Max distance 100m with CAT5 or CAT6 cable Functionality Embedded TCP IP Web Server Web Client SMTP e mail SNMP Modbus TCP_IP STANDARD ETHERNET CABLE 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 4 4 1 ETHERNET PORT 4 4 COMMUNICATION S...

Page 37: ...y All USB flash memories The USB Host port is designed for detailed data recording The period of recording is adjustable through program parameter As soon as a USB flash memory is inserted the unit will start data recording and continue until the memory is removed For more details about data recording please review chapter Data Recording The USB Host port is available in units with COMM option If ...

Page 38: ...120 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 monitori...

Page 39: ... 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 are available for the mains side as well 5 1 SELECTING THE TOPOLOGY 5 TOPOLOGIES Generator Parameters s Topology Selection Topology Selection Mains Parameters s ...

Page 40: ...D 500 MK2 User Manual Firmware V 6 3 40 5 3 3 PHASE 3 WIRE DELTA 5 2 3 PHASE 4 WIRE STAR ...

Page 41: ...D 500 MK2 User Manual Firmware V 6 3 41 5 4 3 PHASE 4 WIRE DELTA 5 5 3 PHASE 3 WIRE DELTA 2 CT L1 L2 ...

Page 42: ...D 500 MK2 User Manual Firmware V 6 3 42 5 7 2 PHASE 3 WIRE DELTA 2 CTs L1 L2 5 6 3 PHASE 3 WIRE DELTA 2 CT L1 L3 ...

Page 43: ...D 500 MK2 User Manual Firmware V 6 3 43 5 9 1 PHASE 2 WIRE 5 8 2 PHASE 3 WIRE DELTA 2 CTs L1 L3 ...

Page 44: ... CT location selection is configured with Controller Configuration CT Location parameter When CTs are located at the alternator side then mains current and power parameters will not be displayed When CTs are located at load side then both mains and genset currents and power parameters will be displayed based on contactor positions Please review AMF functionality connection diagrams for CT connecti...

Page 45: ...de is selected the controller will monitor its REMOTE START input If the remote start input is active it will run the genset depending on settings The remote start signal is usually provided by a Mains Synchronization unit or an ATS controller It can be a manually controlled signal as well If the Genset busbar is not energized when the engine runs the controller will immediately close the genset c...

Page 46: ...ctionality is selected the controller will control the REMOTE START signal for the genset group When sufficient number of gensets are available on the busbar the controller will synchronize the complete busbar to the grid then put them in parallel Different operating modes are available in a grid parallel application The same controller is able to provide all possible functions The controller has ...

Page 47: ...ft transfer enable load transfer between mains and genset is performed in parallel mode Power export enable the genset supplies power to the grid Continuous parallel operation for immediate recovery of mains failures is achieved in peak lopping mode Power may be exported to the grid or load may be shared between grid and genset or simply soft transfers may be performed Different operating modes ar...

Page 48: ... 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 alternator instrumentation and fault monitoring Engine instrumentation an...

Page 49: ...rnal controller Upon reception of this signal it will run the engine and provide engine and alternator instrumentation and fault monitoring The genset contactor MCB control functionality will be available The unit features both MPU and J1939 CANBUS inputs Thus both mechanical and electronic engines are supported 6 7 REMOTE START FUNCTIONALITY ...

Page 50: ...e Start modes When AMF and Engine controller modes are selected the unit will monitor the mains and will run the engine upon mains failure This functionality is useful for the backup electric motor driven systems during mains failures like fire pump or irrigation systems When Remote Start and Engine controller modes are selected the unit will start and stop the engine with external signal only The...

Page 51: ...les but the distance will be limited Typically at 115200 bauds and with adequate cable the distance will be 200m maximum At 9600 bauds and adequate cable the distance can go up to 1200m Below settings are necessary PARAMETER MAIN UNIT REMOTE DISPLAY UNIT Annunciator Mode 0 1 RS 485 Enable 1 1 RS 485 Baud Rate any same as main unit Modbus Slave Address any same as main unit The remote display panel...

Page 52: ...Hz to be measured precisely However the display is limited to 650Hz Frequencies over 650Hz will be displayed as 650Hz The bandwidth of the harmonic analyzer is limited to 1800Hz Thus in case of a 400Hz system only the 3rd harmonic will be displayed The waveform display of a 400Hz signal will be represented with 10 points It will not be as accurate as 50 60Hz signals For more details please read ch...

Page 53: ...D 500 MK2 User Manual Firmware V 6 3 53 7 1 GENSET SYNCHRONIZATION FUNCTIONALITY 7 CONNECTION DIAGRAMS ...

Page 54: ...D 500 MK2 User Manual Firmware V 6 3 54 7 2 MAINS SYNCHRONIZATION FUNCTIONALITY ...

Page 55: ...D 500 MK2 User Manual Firmware V 6 3 55 7 3 SINGLE GENSET PARALLEL WITH MAINS FUNCT ...

Page 56: ...D 500 MK2 User Manual Firmware V 6 3 56 7 4 AMF FUNCTIONALITY ...

Page 57: ...D 500 MK2 User Manual Firmware V 6 3 57 7 5 ATS FUNCTIONALITY ...

Page 58: ...D 500 MK2 User Manual Firmware V 6 3 58 7 6 REMOTE START FUNCTIONALITY ...

Page 59: ...D 500 MK2 User Manual Firmware V 6 3 59 7 7 ENGINE CONTROL FUNCTIONALITY ...

Page 60: ...D 500 MK2 User Manual Firmware V 6 3 60 7 8 REMOTE DISPLAY PANEL FUNCTIONALITY ...

Page 61: ...ut 10 CHARGE Connect the charge alternator s D WL terminal to this terminal This terminal will supply the excitation current and measure the voltage of the charge alternator Term Function Technical data Description 11 DIGITAL INPUT 1 Digital Inputs 0 30Vdc The input has programmable function Factory set as LOW OIL PRESSURE SWITCH 12 DIGITAL INPUT 2 The input has programmable function Factory set a...

Page 62: ...fuse protects the supply against overloads or short circuits 25 MPU Analog input 0 5 to 30V AC Connect the MPU unit to these inputs Use a twisted cable pair or coaxial cable for best results 26 GND 27 CANBUS H Digital communication port Connect the J1939 port of an electronic engine to these terminals The 120 ohm terminating resistors are inside the unit Please do not connect external resistors Us...

Page 63: ...res ex 200 5 Amps 60 GEN I1 61 GEN I2 62 GEN I2 63 GEN I3 64 GEN I3 65 GEN I GND Current transformer inputs 5A AC Connect the earth current transformer terminals to these inputs 66 GEN I GND Term Function Technical data Description 67 MAINS NEUTRAL Input 0 300V AC Neutral terminal for the mains phases 69 MAINS L3 Mains phase inputs 0 300V AC Connect the mains phases to these inputs The mains volta...

Page 64: ...ends only Termination resistors are provided inside the unit Use a balanced 120 ohms low capacitance shielded data cable for the best result 03 DATA LINK_L 04 DATA LINK_GROUND 0 VDC Connect this terminal to the shield of the Datalink from one end only 05 AVR Isolated Output 3VDC AVR voltage control outputs The output has adjustable polarity restpoint and gain through parameter setting The isolatio...

Page 65: ...DULE Term Function Technical data Description 01 I1 Generator current transformer inputs 5A AC Connect the generator current transformer terminals to these inputs Do not connect the same current transformer to other instruments otherwise this may damage the unit Connect each terminal of the transformer to the unit s related terminal Do not use common terminals Do not use grounding Correct polarity...

Page 66: ...rol Output 0 10V DC AVR Control Output 3V DC fully isolated Charge Alternator Excitation 2W Display Screen 2 9 128x64 pixels Ethernet Port 100 Mbits USB Device USB 2 0 Full speed USB Host USB 2 0 Full speed RS 485 Port selectable baud rate Data Link Port Fully Isolated CANBUS 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 condensi...

Page 67: ...e 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 10 1 FRONT PANEL FUNCTIONALITY 10 DESCRIPTION OF CONTROLS AUTO READY indicator Fault condition indicators TEST mode button MANUAL mode button STOP mode button RUN mode button LCD screen Next screen in the same group LAMP TEST if held pre...

Page 68: ...will immediately stop Selects next display screen in the same display group LAMP TEST when held pressed Selects previous display group Selects next display group Selects previous display screen in the same display group Resets the ALARM RELAY Manual MAINS CONTACTOR or BUSBAR CONTACTOR control in RUN mode Manual GENSET CONTACTOR or BUSBAR CONTACTOR control in RUN mode When held pressed for 5 second...

Page 69: ...nds 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 When held pressed for 5 seconds switch to AUTO LEARN mode only in Manual mode ...

Page 70: ...VA kVAr pf etc Synchronization Load Share Display A graphical synchroscope updated 10 times a second target and actual power levels AVR and governor output positions bus total power measurements and a mimic diagram about the system is available Scopemeter Display This group display waveforms of voltages and currents as an oscilloscope All Ph N and Ph Ph voltages as well as phase currents are avail...

Page 71: ...ventually the same parameter can be modified through the front panel programming menu The related parameter is Controller Configuration Screen Scroll Timer If a fault condition occurs the display will automatically switch to the ALARM LIST page When a front panel button is pressed the scrolling is suspended during 2 minutes If the Screen Scroll Timer is set to zero then scrolling will be disabled ...

Page 72: ...D 500 MK2 User Manual Firmware V 6 3 72 ...

Page 73: ...kWh energy meter Gen voltage phase L1 to neutral Gen voltage phase L2 to neutral Gen voltage phase L3 to neutral Gen average voltage phase to neutral Gen voltage phase L1 L2 Gen voltage phase L2 L3 Gen voltage phase L3 L1 Gen 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...

Page 74: ... Start this led will reflect the status of the input When a Simulate Mains signal is present then mains status will become available When a Force to Start signal is present then the mains status will become not available MAINS CONTACTOR ON Turns on when the mains contactor is activated GENSET CONTACTOR ON Turns on when the genset contactor is activated GENSET AVAILABLE This led turns on when all g...

Page 75: ...bit resolution with a sampling rate of 4096 s s Thus one cycle of a a 50Hz signal is represented with 82 points 164 points in color version The vertical scale is automatically adjusted in order to avoid clipping of the signal The waveform is displayed on the device screen and with more resolution on PC screen through the RainbowPlus program The display memory is also available in the Modbus regist...

Page 76: ... be displayed but in a 60Hz system only 29 harmonics will come to the screen In case of a 400Hz system only the 3rd harmonic will be displayed Graphical Harmonic Table Alphanumeric Harmonics Table Harmonic are represented by 2 different ways on the device display The first one is a graphical representation allowing one sight perception of the harmonic structure Because of the display resolution on...

Page 77: ...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 level when program mode is entered Periodic event recorded every 30 minutes when the engine is running and every 60 minutes anyway Mode c...

Page 78: ...d entry screen by pressing the button 4 times The screen below left will come Press again the button The last stored event will open as in the below right picture The first page will display the event number event type fault type and date time information When displaying event logs button will display the next information in the same event button will display the previous information in the same e...

Page 79: ...U input is used for engine speed detection 1 MPU input is used for reading the flowmeter pulses during fuel filling Fuel Pulses per Volume 0 65000 1000 This is the number of pulses produced by the flowmeter for the unit volume This parameter is characteristic of the flowmeter used and should be set according to the flowmeter data Fuel Counter Unit Lt gal liters This is the unit for the fuel counte...

Page 80: ...sumption Related parameters are Parameter Definition Unit Min Max Required Value Description Fuel Pulses from MPU input 0 1 1 0 MPU input is used for engine speed detection 1 MPU input is used for reading the flowmeter pulses during fuel filling Fuel Pulses per Volume 0 65000 any This is the number of pulses produced by the flowmeter for the unit volume This parameter is characteristic of the flow...

Page 81: ...l stop afterwards If the STOP button is pressed during cooldown then the engine will immediately stop 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 Synchronizing Load Sharing Mode If the genset is running under load then it will ramp out then the genset contactor will open The engin...

Page 82: ...requency is outside limits the mains will be supposed failing Otherwise mains is available If a Simulate Mains signal is present then mains are made available If a Force to Start signal is present then mains are unavailable If a Remote Start input is defined then this signal decides of mains availability When mains are evaluated as unavailable then an engine start sequence begins The unit waits du...

Page 83: ...imes during crank timer When the engine fires the crank relay will be immediately deactivated See section Crank Cutting for more details The engine will run at idle speed during Idle Speed Timer The engine will run unloaded until another mode is selected The RUN mode allows also manual contactor control through MC and GC buttons When a contactor button is pressed the related contactor will change ...

Page 84: ... is selected AMF Mode The controller will run the engine and make an interrupted transfer Synchronizing Load Sharing Mode The controller will run the genset If the busbar is not energized it will simply close its genset contactor If the busbar was energized then it will synchronize to the busbar get in parallel ramp up and start sharing the load ATS Mode The controller will activate its REMOTE STA...

Page 85: ...rms 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 the a...

Page 86: ...hus different levels of fault conditions may be generated at different overrun levels Each service counter set has both programmable engine hours and maintenance time limit If any of the programmed values is zero this means that the parameter will not be used For example a maintenance period of 0 months indicates that the unit will request maintenance only based on engine hours there will be no ti...

Page 87: ...Set if no information has been received during 3 seconds from the ECU of the electronic engine This fault condition is only controlled when fuel is on VOLTAGE UNBALANCE Set if any of the generator phase voltages differs from the average by more than Voltage Unbalance Limit for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running CURRENT UNBALAN...

Page 88: ...Power limit for Reverse Power Timer If the power goes below the limit before expiration of the timer then no alarm will be set GENSET PHASE ORDER FAIL Set if the fault is enabled and the genset phase order is reverse MAINS CB FAIL TO OPEN Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor Open Close Fail Timer GENS...

Page 89: ...ltage 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 Busbar Freq Fail Set if busbar frequency is 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 90: ...ediately GENSET LOW HIGH VOLTAGE Set if any of the generator phase voltages goes outside programmed limits for Voltage Fail Timer This fault will be monitored with Fault Holdoff Timer delay after the engine is running LOW HIGH BATTERY VOLTAGE Set if the genset battery voltage is outside programmed limits Low and high limits are separately programmable The detection delay is also programmable FAIL ...

Page 91: ...ill be set MAINS PHASE ORDER FAIL Set if the mains phase order checking is enabled mains phases are present and mains phase order is reversed This fault prevents the Mains Contactor to close GENSET CB FAIL TO CLOSE OPEN Set if the feedback input is defined and the related contactor block feedback signal is not detected after the expiration of Contactor Open Close Fail Timer MAINS CB FAIL TO CLOSE ...

Page 92: ...ge or more then Fuel Theft warning occurs FUEL FILLING If the fuel level measured from the sender input is increased by 20 or more in one hour then Fuel Filling non visual warning occurs the detection delay is 10 seconds not adjustable MAINTENANCE DONE Sent when the periodic maintenance counters are manually reset These warnings are not announced at the device front panel however they appear in ev...

Page 93: ... ALARM MUTE Hold pressed RIGHT ARROW The program mode is used to adjust timers operational limits and the configuration of the unit Although a free PC program is provided for programming every parameter may be modified through the front panel regardless of the operating mode When modified program parameters are automatically recorded into a non erasable memory and take effect immediately The progr...

Page 94: ...rts 3 password levels The level_1 is designed for field adjustable parameters The level_2 is designed for factory adjustable parameters The level_3 is reserved It allows recalibration of the unit The password level 1 is factory set to 1234 and the password level 2 is factory set to 9876 If a wrong password is entered the unit will still allow access to the program parameters but in read only mode ...

Page 95: ...e parameters will be displayed Selected parameter is shown in reverse video blue on white In order display change the value of this parameter please press MENU button Parameter value may be increased and decreased with and buttons If these keys are hold pressed the program value will be increased decreased by steps of 10 When a program parameter is modified it is automatically saved in memory If M...

Page 96: ...D 500 MK2 User Manual Firmware V 6 3 96 16 4 MODIFYING PARAMETER VALUE Decrease parameter value Increase parameter value Previous parameter Long Press Return to the upper menu Next parameter ...

Page 97: ...al Firmware V 6 3 97 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 16 5 PROGRAMMING MODE EXIT Press any mode button ...

Page 98: ...imer sec 0 120 12 This parameter defines the delay after the engine runs and before the fault monitoring is enabled Alarm Relay Timer sec 0 120 60 This is the period during which the ALARM relay is active If the period is set to 0 this will mean that the period is unlimited Intermittent Alarm Relay 0 1 0 0 continuous 1 intermittent turns on and off every second Emergency Backup Operation 0 1 0 0 I...

Page 99: ...cada Refresh Rate sec 0 65535 60 The unit will update the distant monitoring terminal with this rate Rainbow Scada Address 1 Port 0 65535 90 This is the port number of the first monitoring terminal address Rainbow Scada Address 2 Port 0 65535 90 This is the port number of the second monitoring terminal address Web Server Port 0 65535 80 This is the port number of the internal web server The unit w...

Page 100: ...s and genset voltage limits with a hysteresis feature in order to prevent faulty decisions For example when the mains are present the mains voltage low limit will be used as the programmed low limit When the mains fail the low limit will be incremented by this value It is advised to set this value to 8 volts Engine Control Only 0 1 0 0 Genset control 1 Engine control no alternator Alternator Pole ...

Page 101: ...s removed warnings will persist until manually reset Remote Control Enable 0 1 1 This parameter controls remote control of the unit through Rainbow Modbus and Modbus TCP IP 0 remote control disabled 1 remote control enabled Annunciator Mode 0 1 0 0 normal operation 1 the unit becomes an annunciator of the remote unit Engine genset control functions are disabled CT Location Genset Load Genset 0 CTs...

Page 102: ...0 0 After activation of the fuel pump function if the Fuel Pump High Limit level is not reached then the fuel pump will stop for safety If this parameter is set to zero then the timer is unlimited SMS Commands Enabled 0 1 0 0 SMS commands not accepted 1 SMS commands are accepted but from listed telephone numbers only Open with Last Mode 0 1 0 0 The unit powers up in STOP mode 1 The unit powers up ...

Page 103: ...abled CT Secondary Rating 0 1 0 0 xxx 5A 1 xxx 1A Automatic Topology Detection 0 1 0 If this parameter is enabled when the engine runs the controller will detect the connection topology automatically and will select alarm levels accordingly 0 auto detect not enabled 1 auto detect enabled Maintenance Done Warning Enable 0 1 0 If enabled the unit will generate a non visual warning when maintenance c...

Page 104: ...s voltages Voltage limits are defined by reference to this value 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 Nominal Voltage 3 V AC 0 300 120 When tertiary voltage is selected this is the nominal value of genset and mains voltages Voltage limits are defined by refere...

Page 105: ... Timer sec 0 10 1 If the mains frequency goes outside of the limits during this timer it means that the mains are off and starts the transfer to the genset in AUTO mode 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 Genset Low Voltage Shutdown Limit V 100 V 100 V 20 If...

Page 106: ...ow Battery Voltage Warning Limit V DC 5 0 35 0 12 0 If the battery voltage falls below this limit this will generate a LOW BATTERY warning Low Battery Voltage Shutdown Limit V DC 5 0 35 0 9 0 If the battery voltage falls below this limit this will generate a LOW BATTERY shutdown alarm and the engine will stop High Battery Voltage Warning Limit V DC 5 0 35 0 29 0 f the battery voltage goes over thi...

Page 107: ... If one of the genset phase currents goes over this limit when feeding the load this will generate a genset overcurrent fault condition The action taken upon fault condition is programmable If this parameter is set to 0 then overcurrent fault is not monitored Genset Overcurrent Limit 2 Amp 0 50000 0 When secondary voltage is selected if one of the genset phase currents goes over this limit when fe...

Page 108: ...Review chapter Load Shedding for more details Load Subtract Add Delay min 0 120 0 This is the minimum delay required for a load_add pulse after a load_substract pulse Review chapter Load Shedding for more details Mains Waiting Timer sec 0 50000 30 This is the time between the mains voltages and frequency entered within the limits and the generator contactor is deactivated Mains Connection Topology...

Page 109: ...ec 0 600 2 0 If a mains MCB feedback input is defined and if the mains MCB fails to change position before the expiration of this timer then a fault condition occurs Mains Phase Order Check Enable 0 1 0 0 mains phase order checking disabled 1 if mains phase order is faulty then a warning is given and mains contactor deenergized Genset Contactor Timer sec 0 600 0 5 This is the period after the main...

Page 110: ...ti Load Subtract Power Level kW 0 65000 0 When the genset active power goes over this limit the controller will start substracting load as described in chapter Five Step Load Management Multi Load Add Power Level kW 0 65000 0 When the genset active power goes below this limit the controller will start adding load as described in chapter Five Step Load Management Multi Load Substract Start Delay se...

Page 111: ... 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 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 Overspeed Overshoot Limit HRSL 100 HRSL 100 HRSL 10 If the engine rpm goes over the High RPM Shutdown Limit by this quanti...

Page 112: ... the timer Wait Between Starts sec 1 240 10 This is the waiting period between two start attempts Engine Heating Timer sec 0 240 4 This is the period used for engine heating before load transfer Engine Heating Method 0 1 0 The genset will not take the load before engine heating is completed 0 engine is heated during Engine Heating Timer 1 engine is heated until the coolant temperature reaches the ...

Page 113: ...quency reaches this limit Crank Cut RPM rpm 0 65000 500 The crank relay output is deenergized when the engine rpm reaches this limit Crank Cut Charge Voltage V DC 0 40 6 The crank relay output is deenergized when the charge alternator voltage reaches this limit Crank Cut with Oil Pressure 0 1 0 0 no crank cut with oil pressure 1 cranking is cut when oil pressure switch is open or the oil pressure ...

Page 114: ...y fan relay function will become active Canopy Fan Turn Off C 0 250 80 If the canopy temp is below this limit then the canopy fan relay function will become inactive Ambient Fan Turn On C 0 250 90 If the ambient temp is above this limit then the ambient fan relay function will become active Ambient Fan Turn Off C 0 250 80 If the ambient temp is below this limit then the ambient fan relay function ...

Page 115: ...down alarm 2 loaddump alarm 3 warning Service 3 Engine Hours hours 0 5000 250 The SERVICE REQUEST led indicator will turn on after this quantity of engine hours from the last service If the period is set to 0 no SERVICE REQUEST will be generated depending on service 3 engine hours Service 3 Period month 0 24 6 The SERVICE REQUEST led indicator will turn on after this amount of time from the last s...

Page 116: ...Min Max Factory Set Description J1939 Engine Brand 0 15 0 0 GENERIC 1 CUMMINS 2 DETROIT DIESEL 3 DEUTZ 4 JOHN DEERE 5 PERKINS 6 VOLVO 7 CATERPILLAR 8 SCANIA 9 IVECO 10 MTU MDEC 11 BOSCH 12 BAUDOUIN Other values Reserved Do not use 17 3 ENGINE PARAMETERS GROUP continued ...

Page 117: ...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 MDEC 201 2 MDEC 303 3 MDEC 304 4 MDEC 506 BOSCH INJECTION SYSTEM 0 Generic 1 EDC 731 2 EDC 9 3 BAUDOUIN 0 Generic 1 WISE10 2 WISE15 17 3 ENGINE PAR...

Page 118: ...tage V DC 0 35 0 0 If the battery voltage goes below this limit the engine will be automatically started in order to charge the battery using the charge alternator Battery Charge Run Timer min 0 1200 0 If the battery voltage goes below the Battery Charge Run Voltage limit the engine will be automatically run during this period in order to charge the battery using the charge alternator Oil Pump Sto...

Page 119: ...nue to run even if DC power is removed from the unit Parameter Definition Unit Min Max Description Date 01 31 Current day of the month Month 01 12 Current month Year 00 99 Last two digits of the current year Hours 00 23 Current hour of the day Minutes 00 59 Current minute of the hour Seconds 00 59 Current second of the minute 17 4 ADJUST DATE AND TIME ...

Page 120: ... does not start at night or weekends Weekly schedule programs allow an hourly setting of automatic operation of the unit during one week There are 7days x 24hours 144 parameters Each hour of the week can be independently defined as AUTO or OFF period If automatic operation is disabled by the weekly exerciser the AUTO led will flash 17 5 WEEKLY OPERATION SCHEDULE ...

Page 121: ... 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 17 6 EXERCISER SCHEDULE ...

Page 122: ...n 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 shutdo...

Page 123: ...000 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 0 100...

Page 124: ...ected input name is displayed in the 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...

Page 125: ... Inhibit 29 GensetLoadingInhibit 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 Gense...

Page 126: ...elay 15 1 Relay extension module 1 Relay 16 1 Relay extension module 1 Relay 17 1 Relay extension module 2 Relay 18 1 Relay extension module 2 Relay 19 1 Relay extension module 2 Relay 20 1 Relay extension module 2 Relay 21 1 Relay extension module 2 Relay 22 1 Relay extension module 2 Relay 23 1 Relay extension module 2 Relay 24 1 Relay extension module 2 Relay 25 1 Relay extension module 3 Relay...

Page 127: ...ping 69 Protections Disabled 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...

Page 128: ...ned to identify the current controller Th s string is added to GSM SMS messages e mails 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 firs...

Page 129: ...e 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 enter t...

Page 130: ...ic DNS feature The unit will register itself to the dynamic DNS server under this name For more detailed information please review chapter on Dynamic DNS Feature and the document Dynamic DNS Account Setting Domain Name Extension Rest of domain name if it is longer than 20 characters Membership Address members dyndns org This string is used in Dynamic DNS feature This is the address used in registe...

Page 131: ...The unit will check the availability of the internet connection with this interval Rainbow Refresh Rate sec 0 65535 5 The unit will update the distant monitoring terminal with this rate Rainbow Address 1 Port 0 65535 0 This is the port number of the first monitoring terminal address Rainbow Address 2 Port 0 65535 0 This is the port number of the second monitoring terminal address Web Server Port 0...

Page 132: ...t in order to update its internal real time time clock from the servers SNTP Address 1 Port 123 This is the port number of the first SNTP server SNTP Address 2 Port 123 This is the port number of the second SNTP server SNTP Address 1 0 tr pool ntp org This is the IP address of the first SNTP server SNTP Address 2 1 tr pool ntp org This is the IP address of the second SNTP server Wi Fi parameter ca...

Page 133: ...m Genset Fault Action 0 4 0 This is action to be taken if the number of available gensets is less than Genset Number in Multi Genset Systems 0 not used 1 engine shutdown 2 load dump alarm 3 warning Mains Synch Unit Number 0 16 0 This is the number of Mains Synchronizing units in the system Master Change Delay hour 0 255 0 This parameter defines the minimum time period difference between two master...

Page 134: ...ed Governor Output Droop 0 100 0 0 The controller will inject this quantity of droop at the genset rpm at 100 active power load AVR Control Enable 0 1 1 0 AVR control disabled 1 AVR control enabled AVR Reverse Polarity 0 1 1 0 AVR control normal polarity voltage increases with value increase 1 AVR control reverse polarity voltage decreases with value increase AVR Output Low Limit 0 100 0 0 0 This ...

Page 135: ...Sec 0 01 0 50 0 10 The synchronization conditions must remain satisfied during this timeout for the controller to decide to close its contactor Phase Synchronization G Gain 0 200 20 This parameter governs the phase synchronization speed If this parameter is increased the synchronization will be faster but unstable If it is decreased the synchronization will be slower but more stable The best setti...

Page 136: ...d of the kVAr control during soft loading The standard value for this parameter is 20 But it must be readjusted for the genset during manufacturing If this parameter is too high a KVAr oscillation may occur If it is too low the kVAr transfer will be slower Nominal Frequency G Gain 0 200 8 This parameter governs the nominal frequency catching of the master unit If this parameter is increased the op...

Page 137: ...r will be de energized and a warning will be generated Vector Shift Limit Deg 1 30 10 This parameter defines the sensitivity of the vector shift protection while operating in parallel with mains When the parallel protections are enabled if the phase of the mains measured on last 2 cycles jumps over this limit on the phase measured on last 4th and 5th period the mains contactor will be de energized...

Page 138: ...ve Power G Gain 0 200 20 This parameter governs the reactive power catching speed of the synchronization unit If this parameter is increased the operation will be faster but unstable If it is decreased the operation will be slower but more stable The best setting is the fastest stable operation Minimum Exported Power kW 0 65000 100 In the Distributed Power Export to Mains mode the exported power w...

Page 139: ...20 This parameter defines the minimum pulse delay between two of voltage up down control pulses Return to Mid Point 0 1 0 This parameter controls the Return to Mid point output relay function 0 no return to mid point output 1 return to mid point output active during stop timer Reactive Load Sharing Pulse Period msec 0 5000 10 In reactive load sharing this is the period between two voltage up down ...

Page 140: ...ess 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 Modbus TCP IP Port 502 Internal Modbus TCP IP server s port number The unit answers Modbus re...

Page 141: ...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 The ethernet connection status is...

Page 142: ...ion information 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 ...

Page 143: ... 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 Pres...

Page 144: ...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 multi...

Page 145: ...on 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 146: ...mming 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 MCB ...

Page 147: ...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 Coi...

Page 148: ...te the AUTO LEARNING Please enter programming synchronization parameters Disable GOV control enable parameter Gov Low Limit will be 0 Gov Gain will be 100 and Gov rest point will be 50 Disable AVR control enable parameter AVR Low Limit will be 0 AVR Gain will be 100 and AVR rest point will be 50 Start the generator manually Adjust the required nominal frequency on the speed control unit using the ...

Page 149: ... MK2 User Manual Firmware V 6 3 149 Stop the generator and enter programming synchronization parameters Enable Gov control enable parameter Enable AVR control enable parameter Next step will be auto learning ...

Page 150: ... 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 There will be no need to adjust any governor or AVR limits neither PID coefficients All is adjusted to gurantee smooth synchronization and load share ...

Page 151: ... control mode If this parameter is set to zero then no maximum pulse width is used Speed Up Down Pulse Delay Minimum pulse delay between two speed up down control pulses If voltage up down outputs are enabled the master unit will operate in order to adjust itself to the nominal voltage defined in program parameter Nominal Voltage If voltage up or voltage down functions are assigned to digital outp...

Page 152: ...n 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 Engine I...

Page 153: ...nsor 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 pressure ...

Page 154: ... 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 parame...

Page 155: ...chanical 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 Unknown ...

Page 156: ...al generic modem 4 no modem GPS on RS 232 5 Internal modem GPS on RS 232 External Modem GPS Baud Rate bps 2400 115200 115200 This is the data rate of the RS 232 port for the external modem GPS The GPS screen is found under GSM Modem screen group GPS SCREEN The GPS location determination is based on signals transmitted by GPS satellites circulating in earth s orbit 24 satellites are available in to...

Page 157: ...ldings without seeing the sky but location precision will affected by this Geographical location is stored in a non volatile memory once an hour Thus if the GPS signal is lost the unit continues to appear at the same location of the remote monitoring system However a GPS warning will be generated on loss of signal or communication with the module It is possible to program the geographical location...

Page 158: ...troller no answer MODEM RESET Performs a hard reset on the modem no answer GET INFO Returns the alarm list and actual measured values ALARMS if exists GEN Vavg ıAVG kWtot pf Freq MAINS Vavg ıAVG kWtot OIL_PR TEMP FUEL 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 C...

Page 159: ...EST Puts the controller into TEST mode Alarms are also cleared OUT1 ON Sets remote controlled output 1 to active state OUT1 OFF Sets remote controlled output 1 to passive state OUTxx ON Sets remote controlled output xx to active state xx denotes any number between 1 and 16 OUTxx OFF Sets remote controlled output xx to passive state xx denotes any number between 1 and 16 OUT xx OFF OUT xx ON OUT 1 ...

Page 160: ...r Timer and Genset Contactor Timer define the power interruption period Transfer from genset or busbar to mains The generator or busbar contactor releases The unit waits for Mains Contactor Timer The mains contactor is energized Transfer from mains to genset or busbar The mains contactor releases The unit waits for Generator Contactor Timer The generator or busbar contactor is energized If this tr...

Page 161: ...ing frequency phase and voltage Usually with frequencies matching at 2Hz and voltages matching at 10 volts an Uninterrupted Transfer is expected to successful If matching is found before the expiration of the Synchronization Fail Timer then both contactors will be activated If contactor auxiliary contacts are used the other contactor will release immediately If contactor auxiliary contacts are not...

Page 162: ...ll be generated At the end of the Soft Transfer Timer the load contactor will be released If any alarm is encountered during the Soft Transfer sequence the controller will revert to the Interrupted transfer The controller has a set of programmable parameters to define the Soft Transfer operation All parameters used in Uninterrupted Transfer are also used in Soft Transfer Additional parameters are ...

Page 163: ...g D 500 units Always one of the gensets will become the MASTER one The master genset will determine the voltage and frequency of the busbar It should be noted that when the number of gensets in parallel increases the stability of the system will be deteriorated thus smaller kW and kVAr gains should be used When more than one genset start together the master genset will always feed the busbar first...

Page 164: ...n a genset decides to stop it will ramp down then open its genset contactor then cooldown and stop The load sharing takes into account the genset nominal power settings Gensets of various power ratings may be used in parallel Each genset will be loaded with the same percentage of its nominal power Parameters used in the load sharing detailed descriptions are in the programming section Genset Activ...

Page 165: ... in the absence of the Datalink no smart load management is performed When the REMOTE START signal comes the genset runs synchronizes to the busbar and supplies the active power requested by the load share line It will stop only when the REMOTE START signal is removed Parameters used in the analog load sharing details are in the programming section Governor Droop Enable Governor Output Droop AVR D...

Page 166: ... management is performed When the REMOTE START signal comes the genset runs synchronizes to the busbar and closes its genset contactor The amount of active and reactive powers supplied to the load is controlled by the droop function The genset will stop only when the REMOTE START signal is removed Parameters used in the droop mode load sharing details are in the programming section Governor Droop ...

Page 167: ... protections will be explained with more detail in the chapter G59 PROTECTIONS If a mains failure occurs during parallel operation with mains the mains contactor will immediately de energize a general Parallel Mains Fail warning and a specific protection function warning will be generated The load will be supplied by the multi genset system without interruption When mains is restored again the D70...

Page 168: ...onstant defined in Exported Power Factor When the requested output power is reached the ramping will be terminated The requested power is defined by Exported Power program parameter The G59 protections for mains failure in parallel are active during the Export to Mains operation with the exception of Mains Reverse Power protection If a mains failure is detected during paralleling then the mains co...

Page 169: ...pped manually by staff charged of power generation The energy request will depend of the time of the day thus the required number of gensets will vary The operating principle is based on the precise measurement of the mains frequency by the controllers When the frequency is below the nominal value this means a need for extra power and each controller will slowly ramp up the exported power When the...

Page 170: ... Priority the Peak Lopping Enable parameter must be activated and the Peak Lopping Priority parameter must be set as Genset Priority If the total genset power available reaches Multi Genset Quick Start value then the genset system will synchronize to the busbar and the excess load will be supplied by the mains Gensets continue their operation at the power rating defined in Multi Genset Quick Start...

Page 171: ...ect relatively slow changes in mains frequency Related parameter ROCOF df dt If the parameter is set to zero then the protection function will be disabled The Vector Shift measures and stores the period of last 5 cycles At the end of each cycle it compares the average period of last 2 cycles with the average period of 4th and 5th cycles If the difference exceeds the predefined limit then the vecto...

Page 172: ...this power exceeds the predefined limit this will mean a mains failure The mains reverse power detector has a variable response time For a power not exceeding 2 times the predefined limit the response time is 8 cycles The response time is reduced with larger reverse powers It is approximately 1 cycle with a reverse power of 8 times the predefined limit Related parameter Mains Reverse Power Limit I...

Page 173: ...B flash memory As soon as a USB flash memory is inserted the unit will start data recording and continue until the memory is removed USB FLASH MEMORY 33 1 DATA RECORDING MEDIA If USB Device is plugged then USB Host port will not function 33 DATA RECORDING USB HOST Port ...

Page 174: ...ll be named YYYYMMDD like 20120331 representing March 31 2012 Thus alphabetical listing will produce a sorted list by date of recording The recorded file is of CSV comma separated values type This is a text file which can be directly opened with Microsoft Excel program without any loss of information It can be also opened with any text editor like Notepad program Inside the file each record consis...

Page 175: ...ns average current Mains frequency Mains kW phase L1 Mains kW phase L2 Mains kW phase L3 Mains total kW Mains kVA phase L1 Mains kVA phase L2 Mains kVA phase L3 Mains kVAr phase L1 Mains kVAr phase L2 Mains kVAr phase L3 Mains pf phase L1 Mains pf phase L2 Mains pf phase L3 Mains total pf Mains neutral current Gen voltage phase L1 to neutral Gen voltage phase L2 to neutral Gen voltage phase L3 to ...

Page 176: ...sing 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 Load...

Page 177: ...eters 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 between 2 ...

Page 178: ...will start adding load Multi Load Substract Start Delay tLSD If the load stays over the Multi Load Substract Power Level parameter during this timer then 1 step of load is substracted Multi Load Substract Wait Delay 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 then...

Page 179: ...y 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 Disa...

Page 180: ...ither battery positive or battery negative These selections are made using the programming menu If the Delayed Simulate Mains program parameter is set to 1 and the input signal is active when the genset is not feeding the load the mains phases are not monitored and supposed to be inside limits This will prevent the genset from starting when the simulate mains signal is present batteries charged Th...

Page 181: ...ation uses also the Disable Auto Start feature Please review related chapter for a detailed explanation of this feature Priority In Dual Genset Mutual Standby Operation It may be required that the dual genset system starts the same genset at every mains failure This is achieved using the PRIORITY input Any digital input may be assigned as Priority using Input Function Select program parameters It ...

Page 182: ...rk 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 contro...

Page 183: ... 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 work...

Page 184: ...t may be required that the engine runs at the idle speed for a programmed duration for engine heating The idle operation duration is adjusted with the parameter Idle Speed Timer The idle speed will be set by the governor control unit of the engine Any digital output may be assigned as IDLE output using Relay Definition program parameters The Idle speed operation is performed both in engine start u...

Page 185: ...mp 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 openin...

Page 186: ...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 Scad...

Page 187: ... 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 topolo...

Page 188: ...t 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 be cou...

Page 189: ...ters 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 This chapter is a brief description of the Modbus properties of the controller For ...

Page 190: ...e are 3 mask registers available The use of the registers are emphasized in the D500 User Manual Please set the first mask as 255 255 255 0 for the proper operation Ethernet Network IP May be left as 0 0 0 0 for automatic address claim or set to a value in order to claim a defined address Ethernet Gateway IP Should be set in accordance with your local switch configuration Ethernet Subnet Mask Shou...

Page 191: ...age 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 x10 Mai...

Page 192: ... 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 Counte...

Page 193: ...arent Power L1 L2 L3 Total Genset Power Factor L1 L2 L3 Total Genset Phase Angle Genset Frequency Genset Operation Mode Genset Operation Status Charge Input Voltage Battery Voltage Oil Pressure Coolant Temperature Fuel Level Oil Temperature Canopy Temperature Ambient Temperature Engine RPM Total Genset Cranks Counter Total Genset Runs Counter Engine Run Hours Counter Total kW h counter Total kVAR ...

Page 194: ...claim or set to a value in order to claim a defined address Ethernet Gateway IP Should be set in accordance with your local switch configuration Ethernet Subnet Mask Should be set in accordance with your local switch configuration When a fault case occurs or the genset runs or the genset takes the load or the genset unloads or the genset stops an automatic SNMP TRAP message is send to the SNMP Cli...

Page 195: ...l and electronic equipment WEEE this unit should be stored and disposed separately 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 ...

Page 196: ... 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 correct...

Page 197: ...so able to cut cranking from charge alternator voltage and oil pressure input Please read chapter CRANK CUTTING The unit is inoperative Measure the DC supply voltage between terminals BAT and BAT at the rear of the unit If OK turn all fuses off then turn all the fuses on starting from the DC supply fuse Then test the unit again Programming mode can not be entered The program lock input disables pr...

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