The clarification of notation used within this manual ... · PDF fileThe clarification of...

GU601A Controller Operation Manual

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The clarification of notation used within this manual:

WARNING: A WARNING indicates a potentially hazardous situation which, if not avoided, could result in death, serious personal injury or property damage.

CAUTION: A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in damage to equipment or property.

NOTE: A NOTE provides other helpful information that does not fall under the warning or caution categories.

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WARNING: Read this entire manual pertaining to the work to be performed before installing, operating, or servicing this controller. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage. The engine or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury, loss of life, or property damage. The overspeed shutdown device must be totally independent of the prime mover control system. An overtemperature or overpressure shutdown device may also be needed for safety, as appropriate.

CAUTION—BATTERY CHARGING To prevent damage to a controller that uses an alternator or battery-charging device, make sure the charging device is turned off before disconnecting the battery from the system. Controllers contain static-sensitive parts. Observe the following precautions to prevent damage to these parts: Do not disassemble the rear back of controller and touch the components or conductors on a printed circuit board.




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Contents

1. Description ...........................................................................................4

2. The Outline Dimensional Drawings and Wirings of Controller ......5

3. Operation Panel ..........................................................................................8

4. Installation Guide ........................................................................................10

5. Control and Operation Instruction ............................................................11

6. Measure and Display Data ......................................................................16

7. Warning and Shutdown Alarm ......................................................16

8. Parameters Setting ..........................................................................20

9. LCD Display and Menu System....................................................24

10. Preparation before Start the Controller..................................................27

11. Troubleshooting .......................................................................................28

12. Technical Parameters.................................................................................30




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1. Description GU601A is an auto control and protection module of generator. The control modes of manual or auto are selectable by buttons on panel. Manual starts or stops Genset under manual mode by buttons on panel. Auto starts or stops Genset under auto mode by remote switch input signal. The module is adopted LCD, which displays running status and operating parameters of generator. The main characteristics as following: l The core adopts MPU. l Flexible configure running parameters via buttons and LCD on panel. l Measure and display parameters, such as frequency and voltage for generator;

battery voltage; oil pressure, coolant temp and running hours for engine. l The fuel mode (NC or NO) of engine can be set by procedure. l Has five relays control output, others can be defined by user except the

outputs of fuel and start control are fixed. l 5 channels for switch input, others can be defined by user except the inputs of

oil pressure and coolant temperature are fixed. l Internal kinds of P-sensor and T-sensor for user choice. l Optional internal communication interface can be used to configure

parameters via PC. l All connections are connected by pin-like and locked up terminal, easier and more

convenient to connect, move, maintain and replace the device.

This manual only suitable for GU601A generator automatic controller, user must carefully see this manual first.




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2. The Outline Dimensional Drawings and Wirings of Controller 2.1 Following Details:

Operation Panel W88mm×H75mm Install Cutout W78mm ×H65mm Thickness D48mm（unconnected）




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2.2 Connecting Terminals: Pin no. Function Description Signal Dim

1 phase voltage input 1mm²

2 neutral 0-300Vac

1mm²

3 P-sensor or switch signal P-sensor (<2KΩ) 1mm²

4 T-sensor or switch signal T-sensor (<2KΩ) 1mm²

5 configurable switch input signal 1 low level is active 1mm²



8 output fuel solenoid relay N.O. contact, 3A/30Vdc

1mm²

9 start relay output N.O. contact, 3A/30Vdc

1mm²

10 configurable output 1 N.O. contact, 3A/30Vdc

1mm²

11 configurable output 2 N.O. contact, 3A/30Vdc 1mm²

12 configurable output 3 N.O. contact, 3A/30Vdc 1mm²

13 charger excitation power output if not used, do not connect to negative 1mm²

14 plant supply {+} 1mm²

15 plant supply {-} (8-35Vdc continuous)

1mm²

CAUTION： l Pin no. “3” and “4” respectively for “P-sensor or switch

signal” and “T-sensor or switch signal” input, either switch or sensor can be chosen. When sensor is used, can increase the cross section area of cable base on the practical condition, so that to reduce the cable resistance that from controller to engine, to make sure the accuracy of measured values both for oil pressure and temperature.

CAUTION： l If not use pin no. “13” do not connect to negative.




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2.3 Typical Wiring Diagram

(12/24V)

LOA

D

GU601A

CONFIG. OUTPUT

FUEL

CRANK

DC POWER

OIL PRESSURE

COOLANT TEMP.

CONFIG. INPUT

A fuse with the rating of 10A shall be provided external to the equipment.




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3. Operation Panel

The whole operation panel includes 3 sections: LCD displays measuring parameters, indicator light for common failure, and control buttons and select buttons for control modes. LCD cycle displays different measuring parameters. When failure occurs LCD displays corresponding sign. LCD has background-light function so that operator can clearly read information whenever at day or night. After pressing any buttons the background-light will auto turn off in a certain time. LCD display and its control buttons provide a friendly operation interface for operator, which makes operator conveniently read information and set running parameter.

3.1 Control buttons and LED

Function Description Tag

Enter into submenu/modify/confirm modification/scroll menu

AUTO button/ LED The button is used for setting “auto-operation mode”. When controller is running in AUTO mode, LED above the button lights up. According to the “remote start signal” is active or not, to control generator start or stop.

MAN button /LED The button is used for setting “manual-operation mode”. When controller is running in MAN mode, LED above the button lights up. The controller controls generator start and stop by pressing “START” and “STOP” buttons.

START/ VALUE ASCEND “+” button for parameters setting The button is used for MAN start Genset. When controller is setting in MAN-operation mode, press this button can start generator. When enter in parameters setting operation, this button is used for value ascend.




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STOP/ RESET / VALUE DESCEND The button is used for MAN stop Genset. When controller is setting in MAN-operation mode, continuously press this button more than 2s can stop generator. If occur failure output, light press this button, the shutdown lockout can be cleared by controller. When enter in parameters setting operation, this button is used for value descend.

FAILURE LED When controller occur warning, failure LED flash. When controller occur shutdown alarm, failure LED lights up.




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4. Installation Guide 4.1 The dimensional drawing of install cutout on panel, shown as above

attached. The controller is fixed by 2 special mounting fittings. The shock-proof equipment must be installed, if the enclosure that installed on controller is directly installed on Genset body or other heavy vibrant device. A readily accessible disconnect device shall be incorporated external to the equipment;

4.2 Please see above 2.3 Typical Wiring Diagram for wiring connecting. 4.3 The installations of P-sensor and T-sensor for engine:

Port No.

Battery negative (unit enclosure)

Purpose

Sensor Com. PortT-sensor/ temp switch

P-sensor/ low oil pressure switch 3 4

GU601A CONTROLLER

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CAUTION： l Pin no. “3” and “4” respectively for “P-sensor or switch

signal” and “T-sensor or switch signal” input, either switch or sensor can be chosen. When sensor is used, can increase the cross section area of cable base on the practical condition, so that to reduce the cable resistance that from controller to engine, to make sure the accuracy of measured values both for oil pressure and temperature.

l If the control system is simultaneously required for switches and sensors for both oil pressure and temperature, the Pin no. “3” and “4” can be respectively connected to P-sensor and T-sensor, and use another 2 configurable input ports to connect to oil pressure switch and temperature switch, and then matching parameters by setting.




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5. Control and Operation Instruction The controller has 2 kinds of control mode: AUTO mode and MAN mode. 5.1 Operation Mode Setting:

Operation Description

Press “AUTO” button (continue 2s), LED above the button lights up; controller is running in “AUTO” mode.

Press “MAN” button (continue 2s), LED above the button lights up; controller is running in “MAN” mode.

NOTE: Only can select 1 mode from above 2 modes. 5.2 AUTO Control Process: The controller is running in “AUTO” mode. First of all, define one of the configurable inputs as Remote Start Signal. When detects that the remote signal is active, the controller implements following procedure: Start-delay timer begins count, when delay time out, if preset preheat function, preheat relay making output, the timer for preheat time begins count, when time expired, fuel relay takes action, the fuel solenoid of engine opened, after 300ms delay, the start relay making output, the start motor of engine switches on power, begin crank, when the running speed of engine is reach to the crank disconnect speed, controller stop start-output, the safety-on delay time begin count, before time out, if controller detects that parameters of Genset such as voltage, frequency, oil pressure, coolant temperature are normal, and no other failure, means Genset successfully start and running normal, LCD displays corresponding measuring parameters.

NOTE: l When remote signal is active, the timer for start-relay begins

count. During counting, if remote start signal is inactive, the start-relay stop counting immediately, controller stop start procedure and related output, recover to original standby status.

l During the period of crank or idle, if remote start signal is inactive, controller stop start procedure and related output, recover to original standby status.

l 1 configurable input must be set as “Remote Start Signal”, or will not process start procedure under “AUTO” mode.




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NOTE: l During crank, engine ignition, when the output frequency of

alternator is reaches to preset frequency, start motor disconnect power. Or the start motor is disconnected power by one of the following reasons: the output voltage of alternator is reaches to 80% rating voltage; start time over. After the low oil pressure switch of engine opening, delay counting time out.

l Controller can not implement idle procedure, when it detects that the frequency of generator is reached the preset level, or the oil pressure switch of engine is open.

CAUTION： Since the crank disconnect signal of engine is from the output voltage frequency of generator, must make sure the output voltage is greater than controller measurable voltage during the period of generator crank attempt, to avoid the possible damage on start motor.

If preset idle function, simultaneously the start relay making output, the relay which is defined for idle function making output, the timer for idle-relay begins count, when time expired, safety-on delay begins count, the following procedure as above. During crank counting time, engine can not igniting, and controller will not output start signal during crank intermission, and the Fail to Start Sign in LCD flashing at that time. Once crank intermission time out, controller will attempt to restart engine again. Above start phenomena repeat again and again until engine successful ignition and or reach the preset crank times. If any stop failures occur during start process, controller stops control output immediately, until failure eliminated and reset, then it can be operated again. Fail to start: When above start phenomena repeat again and again and over the preset crank times, controller will stop control output, failure LED lights up, and LCD status bar displays Fail to Start Sign.

CAUTION： If occur start failure, operator must check the whole Genset system to make sure failure reason, only after eliminating the failure can press “ STOP/RESET” button to unlock fault-locked status, and restart the Genset.




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The process of generator shutdown: When remote signal is not active, the timer for cooling delay begins counting, when time expired, the fuel relay of controller takes action, breaking fuel solenoid immediately, generator stop and enter into standby status. Fail to stop: When cooling-delay expired, the fuel relay of controller takes action, the timer for fail to stop delay begins counting, when time expired, if controller detects that the voltage and frequency of generator is greater than the internal setting value, or the oil pressure of engine is greater than the internal setting value, failure LED for Fail to stop lights up, LCD displays Fail to stop icon.

NOTE: When occur fail to stop, except failures were removed and reset or can not restart generator.

5.3 The produce of MAN control: The controller is running in “MAN” mode. The process of generator start supply: Press “START” button, fuel relay takes action, the fuel solenoid of engine opened, after 300ms delay, the start relay making output, the start motor of engine switches on power, begin crank, when the running speed of engine is reach to the crank disconnect speed, controller stop start-output, the safety-on delay time begin count, before time out, if controller detects that parameters of Genset such as voltage, frequency, oil pressure, coolant temperature are normal, and no other failure, means Genset successfully start and running normal, LCD displays corresponding measuring parameters. 5.4 The start and stop processes of engine, which fuel solenoid is N. O. type: Start control process: When start running, the fuel relay of controller will not close, fuel solenoid no power, means the electromagnet of solenoid no action. Stop control process: When controller starts at stop control process, the fuel relay of controller is close, fuel solenoid on load, fuel solenoid take action, engine begins stop. After delay (same as fail to stop delay) fuel relay breaking, disconnect the power of fuel solenoid. Other control process same as engine fuel solenoid is N. C. type.




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5.5 Idle function: When one of the configurable outputs is defined as Idle, controller has idle control function immediately. The idle control flow reference to the flow chart for start and stop. 5.6 Preheat function: When one of the configurable outputs is defined as Preheat, controller obtains preheat control function immediately. Controller has 3 optional preheat control modes: Mode 1 — during preheat time, preheat relay making output. Mode 2 — during preheat time, preheat relay making output until successfully

ignition. Mode 3 — during preheat time, preheat relay making output until safety-on

delay expired. No matter setting at which mode, during crank attempt the preheat relay will not making output. The idle control flow reference to the flow chart for start and stop.




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5.7 Flow chart for start and stop

T1－ start delay T2－ crank time T3－ preheat time

T4－ safety-on time T5－ idle time T6－ fail to stop delay

NOTE: When T4>T5 and engine is under the period of idle, the protection of low oil pressure will not operation; When T4<T5 and engine is under the period of idle, the protection of low oil pressure will operation.




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6. Measure and Display Data The AC phase voltage of generator Vac Generator frequency Hz Engine speed RPM (signal from generator frequency) Battery voltage Vdc Engine running hours h Engine coolant temperature ℃ /F (signal from engine T-sensor) Engine oil pressure BAR /PSI (signal from engine P-sensor)

7. Warning and Shutdown Alarm 7.1 Warning (NOTE: Warns are non-critical failure conditions and do not affect the operation of the generator system, they serve to draw the operators’ attention to an undesirable condition and remove it to make sure system continuous running. When warns occur, the status indicator light flash, but failure will not be locked and the unit will not shutdown. Once failure removed warning indicator auto turn off.)

Warning/ Description LCD Display Fail to Charge: if controller detects that voltage has fallen below the “low battery warning value” from the excitation contact of auxiliary AC charger after the safety-on timer has expired, failure indicator light flash, LCD displays Fail to Charge icon.

Battery Low Voltage: if controller detects that battery voltage has fallen below the “low battery warning value”, failure indicator lights up. For example, “low battery warning value” preset as: 23.6V, when battery voltage falls below this value, LCD flashing low value icon. Battery High Voltage: if controller detects that battery voltage has exceeded the “high battery warning value”, failure indicator lights up. For example, “high battery warning value” preset as: 28.2V, when battery voltage exceeds this value, LCD flashing high value icon. Low Oil Pressure: if controller detects that the engine oil pressure has fallen below the “low oil pressure warning value” after the safety-on timer has expired, failure indicator light flash. For example, “low oil pressure warning value” preset as: 2.20BAR, when engine oil pressure falls below this value, LCD flashing low value icon.




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High Temperature: if controller detects that engine coolant temperature has exceeded the “high coolant temperature warning value”, failure indicator lights up. For example, “high coolant temperature warning value” preset as: 95℃, when engine coolant temperature exceeds this value, LCD flashing high value icon.

Overspeed: if engine speed exceeds the “overspeed warning value”, failure indicator lights up. For example, “overspeed warning value” preset as: 1600RPM, when engine speed exceeds this value, LCD flashing high value icon. Underspeed: if engine speed falls below the “underspeed warning value” after the safety-on timer has expired, failure indicator lights up. For example, “underspeed warning value” preset as: 1440RPM, when engine speed falls below this value, LCD flashing low value icon.

High Voltage: if controller detects that the voltage of generator any phase output has exceeded the “high voltage warning value” after the safety-on timer has expired, failure indicator light flash. For example, “rating voltage” preset as: 220A, “high voltage warning value” preset as: 115%, when the generator output voltage exceeds this value, LCD flashing high value icon for corresponding phase.

Low Voltage: if controller detects that the voltage of generator any phase output has fallen below the “low voltage warning value” after the safety-on timer has expired, failure indicator light flash. For example, “rating voltage” preset as: 220A, “low voltage warning value” preset as: 90%, when the generator output voltage falls below this value, LCD flashing low value icon for corresponding phase.

Auxiliary Warning: define a configurable switch as warning input, when the input signal is active, failure indicator light flash. LCD flashing Aux. warning icon.




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Note: To make warnings of “low oil pressure” and “high coolant temperature” active, must use P-sensor and T-sensor, when only use oil pressure switch and temperature switch, both warnings inactive.

Caution: Under the period of safety-on delay, some warnings are inactive, the safety-on time must be carefully and properly set to make Genset has full protection.

7.2 Shutdown Alarm

(NOTE: shutdown failures immediately lock system and stop generator, it only can operate controller again after removing failures and press rest button to unlock)

Failures/ Description LCD Display

Fail to Start: if engine does not fire after the preset number of crank attempts has been made, means fail to start, failure LED lights up. LCD displays “fail to start” icon. Fail to Stop: if engine does not stop after the stop delay expires, failure LED lights up. LCD displays “fail to stop” icon.

Emergency Stop: define a configurable switch as emergency stop input, when the input signal is active, controller immediately stop all relay control output except alarm, failure LED lights up. LCD displays “emergency stop” icon. Low Oil Pressure: if controller detects that the oil pressure level still falls below oil pressure alarm value or oil pressure switch is closing after the safety-on timer has expired, engine stop immediately, failure LED lights up. LCD displays low oil pressure icon.

High Temperature: if controller detects that engine coolant temperature has exceeded the high coolant temperature alarm value or temperature switch is closing, engine stop immediately, and failure LED lights up. LCD displays high temperature icon.




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Overspeed: if controller detects that engine speed exceeds the overspeed alarm value, engine stop immediately, and failure LED lights up. LCD displays overspeed icon. Auxiliary Failure: define a configurable switch as failure input, when the input signal is active, failure LED lights up. LCD displays Aux. warning icon.

Note: l Engine speed signal is from generator output voltage

frequency, is used for control and failure protection parameters, to the convenience of user, some data expressed by RPM, RPM=HZ*60/pair of poles.

l The generator occur failure during its operating: after occur high temperature, low oil pressure and overspeed stop immediately no delay; when occur low oil pressure during coolant delay, only set idle delay at 0 (means on idle function) to make protection, or inactive.

Caution: Under the period of safety-on delay, the protection of low oil pressure failure is inactive, to avoid non oil start engine, must make sure the oil is normal and the safety-on time shall be carefully and properly set for the first commissioning.




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8. Parameters Setting 8.1 System Parameters: NO. Items Preset Value Range 1.1 voltage ratio 1.0 1.0-100.0 1.2 rating voltage 220 45-9999Vac 1.3 begin control mode 0 0-1 / 0 (AUTO) /1 (MAN)

1.4 oil pressure units 0 0-2 (0-BAR,1-PSI, 2-all displayed)

1.5 temperature units 0 0-2 (0-℃,1-℉,2- all displayed)

1.6 communication address 1 1-247

1.7 resume to default 1.8 on-line update 1.9 page scroll time 0S 0-10S /0 (not used)

NOTE: Begin Control Mode is used for the setting the begin control mode of controller when controller switches on power. When the parameter set at “1” and controller switches on power, controller will auto operating in AUTO control mode; When the parameter set at “0” and controller switches on power, controller will auto operating in MAN control mode.

NOTE: Generator running speed is set by pair of poles, RPM=HZ*60/ pair of poles, when rating frequency is 50 HZ, if pole pairs set at “2”, the running speed is 1500 rpm, if pole pairs set at “1” , the running speed is 3000 rpm.

8.2 Generator Parameters:

NO. Items Preset Value Range 2.1 V low alarm 0 20-200% / 0 (not set)

2.2 V low warning 90% 20-200% / 0 (not set)

2.3 V high warning 115% 20-200% / 9999 (not set)

2.4 V high alarm 9999 20-200% / 9999 (not set)

2.5 Failure delay 10S 0-600S




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8.3 Engine Parameters:

NO. Items Preset Value Range 3.1 pair of poles 2 1-4

3.2 fuel mode 0 0-1 / 0(NC) /1 (NO)

3.3 T-sensor mode 3 0-10 / 0 (not use)

3.4 P-sensor mode 3 0-11 / 0 (not use)

3.5 start delay 10S 0-300 S

3.6 crank attempt 3 times 1-10 times

3.7 crank time 8S 0-30 S

3.8 crank rest 15s 0-300 s

3.9 crank disconnect 300RPM 1-9999 RPM

3.10 preheat delay 3S 0-300 S

3.11 preheat mode 1 1-3

3.12 idle delay 0 0-9999s

3.13 safety on delay 10S 0-600S

3.14 cooling delay 300S 0-600 S

3.15 fail to stop delay 20S 0-60S

3.16 underspeed alarm 0RPM 0-9999 RPM / 0 (not set)

3.17 Underspeed warning 1440RPM 0-9999 RPM / 0 (not set)

3.18 overspeed warning 1600 RPM 1-9999 RPM / 9999 (not set)

3.19 overspeed alarm 1710 RPM 1-9999 RPM/ 9999 (not set)

3.20 low oil-press alarm 1.4BAR 0-45.0 BAR

3.21 low oil-press warning 2.2BAR 0-45.0 BAR

3.22 high temp warning 95℃ 70-320℃ / 9999 (not set)

3.23 high temp alarm 105℃ 70-320 / 9999 ℃ (not set)

3.24 low battery warning 8.0V 1-25.0V / 0 (not set)

3.25 high battery warning 28.0V 1-35.0V / 99.9 (not set)

3.26 charge V warning 8.0V 1-25.0V / 0 (not set)




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8.4 Input and Output Setting

4.1 configurable input 1 8 0-12 (define code as follows)



4.4 input 1 delay 2S 0-60S



4.7 configurable relay 1 2 0-80 (define code as follows)

4.8 configurable relay 2 3 0-80 (define code as follows)

4.9 configurable relay 3 5 0-80 (define code as follows) NOTE: configurable input delay is only for 1 to 4 codes in 8.7. 8.5 Calibration Menu

5.1 Gen voltage V1 0 ±10.0

5.2 oil pressure 0 ±10.0

5.3 coolant temp 0 ±10.0

5.4 battery voltage 0 ±10.0 8.6 The optional items for PT-sensor:

Code The brand model of P-sensor The brand model of T-sensor 0 not used not used 1 close for low oil pressure close for high temperature 2 open for low oil pressure open for high temperature 3 VDO 10 bar VDO 120 degrees C 4 KD 10 bar KD KD 120 dc KD 5 YG962 1J1M ZJ WGJ 900131 ZJ 6 KP 6 bar KP KP 130 dc KP 7 3846 N-010-B2 DX 21YB054 DX 8 3967251 KL 3967250 KL 9 MHI 10 bar SL MHI 98 dc SL 10 Datcon 10 bar configurable (base on sensor data) 11 configurable (base on sensor data)




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Note: When controller leave factory, the optional model and function of P-sensor and T-sensor have been preset as above table, if the used sensor not listed in table, user can select the item of “configurable”, read-in sensor parameters to controller by software.

8.7 The optional items for configurable input:

Code Optional Function NOTE 0 not used 1 warning (active immediately) low level is active 2 alarm (active immediately) low level is active

3 warning (active after safety-on delay) low level is active

4 alarm (active after safety-on delay) low level is active

5 low oil pressure low level is active 6 high temperature low level is active 7 emergency stop low level is active 8 remote start low level is active 9 reserved low level is active 10 reserved low level is active 11 low fuel level low level is active 12 lamp test low level is active

8.8 The optional items for configurable output:

Code Failure Type Define Code Failure Type Define 0 Not used 1 Over current tripping 2 Alarm 3 Warning 4 Idle 0 (NC) 5 Preheat mode 6 Speed up 7 Reserved 8 Fuel pump control 9 Running 10 System in AUTO mode 11 Reserved 12 System in MAN mode 13 Reserved 14 Idle 1 (NO) 15 Reserved 16 Reserved 17 Fail to start

Note: Define one of the configurable outputs as Speed Up, after controller detects that engine is successfully crank, speed up relay making output; if has idle function, then speed up relay making output after idle delay expired.




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9. LCD Display and Menu System Adopt TN type LCD displays data information, and LCD has background-light function, after pressing any buttons the background-light will auto turn off in a certain time. In normal operating status, auto scroll page to cycle display each measuring data, also can press “ ” scroll to view each measuring data, when failure occurs, LCD flashing the corresponding failure icon. For parameters setting and modify adopts gradually increase and decrease, when continuously press increase or decrease button, the single digit changed one by one, then the tens digit changed after ten single digit changed, follow this logic, and the hundreds digit changed after ten. Continuously press“ ” 2s enter into setting status, use “+” and “-” can scroll in the same grade menu. Press “ ” again can enter into next submenu, select the required modify item, press “ ” enter into modify. When prompt enter password, enter: “ ” “ ” “ ” “ ” “ ” “ ”， continuously press“ ”2s to quit setting status after finishing modify. 9.1 Static LCD displays: When controller standby:


Controller only displays detected battery voltage and running hour, LCD displays:

When controller normal running, cycle displays each measuring data:

→ → → →

→ → (AC voltage→ frequency→ running hour→ oil pressure→ coolant temperature→ battery voltage→ speed)




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9.2 Setting running parameters For example: (setting VT rate at 2.0)


Continuously press “ ” 2s, enter into parameters setting menu, then LCD display:

press “ ”, then LCD display:

press “ ”, then LCD display:

Key in password “ ” “ ” “ ” “ ” “ ”

“ ”, then LCD display:

Press“ ” or “ ” change parameter, change at 2.0, then LCD display:

After changing press“ ” to confirm，then press“ ” and “ ” ,

then LCD display:

Press“ ” again for quit, or continuously press “ ” more that 2s also can quit:

For example: (setting controller crank attempt at 2)


Continuously press “ ” 2s, enter into parameters setting menu, then LCD display:

Press “ ” 16 times, then LCD display:

Press “ ” again, then LCD display:

Press “ ” then LCD display:

Key in changed password: “ ” “ ” “ ” “ ”

“ ” “ ”

Press“ ”or “ ”change parameter, change at 2, Press“ ”

confirm change, and then continuously press “ ” 2s can quit

parameters setting menu.




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For example: (resume all parameters of controller to factory default)


Continuously press “ ” 2s, enter into parameters setting menu,

then LCD display:

Press“ ” 3 times again, then LCD display:

press “ ”, prompt enter password, then LCD display:

Key in password “ ” “ ” “ ” “ ” “ ”

“ ”, then LCD display:

Press “ ” recover default, continuous press “ ” 2s can quit

parameters setting menu.

For example: (set controller as online program mode)


Continuously press “ ” 2s, enter into parameters setting menu,

then LCD display:

Press“ ” 2 times and then press “ ” one times, then LCD

display:

Key in changed password: “ ” “ ” “ ” “ ”

“ ” “ ” (313232) , then LCD display:

Press “ ” again enter into program mode, in this mode the

power supply must be make sure normal, after connecting to the

communication line, using special program software correctly

duplication, controller will auto repeat reset action, or will not quit

this status, until switch off plant supply.




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10. Preparation before Start the Controller 10.1 Make sure controller is fixed well and its install ambient meet requirements. 10.2 Confirm all wiring connections of controller are meet electric specification and

corresponding to “2.3 typical wiring diagram”. Especially need confirm DC supply source has added fusing element to protect, and correct polarity. Otherwise, it maybe damage controller.

10.3 We recommend mounting “E- stop” button in external, connecting E-stop

signal input terminal to the N. O. contact of “E- stop” button, and another terminal of contact connected to the negative of battery source.

10.4 Switch on DC plant supply, make sure the preset parameter meet practical

condition, such as P-sensor mode, T-sensor mode, etc.




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11. Troubleshooting Failure Phenomenon Failure Eliminate

Genset no crank

No crank attempt either in “MAN” mode press“START” button or in “AUTO” mode the remote start signal is active.

1. Check failure LED, or check LCD display to confirm has failure display or not.

2. Check DC voltage on controller no. “14” terminal, if no voltage, check related circuitry fuse. Such as low voltage, use charger charging battery, restart after battery fully charging.

3. Check DC voltage on controller no. “9” terminal when crank, if no voltage, need change controller.

4. Check starting motor normal operating or not, if not change it.

Diesel fail to start

Controller LCD display: “fail to start”, diesel rotates but can not start or diesel stop after start operating.

1. Check fuel level. 2. Check DC voltage on controller no. “8”

terminal, if no voltage need change controller. 3. Check the connection of fuel control magnet

and the voltage on magnet. 4. Check fuse on the side of alternator. 5. Both check fuel manifold and filter jam or not. 6. If has white smoke release from exhaust

system, means fuel has gone into engine, but diesel not start. Please refer to “Diesel Manual” for further check.

7. If low ambient temp and has heat start function, please preheat first.

8. Once failure removed, press “RESET” button to reset control system.

Diesel high temp shutdown

Controller LCD display high temp failure icon, common failure LED lights up.

1. Check the mode of controller T-sensor correctly set or not, if error need reset.

2. Check radiator jam or not. 3. Check fan belt loose or tighten. 4. Check if ambient temperature meets

generator usage range. 5. After diesel cooling, check coolant position, do

not add a great deal of coolant into diesel before it is not cooling, or will cause serious damage to it.

6. Refer to “Diesel Manual” 7. Once failure removed, press “RESET” button

to reset control system.

Low oil pressure shutdown

Controller LCD display low oil pressure failure icon, common failure LED lights up.

1. Check the mode of controller P-sensor correctly set or not, if error need reset.

2. Check fuel level, if oil not enough, add oil. 3. Refer to “Diesel Manual” 4. Check oil pressure switch by test meter, if

any problems change it. 5. Once failure removed, press “RESET”

button to reset control system.




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Diesel overspeed shutdown

Controller LCD display overspeed failure icon, common failure LED lights up.

1. Check governor speed shaft moved or not, if moved correct it.

2. If installed electronics governor, check if level shaft can freely move, correct it if necessary.

3. Refer to “Diesel Manual”. 4. Once failure removed, press “RESET”

button to reset control system.

Under-speed shutdown

LCD display low frequency failure

1. Check the frequency input value of magnetic pickup on controller correctly set or not, if error need reset.

2. Check supply fuels enough or not. 3. Check governor speed shaft moved or

not, if moved correct it. 4. If installed electronics governor, check if

level shaft can freely move, correct it if necessary.

5. Adjust diesel speed when it is running. 6. Check the parameters setting for

underspeed failure right or not.

Low voltage shutdown

LCD display low voltage failure

1. Switch off load on alternator, remove failure after shutdown and restart unit.

2. Check the setting value of Gen low voltage failure, make sure correct data.

3. If voltage still low, adjust generator output voltage by setting potentiometer to recover to normal value.

4. Refer to “Alternator Manual”

High voltage shutdown

LCD display high voltage failure

1. Switch off load on alternator, remove failure after shutdown and restart unit.

2. Check the setting value of Gen high voltage failure, make sure correct data.

3. Check the measuring voltage of controller, if voltage normal, check load and make sure it is non capacitive (power factor compensation device will casual cause a capacitive load).

4. If voltage still low, adjust generator output voltage by setting potentiometer to recover to normal value.

5. Refer to “Alternator Manual”

Engine fail not stop

Generator still running after stop, LCD display fail to stop failure

1. Check fuel solenoid valve on diesel (or level shaft), make sure oil channel is completely closed under close status.

2. Check fuel control solenoid valve, change it if necessary.




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12. Technical Parameters DC supply: 8.0V to 35V continuous Max. operating current: @12V 150mA, @24V 75mA AC input voltage: phase voltage15~300 Vac RMS (AC frequency ≥40 Hz) AC input frequency: 3~70Hz (voltage ≥15V) Control relay output: 3A/30Vdc Operating ambient temperature: -20 to 70℃ Storage ambient temperature: -40 to 80℃

Version：070A090313



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