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SMART 500Firmware e D-xxx series are next generation genset controlunits combining multi-functionality and widecommunication possibilities together with a reliableand low cost design.The unit complies and mostly exceeds world’stightest safety, EMC, vibration and environmentalstandards for the industrial category.Software features are complete with easy firmwareupgrade process through USB port.The Windows based PC software allows monitoringand programming through USB, serial and GPRS.The PC based Rainbow Scada software allowsmonitoring and control of an unlimited number ofgensets from a single central location.FUNCTIONALITIESAMF unit with uninterrupted transferATS unit with uninterrupted transferRemote start controllerManual start controllerEngine controllerRemote display & control unitWaveform display of V & IHarmonic analysis of V & ICTs at genset or load sideCOMMUNICATIONSGSM-GPRSInternal GPRS modem (optional)GSM-SMSe-mailModbusUSB DeviceRS-485RS-232J1939-CANBUSTOPOLOGIES3 phases 4 wires, star3 phases 3 wires, 3 CTs3 phases 3 wires, 2 CTs (L1-L2)3 phases 3 wires, 2 CTs (L1-L3)2 phases 3 wires, L1-L22 phases 3 wires, L1-L33 phases 4 wires, delta1 phase 2 wires

SMART 500Firmware V-5.5COPYRIGHT NOTICEAny unauthorized use or copying of the contents or any part of this document is prohibited.This applies in particular to trademarks, model denominations, part numbers and drawings.ABOUT THIS DOCUMENTThis document describes minimum requirements and necessary steps for the successful installation ofthe D-xxx family units.Follow carefully advices given in the document. These are often good practices for the installation ofgenset control units which reduce future issues.For all technical queries please contact EMSA at below e-mail address:info@emsa.gen.trQUERRIESIf additional information to this manual is required, please contact the manufacturer directly at below email address:info@emsa.gen.trPlease 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.RELATED DOCUMENTSFILENAMEDESCRIPTION500-Rainbow InstallationRainbow Plus D-500 D-700 Installation Guide500-Rainbow UsageRainbow Plus D-500 D-700 Usage Guide500-GSM Configuration500-Firmware Update500-MODBUS500-Rainbow Scada Installation500-Rainbow Scada UsageGSM Configuration Guide for D-500 D-700Firmware Update Guide for D-500 D-700Modbus Application Manual for D-500 D-700Rainbow Scada Installation GuideRainbow Scada Usage GuideL11D03-EN-2-

SMART 500Firmware V-5.5REVISION First edition, firmware version 5.4TERMINOLOGYCAUTION: Potential risk of injury or death.WARNING: Potential risk of malfunction or material damage.ATTENTION: Useful hints for the understanding of device operation.L11D03-EN-3-

SMART 500Firmware V-5.5ORDERING CODESThe SMART 500 family units are available in various options and peripheral features. Please use belowinformation for ordering the correct version:S500 -M -G -T -00Variant00: standard unit01.99: customerspecific productsFamily CodeWith ConformalCoatingWith InternalGSM-GPRSModemWith SealinggasketSPARE PARTSScrew type bracketStock Code J10P01 (per unit)Self Retaining type bracketStock Code K16P01 (per unit)Sealing GasketL11D03-EN-4-

SMART 500Firmware V-5.5SAFETY NOTICEFailure to follow below instructionswill result in death or serious injury Electrical equipment should be installed only by qualifiedspecialist. No responsibility is assured by the manufacturer orany of its subsidiaries for any consequences resulting from thenon-compliance to these instructions. Check the unit for cracks and damages due to transportation. Donot install damaged equipment. Do not open the unit. There are no serviceable parts inside. Fuses must be connected to the power supply and phase voltageinputs, in close proximity of the unit. Fuses must be of fast type (FF) with a maximum rating of 6A. Disconnect all power before working on equipment. When the unit is connected to the network do not touchterminals. Short circuit terminals of unused current transformers. Any electrical parameter applied to the device must be in therange specified in the user manual. Although the unit is designedwith a wide safety margin, over-range parameters may reducelifetime, alter operational precision or even damage the unit. Do not try to clean the device with solvent or the like. Only cleanwith a dump cloth. Verify correct terminal connections before applying power. Only for front panel mounting.Current Transformers must be used for current measurement.No direct connection allowed.L11D03-EN-5-

SMART 500Firmware V-5.5TABLE OF CONTENTS1. INSTALLATION INSTRUCTIONS2. MOUNTING2.1 DIMENSIONS2.2 SEALING, GASKET2.3 ELECTRICAL INSTALLATION3. TERMINAL DESCRIPTIONS3.1. BATTERY VOLTAGE INPUT3.2. AC VOLTAGE INPUTS3.3. AC CURRENT INPUTS3.4. DIGITAL INPUTS3.5. ANALOG SENDER INPUTS AND SENDER GROUND3.6. CHARGE INPUT TERMINAL3.7. MAGNETIC PICKUP INPUT3.8. MAINS CONTACTOR OUTPUT3.9. GENERATOR CONTACTOR OUTPUT3.10. DIGITAL OUTPUTS3.11. INPUT/OUTPUT EXTENSION3.12. RS-485 PORT3.13. RS-232 PORT3.14. J1939-CANBUS PORT3.15. USB DEVICE PORT3.16. GSM MODEM (OPTIONAL)4. TOPOLOGIES4.1. SELECTING THE TOPOLOGY4.2. 3 PHASE, 4 WIRE, STAR4.3. 3 PHASE, 3 WIRE, DELTA4.4. 3 PHASE, 4 WIRE, DELTA4.5. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L2)4.6. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L3)4.7. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L2)4.8. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L3)4.9. 1 PHASE, 2 WIREL11D03-EN-6-

SMART 500Firmware V-5.55. FUNCTIONALITIES5.1. CT LOCATION SELECTION5.2. AMF FUNCTIONALITY5.3. ATS FUNCTIONALITY5.4. REMOTE START FUNCTIONALITY5.5 ENGINE CONTROLLER FUNCTIONALITY5.6. REMOTE DISPLAY UNIT FUNCTIONALITY5.7. 400HZ OPERATION6. CONNECTION DIAGRAMS6.1. AMF FUNCTIONALITY, CTs AT LOAD SIDE6.2. AMF FUNCTIONALITY, CTs AT ALTERNATOR SIDE6.3. ATS FUNCTIONALITY6.4. REMOTE START FUNCTIONALITY6.5. ENGINE CONTROL FUNCTIONALITY6.6. REMOTE DISPLAY PANEL FUNCTIONALITY7. TERMINAL DESCRIPTION8. TECHNICAL SPECIFICATIONS9. DESCRIPTION OF CONTROLS9.1. FRONT PANEL FUNCTIONALITY9.2. PUSHBUTTON FUNCTIONS9.3. DISPLAY SCREEN ORGANIZATION9.4. AUTOMATIC DISPLAY SCROLL9.5. MEASURED PARAMETERS9.6. LED LAMPS10. WAVEFORM DISPLAY & HARMONIC ANALYSIS11. DISPLAYING EVENT LOGS12. STATISTICAL COUNTERS12.1. FUEL FILLING COUNTER12.2. FUEL CONSUMPTION MONITORING13. OPERATION OF THE UNIT13.1. QUICK START GUIDE13.2. STOP MODE13.3. AUTO MODE13.4. RUN MODE, MANUAL CONTROL13.5. TEST MODE14. PROTECTIONS AND ALARMS14.1. DISABLING ALL PROTECTIONS14.2. SERVICE REQUEST ALARM14.3. SHUTDOWN ALARMS14.4. LOADDUMP ALARMSL11D03-EN-7-

SMART 500Firmware V-5.514.5. WARNINGS14.6. NON-VISUAL WARNINGS15. PROGRAMMING15.1. RESETTING TO FACTORY DEFAULTS15.2. ENTERING THE PROGRAMMING MODE15.3. NAVIGATING BETWEEN MENUS15.4. MODIFYING PARAMETER VALUE15.5. PROGRAMMING MODE EXIT16. PROGRAM PARAMETER LIST16.1. CONTROLLER CONFIGURATION GROUP16.2. ELECTRICAL PARAMETERS GROUP16.3. ENGINE PARAMETERS GROUP16.4. ADJUST DATE AND TIME16.5. WEEKLY OPERATION SCHEDULE16.6. EXERCISER SCHEDULE16.7. SENDER CONFIGURATION16.8. DIGITAL INPUT CONFIGURATION16.9. OUTPUT CONFIGURATION16.10. SITE ID STRING16.11. ENGINE SERIAL NUMBER16.12. MODEM1-2/SMS1-2-3-4 TELEPHONE NUMBERS16.13. GSM MODEM PARAMETERS16.14. ETHERNET PARAMETERS17. CRANK CUTTING18. OVERCURRENT PROTECTION (IDMT)19. MOTORIZED CIRCUIT BREAKER CONTROL20. J1939 CANBUS ENGINE SUPPORT21. GPS SUPPORT22. GSM CONFIGURATION23. CENTRAL MONITORING OF GENSETS24. E-MAIL SENDING25. SMS COMMANDSL11D03-EN-8-

SMART 500Firmware V-5.526. SOFTWARE FEATURES26.1. LOAD SHEDDING / DUMMY LOAD26.2. LOAD ADD / SUBSTRACT26.3. FIVE STEP LOAD MANAGEMENT26.4. REMOTE START OPERATION26.5. DISABLE AUTO START, SIMULATE MAINS26.6. BATTERY CHARGING OPERATION, DELAYED SIMULATE MAINS26.7. DUAL GENSET MUTUAL STANDBY OPERATION26.8. MULTIPLE VOLTAGE AND FREQUENCY26.9. SINGLE PHASE OPERATION26.10. EXTERNAL CONTROL OF THE UNIT26.11. AUTOMATIC EXERCISER26.12. WEEKLY OPERATION SCHEDULER26.13. ENGINE HEATING OPERATION26.14. ENGİNE IDLE SPEED OPERATİON26.15. ENGINE BLOCK HEATER26.16. FUEL PUMP CONTROL26.17. GAS ENGINE FUEL SOLENOID CONTROL26.18. PRE-TRANSFER SIGNAL26.19. CHARGING THE ENGINE BATTERY26.20. EXTERNALLY CONTROLLED DIGITAL OUTPUTS26.21. COMBAT MODE26.22. RESETTING THE CONTROLLER26.23. AUTOMATIC CONNECTION TOPOLOGY DETERMINATION26.24. ZERO POWER AT REST27. MODBUS COMMUNICATIONS27.1. PARAMETERS REQUIRED FOR RS-485 MODBUS OPERATION27.2. DATA FORMATS28. DECLARATION OF CONFORMITY29. MAINTENANCE30. DISPOSAL OF THE UNIT31. ROHS COMPLIANCE32. TROUBLESHOOTING GUIDEL11D03-EN-9-

SMART 500Firmware V-5.51. INSTALLATION INSTRUCTIONSBefore installation: Read the user manual carefully, determine the correct connection diagram. Remove all connectors and mounting brackets from the unit, then pass the unit through themounting opening. Put mounting brackets and tighten. Do not tighten too much, this can brake the enclosure. Make electrical connections with plugs removed from sockets, then place plugs to their sockets. Be sure that adequate cooling is provided. Be sure that the temperature of the environment will not exceed the maximum operatingtemperature in any case.Below conditions may damage the device: Incorrect connections. Incorrect power supply voltage. Voltage at measuring terminals beyond specified range. Voltage applied to digital inputs over specified range. Current at measuring terminals beyond specified range. Overload or short circuit at relay outputs Connecting or removing data terminals when the unit is powered-up. High voltage applied to communication ports. Ground potential differences at non-isolated communication ports. Excessive vibration, direct installation on vibrating parts.Current Transformers must be used for currentmeasurement.No direct connection allowed.Below conditions may cause abnormal operation: Power supply voltage below minimum acceptable level. Power supply frequency out of specified limits Phase order of voltage inputs not correct. Current transformers not matching related phases. Current transformer polarity incorrect. Missing grounding.L11D03-EN- 10 -

BAT BAT OUT 1OUT 2OUT 3OUT 4CHGSND 1SND 2SND 3SGNDI/OEXTENSIONL11D03-EN!GSMANTENNA- 11 -24 PGND25 485-B26 485-ASIMCARD12 IN 113 IN 214 IN 315 IN 416 IN 517 IN 618 IN 719 IN 820 MPU 21 MPU- / PGND22 CANH23 CANL1234567891011596061626364MN-N 656667MN-L368MN-L2 6970MN-L1 71MN-C 72I 1 I 1I 2 I 2I 3 I 3-G-C 51G-L1 5253G-L2 5455G-L3 5657G-N 58SMART 500Firmware V-5.52. MOUNTING2.1. DIMENSIONSDimensions: 200x148x47mm (7.9”x5.8”x1.9”)Panel Cutout: 176x121mm minimum (7.0”x4.8”)Weight: 450g (1 lb)8 to 36Vdc, 500mA max300Vac, 0-600 Hz0.2 to 6.0 AacRS-232USB-DEVICE

SMART 500Firmware V-5.5The unit is designed for panel mounting. The usershould not be able to access parts of the unit otherthan the front panel.Mount the unit on a flat, vertical surface. Before mounting, remove the mounting brackets and connectorsfrom the unit, then pass the unit through the mounting opening.Place and tighten mounting brackets.Panel CutoutRequired Panel DepthL11D03-EN- 12 -

SMART 500Firmware V-5.5Two different types of brackets are provided:Self retaining type bracketScrew type bracketInstallation of screw type bracketInstallation of self retaining type bracketDo not tighten too much, this may break the unit.L11D03-EN- 13 -

SMART 500Firmware V-5.52.2. SEALING, GASKETPanelGasketModuleThe rubber gasket provides a watertight means of mounting the module to the genset panel. Togetherwith the gasket, IEC 60529-IP65 protection can be reached from the front panel. A short definition of IPprotection levels is given below.1st Digit Description of Protection Level0 Not protected1 Protected against solid foreign objects of 50 mm diameter and greater2 Protected against solid foreign objects of 12,5 mm diameter and greater3 Protected against solid foreign objects of 2,5 mm diameter and greater4 Protected against solid foreign objects of 1,0 mm diameter and greater5 Protected from the amount of dust that would interfere with normal operation6 Dust tight2nd Digit Description of Protection Level0 Not protected1 Protected against vertically falling water drops2 Protected against vertically falling water drops when enclosure is tilted up to 15 3 Protected against water sprayed at an angle up to 60 on either side of the vertical4 Protected against water splashed against the component from any direction5 Protected against water projected in jets from any direction6 Protected against water projected in powerful jets from any direction7 Protected against temporary immersion in water8 Protected against continuous immersion in water, or as specified by the userL11D03-EN- 14 -

SMART 500Firmware V-5.52.3. ELECTRICAL INSTALLATIONDo not install the unit close to high electromagneticnoise emitting devices like contactors, high currentbusbars, switchmode power supplies and the like.Although the unit is protected against electromagnetic disturbance, excessivedisturbance can affect the operation, measurement precision and data communicationquality. ALWAYS remove plug connectors when inserting wires with a screwdriver. Fuses must be connected to the power supply and phase voltage inputs, inclose proximity of the unit. Fuses must be of fast type (FF) with a maximum rating of 6A. Use cables of appropriate temperature range. Use adequate cable section, at least 0.75mm2 (AWG18). Follow national rules for 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. Iflonger cable is used, increase the cable section proportionally.Current Transformers must be used for currentmeasurement.No direct connection allowed.The engine body must be grounded. Otherwise faultyvoltage and frequency measurements may occur.For the correct operation of the exerciser andweekly schedule programs, adjust the real timeclock of the unit through programming menu.L11D03-EN- 15 -

SMART 500Firmware V-5.53. TERMINAL DESCRIPTIONS3.1. BATTERY VOLTAGE INPUTSupply voltage:8 to 36VDCCranking dropouts:Survives 0VDC during 100ms. The voltage before surge should be8VDC minimumOvervoltage protection:Withstands 150VDC continuously.Reverse voltage:-33VDC continuousMaximum operatingcurrent: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 36VDCDisplay resolution:0.1VDCAccuracy:0.5% 1 digit @ 24VDCL11D03-EN- 16 -

SMART 500Firmware V-5.53.2. AC VOLTAGE INPUTSMeasurement method:True RMSSampling rate:8000 HzHarmonic analysis:up to 31th harmonicInput voltage range:14 to 300 VACMinimum voltage forfrequency detection:15 VAC (Ph-N)Supported topologies:3 ph 4 wires star3 ph 3 wires delta3ph 4 wires delta2ph 3 wires L1-L22ph 3 wires L1-L31 ph 2 wiresMeasurement range:0 to 330VAC ph-N (0 to 570VAC ph-ph)Common mode offset:max 100V between neutral and BAT-Input impedance:4.5M-ohmsDisplay resolution:1VDCAccuracy:0.5% 1 digit @ 230VAC ph-N ( 2VAC ph-N)0.5% 1 digit @ 400VAC ph-ph ( 3VAC ph-ph)Frequency range:DC to 500HzFrequency displayresolution:0.1 HzFrequency accuracy:0.2% 1 digit ( 0.1 Hz @ 50Hz)L11D03-EN- 17 -

SMART 500Firmware V-5.53.3. AC CURRENT INPUTSMeasurement method:True RMSSampling rate:8000 HzHarmonic analysis:up to 31th harmonicSupported topologies:3 ph 3 CTs3 ph 2 CTs L1-L23 ph 2 CTs L1-L32 ph 2 CTs L1-L22 ph 2 CTs L1-L31 ph 1 CTCT secondary rating:5AMeasurement range:5/5 to 5000/5A minimumInput impedance:15 mili-ohmsBurden:0.375WMaximum continuouscurrent:6AMeasurement range:0.1 to 7.5ACommon mode offset:Max 5VAC between BAT- and any CT terminal.Display resolution:1AAccuracy: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 keptminimum in order to minimize phase shifteffect of the current transformer. Phaseshift in a CT will cause erroneous powerand power factor readings, although ampreadings are correct.Datakom advises CT rating to be selectedfollowing this table for the bestmeasurement accuracy.SELECTING THE CT ACCURACY CLASS:The CT accuracy class should be selected in accordance with the required measurement precision. Theaccuracy class of the Datakom controller is 0.5%. Thus 0.5% class CTs are advised for the best result.L11D03-EN- 18 -

SMART 500Firmware V-5.5 Current Transformers must be used for currentmeasurement. No direct connection allowed. No common terminals or grounding allowed.CONNECTING CTs:Be sure of connecting each CT to the related phase input with the correct polarity. Mixing CTs betweenphases will cause faulty power and pf readings.Many combinations of incorrect CTs connections are possible, so check both order of CTs and theirpolarity. Reactive power measurement is affected by incorrect CTs connection in similar way as activepower measurement.CORRECT CT CONNECTIONSLet’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:kWkVArkVApfPhase L1100.00.01001.00Phase L2100.00.01001.00Phase L3100.00.01001.00Total300.00.03001.00L11D03-EN- 19 -

SMART 500Firmware V-5.5EFFECT OF POLARITY REVERSALThe generator is still loaded with 100 kW On each phase. The load Power Factor (PF) is 1.PF in phase L2 will show -1,00 due to reverse CT polarity. The result is that total generator powerdisplayed by the controller is 100 kW.Measured values are as follows:kWkVArkVApfPhase L1100.00.01001.00Phase L2-100.00.0100-1.00Phase L3100.00.01001.00Total100.00.03000.33EFFECT OF PHASE SWAPPINGThe 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 iscaused by CT swapping. The result is that total generator power displayed by controller is 0 kW.Measured values are as follows:kWkVArkVApfPhase L1100.00.01001.00Phase L2-50.086.6100-0.50Phase L3-50.0-86.6100-0.500.00.03000.0TotalL11D03-EN- 20 -

SMART 500Firmware V-5.53.4. DIGITAL INPUTSType of inputs:all configurableFunction selection:from listContact type:Normally open or normally closed (programmable)Switching:Battery negative or battery positive (programmable)Structure:47 k-ohms resistor to battery positive, 110k-ohms to battery negative.Measurement:Analog voltage measurement.Open circuit voltage:70% of battery voltageLow level threshold:35% of battery voltageHigh level threshold:85% of battery voltageMaximum input voltage: 100VDC with respect to battery negativeMinimum input voltage:-70VDC with respect to battery negativeNoise filtering:yes3.5. ANALOG SENDER INPUTS AND SENDER GROUNDType of inputs:all configurable, additional sender ground inputFunction selection:from listStructure:667 ohms resistor polarizing to 3.3VDCMeasurement:Analog resistor measurement.Open circuit voltage: 3.3VDCShort circuit current:5mAMeasurement range:0 to 5000 ohms.Open circuit threshold:5000 ohms.Resolution:1 ohms @ 300 ohms or lowerAccuracy:2 % 1 ohm ( 7 ohms @300 ohms)Common mode voltagerange: 3VDCNoise filtering:yesL11D03-EN- 21 -

SMART 500Firmware V-5.53.6. CHARGE INPUT TERMINALThe Charge terminal is both an input and output.When the engine is ready to run, this terminal supplies the excitation current to the charge alternator.The excitation circuit is equivalent to a 2W lamp.The threshold voltages for warning and shutdown alarm are adjustable through program parameter.Structure: battery

26.4. remote start operation 26.5. disable auto start, simulate mains 26.6. battery charging operation, delayed simulate mains 26.7. dual genset mutual standby operation 26.8. multiple voltage and frequency 26.9. single phase operation 26.10. external control of the unit 26.11. automatic exerciser 26.12. weekly operation scheduler 26.13.

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