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KPD100 Controller Operation Manual

R

WUXI KIPOR POWER

1

O

Model KPD100

2

AUTO

www.kipor.com Version No.：KPD100.1.1.3

CONTENT CONTENT............................................................................................................................................................... BRIEF INTRODUCTION.................................................................................................................................... 1 CONTROLLER OUTLINE AND WIRING TERMINAL..................................................................................1 1. CONTROLLER OUTLINE..............................................................................................................................1 2. BACK OUTLINE AND OVERALL DIMENSION（UNIT:MM）................................................................ 2 3. WIRING TERMINAL OF CONTROLLER.................................................................................................... 3 OPERATION.........................................................................................................................................................4 1. MANUAL MODE.............................................................................................................................................. 4 2. AUTO MODE....................................................................................................................................................5 3 SWITCH LOAD MANUALLY........................................................................................................................5 4. SKIP DELAY.....................................................................................................................................................6 5. OPERATION SEQUENCE FIGURE............................................................................................................ 6 PROTECTION...................................................................................................................................................... 7 1. ALARMING INFORMATION.......................................................................................................................... 8 2. SHUT DOWN INFORMATION...................................................................................................................... 9 3.TROUBLESHOOTING.................................................................................................................................. 10 4. STATUS INDICATOR FOR POWER GRID AND GENERATOR.......................................................... 10 PARAMETER SETTING.................................................................................................................................. 10 REMOTE START/ANALOG POWER GRID................................................................................................ 14 REMOTE START SETTING AND GENSET STATUS................................................................................14 REMOTE MONITORIN.....................................................................................................................................15 1. MONITORING SOFTWARE........................................................................................................................15 2. COMMUNICATION ADDRESS...................................................................................................................16 RS232 COMMUNICATION..............................................................................................................................17 1. PHYSICAL LAYER FOR COMMUNICATION PROTOCOL...................................................................17 2. ASYNCHRONOUS SERIAL COMMUNICATION.................................................................................... 18 3. CODE TABLE................................................................................................................................................ 18 APPENDIX 1.CRC16-CCITT DATA SHEET................................................................................................ 19 APPENDIX 2.CRC16-CCITT CODE GENERATION METHOD............................................................... 20 APPENDIX 3. OPERATION DATA................................................................................................................ 21 APPENDIX 4. WIRING.....................................................................................................................................22 1. 3-PHASE 4-LINE...........................................................................................................................................22 2. 3-PHASE 3-LINE...........................................................................................................................................23 3. 1-PHASE 2-LINE...........................................................................................................................................23

-I-

- II -

KPD100 Controller Operation Manual

Brief Introduction: KPD100 controller can monitor the power grid. When power grid is abnormal, genset can be started automatically and supply power to the load. When power grid is restored, it will be transfered to grid supply automatically. KPD100 controller can monitor the power grid and indicate power grid status by iuminous diode. Features: 1：Control and protection： Realize genset manual or auto start, shut down, ATS switch and alarming protection. 2：12V/24VDC power supply; 3：Manual and auto working modes for selection; 4：AMFpower grid failure self-start/shut down; 5：Root-mean-square voltage of generator and power grid can be inspected; 6：ATS manual/ auto mode; 7：Self-maintenance function with interval setting available; 8：luminous diode failure display; 9：Engine underspeed/overspeed protection 10：Configurable input/output terminal and status indicating function; 11：Battery voltage checking and battery cahrging inspection; 12：Working time counting function 13：RS232 communication. PC can realize parameter setting and monitoring.

Controller outline and wiring terminal 1. Controller outline Front ：

R

WUXI KIPOR POWER

Power grid abnormal Power grid normal Red：Abnormal Green：Normal

ATS/load power supply indicator lamp Left: Power grid Right: Genset

1

O

Model KPD100

2

Fault, system parameter display

Genset normal Genset abnormal Red：abnormal Green:normal

AUTO

Auto mode Indicator lamp

Control panel alarming symbol description: —— Low oil pressure

—— High water temperature

-1-

—— Low fuel level

KPD100 Controller Operation Manual

—— Over speed of engine

——Under speed of engine

—— Battery charging failure !1—— Configurable input 1 alarming

—— Genset start failure !2—— Configurable input 2 alarming

Functions of buttons: During genset running, press Stop／Parameter decreasing Key

In alarming status, press

to stop the genset, to reset.

In ”Parameter setting” mode, press the key to decrease value. Manual start/Parameter increasing key Auto/Parameter plus key

Manual/Paramete r saving key

In “manual mode”, press

can start the genset.

In ”Parameter setting” mode, press the key to increase value. Press

to set the genset in Auto Mode.

In “System Setting mode” , press this key to increase the data value, equal to “+” In “Auto” mode, press

to set the genset in manual mode.

In manual mode, press this key to switch load between power supplies. In “System Setting mode”, press this key to save the data, equal to “OK”.

Note: ¾ After the controller is powered, ¾

Work mode will set to be “Manual Mode

¾

“Power grid voltage abnormal indicator” will be lit if there is no input of MAINS or power grid is in abnormal situation. If the default setting of ATS is “Power grid power supply”, “Switch on terminal of power grid 34,35”is closed, “Indicator for power grid with load” will be illuminated.

¾

” automatically

2. Back outline and overall dimension（Unit:mm）

-2-

KPD100 Controller Operation Manual

3. Wiring terminal of controller Terminal code

Function

Remark

1

Not be used

2

Aux_Input2

Auxiliary input2 ※1

3

Aux_Input1

Auxiliary input1 ※1

4

Remote Start

Remote start input

5

Fuel Level

Switch input of fuel level

6

Engine Temp

Switch input of cooling temperature

7

Oil Press

Switch input of oil pressure

8

Not be used

9

CHANGE IN

Input end of charging failure

10

AUX1_NC

Auxiliary output 2 normally closed contact

11

AUX1

12

AUX1_NO

Auxiliary output 2normally open contact

13

CRANK_NC

Normally closed contact for starting relay output

14

CRANK_COM

Public end for starting relay output

15

CRANK_NO

Normally open contact for starting relay output

16

FUEL_NC

Normally closed contact for fuel relay output

17

FUEL_COM

Public end for fuel relay output

18

FUEL_NO

Normally open contact for fuel relay output

19

GND

DC working power negative pole：B-

20

VCC

DC working power positive pole：B+

21

COMM_TXD

RS232 communication

22

COMM_RXD

23

COMM_GND

24

COMM_VCC

25

AUX2_NC

Normally closed contact for Auxiliary output 1

26

AUX2_COM

Public end for Auxiliary output 1 ※2

27

AUX2_NO

Normally open contact for Auxiliary output 1

_COM

28

Auxiliary output 2 public end ※2

DC12/24V

Not be used

29

GENSET_NC

Normally closed contact for genset switch on output

30

GENSET_COM

Public end for genset switch on output

31

GENSET_NO

Normally open contact for genset switch on output

32

Not be used

33

MAINS_NC

Normally closed contact for power grid switch on output

34

MAINS_COM

Public end for power grid switch on output

35

MAINS_NO

Normally open contact for power grid switch on output

36 37

Not be used GEN_VOL_N

38 39

Not be used GEN_VOL_A

40 41 42

N-phase input for genset A-phase monitoring input for genset Not be used

MAINS_VOL_N

N-phase input for power grid Not be used -3-

KPD100 Controller Operation Manual 43

MAINS_VOL_C

44

C-phase monitoring input for power grid Not be used

45

MAINS_VOL_B

46

B-phase monitoring input for power grid Not be used

47

MAINS_VOL_A

A-phase monitoring input for power grid

※ 1：Refer to “input configuration” for details ※ 2： Refer to “output configuration” for details

Operation There are two kinds of working modes for controller: Manual mode and auto mode. In manual mode, press the button on the front panel of the controller to start the genset, shut down the genset and switch the power supply for loads. In auto mode, controller will monitor the power grid. When power grid is in abnormal situation, genset will be started automatically and genset will supply power to the loads. When power grid returns to normal, load supply will be switched to mains supply.

1. Manual mode (1) Get into manual mode Manual mode can be access by the following methods: (1) The system will get into manual mode once controller is powered; (2) When in auto mode,press

“Manual” key to enter manual mode.

(3) When in auto mode, press

“Stop” key to enter manual mode.

(4) Set the button on the back of panel from parameter configuration to running status, system can get into manual mode. (2) Operate the genset manually Press

“Manual start” key to start the genset manually and system will get into manual mode:

If preheat output option of auxiliary output is selected, start the preheat hour meter and enable the auxiliary output signal effective. Engine will be started after the preheat delay is terminated.The maximum starting time for starting motor is 10 seconds. Perform a second try after 10 seconds if the first start is failed. If the genset cannot be started in three times, starting fails and related indicator will be lit. Engine is started successfully when 20Hz AC current is detected or the effective time of oil pressure signal reaches rated value(configurable). And starting motor is tripped. Safety delay countdown (12 seconds) starts after successful engine start. During safety delay, low oil pressure, high water temperature, under speed and battery charging failure is permissable. Warm-up timer starts once genset voltage and frequency is normal. Ensure the stability of engine performance before connected with load. Genset will run without load after warm-up delay. If main power supply is abnormal or remote start -4-

KPD100 Controller Operation Manual signal is effective and it is configured as remoter start with load, load will be switched to genset. The genset will continue to run with load regardless of power supply and remote start signal input status until auto mode is selected. If auto mode is selected at present, power supply is in normal situation and remote start signal is invalid, load will be switched to power grid and cooling shut-down delay starts. Cooling and shut down will be followed. Press

“Stop” key to shut down the engine.

2. Auto mode Press

“Auto” key to enter auto mode and related indicator lamp is lit.

In auto mode, genset cannot be started by pressing

key.

Genset start delay timer will be started to prevent momentary failure of power grid supply or false remote start signal. Genset will be started after the delay. If preheat output option of auxiliary output is selected, start the preheat hour meter and enable the auxiliary output signal effective. Engine will be started after the preheat delay is terminated.The maximum starting time for starting motor is 10 seconds. Perform a second try after 10 seconds if the first start is failed. If the genset cannot be started in three times, starting fails and related indicator will be lit. Engine is started successfully when 20Hz AC current is detected or the effective time of oil pressure signal reaches rated value(configurable). And starting motor is tripped. Safety delay countdown (12 seconds) starts after successful engine start. During safety delay, low oil pressure, high water temperature, under speed and battery charging failure is permissable. Warm-up timer starts once genset voltage and frequency is normal. Ensure the stability of engine performance before connected with load. Genset will run without load after warm-up delay. If main power supply is abnormal or remote start signal is effective and it is configured as remoter start with load, load will be switched to genset. If power grid supply is restored, power grid return delay starts. Load will be transfered to the grid after the delay. Then cooling delay will start to ensure the engine cooling before shut down. If power supply is abnormal (or remote starting signal is effective) during the engine cooling, load will be transfered to genset immediately.

3. Switch load manually Controller can swith loads manually. In manual mode, press In auto mode, press will be off. Press

“Manual” key to switch load power supply manually. “Manual” key to enter manual working mode. Indicator lamp of auto mode

“Manual” key at this moment to switch load manually.

-5-

KPD100 Controller Operation Manual

4. Skip d`elay In suto mode, press

“Auto” key or input of skip delay is effective, the following delays can be

skipped： 1．Genset start delay 2．Power grid return delay 3．Genset warm-up delay Corresponding actions can be performed direcly if the above delays are skipped. This function cannot cover other delays.

5. Operation sequence figure

Note: Description of delays： Starting delay ------ When the failure or remote start signal sent by power grid is effective, “genset start delay” countdown starts. If the power gird is normal and remote start signal is invalid during the countdown, the countdown will be reset. Genset will be started when countdown terminates as well as controller is in auto mode. This delay can prevent power grid transient fluctutation and misstart caused by false remote start signal. Preheat delay ------ If “Preheat delay” of configurable output 1 & 2 is selceted, this output is effective when genset is started and controller will start “Preheat delay” countdown. Safety delay ------ During safety delay (12 seconds), protective function for low oil pressure, high water temperature, under speed and battery charging failure does not work. Warm-up delay ------ When genset is started successfully and parameters are normal, controller will start “genset warm-up delay” countdown. If genset paramters are abnormal or shut down failure occurs during the this period, countdown will be reset.Genset can be availabe after the countdown. In auto mode, when power grid is abnormal or remote start with load is effective(remote start signal is valid and remote start with load is configured),load will be switched to genset power supply. This delay ensure the genset with load after stable operation. Return delay ------ To prevent momentary recovery of power grid. Cooling delay ------ In auto mode, load is transfered from genset power supply to power grid supply, -6-

KPD100 Controller Operation Manual controller will start “genset cooling shut down delay” countdown. If power gird is abnormal or remote start with load is effective during this period, the countdown will be reset. Load will be switched to genset supply. Genset will be stopped after the countdown. This delay enable the genset to stop after the cooling. Power grid return delay ------ Controller will start “power grid return delay” countdown. If power grid fails during this period, the countdown will be reset. Power gird will be restored after the countdwn. When in auto mode, remote start with load is invalid(remote start signal is invalid or system is configured as remote start without load), load will be transfered to power grid supply. Shut down output delay ------

If “Shut down output” of configurable output 1 & 2 is selceted, this

output will be effective when the engine shut down. When the delay is terminated or genset is resarted, this output is invalid. Power switch delay ------ Main contactor of transfer switch responses promptly which enbale the attenuation of voltage produced by the inductive load before connected with power supply. Starting oil pressure delay ----- If low oil pressure signal is invalid during the genset start, controller will start “successful start oil pressure delay” countdown. If low oil pressure signal is effecitive during the countdown, the countdown will be reset.If 20Hz AC current is detected during the countdown, genset is started successfully and countdown will be reset. Countdown will be terminated after successful start. 2. Delay time setting depends on the actual situation.

Protection R

WUXI KIPOR POWER

1

O

Model KPD100

2

AUTO

Controller has protective functions to prevent genset against damage, when genst is in abnormal situations: ¾ Controller can send alarming information, related LED indicator lamp is illuminated or twinkles. ¾

When ATS is in “Auto mode

”, it can be switched to “Manual mode

-7-

” automatically.

KPD100 Controller Operation Manual ¾

ATS power supply is switched to “power grid power supply” automatically.

¾

When it sends “alarming” information, alarming LED indicator lamp is illuminated.

¾

When it sends “Shut down” information, alarming LED indicator lamp twinkles.

1. Alarming information Alarming fault: warning but do not shut-down. Related red luminous diode is illuminated. Warning items: Over/under voltage of battery voltage Charging failure of battery Low fuel level Under voltage(Configured as warning alarm) Over voltage(Configured as warning alarm) Under frequency(Configured as warning alarm) Configurable input 1 (Configured as warning alarm) Configurable input 2(Configured as warning alarm) ¾

Over/under voltage of battery voltage

● If battery voltage is detected too low, battery will be discharged and the battery LED fault indicator lamp

is illuminated.

● If battery voltage is detected too high, battery will be charged and battery LED fault indicator lamp is illuminated. ¾

Charging failure of battery

When battery voltage is lower than charging failure voltage and discharge current is higher than 2A, or when charging failure switch signal is detected, battery failure LED indicator lamp ¾

Low fuel level When “Low fuel level” signal is detected, low fuel level LED indicator lamp

¾

is illuminated.

is illuminated.

Under frequency When “Low frequency” is detected, under frequency LED indicator lamp

is illuminated.

Note: Configurable parameter 22# (Shut down due to under speed)is set as “No”. ¾

Over voltage When high voltage is detected, generator abnormal indicator lamp (red) is illuminated.

¾

Under voltage When low voltage is detected, generator abnormal indicator lamp (red) is illuminated.

Configurable parameter 24# (Shut down due to over voltage),23#(Shut down due to under voltage)is set as “No”. ¾

Configurable input 1,2 alarming When warning alarming is configured, if the inspection value of auxiliary input interface exceeds the setting value, configurable input indicator lamp (!1or !2)is lit -8-

KPD100 Controller Operation Manual

2. Shut down information Genset will be shut down in case of shut down failures. Meanwhile failures will be saved and locked automatically. Related luminous diode flashes. Shut down items: Starting failure Low oil pressure High water temperature Under voltage(configured as shut down alarming) Over voltage(configured as shut down alarming) Under frequency(configured as shut down alarming) Over frequency Configurable input 1(configured as shut down alarming) Configurable input 2 (configured as shut down alarming) ¾

Starting failure

If the engine cannot be started in specified period, starting failure LED indicator

flashed and

genset will be stopped. ¾

Low oil pressure

If low oil pressure signal is deteced after 12s safety delay, low oil pressure LED indicator flashes and genset will be shut down. If low oil pressure signal is detected during 12s safety delay, low oil pressure LED indicator

is lit,

genset will not be stopped. Genset will be shut down immediately after delay. ¾

High water temperature

If high water temperature signal is deteced after safety delay, high water temperature LED indicator flashes and genset will be shut down. If high water temperature signal is detected during 12s safety delay, high water temperature LED indicator ¾

is lit, genset will not be stopped. Genset will be shut down immediately after delay.

Over voltage

If genset voltage is detected too high, genset abnormal indicator(red) will be lit and genset will be shut down. ¾

Under voltage

If genset voltage is detected too low, genset abnormal indicator(red) will be lit and genset will be shut down. Note: Configurable parameter 24#(shut down due to over voltage),23#(shut down due to under voltage) is set as “YES” ¾

Under frequency

If engine frequency is detected too low, under frequency LED indicator shut down. -9-

flashes, genset will be

KPD100 Controller Operation Manual Note: Configurable parameter 22#(shut down due to under speed) is set as “YES”. ¾

Over frequency

If genset frequency is detected too high beyond or within safety delay, over frequency LED indicator flashes, genset will be shut down. ¾

Configurable input 1,2 alarming

When shut down alarming is configured, if the inspection value of configurable input interface 1 or 2 exceeds the setting value, configurable input indicator lamp (!1or !2) flashes, and genset will be shut down.

3. Troubleshooting Relevant LED indicator lamp will be on if generator is faulty. Press

to shut down the generator when in abnormal situation.

Engine will be stopped if failures occur. If alarming indicator lamp is lit or flashes,press

key to

elimnate the failure indication and controller will be in standby.

4. Status indicator for power grid and generator If the voltage(or frequency) of power grid (or generator)is detected too high or too low, the power grid (genset) abnormal indicator lamp (red) on the panel is illuminated. The lamp is green in normal situation.

Parameter setting Set the switch behind the controller to the “setting” position to enter system parameter setting.

- 10 -

KPD100 Controller Operation Manual After entering system setting mode, auto mode indicator lamp on the front panel twinkles, and luminous diode indicates the values. See the below figure:

R

WUXI KIPOR POWER

Model KPD100

Code 1

2

Parameter

O

Press

[Parameter decrease] and

[Parameter + ] to set values. Press

AUTO

[Parameter increase] key to switch data, press [Save] to save the data. Parameter table

Ref.

1

Parameter

Alternator winding

Parameter code

○○○○○

2

Rated frequency

○○○○●

3

Rated voltage sheet

○○○●○

4

Rated voltage

Remark (Bold fonts are

Value code

regarded as default value )

○○○

Three phase four line system

○○●

Three phase three line system

○●○

single phase two line system

○○○

50Hz

○○●

60Hz

○○○

Sheet 1 ↓

○○●

○○○●●

- 11 -

Sheet 2 ↓

○○○

100V

230V

○○●

110V

240V

○●○

115V

255V

○●●

120V

277V

●○○

127V

277V

●○●

133V

277V

●●○

139V

277V

●●●

220V

277V

KPD100 Controller Operation Manual

Power gird voltage is low(%rated 5

voltage)(Trip

○○●○○

value/returned value)

Power gird voltage is 6

high(%rated

○○●○●

voltage)(Returned value/trip value)

Genset

voltage

is

low(%rated 7

voltage)(Trip

○○●●○

value/returned value)

Genset 8

voltage

is

high(%rated voltage)(Returned

○○●●●

value/trip value)

Genset

start

delay(Prevent misstart caused by 9

power

grid

○●○○○

momentary fluctuation )

- 12 -

○○○

95%

/ 90%

○○●

95%

/ 85%

○●○

95%

/ 80%

○●●

95%

/ 70%

●○○

90%

/ 90%

●○●

90%

/ 85%

●●○

90%

/ 80%

●●●

90%

/ 70%

○○○

105%

/

110%

○○●

105%

/

115%

○●○

105%

/

120%

○●●

105%

/

130%

●○○

110% /

110%

●○●

110% /

115%

●●○

110% /

120%

●●●

110% /

130%

○○○

95%

/ 90%

○○●

95%

/ 85%

○●○

95%

/ 80%

○●●

95%

/ 70%

●○○

90%

/ 90%

●○●

90%

/ 85%

●●○

90%

/ 80%

●●●

90%

/ 70%

○○○

105%

/

110%

○○●

105%

/

115%

○●○

105%

/

120%

○●●

105%

/

130%

●○○

110% /

110%

●○●

110% /

115%

●●○

110% /

120%

●●●

110% /

130%

○○○

0s

○○●

1s

○●○

3s

○●●

5s

●○○

3h

●○●

4h

●●○

6h

●●●

8h

KPD100 Controller Operation Manual ○○○

0s

○○●

5s

○●○

10s

○●●

15s

●○○

20s

●○●

30s

●●○

60s

●●●

180s

○○○

0s

○○●

1s

○●○

2s

○●●

3s

●○○

4s

●○●

5s

●●○

6s

●●●

8s

○○○

0s

warm-up

○○●

1s

delay( Ensure the

○●○

2s

○●●

3s

●○○

5s

●○●

30s

●●○

120s

●●●

300s

○○○

0m

○○●

0.1m(For testing)

○●○

2m

○●●

5m

●○○

10m

●○●

15m

●●○

25m

●●●

30m

○○○

0s

○○●

5s

○●○

10s

○●●

15s

●○○

20s

●○●

30s

●●○

60s

●●●

180s

Normal

delay

power 10

for grid

return(prevent temporary

○●○○● power

grid recovery)

Genset 11

preheat

delay

(If

“Preheat

delay”

is

effective

when

○●○●○

selected,

delay starting motor)

Genset

12

genset can connect with load after stable

○●○●●

running)

Genset 13

delay(Shut

cooling down

○●●○○

after cooling delay)

Shut

down

delay(“shut 14

output down

output” is effective

○●●○●

when selected, it is invalid after delay)

- 13 -

KPD100 Controller Operation Manual

15

Power switch delay

○○○

0s

(Control

main

○○●

1s

contact of transfer

○●○

2s

○●●

3s

●○○

4s

inductive load before

●○●

5s

connected

●●○

8s

●●●

10s

○○○

12V

○○●

24V

○○○

9V

the

○○●

10V

genset run normally,

○●○

12V

○●●

14V

●○○

22V

setting

●○●

24V

value, then it will be

●●○

26V

charge alarm)

●●●

28V

○○○

Normal open

○○●

Normal close

○○○

Normal close

○○●

Normal open

○○○

Normal open

○○●

Normal close

○○○

Reserved

○○●

0s

○●○

0.2s

○●●

0.5s

●○○

0.8s

●○●

1.0s

●●○

1.5s

●●●

2.0s

○○○

No

○○●

Yes

○○○

No

○○●

Yes

○○○

No

○○●

Yes

○○○

Reserved

○○●

Remote start normal open

switch,reduce

the

voltage produced by

○●●●○

with

power supply.) 16

Battery voltage

○●●●●

Charge voltage(when

17

if the detect value of charge lower

voltage than

is

●○○○○

18

Low pressure

●○○○●

19

High water temp.

●○○●○

20

Low fuel level

●○○●●

21

Delay

time

for

starting oil pressure

●○●○○

22

Low speed stop run

●○●○●

23

Low voltage stop run

●○●●○

24 25

Over voltage stop run Remote function

start

●○●●● ●●○○○

- 14 -

KPD100 Controller Operation Manual

26

27

28

29

30

31

Remote on-load

Input 1

Input 2

Output 1

Output 2

Communication address

start

●●○○●

●●○●○

●●○●●

●●●●○

●●●○●

●●●●○

- 15 -

○●○

Remote start normal close

○●●

Mains start normal open

●○○

Mains start normal close

○○○

No

○○●

Yes

○○○

Immediately alarm open

○○●

Immediately alarm close

○●○

Immediately stop open

○●●

Immediately stop close

●○○

Delay alarm open

●○●

Delay alarm close

●●○

Delay stop open

●●●

Delay stop close

○○○

Immediately alarm open

○○●

Immediately alarm close

○●○

Immediately stop open

○●●

Immediately stop close

●○○

Delay alarm open

●○●

Delay alarm close

●●○

Delay stop open

●●●

Delay stop close

○○○

Reserved

○○●

Preheat

○●○

Genset run

○●●

System warn alarm

●○○

System stop alarm

●○●

System alarm

●●○

System automatic mode

●●●

Stop output

○○○

Ats Invain

○○●

Preheat

○●○

Genset run

○●●

System warn alarm

●○○

System stop alarm

●○●

System alarm

●●○

System automatic mode

●●●

Stop output

○○○

0

○○●

1

○●○

2

KPD100 Controller Operation Manual

32

Maintenance interval

●●●●●

○●●

3

●○○

4

●○●

5

●●○

6

●●●

7

○○○

Reserved

○○●

One week

○●○

Two weeks

○●●

Three weeks

●○○

Four weeks

●○●

Five weeks

●●○

Six weeks

●●●

Seven weeks

Remote start/Analog power grid Remote start setting and genset status Parameter

Remote start(remote start with load is set unavailable)

Setting value

Mains status

Remote Mains start is supply is normally normal open

Genset start for terminal 4 high potential

Load switch

Genset start for terminal 4 low potential

Load switch

OFF Genset cannot start

No ON Genset start power supply for power grid

No power supply for power grid

Mains outage

ON Genset start

Yes Genset power supply

Yes Genset power supply

Remote Mains start is normal normally close

ON Genset start

No OFF power Genset cannot start supply for power grid

No power supply for power grid

Mains outage

ON Genset start

Yes Genset power supply

Yes Genset power supply

Analog Mains normal power grid is normally open

OFF Genset start

No OFF power Genset cannot start supply for power grid

- 16 -

ON Genset start

ON Genset start

No power supply for power grid

KPD100 Controller Operation Manual

Parameter

Setting value

Mains status

Genset start for terminal 4 high potential

Load switch

Genset start for terminal 4 low potential

Load switch

Analog Mains Remote outage start(remote power start with grid is load is set normally unavailable) open

ON Genset start

Yes Genset power supply

OFF Genset cannot start

No power supply for power grid

Analog Mains normal power grid is normally close Mains outage

OFF Genset start

No OFF power Genset cannot start supply for power grid

No power supply for power grid

OFF Genset start

No ON power Genset start supply for power grid

Yes

Remote Remote start(remote start is start with normally load is set open available)

Mains supply is normal

OFF Genset cannot start

No ON ower Genset start supply for power grid

Yes Genset power supply

Mains outage

ON Genset start

Yes Genset power supply

ON Genset start

Yes

ON Genset start

Yes Genset power supply

OFF Genset cannot start

No power supply for power grid

Mains outage

ON Genset start

Yes Genset power supply

ON Genset start

Yes Genset power supply

Mains supply is normal

OFF Genset cannot start

No OFF power Genset cannot start supply for power grid

No power supply for power grid

Mains outage

ON Genset start

Yes Genset power supply

No power supply for power grid

OFF Genset cannot start

No OFF power Genset cannot start supply for power grid

Remote Mains start is supply is normally normal close

Analog power grid is normally open

Genset power supply

Analog Mains power supply is grid is normal normally

- 17 -

Genset power supply

OFF Genset cannot start

No power supply for power grid

KPD100 Controller Operation Manual close

Mains outage

OFF Genset cannot start

ON No Genset start power supply for power grid

Yes Genset power supply

Remote monitoring KPD100 controller can be equipped with three-remote function to meet various needs: PC is connected with KPD100 controller via RS232 communication cable to realize three-remote function with the help of “KPD100 software”.: 100％ Remote configuration,including running and fault status. 100％ Remote measure the data, including all the measured data. 100％ Remote control, covering all the control function for the control panel.

1. Monitoring software PC communication software “KPD100 software” can realize the following functions: Remote start/shut down Remote monitor Remote configurable parameters, including user’s parameters and system parameters(for administer authority). Remote monitoring software can be classified into “Administer” and “Operator” according to the authorities. “Administer” is used for the setting before delivery. Users can click the “OK” button on the initial interface of software directly to get into “User interface” without password. Refer to “KPD100 software operation manual” for detailed information.

2. Communication address Communication connection can only be available when “RS232 address” in the “KPD100 software” is the same with “RS232 communication address” of the KPD100 controller. (1) Default setting of KPD100 controller is “0”; (2) The setting for “RS232 address” in “KPD100 software”: Local setting - communication setting - communication port KPD100 Software drawing:

- 18 -

KPD100 Controller Operation Manual

COM address on PC

RS232 Communication The communication protocol applies for the serial communication between PC and controller RS232. PC and controller use the communication protocol in accordance with industrial control standard as well as main and slave machine mode. Main machine(PC) make a request and slave machine (controller) reply a message frame to perform data communication. Data frame

Frame header+address+code+data length+data+code+frame tail

Data length(Byte)

4

1

1

1

N

2

4

KPD100 controller can select communication software for upper computer and realize the following function by RS232 interface: Remote start/shut down Remote monitoring Remote configuration for user’s parameters and system parameters. Connection drawing for RS232 cable:

- 19 -

KPD100 Controller Operation Manual

1.Physical layer for communication protocol Communication physical link Communication interface Communication mode

EIA/TIA-232-E Asynchronous serial communication

Communication baud rate Odd-even check Start bit Data bits Stop bits Communication overtime

9600bps None 1 8 1 200ms

Bit1 Start bits

Bit2 D0

Bit3 D1

Bit4 D2

Bit5 D3

- 20 -

Bit6 D4

Bit7 D5

Bit8 D6

Bit9 D7

Bit10 Stop bits

KPD100 Controller Operation Manual

2. Asynchronous serial communication Serial communication protocol Data frame Frame header Communication address Code Data length Data Data verification

Frame tail

Data description 0xFA,0xA5,0xA 5,0xFA 1Byte

Data sequence

Low byte is in the front

1Byte 1Byte NByte

Low byte is in the front Low byte is in the front Low byte is in the front

2Byte/CRC16-C CITT verification 0xF5,0x5A,0x5 A,0xF5

High byte is in the front

Remark

Refer to code table for detailed code information, data length, data information. Refer to ATS operation manual for detailed algorithm

3. Code table Code Command code for main machine 0 1 2 3

Function

Data length

Shut down Manual mode Auto mode Configurable system parameters

4 Read system parameters 5 Write in current time 6 Read current time 7 Write in maintenance time 8 Read maintenance time 9 Read system running information Command code for slave machine - 21 -

Data

0 0 0 30 Refer to parameter configuration for details 0 6 Year month day hour minute second 0 4 Maintenance interval, day of week, hour, minute 0 0

KPD100 Controller Operation Manual

0 1 2 3

Shut down Manual mode Auto mode Configurable system parameters 4 Read system parameters 5 Write in current time 6 Read current time 7 Write in maintenance time 8 Read maintenance time 9 Read system running information

10 Module is in setting mode

the

Appendix 1.CRC16-CCITT Data sheet unsigned int CRC16CCITT[]= { 0x0000, 0x1021, 0x2042, 0x3063, 0x4084, 0x50a5, 0x60c6, 0x70e7, 0x8108, 0x9129, 0xa14a, 0xb16b, 0xc18c, 0xd1ad, 0xe1ce, 0xf1ef, 0x1231, 0x0210, 0x3273, 0x2252, 0x52b5, 0x4294, 0x72f7, 0x62d6, 0x9339, 0x8318, 0xb37b, 0xa35a, 0xd3bd, 0xc39c, 0xf3ff, 0xe3de, 0x2462, 0x3443, 0x0420, 0x1401, 0x64e6, 0x74c7, 0x44a4, 0x5485, 0xa56a, 0xb54b, 0x8528, 0x9509, 0xe5ee, 0xf5cf, 0xc5ac, 0xd58d, 0x3653, 0x2672, 0x1611, 0x0630, 0x76d7, 0x66f6, 0x5695, 0x46b4, 0xb75b, 0xa77a, 0x9719, 0x8738, 0xf7df, 0xe7fe, 0xd79d, 0xc7bc, 0x48c4, 0x58e5, 0x6886, 0x78a7, 0x0840, 0x1861, 0x2802, 0x3823, 0xc9cc, 0xd9ed, 0xe98e, 0xf9af, 0x8948, 0x9969, 0xa90a, 0xb92b, 0x5af5, 0x4ad4, 0x7ab7, 0x6a96, 0x1a71, 0x0a50, 0x3a33, 0x2a12, 0xdbfd, 0xcbdc, 0xfbbf, 0xeb9e, 0x9b79, 0x8b58, 0xbb3b, 0xab1a, 0x6ca6, 0x7c87, 0x4ce4, 0x5cc5, 0x2c22, 0x3c03, 0x0c60, 0x1c41, 0xedae, 0xfd8f, 0xcdec, 0xddcd, 0xad2a, 0xbd0b, 0x8d68, 0x9d49, 0x7e97, 0x6eb6, 0x5ed5, 0x4ef4, 0x3e13, 0x2e32, 0x1e51, 0x0e70, 0xff9f, 0xefbe, 0xdfdd, 0xcffc, 0xbf1b, 0xaf3a, 0x9f59, 0x8f78, 0x9188, 0x81a9, 0xb1ca, 0xa1eb, 0xd10c, 0xc12d, 0xf14e, 0xe16f, 0x1080, 0x00a1, 0x30c2, 0x20e3, 0x5004, 0x4025, 0x7046, 0x6067, 0x83b9, 0x9398, 0xa3fb, 0xb3da, 0xc33d, 0xd31c, 0xe37f, 0xf35e, 0x02b1, 0x1290, 0x22f3, 0x32d2, 0x4235, 0x5214, 0x6277, 0x7256, - 22 -

0 0 0 0 30 Refer to parameter configuration for details 0 6 0 5 52 Refer to system running information for details 0

KPD100 Controller Operation Manual 0xb5ea, 0xa5cb, 0x95a8, 0x8589, 0xf56e, 0xe54f, 0xd52c, 0xc50d, 0x34e2, 0x24c3, 0x14a0, 0x0481, 0x7466, 0x6447, 0x5424, 0x4405, 0xa7db, 0xb7fa, 0x8799, 0x97b8, 0xe75f, 0xf77e, 0xc71d, 0xd73c, 0x26d3, 0x36f2, 0x0691, 0x16b0, 0x6657, 0x7676, 0x4615, 0x5634, 0xd94c, 0xc96d, 0xf90e, 0xe92f, 0x99c8, 0x89e9, 0xb98a, 0xa9ab, 0x5844, 0x4865, 0x7806, 0x6827, 0x18c0, 0x08e1, 0x3882, 0x28a3, 0xcb7d, 0xdb5c, 0xeb3f, 0xfb1e, 0x8bf9, 0x9bd8, 0xabbb, 0xbb9a, 0x4a75, 0x5a54, 0x6a37, 0x7a16, 0x0af1, 0x1ad0, 0x2ab3, 0x3a92, 0xfd2e, 0xed0f, 0xdd6c, 0xcd4d, 0xbdaa, 0xad8b, 0x9de8, 0x8dc9, 0x7c26, 0x6c07, 0x5c64, 0x4c45, 0x3ca2, 0x2c83, 0x1ce0, 0x0cc1, 0xef1f, 0xff3e, 0xcf5d, 0xdf7c, 0xaf9b, 0xbfba, 0x8fd9, 0x9ff8, 0x6e17, 0x7e36, 0x4e55, 0x5e74, 0x2e93, 0x3eb2, 0x0ed1, 0x1ef0

};

Appendix 2.CRC16-CCITT Code generation method /******************************************************************* Function: Input:

Generate CRC16CCITT code p

= mouse cursor points to first byte

DataLen = Data length Output:

CRC16CCITT

*******************************************************************/ unsigned int CRC16CCITT(unsigned char *p,unsigned int DataLen) { unsigned int crc16=0; unsigned int i; unsigned char b; for(i=0;i>8); crc16