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12 ZK6201 CONTROLLER USER`S MANUAL

1. Pin no Function Description Signal Dim 1 GEN VL1 N input 0 330Vac 1mm 2 GEN VL2 N input 0 330Vac 1mm 3 GEN VL3 N input 0 330Vac 1mm 4 GEN Neutral 1mm 5 Not used 6 Not used 7 Not used 8 Not used 9 Not used 10 11 Gen current input S1 0 5A 2 5mm 11 l2 Gen current input S1 0 5A 2 5mm 12 13 Gen current input S1 0 5A 2 5mm 13 Comm port for current inputs S2 0 5A 2 5mm 14 LOP sensor lt 1KO 2 5mm 15 HET sensor lt 1KO 2 5mm 16 Sensor com port 2 5mm 17 Auxiliary sensor 1 Resistance type sensor lt 1KQ 2 5mm 18 Auxiliary sensor 2 Resistance type sensor z1 KO 2 5mm 19 Common port for relay outputs 2 5mm 20 Fuel solenoid relay output N O contact 16A 30Vdc 2 5mm 21 Start relay output N O contact 16A 30Vdc 2 5mm 22 Relay output 3 GCB close open N O contact 3A 30Vdc configurable 1 1mm 23 Relay output 4 N O contact 3A 30Vdc configurable 2 1mm 24 Relay output 5 N O contact 3A 30Vdc configurable 3 1mm 25 Relay output 6 N O contact 3A 30Vdc configurable 4 1mm 26 charger excitation power output if not used do not connect to negative 1mm 27 Relay output 7 1mm 28 Relay output 7 N O contact 3A 30Vdc configurable 5 1mm 29 Configurable digital input signal 1 low level is active 1mm 30 Configurable digital input signal 2 low level is active 1mm 31 Configurable digital input signal 3 low level is active 1mm 32 Configurable digital input signal 4 low level is active 1mm
2. 0 not used 1 Over current trip 2 Common alarm 3 Common pre alarm warning 4 Idle relay N C 5 Preheat relay 6 Speed up 7 Speed down 8 Fuel pump control 9 GEN running 10 Auto mode 11 Test mode ZINGS sik 12 Manual mode 13 Reserved 14 Idle relay N O 15 Reserved 16 GCB failure 17 Start failure 18 Stop failure 19 Reserved 20 GCB close open 21 KW overload pre alarm 22 Charge failure 23 Over current pr alarm 24 Battery Under voltage 25 Battery Over voltage 26 Under frequency pre alarm 27 Over frequency pre alarm 28 Low oil press pre alarm 29 Engine high temperature pre alarm 30 Under speed pre alarm 31 Over speed pre alarm 32 GEN under voltage pre alarm 33 GEN over voltage pre alarm 34 A sen1 under level 35 A sen1 over level 36 A sen2 under level 37 A sen2 over level 38 ECU alarm 39 ECU alarm shutdown 40 Over current alarm 41 ECU data fail ZINGS sik 42 Low oil pressure alarm 43 High Engine temperature alarm 44 Under speed alarm 45 Over speed alarm 46 Under frequency alarm 47 Over frequency alarm 48 GEN under voltage alarm 49 GEN over voltage alarm 50 KW overload alarm 51 LOP Sensor open alarm 52 Configurable D input 1 active 53 Configurable D input 2 active 54 Conf
3. Code Type Note 1 Configurable 1 2 Configurable 2 Enter data according to the curve of the fuel sensor configurable 1 only can be set through the software configurable 2 can be set through both the push button on the front panel and software Fuel pump ON Used to configure the low fuel level value the configurable relay output which is defined as fuel pump control would be energised if it reaches this value To active this function the A sensor 1 use is required to define as 1 fuel level Fuel pump OFF Used to configure the high fuel level value the configurable relay output which is defined as fuel pump control would be de energised if it reaches this value To active this function the A sensor 1 use is required to define as 1 fuel level A sen1 under level e Used to configure the under level value for auxiliary sensor 1 If this parameter is configured as not used the function would be inactive A sen1 under act Used to configure the response mode of the controller when the level of auxiliary sensor 1 falls below the under level value There are 3 modes 0 pre alarm warning 1 alarm 2 control gt O pre alarm when the level of auxiliary sensor 1 falls below the under level value prealarm LED illuminates and buzzer sounds LCD displays WARNING LOW FUEL LEVEL or WARNING A sen 1 low temp gt 1 alarm when the level of auxiliary
4. Firmware update Used to load and update firmware for controller lt requires to key in CL2 password ZINGS sik 7 2 GENERATOR NO Items Preset Value Range 2 1 GEN V under preALM 90 20 to 200 not used 2 2 GEN V under Alarm not used 20 to 200 not used 2 3 GEN V over preALM 115 20 to 200 not used 2 4 GEN V over Alarm not used 20 to 200 not used 2 5 GEN Hz under preALM 48 0Hz 10 0 to 100 0Hz not used 2 6 GEN Hz under Alarm not used 10 0 to 100 0Hz not used 2 7 GEN Hz over preALM 55 0Hz 10 0 to 100 0Hz not used 2 8 GEN Hz over Alarm 57 0Hz 10 0 to 100 0Hz not used 2 9 KW Overload preALM not used 20 to 200 not used 2 10 KW Overload Alarm 100 20 to 200 not used 2 11 Alarm delay 5s 0 to 600s 2 12 Overcurrent level 100 20 to 200 not used 2 13 Overcurrent delay 1 1 to 20s 2 14 Overcurrent action 0 0 warning 1 electrical trip 2 shutdown 2 15 Loading Voltage 95 20 to 100 2 16 Loading Frequency 48 0Hz 10 0 to 100 0Hz 2 17 GEN ON Delay 5 1 to 9999s 2 18 GCB closing time 5 2 to 200s 2 19 Test mode 1 0 without load 1 with load Menu descriptions GEN V under preALM Used to configure Gen under voltage pre alarm value the GEN V under preALM is inactive when parameter is configured as not used Expressed by percentage Rated Ph N voltage x GEN V under Alarm Used to configure Gen under voltage alarm value
5. 33 Configurable digital input signal 5 low level is active 1mm 34 Configurable digital input signal 6 low level is active 1mm 35 Configurable digital input signal 7 low level is active 1mm 36 Magnetic pick up signal 1 70Vac pe 37 Common for configurable inputs and magnetic pick up signal 38 Battery supply B 2 5mm 39 Battery supply B 12V 24V 8 35Vdc continuous 2 5mm 40 Ground 2 5mm ZINGS ili NOTE Relay output 3 is configured as GCB close open relay when default setting however it can be reconfigured by user if required 2 4 Typical Wiring Diagram 3 asaan o a o wet zx 2o z a 43e 3S at 2 he o_o CT Ze 8 aaa BE 5 s R z NORMAN MA 2 UNAS LU MORNE CRT AANO aarvoszee wo a i e 3 zs gt E n E 5 i 0 ae Pi aaa g are Fuel CRANK CLOSE ZINGS sik 3 Panel Operation The operation panel consists of 3 sections LCD display indicating measurement parameters LED indicator for common failure and push buttons for Genset and selection of control modes LCD with 12864 pixels can display multi line data in the same time LCD also has a backlight so that the operator can clearly read information day or night After pressing any button the backlight will automatically turn off after a preset time The LCD display and its control push buttons provide a friendly operational interface for the operator
6. after the safety on timer has expired the pre alarm LED illuminates and the buzzer sounds LCD displays OVERLOAD If controller detects that the active power of generator has exceeded the KW Overload preALM after the safety on timer has expired the pre alarm LED illuminates and the buzzer sounds LCD displays D INPUT If one of configurable D inputs has been configured as pre alarm when D input is active the pre alarm LED illuminates and the buzzer sounds LCD displays UNDER SPEED OVER CURRENT OVER FREQ UNDER FREQ GEN OVER VOLT GEN UNDER VOLT KW OVERLOAD D INPUT ZINGS sik AUX1 LOW LEVEL when A sensor 1 use and A sen 1 under act have been configured as fuel level and pre alarm if controller detects that the level has fallen below the under level the pre alarm LED illuminates and the buzzer sounds LCD displays If A sensor 1 use has been configured as temperature LCD displays AUX1 HIGH LEVEL when A sensor 1 use and A sen 2 over act have been configured as fuel level and pre alarm if controller detects that the level has exceeded the over level the pre alarm LED illuminates and the buzzer sounds LCD displays If A sensor 1 use has been configured as temperature LCD displays AUX2 LOW LEVEL when A sensor 2 use and A senor 2 under act have been configured as temperature and pre alarm if controller dete
7. the GEN V under Alarm is inactive when parameter is configured as not used Expressed by percentage Rated Ph N voltage x GEN V over preALM Used to configure Gen over voltage pre alarm value the GEN V over preAlarm is inactive when parameter is configured as not used Expressed by percentage Rated Ph N voltage x GEN V over Alarm Used to configure Gen over voltage alarm value the GEN V over Alarm is inactive when parameter is configured as not used Expressed by percentage Rated Ph N voltage x ZINGS sik GEN Hz under pre ALM Used to configure Gen under frequency pre alarm value the GEN Hz under preALM is inactive when parameter is configured as not used GEN Hz under Alarm Used to configure Gen under frequency alarm value the GEN Hz under Alarm is inactive when parameter is configured as not used GEN Hz over pre ALM Used to configure Gen over frequency pre alarm value the GEN Hz over preALM is inactive when parameter is configured as not used GEN Hz over Alarm Used to configure Gen over frequency alarm value the GEN Hz over Alarm is inactive when parameter is configured as not used KW Overload preALM Used to configure the over load pre alarm value the KW Overload preALM is inactive when parameter configured as not used Expressed by percentage use Rated active power as factor KW Overload Al
8. 14 SYSTEM menu then LCD displays 2 GENERAYOR 3 ENGINE Press V button 2 times then LCD displays Press or button prompted enter password 2213 press ar n to confirm after entering password i 0000 Press or to change parameters change at 500 then LCD displays 0 QUIT Press V to confirm then press B to return then LCD 14 SYSTEM displays 2 GENERAYOR 3 ENGINE Press B again or press and hold gt i 2sec will quit Ready parameter settings menu then LCD displays For example setting controller crank attempt at 2 Operation Description 0 QUIT Press and hold gt i 2sec enter into parameters settings 4 SYSTEM 0 menu then LCD displays 2 GENERAYOR 3 ENGINE 0 QUIT Press 2 times and then press VW then LCD displays 1 Rated speed o 2 MPU input 3 Fly wheel teeth Press 9 times and then press V then LCD displays Press or button prompted enter password 2213 press V button to confirm after entering password aa 0000 Press or to change parameters change at 2 Press V button to confirm and then press B or press and hold gt 2sec will quit parameter settings menu ZINGS sik For example resume parameters of controller to factory defaults Operation Press and hold gt i 2sec enter into parameters settings menu then LCD displays Press V button and t
9. 176 194 212 230 248 266 284 R Q 291 197 134 97 70 51 38 29 22 18 15 VDO 150C T C 50 60 70 80 90 100 110 120 130 140 150 T F 122 140 158 176 194 212 230 248 266 284 302 R Q 322 221 155 112 93 62 47 37 29 23 19 Datcon T C 40 50 60 70 80 90 100 110 120 130 140 TCF 104 122 140 158 176 194 212 230 248 266 284 R Q 900 600 400 278 200 141 104 74 50 27 4 Murphy T C 40 50 60 70 80 90 100 110 120 130 140 T F 104 122 140 158 176 194 212 230 248 266 284 R Q 1029 680 460 321 227 164 120 89 74 52 40 PT100 T C 100 50 0 20 40 60 80 100 150 200 300 TCF 148 58 32 68 104 140 176 212 302 392 572 R Q 60 81 100 108 116 123 131 139 157 176 212 Pre set 1 T C 20 30 40 50 60 70 80 90 100 110 120 TCF 68 86 104 122 140 158 176 194 212 230 248 R Q 900 600 420 282 152 113 86 62 48 40 30 Pre set 2 T C 30 50 60 70 80 90 100 110 120 TCF 86 122 140 158 176 194 212 230 248 R Q 980 400 265 180 125 90 65 50 38 Pre set 3 T C 20 30 40 50 60 70 80 90 100 110 120 TCF 68 86 104 122 140 158 176 194 212 230 248 R Q 805 540 380 260 175 118 83 58 42 30 21 Pre set 4 T C 28 35 40 50 60 70 80 90 95 98 T F 82 95 104 122 140 158 176 194 203 208 R Q 579 404 342 250 179 136 103 77 67 63 ZINGS sik NOTE Configurable means user can input the data manually according to the sensor curve Configurable 1 only can be set through the software configurable 2 or 3 can be done through the push buttons on
10. 7 bar P Bar 0 0 0 7 1 4 2 1 2 8 3 4 4 1 4 8 5 5 6 2 6 9 P PSI 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 0 100 0 R Q 240 205 171 143 123 103 88 74 60 47 33 Pre set 1 P Bar 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 P PSI 0 14 5 29 0 43 5 58 0 72 5 87 0 101 5 116 0 130 5 145 0 R Q 15 31 49 66 85 101 117 132 149 164 178 Pre set 2 P Bar 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 P PSI 0 14 5 29 0 43 5 58 0 72 5 87 0 101 5 116 0 130 5 145 0 R Q 30 41 65 88 110 115 145 150 172 185 190 Pre set 3 P Bar 0 1 7 3 4 5 2 6 9 8 6 10 3 P PSI 0 25 50 75 100 125 150 R Q 21 36 52 72 84 100 120 Pre set 4 P Bar 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 P PSI 14 5 29 0 43 5 58 0 72 5 87 0 101 5 116 0 130 5 R Q 195 155 127 107 88 72 61 54 48 ee NOTE EE Configurable means user can input the data manually according to the sensor curve Configurable 1 only can be set through the software configurable 2 or 3 can be done through the push buttons on the front panel or software When configuring please input the resistance measured value from small to kd NO a Ei Start delay Used to configure the time delay from the remote start signal is active to crank output is energised Crank attempt Used to configure how m
11. 99 times not used 1 12 Telephone 1 NO 00000000000 1 13 Telephone 2 NO 00000000000 1 14 Telephone 3 NO 00000000000 1 15 Default settings 1 16 Language 1 17 Password 0000 to 9999 1 18 Engine ECU type not used 1 to 20 not used 1 19 Display contrast 5 1 to 9 1 20 Auto scroll time not used 1 to 60s not used 1 21 Firmware update Menu descriptions CT Ratio The current is derived from CT on generator or load Secondary current on CT is fixed at 5A Used to calculate for GEN KVA KW KVAr PF KWhr KVArhr Used for shutdown alarm overcurrent overload etc VT Ratio The voltage is derived from VT on Gen and Mains Used to detect frequency of Gen and Mains Used to calculate for GEN KVA KW KVAr PF KWhr KVArhr Used for shutdown alarm over under voltage overload etc Rated ph voltage Used to define the rated voltage phase to neutral of Gen and Mains rated VPh Ph Rated phvoltage 1 732 Reference value for judging over under voltage Rated current ZINGS i Used to define the rated current of generator Reference value for judging over current Voltage type There are 5 kinds of voltage type Y 3P4W A 3P4W 3P3W 1P3W 1P2W Y 3P4W 3 phases 4 wires star ZINGS sil 2 3P4W 3 phases 4 wires angle 3 3P3W 3 phases 3 wires 4 1P3W single phase 3 wires ZINGS ik 5 1P2W singl
12. low level is active 10 Reserved 11 Gen Aux Switch closed low level is active 12 Low fuel level switch low level is active 13 Lamp test low level is active 14 Under speed limit low level is active 15 Over speed limit low level is active 16 Air flap aux switch close low level is active Low level is active Used for preheat mode 4 as the condition of 17 Preheat preheat relay output is energised or not Low level is active In crisis mode all shutdown alarms are 18 Crisis mode changed to pre alarm warning it means the Genset would not be shutdown when shutdown alarm occurs D Input delay e Used to configure the timer for confirmation of the configurable digital input A sensor 1 use Used to configure the purpose of auxiliary sensor 1 lf this parameter is configured as not used the sensor and the relative function would be ZINGS ik inactive A sensor 1 type Used to configure the type of auxiliary sensor 1 from the built in list of the sensor e lf A sensor 1 use is configured as 1 fuel level controller would auto select the built in list of the fuel level sensor If the A sensor 1 use is configured as 2 temperature controller would auto select the built in list of the temperature sensor If the A sensor 1 use is configured as 3 oil pressure controller would auto select the built in list of oil pressure sensor Fuel level sensor selection
13. parameter Deadband Controller will not output the PID signal to raise and lower the speed if the difference between engine speed and rated speed is within the range of this parameter Time pulse minimum e Used to configure the minimum time of PID signal output each time means the minimum closing time of the relay each time Raise rate Used to configure the increase rate of the frequency per second during governing Lower rate _Used to configure the decrease rate of the frequency per second during governing O All above parameters are used for speed control O Speed control function is an optional function on ordering the parameters above are inactive without order EP AA AA AA AA ANAN AA AA AA AA AA AA MAAASAHAN ZINGS sik 7 7 CALIBRATION MENU NO Items Preset Value Range 7A GEN V1 offset 9 9 to 9 9 7 2 GEN V2 offset 9 9 to 9 9 7 3 GEN V3 offset 9 9 to 9 9 7 4 Current 11 offset 9 9 to 9 9 75 Current l2 offset 9 9 to 9 9 7 6 Current 13 offset 9 9 to 9 9 7 7 Pressure offset 9 9 to 9 9 7 8 Temperature offset 9 9 to 9 9 7 9 Batt V offset 9 9 to 9 9 7 10 AUX sensor1 offset 9 9 to 9 9 741 AUX sensor2 offset 9 9 to 9 9 Menu descriptions GEN V1 offset Used to modify the measured value display of GEN Phase 1 voltage Reference to the Rated ph voltage GEN V2 offset Used to modify the measur
14. the controller starts the generator simulating the activation of remote start signal When in parameters setting mode this button is used to enter into submenu confirm modification START Button LED Return The push button is used for manually start the Genset When controller is running in MANUAL mode press this button to start the generator When in parameters setting mode this button is used to return ZINGS sik STOP RESET Button Move Setting The Push button is used for manually stops the Genset No matter what mode the controller is running press and hold this button for 2sec to stop the generator the mode of the controller will be default to MAN mode automatically from AUTO or TEST mode and the generator will be shut down after cool down period during the cool down period if you press and hold this button for 2sec again the generator will be shut down immediately If failure occurs press this button the shutdown alarm lockout can be cleared When in parameters setting mode this button is used to move to next parameters setting position C O Button It is used to close open the switch of Gen when controller is running in MANUAL mode Shutdown Alarm FAILURE LED The LED will illuminate permanently when shutdown alarm occurs Pre alarm WARNING LED The LED will illuminate permanently when pre alarm occurs GEN Normal LED Gen normal LED will illuminate after both voltage
15. the front panel or software When configuring please input the resistance value from small to big one by one P sensor type Used to configure the type of LOP sensor Optional kinds of built in LOP sensors in controller Code Mode Note 1 close for low oil pressure 2 open for low oil pressure 3 VDO 5 bar 4 VDO 10 bar 5 Datcon 7 bar 6 Murphy 7 bar 7 Pre set 1 8 Pre set 2 9 Pre set 3 10 Pre set 4 11 configurable 1 12 configurable 2 13 configurable 3 CAUTION The LOP sensor is used to measure the oil pressure its accuracy is very important to the protection of the Genset so please match the right type of the sensor or configure the right curve of the senor Otherwise it may cause engine The parameters appendix of LOP sensor VDO 5 bar P Bar 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 P PSI 0 7 3 14 5 21 8 29 0 36 3 43 5 50 8 58 0 65 3 72 5 R Q 11 29 47 65 82 100 117 134 151 167 184 VDO 10 bar P Bar 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 P PSI 0 14 5 29 0 43 5 58 0 72 5 87 0 101 5 116 0 130 5 145 0 R Q 10 31 52 71 90 106 124 140 155 170 184 Datcon 7 bar P Bar 0 0 0 7 1 4 2 1 2 8 3 4 4 1 4 8 5 5 6 2 6 9 P PSI 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 0 100 0 R Q 240 200 165 135 115 95 78 63 48 35 25 ZINGS si Murphy
16. this function when no RPM signal input Pair of Poles Used to configure the poles of excitation winding of the alternator Use to calculate the engine speed with the frequency when without MPU input Fuel mode Used to configure the type of engine fuel valve details refer to 4 5 N C type means the fuel channel is closed when fuel can not be used N O type means the fuel channel is opened when fuel can not be used T sensor type Used to configure the type of HET sensor Optional kinds of built in HET sensors in the controller Code Mode Note 1 close for high temperature 2 open for high temperature 3 VDO 120 C 4 VDO 150 C 5 Datcon 6 Murphy 7 Pt100 8 Pre set 1 9 Pre set 2 10 Pre set 3 11 Pre set 4 12 configurable 1 13 configurable 2 14 configurable 3 ZINGS sik CAUTION The HET sensor is used to measure the coolant temperature its accuracyis very important to the protection of the Genset so please match the right type of the sensor or configure the right curve of the senor Otherwise it may cause engine damage The parameters appendix of HET sensor VDO 120 C TOO 40 50 60 70 80 90 100 110 120 130 140 T F 104 122 140 158
17. used 3 37 EX Crank permit 0 0 NO 1 YES Menu descriptions Rated speed Used to configure the Genset rated speed A reference value for speed control MPU input Used to configure whether magnetic pick up unit is used or not When parameter is configured as 1 magnetic pick up is used for the signal source of the engine speed When parameter configured as O the magnetic pick up is not used the engine speed is calculated from the frequency of the generator RPM Hz 60 Pair of Poles For example the frequency of generator is 50Hz when Pair of Poles configured as 2 RPM 50 60 2 1500 RPM Fly wheel teeth e Used to configure there are how many teeth on the fly wheel Set pickup now f user does not know the fly wheel teeth to calculate the fly wheel teeth automatically via the measuring Gen frequency and MPU frequency Fly wheel teeth f1 Pair of Poles f2 f1 is MPU frequency f2 is Gen frequency ZINGS sik Operating procedure gt Configure the parameter of MPU input as 0 gt Start the Genset choose Set pickup now from the menu after the Genset running normally the parameter of fly wheel teeth will be automatically calculated at that time gt Configure the parameter of MPU input as 1 to finish the setting NOTE This function is only used for the debug of the controller and Genset Please do not implement
18. 0 Bar PSI not used 4 28 A sen2 under act 0 0 pre alarm 1 alarm 2 control temp 20 to 320 C F 4 29 A sen2 over level not used Oil P 0 1 to 150 0 Bar PSI not used 4 30 A sen2 over act 0 0 pre alarm 1 alarm 2 control 4 31 User Relay 1 20 1 to 80 not used 4 32 User Relay 2 19 1 to 80 not used ZINGS sik 4 33 User Relay 3 2 1 to 80 not used 4 34 User Relay 4 3 1 to 80 not used 4 35 User Relay 5 5 1 to 80 not used Menu descriptions D Input There are 7 configurable digital inputs Optional items as following Code Optional Functions Note r Low level is active When it is active pre alarm LED illuminates 1 Pre alarm warning i F and buzzer sounds LCD displays warning D input Low level is active When it is active generator stops shutdown 2 alarm alarm LED illuminates and buzzer sounds LCD displays alarm D input Low level is active When it is active after safety on delay 3 Pre alarm 1 pre alarm LED illuminates and buzzer sounds LCD displays warning D input Low level is active When it is active after safety on delay 4 Alarm1 generator stops shutdown alarm LED illuminates and buzzer sounds LCD displays alarm D input 5 LOP switch low level is active 6 HET switch low level is active 7 Emergency stop low level is active 8 Emergency stop high level is active N O is active 9 Remote start signal
19. 01 is a new generation Automatic control module for single Genset which adopts bran new outline configuration focus on the requirements of customers and perfectly improves the performance of controller It fully meets the auto control requirements of different kinds of Genset for user or special assembly factory The module also monitors and protects the engine indicating operational status fault conditions and metering on the front panel LCD and LED s True RMS measure of voltage and current Multi Language menu 128 x 64 pixel LCD display 4 analog inputs for kinds of optional sensors that can be used for measuring oil pressure coolant temperature fuel level and so on parameters can be configured by user More outputs of configurable auxiliary control relays More configurable isolated digital inputs Buttons on control panel are used for selecting control modes starting and stopping the operatingprocedure displaying data and modifying the parameters LED indicators are used for indicatingthe operation mode of controller and the running status of Genset and LCD displays each measuring parameter and status Flexible equipped with RS485 RS232 and USB realizing remote monitor or communicated with PC fully realizing functions of remote signaling telemetering and remote control can read and set the running parameters of controller With GPRS DTU or Ethernet DTU for remote communication instead of RS485 RS232 or USB port for rem
20. A C SUPPLY 131 24 135 Renote start CR 1 9 5 139 C5 Battery 12 24vde 8 138 Bs K J START VOLT F Fuel Config D J Gade config D input active 3 F3 F2 fh hanlanla alls ctl Eng Picky R2 0A 2A A RLI RL2 RL3 RLA RL5 RLG RL7 m press Sparel Sparc3 Temp a Rika 4 12 19 bo 21 22 23 24 25 Ja 28 26 29 30 31 32 33 34 14 15 17 18 16 36 37 ao u ce cee a ee fi a a PIA jm y oa osos 7 Jefa 88 17 jis fie op JET FL RED BLACK f 2 ng r yellow green COMMO N VOLT FREE CONTACT EMER gob Joo dood HON eee PAP ARI RA al STOP 7 y 19 5 8 c XHFCS siy 3 98 99 Ng aan 1 AMP les 78 CHARGING 14 14 Al Al ALTERNATOR OT Bsr CAR RT R2 33 5 ta lag frag 5 26 b 5 5 15 16 WL op Jer FL REF E E07 By o 5 24 MAGNETIC men PICK UP Title ZK6201Controller Circuit Drawing Drawing NO SMEE POWER CORPORATION ZCYK6201102 Date 2009 9 1 Sheetof 1 Drawn By sit Jia cui Audit 1 2 3 4 5 6 Drawing ZINGS iil ZINGS POWER SCIEN TECH HANGZHOU CO LTD Add NO 129 Yifeng Road Economic and Technological Development Zone Hangzhou 310018 Tel Fax 0086 57 1 85803976 E mail zings china zings com Http www china zings com
21. ALARM AUX2 HIGH TEMP NOTE If engine speed signal is derived from generator output voltage frequency it is used for control and failure protection parameters for convenience of user some data is expressed by RPM RPM HZ 60 pair of poles ort n nnn nnn nnn nn nnn nnn nnn nnn nnn nn nn nnn nn nnn nnn nnn nnn nnn nnn nnn nnn a a a a EEEE NOTE While the Genset is running if there is high coolant temperature low oil pressure or over speed failure the controller will shutdown it He without delay During the cool down period if there is low oil pressure failure the controller will shut down the Genset immediately without delay CAUTION During the period of safety on delay low oil pressure protection is inactive To avoid starting an engine with no oil you must make sure the oil levels are normal and the safety on time shall be carefully and properly set for the first commissioning ZINGS si 7 Parameters Setting 7A SYSTEM NO Items Preset Value Range 1 1 CT Ratio 1000 5 5 5 to 30000 5 1 2 VT Ratio 1 0 1 1 0 1 to 100 0 1 1 3 Rated ph Voltage 220 1 to 30000VAC 1 4 Rated current 1000 1 0 to 30000A 1 5 Rated active power 500 1 0 to 16000KW 1 6 Voltage Type 1 1to5 1 7 Comm Address 1 1 to 247 1 8 Startup mode 0 0 MAN 1 AUTO 2 the same as last time 1 9 Press Unit 0 0Bar 1PSI 110 Temperature Unit 0 0C 1 F 1 11 Send SMS count not used 1 to
22. ALM the pre alarm LED illuminates and the buzzer sounds LCD displays HIGH TEMP OVER SPEED If engine speed exceeds the Over SP preALM the pre alarm LED illuminates and the buzzer OVER SPEED sounds LCD displays ZINGS sik UNDER SPEED If engine speed falls below the Under SP preALM after the safety on timer has expired the pre alarm LED illuminates and the buzzer sounds LCD displays OVER CURRENT configure Overcurrent action as warning if controller detects that any phase output current exceeds the Overcurrent level after the safety on timer has expired the pre alarm LED illuminates and the buzzer sounds LCD displays OVER FREQ ff controller detects that generator s frequency has exceeded the GEN Hz over preALM after the safety on timer has expired the pre alarm LED illuminates and the buzzer sounds LCD displays UNDER FREQ If controller detects that generator s frequency has fallen below the GEN Hz under preALM after the safety on timer has expired the pre alarm LED illuminates and the buzzer sounds LCD displays GEN OVER VOLT If controller detects that any phase output voltage of generator has exceeded the GEN V over preALM after the safety on timer has expired the pre alarm LED illuminates and the buzzer sounds LCD displays GEN UNDER VOLT If controller detects that any phase output voltage of generator has fallen below the GEN V under preALM
23. ARGING To prevent damage to a controller that uses an alternator or attery 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 CAUTION prevent damage to these parts Do not disassemble the rear back of controller and touch the components or ku EN a pm aR Re naa nea R kan aannael ZINGS sik Contents LA 0 9 Peerenereetee me teres rer cre deere eeepeee ricer ery reer rere ree ceres tree cre terecterte EEEE EEEE 5 2 The Outline Dimension Drawings and Controller Wiritng ccc ceeeseseseseseeeeseeeeeseseeeeeeeeeeseaeneeees 6 3 Panel Op ratio GAGANA GANANG 10 4 Control and Operation INStruction oo cece eeeseseseeeeeeeseseseneeeeeseseseseseeeeseseaeneeeeseseaeaeeeeeeseseaeaenees 12 5 Measure and Display Data u 1 1111171111 7na 19 6 Warning and Shutdown Alarm ANA 20 T Parameters Setting AA NAN NAN NGA NAA AA asia eal posing 27 8 Installation BUNGANGA AA e n ANAN UNA 54 9 LCD displays and Menu System cc eeeescssesssecesesesseseeesescscseseeeeeesescseseeeeeeacacseeeeeeeeacacseeeeneesaeaceees 63 10 Technical Specification ABG BANA ANNA 67 Drawing aa AA ANNA sheesh NA NNANNN ESA a Ea aE a aa EEE Aaaa 69 This manual is only suitable for ZK6201 Automatic control module user must carefully read this manual first ZINGS sik 1 Description ZK62
24. CD displays ECU SHUTDOWN when the ECU detects a shutdown alarm and sends it to controller the Shutdown alarm LED ECU SHUTDOWN illuminates and buzzer sounds LCD displays LOW FUEL LEVEL when A sensor 1 use and A sen 1 under act have been configured as fuel level and alarm if controller detects that the level has fallen below the under LOW FUEL LEVEL level Genset stops immediately the shutdown alarm LED illuminates and the buzzer sounds LCD displays AUX1 HIGH TEMP when A sensor 1 use and A sen 1 over act have been configured as temperature and alarm if controller detects that the temperature has AUX1 HIGH TEMP exceeded the over level Genset stops the shutdown alarm LED illuminates and the buzzer sounds LCD displays AUX2 LOW LEVEL when A sensor 2 use and A sen 2 under act have been configured as oil pressure and alarm if controller detects that the oil pressure has fallen below the under level Genset stops immediately the shutdown alarm LED illuminates and the buzzer sounds LCD displays itis active after safety on delay expired AUX2 LOW PRES ZINGS sik AUX2 HIGH LEVEL when A sensor 2 use and A sen 2 over act have been configured as temperature and alarm if controller detects that the temperature has exceeded the over level Genset stops immediately the shutdown alarm LED illuminates and the buzzer sounds LCD displays
25. GS sik 6 Warning and Shutdown Alarm 6 1 Pre alarm warning NOTE Pre alarms are non critical failure conditions and do not affect the operation of the generator system they serve for drawing the operators attention to an undesirable condition so they can remove it to ensure continuous running of the system When Pre alarms occur the Pre alarm LED illuminates but failure will not be locked out and the unit will not shutdown Once the Pre alarm failure is removed the Pre alarm LED will automatically turn off CHARGE FAILURE After safety on times up if the charging voltage from the excitation contact of alternator is lower than the ALT low preALM the pre alarm LED illuminates and the WARN CHARGE FAILURE buzzer sounds LCD displays BATT UNDER VOLT If controller detects that battery voltage has fallen below the Batt Undervolt pre alarm LED WARN BAT UNDER VOLT illuminates and the buzzer sounds LCD displays BATT OVER VOLT If controller detects that battery voltage has exceeded the Batt overvolt the pre alarm LED BAT OVER VOLT illuminates and the buzzer sounds LCD displays LOW OIL PRESS If controller detects that the engine oil pressure has fallen below the Oil P low preALM after the safety on timer expired the pre alarm LED illuminates and LOW OILPRESS the buzzer sounds LCD displays HIGH TEMP If controller detects that engine coolant temperature has exceeded the Coolant pre
26. ING A sen 2 low temp or ZINGS ik WARNING A sen 2 low oil pressure gt 1 alarm when the level of auxiliary sensor 2 falls below the under level value the Genset stops shutdown alarm LED illuminates and buzzer sounds LCD displays ALARM A sen 2 low oil pressure gt 2 control when the level of auxiliary sensor 2 falls below the under level value the relative configurable relay output would be energised A sen2 over level e e Used to configure the over level value for auxiliary sensor 2 If this parameter is configured as not used the function would be inactive A sen2 over act Used to configure the response mode of the controller when the level of auxiliary sensor 2 exceeds the over level value There are 3 modes 0 pre alarm warning 1 alarm 2 control gt O pre alarm when the level of auxiliary sensor 2 exceeds the over level value pre alarm LED illuminates and buzzer sounds LCD displays WARNING A sen 2 high temp gt 1 alarm when the level of auxiliary sensor 2 exceeds the over level value the Genset stops shutdown alarm LED illuminates and buzzer sounds LCD displays ALARM A sen 2 high temp gt 2 control when the level of auxiliary sensor 2 exceeds the over level value the relative configurable relay output would be energised User relay There are 5 configurable output relays Optional functions as following Code Alarm mode defined
27. NGS sii 1P2W single phase 2 wires MCCB UP 1A Measure and Display Data VPh N L1 N frequency Hz L1 current 11 apparent power A active power P reactive power Q power factor PF active energy KWhr ZE reactive energy KVArhr 2E ZINGS sik 8 2 6 The connection of configurable digital inputs There are 7 configurable Inputs which used for monitoring and control status all of the Inputs adopt electrical isolation and controller internal provides 8vdc power supply no need an additional power User Switch D Input 1 D Input 2 D Input 3 D Input 4 D Input 5 D Input 6 D Input 7 DC8V connected to power negative terminal 39 inside the controller i The maximum acceptable resistance for each input is 10KQ it means whether the switch of loop circuit is closed or not the status monitored by controller are all open when the resistance in loop circuit exceeds 10KQ status monitored by controller are all close when the resistance in loop circuit falls below 10KQ To avoid error monitoring of switch status do pay attention to the wiring resistance and switch on resistance in loop circuit and total resistance must be less CAUTION Terminal 37 on controller should not be used as the negative input of battery CAUTION ZINGS sik 8 2 7 Connection for the configurable output relays There are 7 relay outputs except fuel and crank relays which are fixed function other relays fu
28. Phase 25 to 572VAC Max power wastage per line lt 0 1W Accuracy 1 Display 0 to 600KV 10 2 AC voltage frequency Input frequency 3 to 70Hz voltage 215VAC Accuracy 0 1 Display 0 to 100Hz 10 3 Current isolated Measurement True RMS Measuring current 5A Accuracy 1 Display 0 to 30000A Max power wastage per line lt 0 01W 10 4 Power supply Range 12V 24V 8 35V continuous Max operating current 12V 310mA 24V 155mA Max standby current 12V 100mA 24V 50mA Cranking dropouts OV for 80ms assuming battery supply was at least 10V before dropout and recovers to 5V Accuracy 1 Display 0 to 40V 10 5 Configurable digital inputs Number 7 Max contact resistance 10KO Type Isolated Max contact current per line 1mA 10 6 Configurable relay outputs Fuel relay 16A 30Vdc Start relay 16A 30Vdc Aux relay 3A 30Vdc ZINGS sik 10 7 Charge failure input Range 0 to 35Vdc Accuracy 1 Max output current 12V 120mA 24V 240mA 10 8 Analog Inputs Number 4 Sensor type resistance Resolution 10 bits Range 0 to 1KQ 2 When full scale except for sensor Accuracy error 10 9 Magnetic pickup Voltage range 1 to 70V Max frequency 10000Hz Fly wheel teeth 5 to 300 10 10 Ambient param
29. Telephone 3 NO Same as above Default settings Some parameters are resumed to default setting Language Used to select the Language which is displayed on the LCD Password There are 3 levels of password CLO CL1 CL2 for different users CLO for the operator who can read parameters start and stop controller The default setting is no password 5 CL1 for the technician who has the authority of CLO and can modify all parameters the default setting is 2213 CL2 for factory who have the authority of CL1 and Firmware update the default setting as 3132 All passwords are automatically inactive 60 seconds after exiting menu Engine ECU type Used to define the J1939 interface function and ECU type There are several ECU types have been built in the controller Code Description 1 Receive standard J1939 information 2 Standard J1939 information specified VOLVO EMS2 information 3 Standard J1939 information specified CUMMINS QSX15 information 4 CUMMINS MODBUS information To make the J1939 interface of controller active external CANBUS module is required on ordering Display contrast Used to adjust the display contrast of the LCD Auto scroll time Used to configure the cycle of page scroll When parameter is configured as not used manually scroll page via Start to scroll automatically 30 seconds after not pressing any button button
30. ZINGS tik ZK6201 CONTROLLER USER S MANUAL ZINGS sik 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 ne oe ene ieee ee ee ee ee ee ee eee ee ee ee a ee ee ee eee ee ree eee ae CAUTION A CAUTION indicates a potentially hazardous situation which if not avoided could result in damage to equipment or property ee ngn ee ee ee nn en ee ee ee ee nn NOTE A NOTE provides other helpful information that does not fall under the warning or caution categories ZINGS sik 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 WARNING 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 over temperature or low pressure shutdown device may also be needed for safety as appropriate 1 H a na AO NA Ek a Bhd aa KG ra mka ra tee AEE E ee Ee eee APA AAP AAP NGPA AE J CAUTION BATTERY CH
31. and frequency of the Gen Reach loading voltage and frequency GCB Closed LED LED will illuminate when GCB is closed and power supplied by Gen LED will flash when GCB failure occurs ZINGS sik 4 Control and Operation Instruction The controller has 3 modes AUTO MANUAL and TEST 4 1 Operation Modes Setting Press and hold the AUTO button for 2sec the LED above the button is illuminated the controller is running in AUTO mode Press and hold the MAN button for 2sec the LED above the button is illuminated the controller is running in MAN mode Press and hold the TEST button for 2sec the LED above the button is illuminated the controller is running in TEST mode NOTE Only 1 mode can be selected from above 3 modes Controller keeps the states for the previous mode when changing the operation mode then implements the control procedure of the next mode according to the present states l 1 4 2 AUTO Control Sequence The controller is running in AUTO mode Generator Auto Start Sequence NOTE To achieve remote start one of configurable inputs must be defined as remote start signal The Start delay timer Is activated when It times out the preheat relay output Is energise
32. and stop for idle control flows NOTE Controller will not detect under voltage under frequency under speed and charge failure during idle period 4 7 Preheat function For Preheat function configure one of the configurable outputs as Preheat the controller has 5 selectable preheat control modes as below Mode 1 during preheat time preheat relay output energises Mode 2 during preheat time preheat relay output energises until the successful ignition Mode 3 during preheat time preheat relay output energises until safety on delay times out Mode 4 one of the configurable inputs is defined as Preheat preheat relay output energises when this configurable input is active and de energises when configurable input is inactive Mode 5 the A sensor 2 use is defined as Preheat preheat relay output energises when the temperature falls below the Preheat ON value and de energises until the temperature reaches the Preheat OFF value For preheat mode 1 to 3 please refer to the flow chart 4 10 for start and stop for Preheat control flows For preheat mode 4 to 5 Preheat function is active immediately when the controller is switched on power During crank period the Preheat relay output will not energise in any of above modes 4 8 The function of forcing start Reason to add this function to the controller is that when the engine under abnormal conditions e g the battery voltage is too low or ambient temperature is too lo
33. any times the controller repeat to crank the engine this value is equal to the maximum crank times Crank time e Used to configure the maximum time permit of engine cranking Crank time add Used to adjust the maximum time permit of the repeat cranking The second time of crank time is equal to the first crank time plus the extra time For example crank time set at 5s Crank time add set at 3s then since the second crank the maximum crank time permit is 8s ZINGS sik CAUTION The maximum crank time permit can not exceed the range of the equipment safety CAUTION Crank rest The time between last crank and next crank Engine only can be cranked again after the crank rest time has expired Crank cutout RPM The crank cutout speed Crank cutout volt The crank disconnect voltage Expressed by percentage use Rated ph voltage as factor Crank cutout ALT V The crank cutout Charger voltage signal is from the W L terminal of charger When parameter is configured as not used this function is inactive Crank cutout Oil P The crank cutout engine oil pressure signal is from LOP sensor When parameter is configured as not used this function is inactive Crank cutout P delay Used to configure the period from engine LOP switch opened or oil pressure reaches oil Pressure Crank cutout value to crank disconnection When parameter is configured as not used this func
34. arm Used to configure the over load alarm value the KW Overload Alarm is inactive when parameter configured as not used Expressed by percentage use Rated active power as factor Alarm delay Use a timer for confirmation of overcurrent alarm Overcurrent level Used to configure the over current value of the Gen or the load the over current alarm is inactive when parameter configured as not used Expressed by percentage use Rated current as factor Overcurrent delay Use a timer for confirmation of over current alarm Overcurrent action Used to configure the action which is implemented after overcurrent alarm confirmed 3 types of parameters can be configured O pre alarm warning 1 electrical trip 2 shutdown When parameter is configured as O the pre alarm warning LED illuminates and buzzer sounds if over current happen and if the relative configurable relay defined as over current pre alarm warning then the relay output is energised LCD displays warn over current When parameter is configured as 1 the pre alarm warning LED illuminates and buzzer sounds if ZINGS sik over current happen and if the relative configurable relay defined as electrical trip then the relay output is energised LCD displays warn over current UnL the Genset will not be stopped When parameter is configured as 2 the shutdown alarm LED illuminates and
35. ates the Genset has successfully started and running normally The LCD displays the Genset Measurement Parameters After both voltage and frequency of generator respectively reached the loading value the Gen Normal LED illuminates the GCB close open relay will not be closed automatically Press the C O button of Gen to close the Gen switch manually then Gen is on load the Gen Aux switch s contact feeds back the signal to a configurable input on our controller GCB closed LED illuminates Press the C O button of Gen again to open the Gen switch manually the Gen is off load the GCB closed LED is turned off at the same time NOTE When the controller is running in MANUAL mode the Gen must be normal or the C O button of Gen will be disabled Generator stopping sequence Press STOP button GCB close open relay opens the generator is off load the cool down timer starts when it times out the fuel relay is de energised then the fuel solenoid opens immediately generator stops and goes to standby status If press STOP button again during cool down period generator stops immediately without cool down time 4 4 TEST control Sequence When the Controller is running in TEST mode means it simulates remote start signal is activated There are two kinds of TEST modes one is Test with load another is Test without load and they can be selected through parameter setting Test wit
36. ays total active and reactive energy Press G KVArHr 0 D to scroll next page RUN Relay Outputs AA oeei Relay Outputs is the status of configurable relay output Digital Inputs Digital Inputs is the status of configurable inputs SE NG 0 stand for it is active Press D to scroll next page Sa M A 0KVA M Q 0KVAr M PF 1 00 RUN 9 2 Setting running parameters Press and hold gt i button 2sec to enter into parameter settings menu then use or to scroll page in the same menu list press V enter into submenu press D can return to upper menu go to menu 1 17 password to enter password first or select the required item press W enter into modify mode press or the LCD displays O 0 O O when prompted enter password then use or to modify the first digital value press move to modify next digital value the first digital value will be displayed as after moving to next digital value press V to confirm after the password is set as 2213 then you can modify parameters Otherwise it will prompt to key in password again Press and hold k for more than 2sec or press B to quit parameter settings mode after finishing configuration ZINGS sik CT ratio at 500 5 then CT should be configured as 500 Operation Description For example setting 0 QUIT Press and hold gt i 2sec enter into parameters setting
37. buzzer sounds if over current happen and if the relative configurable relay defined as over current shutdown then the relay output is energised and the Genset will be shut down LCD displays alarm over current Loading Voltage Used to configure the voltage trigger value of the GCB close Expressed by percentage use Rated ph voltage as factor Loading Frequency e Used to configure the frequency trigger value of the GCB close GEN ON delay Use a timer for confirmation of voltage and frequency trigger value for Gen supply GCB closing time Use a timer for confirmation of the Gen Aux Switch s contact has been closed When the GCB output is energised if the controller does not receive the feed back signal from the Gen Aux Switch s contact after the GCB closing time has expired then means Gen fails to load Test mode Used to select a function of the controller in the test mode There are two test modes one is O without load stand for test the Genset without load the GCB close output will not be energised another is 1 with load stand for test the Genset with load the GCB close output will be energised 7 3 ENGINE NO Items Preset Value Range 3 1 Rated speed 1500RPM 99 to 9999 RPM 3 2 MPU input 0 0 NO 1 YES 3 3 Fly wheel teeth 120 5 to 300 3 4 Set pickup now 3 5 Pair of Poles 2 1to4 3 6 Fuel mode 0 ON C 1N O 3 7 T sen
38. cted Operation Description U 0V I 0A Controller does not detect oil pressure and engine coolant P 0kW F 0 0Hz temperature the related data would be displayed as SP 0rpm Bat 24 0V OPEN if controller is in standby OP OPEN TEMP OPEN Ready When HET sensor or LOP sensor is set as not used LCD will not display the related data a When Genset is running LCD circularly displays each measuring data Operation Description U 380V I 0A The voltage current value displayed on this page is the P OkW F 50 0Hz SP 1500rpm Bat 25 4V average value of 3 phases Press 2 to scroll next page OP 4 6Bar TEMP 70 C RUN V1 220V U12 380V 11 0A A1 0kVA This page displays electrical parameters for L1 Press D P1 0kW PF1 1 00 to scroll next page Q1 0kVAr RUN V2 220V U23 380V I2 0A A2 0kVA This page displays electrical parameters for L2 Press gt P2 0kW PF2 1 00 to scroll next page Q2 0kVAr RUN V3 220V U31 380V I3 0A A3 0kVA This page displays electrical parameters for L3 Press D P3 0kW PF3 1 00 to scroll next page Q3 0kVAr RUN ZINGS sik G P 0KW This page displays Gen power and average power factor G A 0KVA G Q 0KVAr G PF 1 00 RUN Run Hour 0 0 This page displays running hours crank attempt and COUNTERS 0 Press D to scroll next page Auxiliary sensor level Press gt to scroll next page Fuel 46 HEAT 40 C RUN G KWHr 0 This page displ
39. cts that the temperature has fallen below the under level the pre alarm LED illuminates and the buzzer sounds LCD displays If A sensor 2 use has been configured as oil pressure LCD displays it is active after safety on timer has expired AUX2 HIGH LEVEL when A sensor 2 use and A sen 2 over act have been configured as temperature and pre alarm if controller detects that the temperature has exceeded over level the pre alarm LED illuminates and the buzzer sounds LCD displays ECU ALARM When using J1939 CAN bus if the failure detected by ECU the controller will receive this information from the ECU immediately the pre alarm LED illuminates and the buzzer sounds LCD displays GCB FAILURE If GCB close open relay is closed the timer for GCB closing time is activated when it times out if the controller does not receive the feed back signal from Gen Aux Switch s contact then Gen fail to load alarm is activated The GCB closed LED flashes and the buzzer sounds LCD displays LOW FUEL LEVEL AUX1 LOW TEMP HIGH FUEL LEVEL AUX1 HIGH TEMP AUX2 LOW TEMP AUX2 LOW PRES AUX2 HIGH TEMP ECU ALARM GCB FAILURE ZINGS sik NOTE Controller continuously detects battery voltage during standby period and Battery Under Over Voltage Pre alarms are active Battery under Voltage pre alarm is inactive during cranking CAUTION Under the period of sa
40. d If preheat function selected the timer starts When it times out the fuel relay output is energised and operates the fuel solenoid of the engine After 300ms delay the start relay output is energised the start motor engages and begins to crank When the engine speed reaches the crank cutout RPM the start relay output is de energised and the safety on delay starts When the safety on times out if the controller detects that the parameters of the Genset such as voltage frequency oil pressure coolant temperature are normal and no other failure is detected this indicates the Genset has successfully started and running normally The LCD displays the Genset Measurement Parameters When Generator is running normally Gen Normal LED illuminates the timer for GEN ON delay is activated when it times out GCB close open relay closes then the transfer switch switches on Gen The Gen Aux Switch s contact feeds back a signal to a configurable input on the controller GCB closed LED illuminates ZINGS sik When remote signal is active the start delay timer is activated if remote start signal is inactive during this period the start delay timer terminates immediately the controller terminates the starting procedure then recovers to the original standby status During cranking or idle period if the remote start signal is inactive the controller stops the start procedure then recovers to the original standby status Under any condi
41. e phase 2 wires L1 nrn mn rmn nN os pang ar Comm Address Used to configure ID address for MODBUS Each controller on the same MODBUS has a unique communication address Startup mode Used to configure the Startup mode of controller when it is powered up When parameter is configured as O the controller will be in Manual mode when it is powered up When parameter is configured as 1 the controller will be in Automatic mode when it is powered up When parameter is configured as 2 the controller will be in the mode which is the same as last time when it is powered up Press Unit Used to define oil pressure unit which is displayed on the LCD 0 stand for Bar 1 stand for PSI Transfer formula P psi P bar 14 503 Temperature Unit Used to define temperature unit which is displayed on the LCD O stand for C 1 stand for F Transfer formula T F T C 1 8 32 Send SMS count Used to activate the Text Message function and choose the quantity of text message When parameter is configured as not used the function of Text Message is inactive To obtain the function of Text Message Service equipped with GPRS DTU module is required Telephone 1 NO Used to configure the mobile hone number which the Text Message will be sent to There are total 3 mobile phone numbers can be configured ZINGS sik Telephone 2 NO Same as above
42. e type of auxiliary sensor 2 from the built in list of the sensor f A sensor 2 use is configured as 1 preheat or 2 temperature controller would auto select the built in list of the temperature sensor If the A sensor 2 use is configured as 3 oil pressure controller would auto select the built in list of oil pressure sensor Pre heat ON Used to configure the under engine temperature value the configurable relay output which is configured as preheat would be energised if it reaches this value To active this function the A sensor 2 use is required to configure as 1 preheat Pre heat OFF Used to configure the high engine temperature value the configurable relay output which is configured as preheat would be de energised if it reaches this value To active this function the A sensor 2 use is required to configure as 1 preheat A sen2 under level Used to configure the under level value for the auxiliary sensor 2 If this parameter is configured as not used the function would be inactive A sen2 under act Used to configure the response mode of controller when the level of auxiliary sensor 2 falls below the under level value There are 3 modes 0 pre alarm warning 1 alarm 2 control gt O pre alarm when the level of auxiliary sensor 2 falls below the under level value the prealarm LED illuminates and buzzer sounds LCD displays WARN
43. ed value display of GEN Phase 2 voltage Reference to the Rated ph voltage GEN V3 offset Used to modify the measured value display of GEN Phase 3 voltage Reference to the Rated ph voltage Current 11 offset Used to modify the measured value display of Phase 1 current 11 Reference to the Rated current Current 12 offset Used to modify the measured value display of Phase 2 current 12 Reference to the Rated current Current 13 offset Used to modify the measured value display of Phase 3 current 13 Reference to the Rated current Pressure offset Used to modify the measured value display of LOP sensor Temperature offset ZINGS sik Used to modify the measured value display of HET sensor Batt V offset Used to modify the measured value display of battery voltage AUX sensor1 offset Used to modify the measured value display of auxiliary sensor 1 AUX sensor2 offset Used to modify the measured value display of auxiliary sensor 2 ZINGS ik 8 Installation Guide 8 1 The cutout dimensional drawing installed on panel as above follows 174 mm 172 mm 124 mm 126 mm Cutout dimension 174mm W x 126mm H The controller is fixed by 6 special fittings on Genset or other heavy vibrant device O In order to ensure the degrees of protection of the mounted controller meet P65 the cutout dimension on the panel must be correct D O The
44. eters Operating ambient temperature Standards 20 to 70 C IEC60068 2 1 and IEC60068 2 2 Storage ambient temperature Standards 30 to 80 C IEC60068 2 1 and IEC60068 2 2 Humidity Standards 60 C 95 RH 48 hours IEC60068 2 30 Electro Magnetic compatibility EMC Standards EN 61000 6 4 and EN 61000 6 2 Vibration Standards EN 60068 2 6 Shock Standards EN 60068 2 27 Electrical safety Standards EN 60950 1 Degrees of protection Standards IP65 front IP20 back BS EN 60529 Version 090720A01 NOTE JF 4 POLE BREAKER FITTED NE MN LI 7 NN ap Ng N1 E LOCATED 104 103 102 101 jera ON ALTERNATOR pii TERMINAL BOX 4 POLE BREAKER OPTIONAL SEE NOTE REF AOL 104 103 102 fioi fcro c3o cso c90 Z RIN 2 139 Pl aaa 1 oP AUTO F4 F6 M 6 3A 6 3A 20 FUEL VALVE T i 9 f fee 139 108 109 i10 fioi fcio leso lcso c90 COMMON ALARM j VOLT FREE CONTACT 131 FR 1 N 1 2 3 4 10 11 12 13 9 136 CAR 2 8 4 P7 6A AUXILIAR m
45. fety on delay some pre alarms e g under speed under voltage low oil pressure are inactive the safety on time must be carefully and properly set to make Genset have full protection i a To make the pre alarm for GCB FAILURE active please configure one of the configurable inputs as Gen Aux Switch Closed and connects the switch s N O Aux contact to this port After pre alarm occurred the controller is locked 6 2 Shutdown Alarm NOTE shutdown alarm failures immediately lock out the system and stop the Genset The failure must be removed and the controller reset before restarting the Genset START FAILURE if engine does not fire after the preset number of crank attempt has been made the Shutdown START FAILURE alarm LED illuminates and buzzer sounds LCD displays STOP FAILURE if engine does not stop after the Stop delay expired the Shutdown alarm LED illuminates and buzzer STOP FAILURE sounds LCD displays EMERGENCY STOP Configure a configurable input as emergency stop when the input signal is active controller immediately stops all relay control outputs except alarm Genset is shut down the Shutdown alarm LED illuminates and buzzer sounds LCD displays LOW OIL PRESS if controller detects that the oil pressure level still falls below Oil P low Alarm or LOP switch closes after the safety on timer has expired engine stops LOW OILPRESS immediately the Shutdown alarm LED illuminates and buzze
46. g one by one as following D Configurable sensor data means user can input the data manually according Fix Point 1 2 3 4 5 6 7 8 9 10 Resistance 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Measured Value 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ZINGS ik 7 6 SPEED CONTROL NO Items Preset Value Range 6 1 Proportional gain 10 0 0 1 to 100 0 6 2 Integral gain 1 0s 0 1 to 100 0s 6 3 Derivative ratio 1 0s 0 1 to 100 0s 6 4 Deadband 0 2Hz 0 1 to 9 9Hz 6 5 Time pulse minimum 0 2s 0 1 to 2 0s 6 6 Raise rate 5 s 1 to 100 s 6 7 Lower rate 5 s 1 to 100 s Menu descriptions Proportional gain Used to configure the P section of PID signal Increase proportional gain will increase the response range of speed governing control the larger response range the lager governing error Maybe cause over speed if parameter is configured too large Integral gain Used to configure the section of PID signal Integral gain will auto modify all offset and smoothly control The factor of integral gain must bigger than derivative s Genset will continue oscillation if the factor of integral gain too big Genset will need a long time to go into stable status if the factor of integral gain too small Derivative ratio Used to configure the D section of PID signal The stability of governing system can be better via increasing this
47. h load GCB close open relay will be closed after the generator is started successfully and running normally then Gen will be on load Test without load GCB close open relay will not be closed after the generator is started successfully and running normally the Mains remain on load 4 5 The start and stop sequence of engine whose fuel solenoid is N O type There are two kinds of fuel solenoids for an engine one is N C type the valve of this solenoid is closed when the engine is in standby and it can be opened by switching on power another is N O type the valve of this solenoid is opened when engine is in standby and it can be closed by switching on power All control sequences above are for N C type Start control sequence for N O type During the starting sequence the fuel relay of controller will not energise fuel solenoid is off power fuel solenoid is normally open so no signal required for fuel solenoid to activate Stop control sequence for N O type During the controller s stop sequence the fuel relay energises fuel solenoid is on power the fuel solenoid closes the fuel valve and the engine begins to stop After a delay same as Stop delay fuel relay deenergises disconnecting the supply from the fuel solenoid Other control sequences same as engine whose fuel solenoid is N C type ZINGS sik 4 6 Idle function For idle function configure one of the configurable outputs as idle Refer to the flow chart 4 10 for start
48. hen press 8 times then LCD displays Press V button prompted enter password 2213 press V button to confirm after entering password Press V button to confirm and then press B or press and hold 4 2sec will quit parameter settings menu For example configure controller at online program mode Operation Press and hold Po 2sec enter into parameters settings menu then LCD displays Press V and then press twice then LCD displays Press V button prompted enter password 3132 press V button to confirm after entering password Press V again to enter into online program mode then LCDdisplays Use the comm cable and the software to program please make sure the power supply is normal during programming the controller will reset automatically after programming If you have entered into this mode already but you do not program you need to turn the controller off to exit this mode Description 0 QUIT 2 GENERAYOR 3 ENGINE 0 QUIT 12 Telephone 1 NO 13 Telephone 2 NO 14 Telephone 3 NO Password 0000 Description 0 QUIT 2 GENERAYOR 3 ENGINE 18 Engine ECU type 19 Display contrast 20 Auto scroll time Password 0000 Firmware Update Download from PC Don t turnoff power before finished ZINGS sik 10 Technical Specification 10 1 AC voltage Measurement True RMS Phase to Neutral 15 to 330VAC Phase to
49. igurable D input 3 active 55 Configurable D input 4 active 56 Configurable D input 5 active 57 Configurable D input 6 active 58 Configurable D input 7 active 59 Buzzer sounds alarm 60 Air flap control 61 Reserved 62 Test without load mode 63 Test with load mode 64 Emergency stop 65 Reserved 66 Cooling down started successfully the controller can output a PID signal to the actuator motor for raising lower the speed of engine so that the speed of the engine will be stable in a setting range D If configure one of configurable digital output as speed up down after the engine ZINGS sik 7 5 Configurable sensor data No Item Preset Value Range 5 1 PRES Sensor 1 5 2 PRES Sensor 2 5 3 TEMP Sensor 1 5 4 TEMP Sensor 2 5 5 Fuel Level Sensor Menu Descriptions PRES Sensor 1 Corresponds to the configurable 2 in the LOP Sensor type PRES Sensor 2 Corresponds to the configurable 3 in the LOP Sensor type TEMP Sensor 1 Corresponds to the configurable 2 in the HET Sensor type TEMP Sensor 2 Corresponds to the configurable 3 in the HET Sensor type Fuel Level Sensor Corresponds to the configurable 2 in the Fuel level sensor selection to the sensor curve When configuring please input the resistance measured value from small to bi
50. installation of PB switch to avoid cranking when the Genset is running i 4 9 Speed control for actuator motor optional Controller with this speed control function controls the speed motor of engine and regulates the size of fuel via continuously output speed raise lower switch control signal with PID function making engine s running speed stabile within the setting range ZINGS ik 4 10 Flow chart for start and stop RPMA _ 12 T1 start delay T2 safety on delay T3 crank time T4 idle time T5 pre heat time T6 Stop delay NOTE If T4 is longer than T5 oil pressure protection is ignored during T5 If T4 is shorter than T5 oil pressure protection becomes effective after T4 in T5 bum zz ma a a ZINGS sik 5 Measure and Display Data Gen VPh N L1 N L2 N L3 N Gen VPh Ph L1 L2 L2 L3 L3 L1 Gen frequency Hz L1 Gen 3 phases current 11 12 13 Gen 3 phases apparent power KVA AL1 AL2 AL3 2A Gen 3 phases active power KW PL1 PL2 PL3 2P Gen 3 phases reactive power KVAr QL1 QL2 QL3 Q Gen 3 phases power factor PFL1 PFL2 PFL3 PF AV Gen total active energy KWhr 2E Gen total reactive energy KVArhr 2E Engine speed RPM signal derived from magnetic pick up or generator Hz Engine oil pressure Bar PSI signal from engine LOP sensor Engine coolant temperature C F signal from engine HET sensor AUX analog input 1 AUX analog input 2 Battery voltage Vdc Genset Running hour Hour ZIN
51. ive GCB close open relay de energises Gen is off load the timer for cool down is activated when it times out the fuel relay de energises generator stops and recovers to its lana status NOTE When remote start signal is inactive directly enter into cooldown status if none relay is defined as GCB close open relay output i Siop Failure When cool down times out the fuel relay opens and the timer for Stop delay begins If the controller detects that the voltage of the generator or oil pressure or the speed of engine is greater than the cutout values or LOP switch is open when it times out the failure LED illuminates and the LCD SEE Fail to stop NOTE After stop failure the controller will not energise the crank relay output if the failure has not been removed and the controller reset 4 3 MAN control Sequence 0 The controller is running in MANUAL mode Generator starting sequence Pressing START button the fuel relay is energised and operates the fuel solenoid of engine After 300ms delay the start relay output is energised the start motor engages and begins to crank When the engine speed reaches the crank cutout RPM the start relay output is de energised and the safety on delay starts When the safety on times out if the controller detects that the parameters of the Genset such as voltage frequency oil pressure coolant temperature are normal and no other failure is ZINGS sik detected this indic
52. n idle during cooling down Cool down time The time permit for running without load before engine stop Itis necessary to set cool down time it can make the engine stop at a lower temperature after a long time running with load Stop delay The maximum time permit for the engine stop After the fuel relay output is de energised fuel relay output is energised for N O type fuel valve fail to stop delay timer begins when it time s out if controller detects generator s voltage exceeds crank cutout voltage or the speed exceeds crank cutout RPM or LOP switch is open or oil pressure exceeds crank cutout oil pressure then stop failure occurs If the fuel valve is N O type the fuel relay output is de energised after Stop delay has expired Under SP preALM Used to configure the under speed pre alarm value for the engine Under SP Alarm Used to configure the under speed alarm value for the engine Over SP preALM Used to configure the over speed pre alarm value for the engine Over SP Alarm Used to configure the over speed alarm value for the engine Oil P low preALM Used to configure the low oil pressure pre alarm for the engine The signal is derived form the LOP sensor this function would be inactive if do not use the LOP sensor This function is active after safety on delay ZINGS sik If this parameter is configured as not used the function would be inactive Oil P low Ala
53. nction all can be configured by user RL1 FUEL REALY 16A 30Vde RL2 CRANK RELAY 16A 30Vdc RELAY3 OUTPUT 3A 30Vdc RELAY4 OUTPUT 3A 30Vdc r Jana 7 a Fit RELAYS OUTPUT 3A 30Vde pu a RELAY6 OUTPUT 3A 30Vdc RELAY OUTPUT 3A 30Vdc COMMON SUPPLY V elsje e 8 BN s pay iE 6 po cn a BE a ad NOTE i Terminal 19 is the common port for RL1 to RL6 and it is connected to power positive The output current for each relay can not exceed the rated current of respective relay the total output current for 6 relays from RL1 to RL6 can not exceed 16A e A switch or fuse for over current protection must be mounted between power and terminal 19 the recommended capacity is 16A In practical application controller output will generate instantaneous peak current you must consider the peak current when choosing a switch or fuse for over current protection ZINGS sik 9 LCD displays and Menu System 9 1LCD displays measuring parameters Use a back light graphic LCD to display data and information Each page can display multi row information simultaneously the above 4 rows display measuring data the last row displays status information press D to scroll for viewing next page it can be configured as auto scroll as well When alarm occurs the alarm status is displayed on the LCD immediately When controller is configured to use LOP sensor and HET sensor but not conne
54. nnection for single pole sensor Variable raer oOo 1 14 Oil Pressure oo oaoa 15 Temp SS EEE 16 common Port Sensor Input sot en 18 Aux 2 ZINGS sik The connection for single pole 2 poles sensor Variable Resistor 14 Oil Pressure 15 Temp 16 Common Port Sensor Input 17 Aux 1 s 18 Aux 2 BO NOTE EE For ensuring the accuracy of sensor please reduce the cable resistance between controller and sensor as much as possible the cross section area of cable should not be less than 2 5mm2 When single pole sensor is used the terminal 16 must be directly connected to the generator s earth point but not to the control panel or other earth point It will impact the accuracy of sensor if the common port is connected to the power supply negative The sensor shell and engine must be well connected and do not use insulated material on sensor screw thread when installing single pole sensor I MIA BIME BALE TREE BALE NT TULA PG BM TIN TOO TITO TEL SINNE ae BT AA AIDE ABA AA TSE 36 SE KAGNET IC PICK UP The measuring accuracy of magnetic pick up is related to fly wheel teeth Accuracy 120 fly wheel teeth RPM As the above formula more fly wheel teeth leads to higher measuring accuracy Shield cable must be used for connection between controller and sensor and the shield should be earthed i Please play attention that the terminal 37 is connected to negative of the po
55. o configure the permit of external crank Refer to 4 8 for details ZINGS sik 7 4 Configurable Inputs and Outputs NO Items Preset Value Range 4 1 D Input 1 5 1 to 20 not used 4 2 D Input 2 6 1 to 20 not used 4 3 D Input 3 7 1 to 20 not used 4 4 D Input 4 9 1 to 20 not used 4 5 D Input 5 10 1 to 20 not used 4 6 D Input 6 11 1 to 20 not used 4 7 D Input 7 13 1 to 20 not used 4 8 D Input 1 delay 0 0 to 60s 4 9 D Input 2 delay 0 0 to 60s 4 10 D Input 3 delay 0 0 to 60s 4 11 D Input 4 delay 0 0 to 60s 4 12 D Input 5 delay 0 0 to 60s 4 13 D Input 6 delay 0 0 to 60s 4 14 D Input 7 delay 0 0 to 60s 4 15 A sensor 1 use 1 1 fuel level 2 temp 3 Oil P not used 4 16 A sensor 1 type 1 1 to 15 4 17 Fuel pump ON 20 0 to 100 4 18 Fuel pump OFF 70 0 to 100 fuel level 0 to 100 4 19 A sen1 under level not used eee ae Oil P 0 1 to 150 0 Bar PSI not used 4 20 A seni under act 0 0 pre alarm 1 alarm 2 control fuel level 0 to 100 4 21 A sen1 over level not used pah Ey s Oil P 0 1 to 150 0 Bar PSI not used 4 22 A seni over act 0 0 pre alarm 1 alarm 2 control 4 23 A sensor 2 use 1 1 preheat 2 temp 3 Oil P not used 4 24 A sensor 2 type 3 1 to 15 4 25 Pre heat ON 20 C 20 to 320 C F 4 26 Pre heat OFF 70 C 20 to 320 C F temp 20 to 320 C F 4 27 A sen2 under level not used Oil P 0 1 to 150
56. ote communication Optional CANbus read and control the parameters for ECU engine All connections of the controller by secure plug and socket for ease and convenience to connect move maintain and replace the device Optional ultra low temperature function the ambient temperature is from 40 C to 70 C Built in smart charger and auxiliary circuit protect and control the charging of accumulators effectively intelligent selection 12V 24V long run floating charge which stops automatically and begins charging by the charging device distribution in the genset when the genset starts The box of controller which accord with IEC standard production strictly adopting steel structure and plastic spraying surface is beautiful and durable All internal input and output cable terminals arranged in unison ZINGS sik 2 The Outline Dimension Drawings and Controller Wiring 2 1 Outline dimensions of the controller Wall mounted type Control Panel Board Enclosure Door Sheet ZINGS sik 2 2 Following Details Module Dimensions W192mmxH144mm Panel Cutout W174mmxH126mm Thickness D56m without connection 192 mm 144 om 66 mo 3 mu 124 mn 172 mn ZINGS sik 2 3Terminal Connections
57. pen relay should have been closed i you have selected idle function the idle relay will be closed at the same time as the crank relay is closed the idle timer will begin counting down after successful crank when it times out the idle relay opens other procedure is the same as above ZINGS sik NOTE Controller will not detect under voltage under frequency under speed and charge failure during idle period Repeat Crank During the crank period if the engine can not ignite and controller will not output start signal during crank rest Once crank rest timer times out the start relay energises once again and will attempt to start engine again The above procedure will be repeated until engine successfully ignites or reaches the preset number of crank attempt If any shutdown alarm occurs during crank controller will stop cranking immediately and the Genset only can be restarted after clearing the failure and reset Start Failure When the procedure above repeats again and again and reaches the preset number of crank attempt the crank relay output is then de energised The failure LED illuminates and the LCD Ha Fail to Start CAUTION If Fail to Start occurs operator must check the whole Genset system to find out failure reason only after clearing the failure can press STOP RESET button CAUTION to relieve fault lock out status and restart the Genset Generator shutdown sequence When remote start signal is inact
58. r sounds LCD displays ZINGS sik ENGINE HIGH TEMP if controller detects that engine coolant temperature has exceeded the Coolant Alarm or HET switch closes engine stops immediately the Shutdown alarm LED illuminates and buzzer sounds LCD displays OVER SPEED if controller detects that engine speed exceeds the Over SP Alarm engine stops immediately the Shutdown alarm LED illuminates and buzzer sounds LCD displays UNDER SPEED if controller detects that engine speed falls below the Under SP Alarm after the safety on timer has expired engine stops immediately the Shutdown alarm LED illuminates and buzzer sounds LCD displays OVER CURRENT configure Overcurrent action as shutdown after safety on delay times out if controller detects that any phase output current is higher than Overcurrent level the Genset will be shut down immediately the Shutdown alarm LED illuminates and buzzer sounds LCD displays OVER FREQ if controller detects that Genset s frequency exceeds the GEN Hz over Alarm after the safety on timer has expired Genset stops immediately the Shutdown alarm LED illuminates and buzzer sounds LCD displays UNDER FREQ if controller detects that Genset s frequency falls below the GEN Hz under Alarm after the safety on timer has expired Genset stops immediately the Shutdown alarm LED illuminates and buzzer sounds LCD displays GEN OVER VOLT After safe
59. rm Used to configure the under oil pressure alarm value for the engine The signal is derived form the LOP sensor this function would be inactive if do not use the LOP sensor This function is active after safety on delay If this parameter is configured as not used the function would be inactive Coolant preALM Used to configure the high engine temperature pre alarm value for the engine The signal is derived form the HET sensor this function would be inactive if do not use the HET sensor If this parameter is configured as not used the function would be inactive Coolant Alarm Used to configure the high engine temperature alarm value for the engine The signal is derived form the HETsensor this function would be inactive if do not use the HET sensor If this parameter is configured as not used the function would be inactive Batt Undervolt Used to configure the low battery voltage pre alarm If this parameter is configured as not used the function would be inactive Batt overvolt Used to configure the high battery voltage pre alarm If this parameter is configured as not used the function would be inactive ALT low preALM Used to configure the low charger voltage value Voltage signal is derived from the excitation winding of charger If this parameter is configured as not used the function would be inactive EX Crank permit Used t
60. sensor 1 falls below the under level value the Genset stops shutdown alarm LED illuminates and buzzer sounds LCD displays ALARM LOW OIL PRESSURE gt 2 control when the level of auxiliary sensor 1 falls below the under level value the relative configurable relay output would be energised A sen1 over level Used to configure the over level value for auxiliary sensor 1 ZINGS sik If this parameter is configured as not used the function would be inactive A sen1 over act Used to configure the response mode of controller when the level of auxiliary sensor 1 exceeds the over level value There are 3 modes 0 pre alarm warning 1 alarm 2 control gt O pre alarm when the level of auxiliary sensor 1 exceeds the over level value pre alarm LED illuminates and buzzer sounds LCD displays WARNING HIGH FUEL LEVEL or WARNING A sen 1 high temp gt 1 alarm when the level of auxiliary sensor 1 exceeds the over level value the Genset stops shutdown alarm LED illuminates and buzzer sounds LCD displays ALARM A sen 1 high temp gt 2 control when the level of auxiliary sensor 1 exceeds the over level value the relative configurable relay output would be energised A sensor 2 use Used to configure the purpose of auxiliary sensor 2 If this parameter is configured as not used the sensor and the relative function would be inactive A sensor 2 type Used to configure th
61. shock proof equipment must be mounted if the enclosure is mounted 8 2Wiring Please refer to the above 2 3 Typical Wiring Diagram for connection 8 2 1Grounding Protection Make sure the connection between terminal 40 of controller and protective earth is good the cross section area of cable should not be less than 2 5mm CAUTION A good ground is very important for operation of controller otherwise it will WARNING impact the electrical measurement and even damage the controller ZINGS sik 8 2 2Power supply Power specification DC voltage range 8 35Vdc continuous Max operating current 12V 310mA 24V 155mA OV for 80ms assuming dc supply was at least 10V before dropout and Cranking dropouts recovers to 5V controller can be normally operated dispenses with additional aux power POWER SUPPLY L 12 24 HU A switch or fuse for over current protection between power supply and controller must be mounted the recommended capacity is 1A O When powering the controller will generate significant instantaneous peak current the maximum instantaneous peak current is relative to the power impedance You must consider the peak current when choosing a switch or fuse for over current protection 8 2 3The installations of LOP sensor HET sensor and Auxiliary sensor The connection for 2 poles sensor variable resistor Oil Pressure Temp i Port Sensor Input Aux 1 Aux 2 The co
62. sor type 3 1 to 15 not used 3 8 P sensor type 4 1 to 15 not used 3 9 Start delay 10s 0 to 300s 3 10 Crank attempt 3 times 1 to 10 times 3 11 Crank time 5s 1 to 30s 3 12 Crank time add not used 1 to 30s not used 3 13 Crank rest 10s 1 to 300s 3 14 Crank cutout RPM 300RPM 1 to 9999 RPM 3 15 Crank cutout volt 85 1 to 100 not used ZINGS sik 3 16 Crank cutout ALT V not used 1 0 to 40 0V not used 3 17 Crank cutout Oil P 1 0Bar 0 1 to 150 0 Bar PSI not used 3 18 Cutout P delay not used 1 to 60s not used 3 19 ldle time not used 1 to 9999s not used 3 20 Pre heat mode 1 1to5 3 21 Pre heat time 3s 1 to 9999s not used 3 22 Safety on delay 10s 0 to 600s 3 23 Cool down mode 0 0 full speed 1 idle 3 24 Cool down time 300s 0 to 600s 3 25 Stop delay 20s 0 to 60s 3 26 Under SP preALM 1440RPM 1 to 9999 RPM not used 3 27 Under SP Alarm not used 1 to 9999 RPM notused 3 28 Over SP preALM 1600RPM 1 to 9999 RPM not used 3 29 Over SP Alarm 1710RPM 1 to 9999 RPM notused 3 30 Oil P low preALM 1 4Bar 0 1 to 150 0 Bar PSI not used 3 31 Oil P low Alarm 1 1Bar 0 1 to 150 0 Bar PSI not used 3 32 Coolant preALM 92 C 50 to 320 C F not used 3 33 Coolant Alarm 100 C 50 to 320 C F not used 3 34 Batt Undervolt 8 0V 1 0 to 40 0V not used 3 35 Batt overvolt 28 0V 1 0 to 40 0V not used 3 36 ALT low preALM 8 0V 1 0 to 40 0V not
63. tion is inactive also both being the condition of judging stop failure and can not implement crank process are inactive Idle time The duration of engine idle running When you choose the idle mode the configurable relay defined as idle output is energised idle timer begins after start successfully and the relay recovers to open after the idle time has expired When parameter is configured as not used idle function is inactive Pre heat mode Used to configure the mode of preheat There are 5 pre heat modes for selection please read the description of 4 7 preheat function for details Pre heat time The preheat duration before engine crank When parameter is configured as not used pre heat function is inactive ZINGS sik Safety on delay Used to configure the period from engine started successfully to Genset stable running The protection of under speed under voltage under frequency low oil pressure is disabled by the controller during safety on time delay AQ CAUTION 7 As some of the protection are disabled during safety on time delay so the safety on delay should be set carefully and properly this is very important or it BOB CAUTION ___ may cause engine 02 AP Cool down mode Used to configure the mode of cool down When parameter is configured as full speed the engine will run at rated speed during cooling down When parameter is configured as idle the engine will run i
64. tions GEN ON delay only can be started after Safety on The start motor will power off while cranking if there are one of the following conditions occur The generator s frequency reaches the preset value configurable cranking cutout value The AC engine speed reaches crank cutout value Generator s Voltage reaches the crank cutout value optional Charger voltage reaches crank cutout value optional Cutout P delay time s up optional Cranking time s up Controller can not implement crank procedure in one of following conditions The generator s frequency reaches the preset value configurable cranking cutout value The AC engine speed reaches crank cutout value Generator s Voltage reaches the crank cutout value optional LOP switch is opened or oil pressure is higher than crank cutout value optional CAUTION If magnetic pickup is not used to avoid damage to the start motor please make sure the generator s voltage is higher than the measurable value of controller while cranking since the crank cutout signal is sensed from the generator CAUTION voltage and frequency NOTE Above control procedure assumes that one of configurable inputs has been configured as Gen Aux Switch Closed and connects the switch s N O Aux contact signal to this port If you do not configure an input as Gen Aux Switch Closed then the GCB closed LED illuminates is only an indication that the GCB close o
65. to easily control the Genset read information and parameter setting Control buttons and LED Scroll Button Scroll menu for parameters display enter into or exit parameters setting by pressing and holding this button for 2sec MUTE Lamp Test Button When failure occurs alarm buzzer sounds Pressing mute button will mute the sound LCD displays mute icon Press it again will clean mute function buzzer continues to sound Press and hold this button for 2sec all LEDs illuminate simultaneously AUTO Mode Button LED Value Increase The push button is used for selecting auto mode When the controller is running in AUTO mode the LED above the button is illuminated The activation and deactivation of the remote start signal input controls the starting and stopping of the Genset When in parameters setting mode this button is used to increase value scroll down menu MAN Mode Button LED Value Decrease The push button is used for selecting manual mode When the controller is running in MANUAL mode the LED above the push button is illuminated The Start and Stop push buttons control the starting of the Genset When in parameters setting mode this button is used to decrease value scroll up menu TEST Mode Button LED Confirm Parameters Configure The push button is used for selecting test mode When controller is running in TEST mode the LED above the push button is illuminated
66. ty on delay times out If controller detects that any phase output voltage of generator is higher than GEN V over Alarm Genset stops the Shutdown alarm LED illuminates and buzzer sounds LCD displays GEN UNDER VOLT After safety on delay times out If controller detects that any phase output voltage of generator is lower than GEN V under Alarm Genset stops the Shutdown alarm LED illuminates and buzzer sounds LCD displays HIGH TEMP OVER SPEED UNDER SPEED OVER CURRENT OVER FREQ UNDER FREQ GEN OVER VOLT GEN UNDER VOLT ZINGS sik OVERLOAD After safety on delay times out if controller detects the active power is higher than KW Overload Alarm Genset stops the Shutdown alarm LED illuminates and KW OVERLOAD buzzer sounds LCD displays LOSS OF PICKUP if magnetic pick up is used when the controller detects no signal from magnetic pickup during safety on or idle period Genset stops the Shutdown alarm LOSS OF PICKUP LED illuminates and buzzer sounds LCD displays LOP SENSOR OPEN when controller detects that the resistance of LOP sensor exceeds the range of measurement it means LOP sensor open Genset stops the P SENSOR OPEN Shutdown alarm LED illuminates and buzzer sounds LCD displays ECU DATA FALL when using J1939 CAN bus if controller detects no data from the ECU Genset stops the Shutdown ECU DATA FAIL alarm LED illuminates and buzzer sounds L
67. w or generator only outputs voltage at a high speed when magnetic pick up is not used the Genset cannot be started successfully when it implements the build up cranking process of controller There are 2 methods to solve these conditions in the controller First method when controller is running in MANUAL mode normally the crank time will not exceed the pre set value but you can press START button and hold without changing the related parameters until it has started the crank time depends on the holding time on the button Safety on timer begins after it has successfully started The other processes and protections are the same as for a normal start Second method when controller is running in MANUAL mode configure the EX Crank permit as 1 shown as schematic below a PB switch is externally mounted to control cranking Close PB switch engine cranks when the speed reaches 150RPM or generator voltage output is not less than AC 20V if magnetic pick up is not used then controller functions are triggered the fuel relay output is energised safety on timer begins after the speed reaches crank cutout value the other processes and protections are the same as normal start If the speed falls below 150RPM within safety on time controller will be reset and return to standby status ZINGS iii CAUTION We normally don t recommend using the second method to solve this condition CxUTION Pay attention to the
68. wer supply inside the controller ZINGS sik 8 2 5Typical connection for voltage input and current that corresponding to difference generator winding 3P4W 3 phases 4 wires Measure and Display Data Y 3P4W 3 phases 4 wires star A 3P4W 3 phases 4 wires angle 3 phases VPh NLI NL2 N L3 N 3 phases VPh NLI NL2 N L3 N 3 phases VPh Ph L1 L2 L2 L3 L3 L1 3 phases VPh Ph L 1 L2 L2 L3 L3 L1 frequency Hz L1 3 phases current 11 12 13 frequency Hz L1 3 phases apparent power AL1 AL2 AL3 5A 3 phases current 11 12 13 3 phases active power PL1 PL2 PL3 JP active power 3 P 3 phases reactive power QL1 QL2 QL3 Q reactive power JQ 3 phases power factor PFL1 PFL2 PFL3 PF power factor PF active energy KWhr JE active energy KWhr JE reactive energy KVArhr 2 E reactive energy KVArhr JE ZINGS iii 3P3W 3 phases 3 wires Measure and Display Data 3 phases VPh Ph L1 L2 L2 L3 L3 L1 frequency Hz L1 3 phases current 11 12 13 Gen total apparent power 2A total active power ZP total reactive power 2Q average power factor PF active energy KWhr 2E reactive energy KVArhr ZE ZINGS sili 1P3W single phase 3 wires Measure and Display Data VPh N L1 N L2 N VPh Ph L1 L2 frequency Hz current 11 12 apparent power A active power P reactive power Q power factor PF active energy KWhr ZE reactive energy KVArhr 2E ZI

12 ZK6201 CONTROLLER USER`S MANUAL

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