Operation Manual 210 Eng
Operation Manual 210 Eng
Operation Manual 210 Eng
210
Operation Manual
Ver1.0
Note
DANGER
Danger is used to indicate the presence of a hazard that will cause severe
personal injury, death, or substantial property damage if the warning is
ignored.
WARNING
Warning is used to indicate the presence of a hazard that can cause severe
personal injury, death, or substantial property damage if the warning is
ignored.
CAUTION
Caution is used to indicate the presence of a hazard that will or can minor
personal injury or property damage if the warning is ignored.
NOTE
Note is used to notify people of installation, operation, or maintenance
information that is important but not hazard-related.
WARNING
CAUTION
All parameter are pre-adjusted to their typical values. But all the set points
must be adjusted correctly before the first startup of the Generator set.
Wrong adjustment of set points can destroy the Generator set!
I
Introduction
The 210 is a single diesel generator set controller. It is able to realize the automatic
start and stop, self-protection and etc.
Note* indicate this function depend on the set points of the controller in field.
II
Section 1.Feature
Front Panel
The front panel of 210 includes alarm indicators, status indicators, keypad and LCD
display. See figure 1-1 for LED, Key and Display location.
The information of program version of the controller, product code, and self-test will
be displayed at power up, and then you can press the Display key to enter the
keypad and led test screen.
Alarm Indicators
There are four red LEDs for alarm indicators on the front panel, as follow:
Over speed led
LED illuminates when engine speed exceeds the Overspeed
threshold after delay setting (max delay are 3s).
Coolant temperature high led
LED illuminates when coolant temperature approaches the threshold,
or the sensor channel is shorted or opened after delay setting. The
alarm can be shutdown by Redit2000 software in sensor configuration..
Oil pressure led
Led illuminates when oil pressure approaches the threshold, or the
sensor channel is shorted or opened after delay setting. The alarm can
be shutdown by Redit2000 software in sensor configuration.
Battery led
LED illuminates if battery voltage drops below the Batt<V setting or
rises above the Batt.>V setting after delay setting.
1
Status Indicators
There are four red/green dual color LEDs for status indicators, as follow:
START key LED
Green LED illuminates when generator set is starting or running
LED off when the generator set stopped
STOP key LED
Red LED illuminates when the generator set stopped
LED off when the generator set is starting or running
DISP key LED
Green LED illuminates when the displays are at static display mode
(page displayed at static for 300 seconds) or at contrast adjustment
menu.
LED is off when the displays are at scroll display mode (displays
scrolling a page per 2 seconds).
RESET key LED
Red LED illuminates when the Alarm List is not blank (there are
activated alarms in the list. Inverted alarms are still active, non-inverted
alarms are not active, but not yet reset.)
LED is off when the Alarm List is blank (there are no alarms in the list.)
Keypad
There are four key buttons on the front panel, as follow:
START key
Reset the Horn Output and Alarm List at MANUAL mode and
AUTO mode. Exit the set point edit save or without save. With DISP key
switch operation menu.
2
LCD Display
210 are equipped with a powerful backlight graphic display, showing icon, symbols
and bar-graphs for intuitive operation, setting parameter. The contrast of LCD can be
adjusted easily.
Rear Panel
The rear panel of 210 include all the terminals which are Power Supply, Binary
Inputs, Analog Inputs, Speed Sensor Inputs, Generator Voltage Inputs, Current CT
Input Open Collector Outputs, Relay Output and communication extension
interface. See figure 1-2 for terminals location.
3
Power Supply
The normal voltage range is from 8VDC to 36VDC. The controller will be damaged if
the voltage exceeds 43VDC.
CAUTION
Poor battery connection will damage the controller when generator set is running.
Binary Inputs
The function of five binary inputs of 210 (signed as BI1-BI5) can be separately
defined by Redit2000 software. The user can choose the definition from the
following:
Emergence Stop Manual/Auto Mode
Remote Off Selection
Oil Pressure Switch Mode Locked
Coolant Temperature Remote Start/Stop
Switch Reserve 1
Body Temperature Switch Reserve 2
Fuel Level Switch Speed Down Feedback
Belt Switch Oil Temperature Switch
Coolant Level Switch Not Defined
Analog Inputs
Three analog inputs WAT.T, OIL.P, FUEL.L are available on the 210 controller. They
can be connected with resistor sensor. Each analog input can be configured by
Redit2000 software.
4
Relay Outputs
START relay closed energizes the starter motor. The relay opens if:
The startup RPM is reached or
Any phase voltage of the generator exceeds 15V or
Oil Pressure exceeds CrankOilPre set point or
Request to stop comes up
When Fuel Solenoid is defined as FUEL, the relay closes to open the fuel
solenoid and enable the engine start. The relay opens if:
Emergency stop comes or
The generator set is stopped or
The generator set is in Pause state
When Fuel Solenoid is defined as STOP, the closed relay energized stop
solenoid to stop the engine. The relay opens again if engine speed is lower than
30rpm or the delay from the relay closed is over 25 seconds.
AC Voltage Inputs
Generator voltage terminals are available on the 210.
Notes:
The input AC voltage on terminals should not be exceed 290V
Current CT Inputs
Each line of three-phase current terminal is available on the module.
5
Section 2 Operation
Operating Checklist
WARNING
Menu Operating
The menu of General Display and Parameter Setting can be displayed on the screen
of the controller. After power up, the General Display screen displays the default
General Display page. Press RESET key following DISP key (DISP key + RESET
key) to exchange the menu between General Display and Parameter Setting.
Operation Mode
Three operation mode MAINTENANCE mode, MANUAL mode and AUTO are
available on the 210 controller.
If a binary input is defined as Mode Locked is activated, the operation mode will be
locked that also can not be changed.
MAINTENANCE mode
The controller is at MAINTENANCE mode when the operation menu
switch to Parameter Setting menu by press RESET key following DISP
key ( DISP key + RESET key) .
MANUAL mode
6
AUTO mode
General Display
The General Display includes five screens. Use the DISP key to page down the
display.
Operation Mode, Generator set State, Engine Speed, Apparent Power and
Real Time Clock
See figure 2-1 for illustration of the value display.
See Appendix A for the states of generator set.
The Engine Speed Meter display the speed pick up value if the Gear Teeth set
point is not zero, otherwise the display value is generator frequency multiplied by 30.
Figure 2-1
The name, unit and dot of three analog inputs can be configured by Redit2000
software separately.
7
Figure 2-2
Figure 2-3
Act Power, Power Factor, Running Hours, Number of Starts, Binary Inputs,
Open Collector Outputs and Relay Outputs
See figure 2-4 for illustration of the value display.
The value of Active Power and Power Factor is available when the generator set
loaded.
The Running Hours and the Number of Starts begin to count when engine speed
reaches the Startup RPM set point.
With Binary Inputs, the state is marked with 0 if the function is activated, otherwise
is marked with 1. The active polarity can be configured by Redit2000 software.
With Open Collector Outputs and Relay Outputs, the state is marked with 0 if the
function is activated, other wise is marked with 1. The activated polarity of Open
Collector Outputs can be configurable by Redit2000 software.
Note: If the power factor and the active power are displayed with wrong value, try
change the order of the generator voltage terminals or current CT terminals to
correct.
8
Figure 2-4
Alarm List
See figure 2-5 for illustration of the Alarm List display.
Four out of a maximum of sixteen alarms will be seen in one screen by active time
sort. Press RESET key at MANUAL mode or AUTO mode accepts all alarms, and
non-active alarms immediately disappear from the list. Active Alarm List appears on
the screen when a new alarm comes up and General Display screen is active.
Figure 2-5
Set Points
The 210 controller supports parameter configuration on the front panel at
MAINTENANCE mode. Using DISP key to select the set point to be changed or
press and hold on DISP key to page down the screen.
All the set points are protected by password. You can enter right password to unlock
the protection. The status of protection is displayed at the top-right corner of the
screen. The parameter will be re-locked again if no parameter saved in five minutes
or exiting MAINTENANCE mode. The default password is 0, and can be changed.
9
See figure 2-8, for illustration of the Set Points display.
To set a parameter:
At first the password has to be set as following:
Activate the Set Points screen
Use DISP key Select Password set point, press RESET key to enter
editing status
Press DISP key to adjust it to the correct value
Press and hold on RESET key until the protection unlocked
2-8
You can set Nomin Power as follow:
Select Nomin Power set point, press RESET key to enter editing
status, see figure 2-9
Press the DISP key to adjust the set point to the desired value
Press and hold on RESET key to save the value and exit editing
You can speed up the adjustment by press and hold on DISP key. Press
RESET key to exit editing without saving.
Figure 2-9
All Set Points defined in the screen of 210 as follow:
Password: Password is a maximum four-digit number. Password
disabled adjustment of selected set points.
Range: 09999
ChangePassword: Change the password to new value.
Range: 09999
10
Range: 13000 kW
Nomin Curr: The nominal current of the alternator
Range: 15000 A
Gear Teeth: The number of teeth on the engine gear for the pick-up.
Set to zero, if no pick-up is used, and the engine speed is counted from
the generator frequency.
Range: 0500
CrankOilPre: The oil pressure which the START relay opened to stop
cranking
Range: 010bar
CT Ratio: The generator current transformer ratio
Range: 15000 A/5A
Fuel Solenoid: Selecting fuel or stop solenoid at FUEL relay output in
stopping operation
FUEL: The relay closes when generator sets starts, opens when
generator set stops
STOP: The relay close when generator set stops, opens when
RPM<30 or stop time >25s
MaxCrank Time: The maximum time limit of cranking
Range: 160 s
Startup RPM: a little higher than the minimum stable speed. The
START relay opened to stop cranking
Range: 1-50 % of nominal speed
Idle Time: The generator set runs at lower speed than nominal speed
before MaxStab state for warming up the engine
Range: 03600 s
Batt >V: The threshold for high power supply voltage warning
Range: Batt <V36 V
Batt <V: The threshold for low power supply voltage warning
Range: 8VBatt >V
Gen >f: The ratio of maximum generator over frequency to the nominal
frequency. Choose the maximum value out of three phases
Range: 100150 % of nominal frequency
Gen <f: The ratio of minimum generator under frequency to the nominal
frequency. Choose the minimum value out of three phases
Range: 50100 % of nominal frequency
MinStab Time: Delay for Generator set Running output is activated after
MaxStab state
Range: 0300 s
11
PM Hours: Next Running Hours for preventive maintenance. When
RunHours exceeding the hours, a pm hours arrival alarm is activated.
Set to zero if you want to leave the alarm activated
Range: 032767 h
AI1 Sensor Type:
AI2 Sensor Type:
AI3 Sensor Type:
NOTE
The sensor chart supports maximum 10 characteristic. When you set less
than 10 characteristic, the resistor value must be set to -1 of next point after
last valid one to terminate the chart.
Contrast Adjustment
Press and hold on the DISP key until the screen enter the contrast adjustment
screen, you can adjust the best display contrast by press the DISP key, press the
RESET key to save and exit contrast adjustment page.
Language Selection
T210 support language selection between Chinese and English. Press and hold on
the DISP key on power up until the current language displayed inverted at the
top-left corner.
Starting
MANUAL mode
When the state of generator set display is Ready, press START key to
start the generator set, and then the screen displays PreStart. The
generator set begins the start procedure.
AUTO mode
If the Remote Start/Stop input is activated, the 210 controller will start
the generator set.
CAUTION
The all protection function will not work if the generator set was started not
by the controller.
12
Stopping
MANUAL mode
Press STOP key will stop the running generator set.
AUTO mode
When the Remote Start/Stop input is de-activated, the running generator
set will stop after the cooling delay elapsed.
Emergence Stop
When Emergence Stop input is activated, the controller will shuts down
the generator set in emergency situation and alarm raises in Alarm List.
Protection Stop
At MANUAL mode and AUTO mode, any shutdown protection alarm
raises in Alarm List, the 210 controller will shut down the generator set.
WARNING
The running generator set will be shut down, when operation mode worked
at MAINTENANCE mode.
CAUTION
Make sure the load is not present at generator before generator set starts.
13
Section 3 Specifications
Power Source
8V-36V DC
Consumption: 0.1A-0.4Aat 24V
Environment
Storage temperature-30~+80
Operating temperature-20~+70
Humidity90%RH Max at 40
Dimensions
Width: 200mm
Height: 100mm
Depth: 4 7mm
Weight
1.0kg
Generator Related
Nominal frequency50-60Hz
Frequency measurement tolerance0.1Hz
Max. measured voltage:
290V (phase to neutral)
400V(phase to phase)
Voltage measurement tolerance2%220V
Rated input current (from CT)5A
Current measurement tolerance2%5A
Binary Inputs
Input resistance: 4.7k
Low voltage level for active indication0-2V
High voltage level for de-active indication8-36V
Relay Outputs
Max. current
10A resistive load
14
3A inductive load
Max. switching voltage36V
Analog Inputs
Resolution: 10bits
Sensor resistor range: 0-2.4k
Speed Sensor Inputs
Type of Sensor: Magnetic pick-up
Min. Input Voltage: 2Vpk-pk(4Hz to 4kHz)
Max. Input Voltage: 50V
Frequency measurement rang: 4Hz-10kHz
15
Section 4 General Troubleshooting
This section contains generator sets troubleshooting, diagnostic information.
Use the following chart to diagnose and correct common problems. The chart
includes a list of common problems, possible causes of the problem, recommended
corrective actions. If the procedures in this manual do not explain how to correct the
problem, record all the set points in field reference to Appendix C and contact an
authorized distributor/dealer.
Does not enter MANUAL Remote Off input is activated Release the input
or AUTO mode
Self-test error on power up Contact dealer
Prepare-fail stop alarm The oil pressure is above the Check the oil pressure
arise in starting CrankOilPre set point when sensor correlation
procedure starting
The W.T. display The resistor of sensor Adjust the sensor chart
OPEN or SHRT, outranges the sensor chart
generator set Not Ready
The input is opened or Check the sensor input
in clod weather
shorted connections
16
Frequency display ****, Load harmonics affected Improve load feature;
but engine speed is Mask frequency
normal protection by setting
Gen >f and Gen <f
set points to 100
17
Appendix A. Generator set States Table
Idle Waiting for generator sets to warm up, Over SPD, MaxStab, Fail
Idle Output is activated Stop
MaxStab Generator sets waiting to get proper Under SPD, Over SPD, AVR
voltage level after reaching of defined Fail, MinStab
level of RPM
MinStab Generator sets waiting for loaded after Running, Over SPD, Fail
got proper voltage level Stop, RPM Fail, Under SPD
Fail Stop Generator sets stop by alarm of failure Not Ready, Ready
Cooling Generator sets is cooling before stop Not Ready, Ready, Fail Stop,
Running
18
Appendix B. Alarm Event
Event Description
Stopping sequence activated when unsuccessful Generator
fail-stop stop
sets Stop happening
o.p. sen. Pre_alm Oil pressure sensor pre-alarm under O.P. Lev1 set point)
o.p. sen alm Oil pressure sensor alarm(under O.P. Lev2 set point)
f.l. sen. Pre-alm Fuel level sensor pre-alarm(under F.L. Lev1 set point)
f.l. sen. alm Fuel level sensor alarm(under F.L. Lev2 set point)
active power over Generator active power over Curr Over set point
19
under-speed stop Generator set under speed stop
20
Appendix C. User Defined Settings
Program version of the controller
Serial Number
Below is all the set points for T210.
User
Default
Set Points Range Setting Defined
Setting
Setting
Nomin Power (kW) 13000 100
Nomin Volt (V) 80300 230
Nomin Curr (A) 15000 200
Nomin Freq (Hz) 4565 50
Nomin RPM (r/min) 100-4000 1500
Gear Teeth 0500 0
CT Ratio (/5A) 15000 200
Fuel Solenoid Fuel/Stop Fuel
PreStart Time (s) 0-600 0
Idle Time (s) 03600 0
Crank Attempts 110 3
CrankOilPre (bar) 0-10 3
Start Delay (s) 0600 5
Startup RPM (%) 150% of Nominal RPM 25
MaxCrank Time (s) 160 10
CrankFail Pause (s) 560 30
MinStab Time (s) 0-300 0
MaxStab Time (s) 0300 60
Cooling Time (s) 03600 180
PM Hours (h) 0-32767 0
Underspeed (%) 0-100 90
UnderspeedDel 0-600 10
Overspeed (%) 100-150% of Nominal RPM 110
OverspeedDel (s) 0-3 3
Protection Del (s) 0300 15
Horn Timeout (s) 0600 60
Batt >V (V) 836 31
Batt <V (V) 8Batt >V 20
Batt V Delay (s) 0600 60
W.T. Lev1 () 09999 95
W.T. Lev2 () 09999 100
W.T. Del (s) 0180 10
O.P. Lev1 (Bar) 0999.9 2.0
O.P. Lev2 (Bar) 0999.9 1.5
O.P. Del (s) 0180 10
F.L. Lev1 (%) 0100 20
F.L. Lev2 (%) 0100 10
21
F.L. Del (s) 0180 30
100300% of Nominal
Curr Over (%) 105
current
Curr Over Dels 0.0600.0 30
100500% of Nominal
Curr Short (%) 150
current
Curr Short Del (s) 0.0600.0 1
Curr Unbal (%) 1100% of Nominal current 45
Current Unbal Del (s) 0.0600.0 30
100150% of Nominal
Gen >V (%) 120
Voltage
50100% of Nominal
Gen <V (%) 80
Voltage
Gen V Del (s) 0.0600.0 10
100150% of Nominal
Gen >f (%) 110
Frequency
50100% of Nominal
Gen <f (%) 90
Frequency
Gen f Del (s) 0.0600.0 8
(Gen)Volt Unbal (%) 1150% 25
(Gen)Volt Unbal Del (s) 0.0600.0 5
Password 09999 0
GName --
Language Chinese/English Chinese
Below is Analog Inputs, Binary Inputs and Open Collect Outputs setting
Channel User Defined Notes
Default Setting
Name Setting
Name: W.T.
Unit:
AI1
Type: VDO
Alarm Action: Masked
Name: O.P.
Unit: Bar
AI2
Type: VDO
Alarm Action: Masked
Name: F.L.
Unit: %
AI3
Type: Not Defined
Alarm Action: Masked
Name: Emergence Stop
BI1 Polarity: Open to active
Alarm Action: ---
Name: Remote Start/Stop
BI2 Polarity: Close to active
Alarm Action: ---
22
Name: Oil pressure switch
BI3 Polarity: Close to active
Alarm Action: Unload
Shutdown
Name: Coolant temperature
switch
BI4 Polarity: Close to active
Alarm Action: Cool down
Name: Mode Input 0
BI5 Polarity: Close to active
Alarm Action: ---
Name: Alarm Horn Output
BO1
Polarity: Close to active
Name: Running Output
BO2
Polarity: Close to active
Name: Idle Control Output
BO3
Polarity: Open to active
23