Khenkikian Electronics Design & Construction

820B Genset Controller Manual

1. Summarization
820B genset controller adopts high performance microprocessor and industry components. It has measuring, controlling, protection, four remote controls, flexible software setting functions and high anti-jamming ability. Can display all the measuring parameters, control parameters and genset running state. Actually meets different types of generator, auto control requirements. When the mains supply is failure, the control system will automatically give a start signal to start the genset and resume the power supply in short time. After the mains supply is normal, the control system will unload and shut down automatically. Adding the monitoring function of mains supply electric quantity, applies to mains supply and genset supply automatic transfer power supply system.

2. Characteristics
Double processing chip, real virtual value measuring, action smartly; Mains and genset double power manager, Automatic Transfer Switch system; Wide-screen LCD display with back-light; Chinese and English double language menu, mutual operation, can be set and operated individually; Auto start, Auto protection, ATS control; Perfect auto protection, warning details and working statement character display directly, fault record more than 50 items; 7. Double coolant temp., double oil pressure, fuel level and oil temp. etc connected parameters and so on; 8. All relay contact capability is above 10A/250VAC/30VDC; 9. Electronic speed adjustment and mechanical speed adjustment control compatible, timing start or stop and etc. custom setting; 10. RS232 communication, attached four remote controls monitor software. 1. 2. 3. 4. 5. 6.

3. Fix up dimension drawing

Operate panel Install hole Depth W 213 X H 153mm W 199 X H 139mm D 52mm

4. Function define and operate instruction

4.1Operate panel function instruction Operate panel is composed of 128X64 LCD display, operation keys and state indicator light and system menu operate press keys. (1). System menu operate press keys Content Function Parameter setting /enter to next menu / confirm to revise ENT Exit / back to the superior menu Exit Switch the screen display content, view all the measuring parameters of the genset and the current state; Page up the menu / add value Switch the display content; examine all the genset parameters and the current state. menu page down/degree value (2). LCD display Genset runs in normalnot setting state or not fault state) Operation Description Normal P 00.0 HZ Main screen 1 A :000 V Press or can switch B :000 V the display interface C :000 V Generator 00.0 HZ Main screen 2 A :000 V 0000 A Press or can switch B :000 V 0000 A the display interface C :000 V 0000 A Rotate speed: 0000 RPM Main screen 3
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Press or can switch the display interface Main screen 4 Press or can switch the display interface

Main screen 5 Press or can switch 08-06-03/09:12:15 the display interface Attention: If display change mode set in auto switch state, the LCD display screen will switch to next page after each 10 seconds; if background light control set in auto state, the LCD screen background light will be auto turn off after three minutes without any operate. Once the fault appears or presses any key the background light turns on. If Background light control setting as constant light, the LCD background light will keep lighting.

Power: 0000.0 KW Power factor: 0.00 Run Time: 00000.0 H Coolant temp.: 010/010 (0) Oil pressure: 999/999 KPa (0) Oil temp.: 010 (0) Battery: 25.0 V Stop/OFF status

(3). Operation keys Content Function Press the key, when the above green LED keep bright, the controller is in start state, start the genset in manual and keep running. Press the key, when the above yellow LED keep bright, the controller is work in auto state, once the Remote start switch input turn off and mains get right, the genset will be stopped after delay. When Remote start switch input turn on the genset delay start otherwise its delay cool down; If the genset reset by remote reset, once the remote reset switch input turn off, the controller is in auto state. Press the key, when the above red LED keep bright, the controller is work in stop/reset state, it will unload, decelerate and idle stop, through idle stop cut off the fuel. During decelerate and idle the reset indicator keep flash, keep light after stop. Press the key, when the above red LED keep bright, the controller works in testing state. Start the generator in manual, when the generator runs in normal, whatever the mains supply is normal or not. The controller will automatically close, onload and keep running onloading.

(4). State indicator light Content Function Indicate the genset failure, protected stop, fault content display in the LCD screen. Indicate the genset warning information, alarm detail see screen. Indicate remote start port state, use in monitor the main state generally.

4.2Connection port define Port Function No. Power supply 836V DC, normal working current <300 mA 1 battery anode input 2 battery cathode input Analog inputinput voltage range 05.0V DC 3 Analog AGNDinside connect with battery cathode. 4 Oil temp./fuel level input 5 Oil pressure input 1 6 Coolant temp. input 1 7 Oil pressure input 2 8 Coolant temp. input 2 9 User-defined sensor Main three phase voltage input (0-300VACinsulation inside) 10 Mains voltage phase R 11 Mains voltage phase S 12 Mains voltage phase T 13 Mains zero line N Three phase load current input 0-5A AC, without inside isolation must add current transformer 1415 A phase load current 1617 B phase load current 1819 C phase load current Three phase genset voltage input0-300V AC, voltage transformer with inside isolation 20 U phase genset voltage 21 V phase genset voltage 22 W phase genset voltage 23 Zero line N Relay output port(Relay insulated, contact capability 10A/250VAC/30VDC) 24 Emergency supply (Genset supply) 25 26 Normal supply (Mains supply) 27 Electronic governor Mechanical speed control 28 Idle NC (normal closed) Battery negative 29 Idle NO (normal open) Battery positive 30 Not connected DC speed adjust motor negative pole 31 Idle common DC speed adjust motor positive pole 32 Pre-fuel 33 Common port 2(Pre-fuel and fault common contact port) 34 Fault 35 Fuel (stop when ETS) 36 Common port 1(Fuel and Crank common contact port) 37 Crank Switch input portadd photo electricity insulationvalid when connect to GND Electronic governor Mechanical speed control

38 39 40 41 42 43 44 45 46 47

Not connected Not connected High oil temp./low fuel level Low oil pressure High coolant temp. Remote reset Remote start Emergency stop Rotate speed signal input GND, inside connect with battery cathode

DECelerate limited ACCelerate limited

5. Parameter setting
All parameters can be read and written, through communication port, details see communication protocol. Except coolant temp., oil press., oil temp./ fuel level sensor option input sensor curve data adjust, all the parameters can be setting by the controller. Enter to parameter setting interface Switch Inputs status Alarm limit set Relay Outputs status Measure regulate Press ENT Shutdown Record Delay time set Date and time set System set Press or Select the examine /setting parameter content (reversed display when selected) Press ENT Enter to the selected menu Press Exit Exit the parameter setting state Attention: If didnt press any keys over three minutes it will auto exit the parameter setting state, to avoid illegimate operation the controller. 5.1Parameter setting instruction Real time display controller input port state Remote run: 0 Emergency stop: 0 Remote off: 0 High coolant temp.: 0 Switch Inputs status Acceleration limit: 0 Low oil pressure: 0 Deceleration limit: 0 High oil temp/Low fuel level.: 0 Attention: Press any menu key will be exit Real time display controller output port state Crank: 0 Fuel: 0 Relay Outputs Shutdown : 0 Pre-fuel: 0 status Normal: 1 Genset: 0 Acceleration: 0 Deceleration: 0 Attention: Press any menu key will be exit Shutdown record 01/04 (Fault serial number/ Fault total number) Emergency Stop (Fault reason) Shutdown 08-06-03/11:26:38 (Fault time) Record Attention: Press , , display up and down fault record; Press ENT or Exit will be exit. Press , to change the reverse display data. Press Exit reverse display move to the left, move to the first position then press Exit then back to the superior menu, date Date and time and time will not changed; Press ENT reverse display move to the right, move to the set last position press ENT then back to the superior menu, date and time have been changed.

Alarm limit set

Measure regulate

Default setting: High Voltage: 0250 High oil temp. : 0100 High acceleration: 1550 Low Voltage: 0200 Low battery: 0105 Low deceleration: 0800 High current: 0450 High frequency: 0530 High Coolant temp. : 0096 Low frequency: 0470 Low oil pressure: 0050 High speed: 1650 Press , choose content and the content reversed display. Press Exit back to superior menu. Press ENT enter choosing parameter setting state, the selected parameter is underline, enter the parameter setting state. press , to change the reversed display data. Press Exit move to the end of left, press Exit and back to the superior menu, parameter will not be changed. Press ENT reversed display move to the end of right, press ENT and back to the superior menu, parameter changed and saved. Password: 8421(default password of the factory) Current A: 0000 Normal A: 0000 Current B: 0000 Normal B: 0000 Current C: 0000 Normal C: 0000 Generator A: 0000 Coolant temp. : ----Generator B: 0000 Oil pressure: ----Generator C: 0000 Oil temp./Fuel level: ----Battery voltage:0120 Attention: Coolant temp. , oil pressure and oil temp. /fuel level adjusting value is relevant to the real measuring error. Password authentication input method Press , Exit when the selected content move to the end press Exit and back to the superior menu; Press ENT move to the end of right, enter the password press ENT then get through the next menu. Users according the error value of the controller measuring data and the real data to decide whether you need to data adjust. The controller already adjusted before leave factory, but it may be some warp in the use environment, if the warp is in the error range, we suggest not adjusting the data, especially the three phases current. If the error over too much and need to adjust, please read the < 820B Genset controller adjustment instruction>. Press choose content reversed display, press Exit and back to superior menu; Press ENT enter to choose data adjustment state, and the adjusting parameter underline. Enter to data adjusting state, press to change the data, press Exit cursor turn left, when move to the end, press Exit then back to the superior menu, data adjustment in validPress ENT cursor turn right, move to the fourth position press ENT back to the superior menu ,data adjustment achieved, parameter change saved. For three phase voltage, three phase current and battery voltage adjustment, enter data adjust state, change the data then press ENT (Current keep two decimal fraction, battery voltage keep one decimal).Coolant temp.. Oil pressure, oil temp., fuel level option input are different, 820B controller provide coolant temp. adjust, oil pressure adjust, oil temp./fuel level adjust to adjust the measuring data. For the possible error of the coolant temp. ,oil pressure, oil temp./fuel level, 820B provide 10 adjusting rangeSpecial explain, for coolant temp. , oil pressure ,oil temp./fuel level sensors maybe positive modulus (it means the sensor output added along with input added), it maybe negative modulus (it means the sensor output minish along with input added), add or minish adjust value lead to adjust effect decide by the real situation.

Password input: 8421default Cool stop(down): 020 Idle(stop): 015 Transform: 002 Genset start : 005 Acc. time: 020 Over current: 003 Crank INTerval: 015 Low oil pressure: 003 Over voltage: 003 Crank time: 008 High coolant temp.: 005 Over frequency: 003 Bypass time: 025 Over speed: 002 Warm up: 010 ETS fuel: 030 High oil temp./low fuel level : 005 Dec. time: 030 Pre-fuel: 006 Loss speed: 030 Delay time set Idle (start): 010 Low battery : 020 Press choose content reversed display Press Exit back to superior menu; Press ENT , enter to choose parameter setting state, the adjusting parameter is underline. Enter the setting state, press to change data, press Exit cursor turn left, move to the end press Exit back to the superior menu, data will not be changed, if press ENT parameter change saved. Delay time up limit cannot be over 255 seconds, if setting over 255 seconds system will change to 255 seconds automatically. Input password: 8421 (default) Trip speed: 0400 Speed source: 0 Oil/Fuel select: 1 CT ratio: 0500 Load mode: 0 Phase/Line: 0 Passport: 8421 Coolant source: 0 Display mode: 0 Address: 120 Oil pressure source: 003 Language C/E: 1 Crank limit: 003 Oil temp. source: 0 LCD mode:1 System set Gear tooth number: 135 Oil temp. action: 0 Opt.2 set: 003 Battery action:1 Press choose content, press Exit back to superior menu, press ENT, enter the setting state, the adjusting parameter is underline. Press change data, press Exit data will not be saved, press ENT can be saved the data, and then back to the superior menu. 5.2System parameter setting When start the genset, if examine the genset rotate speed >trip speed, it considers the Trip speed genset start successful and stop the crank output (trip speed generally setting to 1/3 of genset normal working rotate speed ) CT rate setting correspond ratio is 5, for example the current rate setting in 500, its CT ratio correspond with 500:5 Passport Leave factory password 8421please change the password on your own. Address Only uses for multi equipment network to differentiate between the equipments. When Genset starts, if the continuums start failure time over the parameter, it will lead Crank limit to over crank fault. Gear tooth number Opt.2 set Speed source Load mode Coolant source Oil pressure source Only valid in rotate speed measuring method setting in speed sensor Setting coolant temp. 2 and oil pressure 2 0: None coolant temp. 2 and oil pressure 2 1: Only have coolant temp. 2 2: Only have oil pressure 2 3: Have coolant temp. 2 and oil pressure 2 0 : From Genset power supply frequency 1 : From Speed sensor 0 : Keep 1 : Pulse(cut off after closed 2 seconds) 0: Coolant temp. alarm switch 0 : Oil pressure alarm switch 1 : Coolant temp. sensor 1 : Oil pressure sensor

0 : Alarm and stop 1 : Alarm but not stop Configure with oil temp./fuel level input Oil/Fuel select 0 : Define fuel level 1 : Define oil temp. Phase/Line 0 : Measuring phase voltage 1: Measuring line voltage Display mode 0 : Switch in manual 1 : Auto switch 0 : Chinese 1: English Language C/E Shortcut method module power off press at the same time and afresh electrify until the language changed. LCD mode 0 : Auto 1 : Constant light 5.3Delay time instruction Delay of cool When the controller is in Auto state, once the Remote start switches input turn off stop(down) and mains get right, the genset will be stopped after delay. Delay of When the controller is in Auto state, once the Remote start switch input turn on or genset start mains failure, the genset will be started after delay. Delay of When the genset start and begin to delay, if the start succeed condition is satisfied cranking (genset rotate speed>trip speed) it is consider to be genset start successful and stop time delay. Delay of When the cranking time delay ended, if the start succeeds condition is not satisfie and Crank not reaches, the crank times limit, the delay will be repeated and crank times added 1. INTerval After the gen-set start successfully, that begins to start delay of the bypass. The term of Delay of delay, not monitor "low oil pressure", "high coolant temperature" etc, to avoid mistake bypass time alarm when gen-set in start early. ETS setting in 0, controller work as Energize to run (ETR),the fuel supply will have output until stop; ETS fuel delay setting in is not in 0, the controller work as Delay of energize to stop (ETS), the fuel supply act as stop. The fuel supply's relay also have ETS fuel output when the delay start, the fuel supply relay stop output when delay ended and the oil pressure be lowed. Before the gen-set to start, that begins the delay of pre-fuel. At the same time, the relay Delay of of pre-fuel to closed. After the delay is over, the relay of pre-fuel to open, the gen-set pre-fuel start to crank. Delay of idle After the gen-set start successfully, the delay of idle (start) is begin, in the term of (start) delay, the relay of idle begin to work. Delay of idle When stopping machine, the delay of idle (stop) begins. In the term for delay, the relay (stop) of idle begins to work. Genset start successful and idle (start) over, it is beginning ACC delay, ACC relay Delay of closed, if the delay ended but still not get the ACC in the right position signal, it will ACC be a ACC failure alarm. When genset running, if the pressure of oil is over low, the delay is begin. In the term Delay of low of delay, if the oil pressure comeback normal state, the delay will be interrupt. After oil pressure the delay is over, if the oil pressure is over low yet, that will appear the alarm of low oil pressure. Delay of high coolant It is similar to the delay of low oil pressure alarm. temp.

Oil temp. source Oil temp. action Battery action

0 : Oil temp/fuel level alarm switch 0 : Alarm and stop

1: Oil temp/fuel level input sensor 1 : Alarm but not stop

Delay of over speed Delay of high oil temp./low fuel level Delay of loss speed Delay of low battery Delay transform Delay of over current Delay of over voltage Delay of over frequency Delay of Dec.time Delay of warm up Failure

Start when the genset rotate speed is over the upper limited. If the speed of gen-set comeback in normal state, the delay will be interrupt. If the speed still over limit when delay ended, It will be a over speed alarm. Similar to the delay of low oil pressure If not detect the speed signal in the term of starting or running, the delay of lose speed is begin. If no yet detect the speed signal, when the delay is over, that will appear the alarm of lose speed. Similar to the delay of low oil pressure alarm. When the normal supply comeback normal state, after gen-set on load it is action. The normal supply must be stable for a period, until the delay retransform is over that switch to normal supply on load. It is similar to the delay of low oil pressure alarm. Similar to the delay of low oil pressure alarm. Similar to the delay of low oil pressure alarm. Delay of Dec start when the genset stop, Deceleration relay closed, if the delay ended but still not get the Dec in the right position signal, it will be a Dec failure alarm. Happenned during the time when the gen-set starting successfully. To extend the time of power supply swiching to genset on load. Power supply until the gen-set reach to optimal state if not emergency, and availably reduce the abrasion. Describtion Solution Press the ENT keythe Check whether the greenlight is broken,if the LED light green light isnt bright on isnt broken,please contact with the factory;If the LED the aboved and the motor light is broken,please see below solution. doesnt work. Check the menu oflow oil pressurein the input port state,if display 0,please check whether the oil pressure Press the ENT keythe sensor is ok;if display 1,the oil pressure sensor is ok,now green light is bright on please press START ,measuring the module port 34 start the above and the motor whether theres 24V with a multimeter,if the voltage is 24V,check whether the outside middle relay,start moter is doesnt work. broken,and whether the battery voltage is enough;If port 34 no output,the module might be damaged. Module in Auto state, inspection remote start Check the menu of remote start in the input state, if the remote start display 0 means that the outside timer etc have input, the remote module relay is broken cause did not receive the input start state light isnt signal; If display 1, the module might be broken. bright and the motor doesnt work. Module in Auto state, Check the oil pressure sensor; Switch to the manual start, inspection remote start check whether there are output signal of the port 34has input, the remote remote start, the outside components and the battery start state light is bright voltage.

6. Normal failure and handling method

Manual start failure

Auto start failure

on and the motor doesnt work. Wheel tooth is Start successful and Lower down the trip speed; fighting when motor keep running, the Suggest used speed sensor to get the rotate speed. start wheel tooth is fighting. On load current Current ratio setting is Reset the current ratio. displays incorrect. incorrect.

1. Outside wire connection drawing

820B outside wire connection drawing (Mechanical speed control)

820B controller outside wire connection drawing (Electronic governor)

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8. Front and back panel diagram

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