Operation and maintenance Manual

CONTENT
PREFACE............................................................................................................................................................................4
1. SAFETY...........................................................................................................................................................................4
1.1 General..................................................................................................................................................................4
1.2 Installation, Handling, and Towing.....................................................................................................................4
1.3 Fires and Explosion.............................................................................................................................................5
1.4 Protection Enclosure ...........................................................................................................................................6
1.5 Chemical ...............................................................................................................................................................6
1.6 Noise......................................................................................................................................................................6
1.7 Electrical Devices ................................................................................................................................................6
1.8 First Aid For Electric Shock ................................................................................................................................7
WARNING ...................................................................................................................................................................8
2. GENERAL DESCRIPTION...........................................................................................................................................9
2.1 Generating Set Description and Identification.................................................................................................9
2.2 Diesel Engine .......................................................................................................................................................9
2.2.1 Engine Electrical System.........................................................................................................................9
2.2.2 Cooling System.......................................................................................................................................10
2.2.3 Silencers and Exhaust System.............................................................................................................10
2.3 Alternator.............................................................................................................................................................10
2.4 Control System (Identification).........................................................................................................................10
2.4.1 Output Circuit Breaker ...........................................................................................................................10
2.5 Fuel Tank and Base frame ...............................................................................................................................10
2.6 ATS Cabinet........................................................................................................................................................10
3. INSTALLATION.........................................................................................................................................................11
3.1 General instruction ............................................................................................................................................11
3.2 Preparation before installation .........................................................................................................................11
3.2.1 Genset lifting ...........................................................................................................................................11
3.2.2 Case open check....................................................................................................................................12
3.2.3 Line and position ....................................................................................................................................12
3.2.4 Familiar with installation tools and hard wares ..................................................................................12
3.3 Genset installation .............................................................................................................................................14
3.4 Auxiliary installation ...........................................................................................................................................14
3.4.1 Fuel refilling system installation............................................................................................................14
3.4.2 Exhaust system installation...................................................................................................................14
3.4.3 Ventilation and cooling radiator ............................................................................................................15
3.4.4 Battery start system ...............................................................................................................................15
3.4.5 Electric system connection ...................................................................................................................15
3.5 Outdoor canopy genset installation.................................................................................................................17
3.5.1 Genset installation..................................................................................................................................17
3.5.2 External fuel tank installation ................................................................................................................17
3.5.3 ATS installation .......................................................................................................................................19
3.5.4 Cables layout ..........................................................................................................................................20
4. Debugging and Operation ..........................................................................................................................................21
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 4.1 Replenish qualified fuel, oil and coolant (suitable for water cooled genset) .............................................21
4.1.1 Fuel...........................................................................................................................................................21
4.1.2 Lubricant oil .............................................................................................................................................22
4.1.3 Coolant.....................................................................................................................................................23
4.2 Genset examination ..........................................................................................................................................23
4.2.1 Engine examination................................................................................................................................23
4.2.2 Alternator examination ...........................................................................................................................23
4.3 Genset debugging .............................................................................................................................................24
4.3.1 Genset startup.........................................................................................................................................24
4.3.2 Non load eaamination............................................................................................................................24
4.3.3 Data configuration ..................................................................................................................................24
4.3.4 Take load step by step ...........................................................................................................................25
4.3.5 Genset stop .............................................................................................................................................25
4.3.6 Examine genset self protect functions ................................................................................................25
4.3.7 Test other functions ................................................................................................................................25
5. Maintenance and Repair Instruction .........................................................................................................................26
5.1 General................................................................................................................................................................26
5.2 Common maintenance classification and period ..........................................................................................26
5.3 Maintenance content .........................................................................................................................................26
5.3.1 Class A maintenance .............................................................................................................................26
5.3.2 Class B maintenance .............................................................................................................................27
5.3.3 Class C maintenance.............................................................................................................................27
5.3.4 Class D maintenance.............................................................................................................................27
5.3.5 Seasonal maintenance ..........................................................................................................................27
5.4 Maintenance procedures ..................................................................................................................................28
5.5 Maintenance measures ....................................................................................................................................28
5.5.1 Air filter .....................................................................................................................................................28
5.5.2 Oil filter .....................................................................................................................................................29
5.5.3 Fuel filter ..................................................................................................................................................29
5.5.4 Coolant filter replacement (if configured)............................................................................................29
5.5.5 Lubricant oil replacement ......................................................................................................................30
5.5.6 Coolant replacement and water tank clean ........................................................................................30
5.5.7 Battery maintenance ..............................................................................................................................30
5.5.8 Alternator maintenance..........................................................................................................................31
5.6 Genset common fault troubleshooting............................................................................................................31
6. ZK3201 Control panel manual ...................................................................................................................................33
6.1 general.................................................................................................................................................................33
6.2 Connection Port .................................................................................................................................................34
6.3 Operation Panel .................................................................................................................................................38
6.3.1 Preparations before operation ......................................................................................................................38
6.3.2 The whole operation panel includes 3 sections: measuring parameter display by LED, operation
switch and running status LED indication.............................................................................................................38
6.3.3 LCD Display and Control Keys:....................................................................................................................39
6.3.4 Measuring data ...............................................................................................................................................41
6.4 System Parameter .............................................................................................................................................41
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6.5 Alarm and Stop failure.......................................................................................................................................44
6.5.1 Alarm ................................................................................................................................................................44
6.5.2 Stop Failure .....................................................................................................................................................44
6.6 Communication Function..................................................................................................................................45
6.6.1 Brief Introduction ............................................................................................................................................45
6.6.2 CI485 Communication Connection ..............................................................................................................45
6.6.3 Communication Protocol ...............................................................................................................................47
6.7 Troubleshooting..................................................................................................................................................53

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PREFACE

This manual is designed for gensets installation, debugging, operation, maintenance and repair. It should be used in
conjunction with the Engine Manual, and Alternator Manual. All documents should be laid down besides genset in order
to easy reading.

All specifications and marks are assembled in recent version, if there is any change wont have notice. For easy
instruction, canopy, enclosure and baffle have been released.

Genset is designed for industrial use; it can be operated after refilling coolant, fuel and battery electrolyte. Experience
manufacturer makes sure to provide stable and reliable power sources. But pay much attention to genset maintenance if its
used in dirty or dusty environment.

All maintenance, debugging and repair should be done by experienced trainer.

1. SAFETY

1.1 General
The generating set is designed to be safe when used in the correct manner. Responsibility for safety, however, rests with
the personnel who install, use and maintain the set. The following safety precautions, if followed, will minimize the
possibility of accidents. Before performing any procedure or operating technique, it is up to the user to ensure that it is
safe. Personnel who are authorized and trained should only operate the generating set.

WARNING:
! Read and understand all safety warnings before operating or performing maintenance on the generating set.

! Failure to follow the instructions, procedures, and safety precautions in this manual may increase the possibility of
accidents and injuries.

! Never start the generating set unless it is safe to do.

! Do not attempt to operate the generating set with a known unsafe condition.

! If the generating set is unsafe, fit danger notices and disconnect the battery negative (-) lead so that it cannot be
started until the condition is corrected.

! Disconnect the battery negative (-) lead prior to attempting any repairs or cleaning inside the enclosure, if equipped.

! Install and operate this generating set only in full compliance with relevant National, Local, or Federal Codes,
Standards or other requirements.

1.2 Installation, Handling, and Towing

The following safety precautions should be noted:

! Make electrical cable earthling comply with local relevant Electrical requirements.

! For stationary gensets, the storage system must isolated from rain, dust or other corrosion chemicals installed in
comply with local Standards or other Standards whichever applicable

! Engine exhaust emission is detrimental to the health of personnel. The exhaust for all indoor generating sets must be
piped outdoors via leak-free piping in compliance with relevant Codes, Standards and other requirements. Ensure hot
exhaust silencers, piping and turbochargers, if equipped, are clear of combustible material and are guarded for
personnel protection per safety requirements. Ensure that fumes from the exhaust outlet will not be a hazard.

! Never lift the generating set by attaching to the engine or alternator lifting lugs. Use a sling with a 'spreader bar'
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connected to the base frame.

! Ensure the lifting rigging and supporting structure is in good condition and has a capacity suitable for the load.

! Keep all personnel away from the generating set when it is suspended.

! Make sure all personnel are out of the generating set canopy or container, if equipped, before closing and latching
enclosure doors.

! When towing a mobile generating set, observe all Codes, Standards or other regulations and traffic laws. These
include those regulations specifying required equipment and maximum and minimum speeds. Ensure brakes, if fitted,
are in good order.

! Do not permit personnel to ride in or on the mobile generating set. Do not permit personnel to stand or ride on the
drawbar or to stand or walk between the generating set and the towing vehicle Do not install or use the generating set
in any classification of hazardous environment unless it has been specifically designed for that environment.

1.3 Fires and Explosion

Fuels and fumes associated with generating sets can be flammable and potentially explosive. Proper care in handling
these materials can dramatically limit the risk of fire or explosion. However, safety dictates that fully charged dry fire
extinguishers are kept on hand Personnel must know how to operate them.

WARNING:
! Ensure the generating set room is properly ventilated.

! Keep the room, the floor and the generating set clean. When spills of fuel, oil, battery electrolyte or coolant occur,
they should be cleaned up immediately.

! Never sto r e flammabl e liq uids n e ar the eng in e

! Store oil y rags in cov ered meta l contai ners.

! Do not smoke or allow sparks, flames or other sources of ignition around fuel or batteries. Fuel vapors are explosive.
Hydrogen gas generated by charging batteries is also explosive.

! Turn off or disconnect the power to the battery charger before making or breaking connections with the battery.

! Keep grounded conductive objects, such as tools, away from exposed live electrical parts, such as terminals, to avoid
arcing. Sparks and arcing might ignite fuel or vapors.

! Avoid refilling the fuel tank while the engine is running.

! Do not attempt to operate the generating set with any known leaks in the fuel system.

! The excessive build-up of unburned fuel gases in the exhaust system can create a potentially explosive condition.
This build-up can occur after repeated failed start attempts, air flap valve testing, or hot engine shutdown. Open exhaust
system purge plugs, if equipped, and allow the gases to dissipate before attempting to restart the generating set.

NO FIRE NO SMOKING

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1.4 Protection Enclosure

The generating set is designed with guards for protection from moving parts. Care must still be taken to protect
personnel and equipment from other mechanical hazards when working around the generating set.

! Do not attempt to operate the generating set with safety guards removed. While the generating set is running do not
attempt to reach under or around the guards to do maintenance or for any other reason.

! Keep hands, arms, long hair, loose clothing and jeweler away from pulleys, belts and other moving parts.

Attention: Some moving parts cannot be seen clearly when the set is running.

! Keep access doors on enclosures, if equipped, closed and locked when not required to be open.

! Avoid contact with hot oil, hot coolant, hot exhaust gases, hot surfaces and sharp edges and corners.

! Wear protective clothing including gloves and hat when working around the generating set.

! Do not remove the radiator filler cap until the coolant has cooled. Then loosen the cap slowly to relieve any excess
pressure before removing the cap completely.

! Ethyl Ether starting aids must not be used on engines with combustion air preheating devices. In general these
starting aids are not recommended on any engine. They will reduce the efficient working life of the engine.

1.5 Chemical

Fuels, oils, coolants, lubricants and battery electrolyte used in this generating set are typical of the industry. However,
they can be hazardous to personnel if not treated properly.

WARNING:
! Do not swallow or have skin contact with fuel, oil, coolant, lubricants or battery electrolyte. If swallowed, seek
medical treatment immediately. Do not induce vomiting if fuel is swallowed. For skin contact, wash with soap and
water.

! Do not wear clothing that has been contaminated by fuel or lube oil.

! Wear an acid resistant apron and face shield or goggles when servicing the battery. If electrolyte is spilled on skin
or clothing, flush immediately with large quantities of water.

1.6 Noise
Generating sets that are not equipped with sound attenuating enclosures can produce noise levels in excess of 105
dB (A). Prolonged exposure to noise levels above 85 dB (A) is hazardous to hearing.

WARNING:
! Ear protection must be worn when operating or working around an operating generating set.

1.7 Electrical Devices

Safe and efficient operation of electrical equipment can be achieved only if the equipment is correctly installed,
operated and maintained.

WARNING:
! The generating set must be connected to the load only by trained and qualified electricians who are authorized to do
so, and in compliance with relevant Electrical Codes, Standards and other regulations. Where required, their work
should be inspected and accepted by the inspection agency prior to operating the generating set.

! Ensure the generating set, including a mobile set, is effectively grounded/earthed in accordance with all relevant
regulations prior to operation.
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! The generating set should be shutdown with the battery negative (-) terminal disconnected prior to attempting to
connect or disconnect load connections.

! Do not attempt to connect or disconnect load connections while standing in water or on wet or soggy ground.

! Do not touch electrically energized parts of the generating set and/or interconnecting cables or conductors with any
part of the body or with any non-insulated conductive object.

! Replace the generating set terminal box cover as soon as connection or disconnection of the load cables is
complete. Do not operate the generating set without the cover securely in place.

! Connect the generating set only to loads and/or electrical systems that are compatible with its electrical
characteristics and that are within its rated capacity.

! Be sure all electrical power is disconnected from electrical equipment being serviced.

! Keep all electrical equipment clean and dry. Replace any wiring where the insulation is cracked, cut, abraded or
otherwise degraded. Replace terminals that are worn, discolored or corroded. Keep terminals clean and tight.

! Insulate all connections and disconnected wires.

! Use only dry powder extinguishers on electrical fires.

1.8 First Aid For Electric Shock

Electric shock hazard

WARNING:
! Do not touch the victim's skin with bare hands until the source of electricity has been turned off.
Switch off power, if possible.
Otherwise pull the cable away from the victim.
If this is not possible, stand on dry insulating material and pull the victim clear of the conductor, preferably
using insulated material such as dry wood.
If victim is breathing, turn the victim into the recovery position described below.
If victim is unconscious, perform resuscitation as required:
OPEN THE AIRWAY:

1. Tilt the victim's head back and lift the chin upwards.
2. Remove objects from the mouth or throat (including false teeth, tobacco, or chewing gum).

BREATHING:
1. Check that the victim is breathing by looking, listening and feeling for the breath.

CIRCUL AT I O N:
1. Check for pulse i n t h e v i c t i m ' s n e c k

IF NO BREATHING BUT PULSE IS PRESENT:

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1. Pinch the victim's nose firmly.
2. Take a deep breath and seal lips around the victim's lips.
3. Blow slowly into the mouth watching for the chest to rise. Let the chest fall completely. Give breaths at 10 per
minute.
4. If the victim must be left to get help, give 10 breaths first and then return quickly and continue.
5. Check for pulse after every 10 breaths.
6. When breathing restarts, place the victim into the recovery position described later in this section.

IF NO BREATHING AND NO PULSE:

1. Call or telephone for medical help.

2. Give two breathes and starts chest compression as follows:
3. Place heel of hand 2 fingers breadth above ribcage/breastbone junction.
4. Place other hand on top and interlock fingers.
5. Keeping arms straight press down 4-5 cm (1.5-2 inch) 15 times at a rate of 80 per minute.
6. Repeat cycle (2 breaths, 15 compressions) until medical help takes over.
7. If condition improves, confirm pulse and continue with breaths. Check for pulse after every 10 breaths.
8. When breathing restarts, place the victim into the recovery position described below.

Recovery position:

1. Turn the victim onto the side.

2. Keep the head tilted with the jaw forward to maintain the open airway.
3. Make sure the victim cannot roll forward or backwards.
4. Check for breathing and pulse regularly. If either stops, proceed as above.

WARNING
! Do not give liquids until victim is conscious.

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 Basic structure of gensets

1. Genset brand logo (fixed on alternator)

2. Engine
3. Air cleaner
4. Turbo-charger (apply to some models)
5. Speed governer (apply to some models)
6. Start motor
7. Battery/battery bracket
8. Batter charger motor
9. Radiator
10. Alternator
11. Circuit connection box
12. Base frame and fuel tank
13. Vibration damper
14. Control panel
15. MCCB

2. GENERAL DESCRIPTION
2.1 Generating Set Description and Identification

This generating set has been designed as a complete package to provide superior performance and reliability.

Each generating set is provided with a Rating Label generally affixed to the alternator housing. This label contains the
information needed to identify the generating set and its operating characteristics. This information includes, but is not
limited to, the model number, serial number, output characteristics such as voltage, phase and frequency, output rating in
kVA and kW, and rating type (basis of the rating). For reference, this information is repeated on the Technical Data Sheet
provided with this manual. The model and serial numbers uniquely identify the generating set and are needed when
ordering spare parts or obtaining service or warranty work for the set.

2.2 Diesel Engine

The diesel engine powering the generating set has been chosen for its reliability and the fact that it has been specifically
designed for powering generating sets.

The engine is of the heavy-duty industrial type with 4-stroke compression ignition and is fitted with all accessories to
provide a reliable power supply. These accessories include, among others, a cartridge type dry air filter, a turbocharger
fitted on some engines, and a mechanical or electronic close control engine speed governor.

2.2.1 Engine Electrical System

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The engine electrical system is negative ground/earth and either 12 (KJ, KV series) or 24 volts (KM series) DC.

This system includes an electric engine starter, battery, battery rack and a battery-charging alternator.

Most sets are provided with lead-acid batteries, which are discussed more fully in Section 9, however other types of
batteries may be fitted if they had been specified.

2.2.2 Cooling System

The engine cooling system is comprised of a radiator, a high capacity pusher fan and a thermostat. The alternator has its
own internal fan to cool the alternator components. Note that the air is "pushed' through the radiator so that the cooling
air is drawn past the alternator, then past the engine and finally through the radiator.

2.2.3 Silencers and Exhaust System

An exhaust silencer is provided loose for installation with the generating set. The silencer and exhaust system
reduce the noise emission from the engine and can direct exhaust gases to safe outlets.

2.3 Alternator

A screen protected and drip-proof, self-exciting, self-regulating, brush fewer alternators fine-tuned to the output of this
generating set, normally produces the output electrical power. Mounted on top of the alternator is a sheet steel terminal
box.

2.4 Control System (Identification)

One of several types of control systems and panels may be fitted to control the operation and output of the set and to
protect the set from possible malfunctions.

Section 8 of this manual provides detailed information on these systems and will aid in identification of the control system
fitted on the generating set.

2.4.1 Output Circuit Breaker

To protect the alternator, a suitably rated circuit breaker selected for the generating set model and output rating is
supplied mounted in a steel enclosure. In some cases the output circuit breaker may be incorporated in the automatic
transfer system or control panel.

2.5 Fuel Tank and Base frame

The engine and alternator are coupled together and mounted on a heavy-duty steel base frame.

Except for the KM series sets, this base frame includes a fuel tank with a capacity of approximately 8 hours operation at
full load. An extended capacity fuel tank of approximately 24 hours operation may be fitted. Where a fuel tank is not
provided with the base frame, a separate fuel tank must be provided.

The generating set is fitted with vibration isolators, which are designed to reduce engine vibration being transmitted to
the foundation on which the generating set is mounted. These. Isolators are fitted between the engine/alternator feet and
the base frame.

2.6 ATS Cabinet

Automatic genset needs to fit ATS cabinet to keep continuous power source. We provide different specifications of ATS to meet different
requirements.

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3. INSTALLATION

3.1 General instruction

Correct installation and debugging will play an important role to last genset life, keep genset running reliable and stable.
Before genset room design and installation, users need to acknowledge genset clearly. If there is any technical problem, users
need to consult with manufacturer.
Standard genset is indoor type, if customer needs outdoor type, soundproof canopy will be necessary.

Factors to be considered in the installation of a generator are:

a) Groundwork and load: concrete base (not less than C15) should have enough space and weight (1-2 times of
genset wet weight) to load genset and absorb vibration. Genset concrete base with base frame should be
20-300mm higher than ground. Concrete base depth, length and width depend on DEG power, weight and soil
conditions (0.15-0.25MP), generally 500-1100mm depth is enough. While making concrete base, no reservation
for bolts is needed, but drill a hole for bolts to fix on the base is necessary during installation.
b) Genset layout in room: the distance between genset and wall should be not less than 1.5cm except the coolant
radiator side to make sure enough space for handle, operation, maintenance and move. Exhaust pipes suspend in a
space 2.2m higher than the engine. Genset room is required not less than 4.5m high, and space between roof and
genset should be not less than 1.5m, thats the reasonable requirement for genset maintenance and repair. For large
genset, hoist tackle need to be considered, and the rooftree should carry 3 times genset weight, 16-20# I-beam
needed if necessary. Cables, water and fuel pipe will be buried in ground groove whose depth is about 0.5-0.8m with
a slope to remove seeper and steel/fireproof wood/concrete cover plate.
If there are several gensets in one room, attention:
*Gensets should not be laid in line array;
*Gensets should be laid in parallel with enough space for easy maintenance and radiation. Specific space should
consult manufacturer before design.
Other notes:
*Carefully consider the cable length and layout to avoid any cross;
*Genset room should be firm and safe with excellent radiation and ventilation system;
*Lighting, hot insulation and fire fighting system in room is necessary;
*Room space should be designed according to genset power output and expansion.
*Complete feed and drainage system is needed.

c) Noise reduction and vibration damper: To reduce exhaust system noise, industrial silencer is needed to, if
customer need less noise, residential silencer can be fitted. Then reduce the whole genset noise, thats to fit
soundproof canopy in case outdoor type. If genset is installed indoor, room noise treatment is necessary, noise
absorption materials would be fitted on door, roof and holes. Vibration dampers are fitted to reduce the shake.
d) Ventilation of room and radiation: ventilation system is necessary for genset room in order to emit energy,
smoke and frog and feed enough fresh air for ignition, Genset room should be below 30F temperature. Genset
axis should be at the same direction as air inlet and outlet holes, fresh air flows from genset end through control
panel, alternator, engine, radiator, and released by fan. The minimum air inlet capacity must meet engine
ignition, engine cooling (including radiator), and alternator cooling.

While outdoor installation, factors like concrete base load, noise treatment, exhaust direction etc. must be considered, esp.
rainproof degree.

3.2 Preparation before installation

3.2.1 Genset lifting
Gensets and electrical equipments have packages, generally is wooden case, pay much attention to lift at suitable
position, and check any wreckage, loose screws, and suspend safely. Do not lift genset in strong wind. Make sure
genset is laid on flat and loadable place.
Warning:
! Keep human away from the genset bottom while lifting;
! Lift ring must be used with helicopter.
When genset arrives at station, it should be stocked in room. If no genset room is available, and genset is placed
outdoor, canopy should be considered to avoid weather damages.

11
For genset is large and heavy, transport circuit have to be designed before installation, esp indoor type. Enough
space has to be reserved for genset in. If the door is not large enough, it should be demolished for move and
mended after location. There is a special design for genset move, wrong action will damage genset. When move
genset by a forklift, pay attention to lift slowly and push or pull carefully at gravity. If genset need to move at times,
lubricated wheels at bottom are preferred with forklift groove and lift hole. Some small gensets have fitted wheels at
bottom when ex factory.
Warning:
! Dont lift by engine and alternator stationary rings.
! Make sure the lift equipment is in good condition with enough load capacity.
! Keep human away while lifting;

3.2.2 Case open check

Clean the case surface, check the package no. and qty. and examine whether there is any damage.
Avoid hurt to any genset body and accessories during opening the case.
The schedule would be: open the top cover first, and watch clearly the genset and accessories, then open side
covers. In case the top cover is difficult to remove, convenient side cover is preferred.
Count all equipment and parts in package according to packing list.
Check whether genset dimension is the same as drawing.
Examine whether any damage occurs.
After opening, all equipment and parts need to place at flat position; flanges and tie-ins need to be packed to avoid
any rain and dust.

3.2.3 Line and position

Line the installation positon of genset in power room according to layout drawing. The error from genset to wall would
be 20mm; from genset to genset would be 10mm.

3.2.4 Familiar with installation tools and hard wares

General installation tools including:
Picture 1:

Tapper 1pc;
Slot screwdriver 2pcs;
Cross screwdriver 1pc;
Diagonal pliers 1pc;
Square mouth tongs 1pc;
Sharp nose pliers 1pc;
Riveter 1pc;
Monkey wrench 1pc;
Cutter 1pc;
Saw 1pc;
Hammer 1pc;
Tape 1pc;
Socket wrench 1set;
Level ruler 1pc;
50 tapper 1pc;
12
Mark pen 1pc;
Electric drill 1pc;
Churn drill 1pc.

Picture 2:

Electric drill, churn drill and aiguilles several.

Aiguilles for electric drill specifications:
5, 5.5, 6,
Aiguilles for churn drill specifications:
10, 12, 14.

Picture 3:

Open end wrench Screws, rivet, insulation tape and binding.

Seal glue and fuel tank accessories Fuel pipes, tubes and fuel-water separator

Electrical cables PVC pipes, waveform tubes, ground cable etc.

13
3.3 Genset installation
a) Test centre line vertically and horizontally;
Find centre line of concrete base and genset and vibration damper line according to drawing before location.
Concrete base must be cleaned.
b) Lifting
Bind rope at genset gravity position and lay at datum line.
c) Genset lay flat and fixed
Level the genset by sizing block. Installation precision is 0.1mm each meter vertically and horizontally. Fix the genset
by expandable bolts, in case vibration damper is used between base frame and concrete base, no expandable bolts
are needed any more.

3.4 Auxiliary installation

3.4.1 Fuel refilling system installation
For different gensets, ZINGS can provide different configuration of fuel tank and fuel refilling system for options. The fuel tank
can be separated one or base frame type or customer designed, anyhow, the basic principle should as follows:
a) Fuel tank should be stored in safe and fire-proof place and keep a certain distance from genset, exhaust pipes, vibration
sources and any smoke is prohibited. For diesel fuel will be vaporized above 65 and cant start engine any more.
Vibration may mix the contamination in fuel and block fuel way.
b) After fuel tank is located, the fuel level should not be 2.5M higher than base frame. If exceed 2.5M, additional day fuel tank
should be fitted. The lowest fuel level should not be lower than 1m of fuel pump mouth while fuel pump mouth to the bottom
of fuel tank not less than 100mm to avoid water or contamination injected into engine.
c) Fuel leakage must be avoided during fuel system installation. Fuel tube have to use ring band for winding instead of iron
wire, fuel pipes can use black iron pipe or steel wire pipe.
d) Fuel-water separator can bring big benefit. For water in fuel is dangerous to engine, which makes engine rusty and
damages injector mouth.

3.4.2 Exhaust system installation

The function of exhaust system is to emit smoke or others safely outdoor and keep away from building and human. Attention:
a) Exhaust pipe should connect flexible stainless steel waveform type. Waveform pipe cant be used as elbow or appendix for
fuel pipe.
b) Silencer and exhaust pipe should be supported by bracket rather than exhaust pipe or it will be damages.
c) Heat insulation is suggested to silencer and exhaust pipe to avoid any accidental fire or extinguish equipment error.
d) Distance between tinder and exhaust pipe should be at least 290mm (9 inch). Anti flaming materials or heat insulation
gloves will be opted if exhaust pipe have to pass through ceiling and wall.
e) The end of exhaust system should be away from building and air inlet to avoid pollution.
f) Its better to install exhaust system at the back of building.
g) End of exhaust pipe distance in some regulations:
3m from ground; 1m from ceiling or wall;
3m from building entrance;
at least 3m higher than other buildings.
h) Exhaust pipe outdoor should be 60bent to ground if horizontal design or rainproof cover in addition if vertically design.
i) Two genset with one exhaust pipe is prohibited, neither with exhaust pipe of other equipments.
j) Exhaust pipe backpressure cant exceed instruction limitation. High backpressure may cause high temp. Exhaust air and
dust which will hurt engine. As a result, its necessary to test genset backpressure at full load before get into use. To reduce
backpressure, exhaust pipe is better to be shorter, and straighter, if bending; the semi diameter should be 1.5 times of pipe
diameter.
Warning:
Exhaust air may hurt human body;
14
All indoor genset should exhaust through non-leakage pipe, the installation must apply to relevant regulations, standards and
other requirements;
Silencer, exhaust pipe and turbo charger may cause high temperature; human must keep away from them;
Avoid exhaust smoke and air to be the public hazard.

3.4.3 Ventilation and cooling radiator

Power room ventilation is very important for equipment. Room temperature should keep below 30 F. Genset axis direction
should be the same as air flow and airlet. Fresh air enters from genset end, through control panel, alternator, engine, radiator
and exit by cooling fan. The min airflow capacity is the summation of engine ignition air and cooling air capacity. The common
component of cooling system is radiator.
a) When the radiator is at the end of genset, location should be reasonable to make it near the exhaust hole, the max
distance from radiator to the exhaust hole is 150mm.
b) If above location is not feasible, another exhaust slot is needed, whose min across sectional area should be the same as
radiator cooling area, canvas wind slot with steel-made flanges is generally used to connect radiator and exhaust shutter.
c) Blocks are necessary near air inlet and outlet to reduce fan noise. Invalid area for shutter and gridding and engine cooling
and ignition air should be considered while calculating air inlet or air outlet area, ZINGS suggest to keep the air inlet area
twice of radiator area.

3.4.4 Battery start system

Normal voltage for engine start system is 12V or 24V, standard configuration includes battery bracket and battery cables.
Battery can be acid-lead type or free maintenance type, the former need to add electrolyte before usage while the latter can be
used directly. Notice for installation:
a) Keep clean surface and around;
b) Open the filling hole and add electrolyte, keep the level 10-15mm higher than battery panel. New added electrolyte is easy
to be absorbed by battery panel, regular complement is necessary. Due to electrolyte is heating, its necessary to keep it
stand still after filling;
c) Connect battery panel correctly;
d) Charge battery shortly after discharging to avoid panel sulfating. While charging, make sure the polarity is correct.
e) Check other connection whether correct.

3.4.5 Electric system connection

Genset has configured control panel and complete cable devices, together with running, faulty etc. input and output terminals.
a) Power cable, control panel and signal cable are PVC insulation copper cable. 1.5mm2 control cable is enough for use.
Power cable reference:
1. Single core cable

Genset Phase Neutral Ground

power cable cable cable
(KW) (mm2) (mm2) (mm2)

40-50 16 6 4

65-85 35 16 4

100 50 16 6

120-140 95 25 6

175 120 35 10

15
 200-220 150 50 10

250-275 295 95 10

310 2120 120 10

400 2150 150 16

450 2150 150 16

550 3120 185 16

620-700 3150 240 25

800-880 4150 2150 25

1120 4240 2240 25

2. 4 core cable
Genset Phase Neutral Ground
power cable cable cable
2 2
(KW) (mm ) (mm ) (mm2)

40-50 25 16 4

65-85 70 35 4

100 95 50 6

120-140 120 70 6

175 270 235 10

200-220 295 250 10

250-275 370 335 10

310 395 350 10

400 3120 370 16

450 495 450 16

550 4120 470 16

620-700 4185 495 25

800-880 4240 4120 25

1120 5240 5120 25

b) Direct burial cable requirements

Cable should be keep away from acid, and alkali area;
Depth should be not less than 500mm, with 100mm sand or soil at upper and lower layer;
Direction note at cross, turn, connection etc. should be marked by stake which should be 150mm higher than
ground.

16
 1---cable; 2---sand layer; 3---protection layer Cable slot

c) Grounding system
Genset and distribution devices must be grounded to avoid any damages caused by electricity leakage. Grounding
devices include ground body and ground cable laid on under ground or upper ground.
Ground body is angle steel 5 pcs about 50mm*50mm*5mm as follow display:

Grounding cable connection port is at base frame end, if no suitable place, grounding rob or pad should be opted.
Grounding devices play an utmost important role which can avoid any damages by electricity faulty or electricity
misuse.
Its customers duty to find suitable electrician to keep reasonable grounding, and make maintenance strictly according
to instructions.
ZINGS and his agent will not be responsible for any accidents arising from no-grounding or grounding error.

3.5 Outdoor canopy genset installation

ZINGS genset designed based on locale installation requirements, which make installation easy and convenient, the
installation includes: canopied genset, ATS, and external fuel tank.

3.5.1 Genset installation

Clean the dust and contamination before installation, lay genset direction based on the locale distribution and avoid high
temperature exhaust to external fuel tank. Genset should be placed in the middle of concrete platform, fixed with bolts and keep
at same level (parallel with cabinet if near cabinet).

3.5.2 External fuel tank installation

Fuel tank should be located in the middle of platform.

17
Fuel inlet and outlet side should be in the opposite of genset fuel inlet and outlet side. It should be fixed with expandable bolts
and keep the same level (parallel with genset if near genset).

a) Fuel inlet and outlet installation and connection

Glue and thread sealing tape is opted for metal accessories connection to avoid any leakage; while waveform tube and PVC
pipe should be outside winded for fuel inlet and outlet pipes. Any pipes knot, distortion or non-natural bent should be avoided.
Pay much attention on float ball direction and pipes tie-in while installation.

b) Fuel pipe tie-in connection

Remove factory fitted fuel in and out connection, and install parts accompanied with genset as display:

After
Remove original
replacement
tie-in

Original

Inside base frame

18
 Tie-in connection
Accompanied parts
c) Water fuel separator installation
Clear the separator in and out, if some separator IN cant meet fuel tank OUT, remove the 4 screws on separator
and turn the bracket to another direction then fasten the previous 4 screws.
Remove
screws

Original separator

Fuel tank OUT

Wrong direction

After turn Vent hole for IN

3.5.3 ATS installation

ATS can be indoor or outdoor (weather proof) type, generally indoor type is wall-suspended, while outdoor stand which need
base platform.
Indoor ATS installation:
a) If there is installation drawing, install ATS according to drawing, if no, place the ATS bottom at 1.4m level from the ground
and keep parallel with ground;
b) Make sure ATS door can be opened freely after installation;
c) Installation place should be keep away from water and drops;
d) If there is air conditioner on the head of ATS, protection measures have to be opted such as anti drop block;
19
e) When indoor install outdoor type, remove the base first and fasten by blind rivets if cabinet install;

5 blind rivet

ATS

Loose bolt

Remove base

Hanger loop and

screws in ATS

Drill 2 holes

Bolts fixed

3.5.4 Cables layout

Cable specification and Qty (22KVA for example)

Cable specification Qty

2 2
Power cable: 410mm +16mm 1 pc

Grounding cable: 70mm2 1 pc

2 2
Signal cable 21.5mm ,41mm 2 pcs
Requirements:
a) Make sure the cable length and qty is correct;
b) PVC pipe 50mm should be opted when cable is laid under ground;
c) Trench dimensions: 150 mm*200 mm;
d) Control cable and power cable should covered by PVC pipes;
20
e) Mark cables before cover PVC pipes for identification.

ATS control cable:

ATS cable label A1 N 31 33

Color Red Green Blue Red

2
21.5mm
Specification 21mm2 (DC power source to ATS)
For battery charge

Genset control panel:

ATS cable label L N 31 29

Color Red Green Blue Red

21.5mm2
Specification 41mm2 (DC power source to ATS)
For battery charge

4. Debugging and Operation

4.1 Replenish qualified fuel, oil and coolant (suitable for water cooled genset)

4.1.1 Fuel
Standards: BS.2869A1 or A2 class, or GB252 or DIN/EN590, ASTMD975-881-D and 2-D
GB252 for example:
Ambient Light diesel type

>4 0#

>-5 -10#

-5~ -14 -20#

21
 -14~ -29 -35#

-29C~ -44 -50#

Diesel fuel needs strict selection to make sure clean and avoid any damages to engine. Before filling, keep the fuel tank stand
still for 24h to deposit contaminations. Clean the fuel hole before open, and keep rubber sac and manual pump in clean
environment.
Attention: exhaust air in fuel system before startup after refilling.

4.1.2 Lubricant oil

SAR classification as follows:

SAE class Low temp. Viscosity Pump limit Temp 100 move viscosity Domestic

max. mpa.s max. min.mm2/s class

0W -30 3250 -35 3.8

5W/40 -25 3500 -30 3.8

10W -20 3500 -25 4.1

15W -15 3500 -20 5.6

20W -10 4500 -15 5.6

25W -5 6000 -10 9.3

20 5.6-9.3 6# 8#

30 9.3-12.5 10# 11#

40 12.5-16.3 14#

50 16.3-21.9 15# 16#

Test ASTM D5293 ASTM D4684 ASTM D445

W means oil for winter, this classification distributes into 6 viscosities (0W-25W) for winter and 4 viscosities (20-25) for
summer.
Zings recommend 15W/40 oil for most domestic area and 5W/30, 5W/40 for north severe condition in winter.

Lubricant oil classification

API classification CA CB CC CD CE CF-4

22
ASTM range Low sulfur, High sulfur, Operate under sever High speed, Direct injection, Heavy duty

light, mid heavy light, mid Condition, non turbo high turbo turbo charge engine produced

engine heavy engine charging or low turbo charging engine engine produced by 1991 and non

charging engine after 1978 turbo charge

engine

Recommend Solve viscidity Reduce Solve mixed SC oil Solve viscidity Reduce viscidity Excellent high

reason ruin caused by sediment and CB fuel ruin and bruise and oil temp cutting and

high temp caused by fuel by high turbo consumption cleanness

sediment with 1% charging engine dispensation

sulfur

Time 1935 1949 1955 1964 1987 1991

4.1.3 Coolant

For water cooled engine with radiator or heat inverter, coolant have to be filled to protect engine.
Coolant can be following 2 kinds:
a) Factory fitted cooling system protect liquid;
b) Factory fitted inspissations mixed with distill water or intenerated water.
In cold weather, coolant may be frozen, and then anti-frozen liquid will be necessary which should be applicable to B.S.3151.
Customer may choose which kind is applicable according to users manual.
Note: When engine is running, coolant system pressure is almost 0.7KG/square, dropping valve should keep at radiator mouth.
And never to move radiator mouth when engine is running or body damages may occurred by hot water.

4.2 Genset examination

4.2.1 Engine examination
a) Check engine surface and screws, keep surface clean and screws tight;
b) Examine clearance especially intake valve and exhaust valve.
c) Examine cylinder pressure and running axle if there is any noise, or running freely,
d) Examine fuel supply system:
*Check vent to avoid any feculence, fuel type and capacity
*Open crank shaft to examine fuel injection; if sounds liquidly, means normal; if sounds no fuel, means air exists in fuel
system; at this time, loose deflate bolt of fuel filter and injection pump and exhaust air by manual pump;
*Check fuel tie-ins to avoid any leakage.
e) Examine cooling system:
*Check coolant to keep enough capacity;
*Check water tie-ins to avoid any leakage;
*Keep transmission belt at reasonable tightness. Test method: press down the middle of belt, 10-15mm content is
reasonable.
f) Examine lubricant system:
*Check tie-ins to avoid any leakage;
*Examine oil capacity;
*Oil should be filled in all manual filling holes
g) Check electric startup system:
*Electrolyte density should be 1.24-1.28, if below 1.18 means battery capacity is not enough, more electrolyte should be
filled;
*Make sure circuit connection is correct;
*Check if any dirt and oxidation on battery connection post;
*Examine all electrical devices whether contact fine.

4.2.2 Alternator examination

a) Engine and alternator coupling parallel depth and concentricity should be less than 0.1mm, check coupling before startup;

23
b) Alternator gravity should be lower than engine gravity when sliding bearing coupling;
c) Make sure no block in air intake and avoid exhaust air reenter alternator;
d) Pay much attention to keep equality clearance between rotors and stators when single bearing coupling;
e) Select suitable cables, copper connection, connection clearance not more than 0.05mm, leads distance not more than 10mm
and grounding cables;
f) Alternator terminals in outlet box marked U, V, W, N, it doesnt means actual phase order but the rotating direction. UVW
means clockwise rotating, VUW means anticlockwise rotating.
g) Test neutral current, keep it not more than 50% of alternator rated current, if current is to large, a reactance device may be
fitted.
h) Examine control panel circuit.

4.3 Genset debugging

4.3.1 Genset startup
Make sure all examinations have done before startup.
Put controller mode at REMOTE or AUTO in case of auto startup, or at MANUAL in case of manual startup
No matter in whick mode,make sure the genset is ai ready condition

4.3.2 Non load eaamination

After genset starts up, check genset revolutions, frequency, voltage, oil pressure, coolant temp., and charging

voltage whether normal, engine and alternator whether abnormal shock, noise, engine exhaust smoke whether

normal and whether any leakages. If genset non-load running for 5m everything is normal, and power circuit is at

natural working condition, close genset output switch and make genset take load and then recheck above data and

phenomenon. If any abnormal occurs, open genset output switch and examine after genset stops, restart genset

after trouble settled.

4.3.3 Data configuration

Genset frequency generally sets at 51.5Hz (Electronic governor genset at 50Hz); engine revolutions at 1545RPM

(if revolutions configured, injection capacity need to be configured); Voltage at 400V, AVR regulating system as

follows:

1Set voltage by starting up genset;

2Slowly adjust VOLT button on AVR to rated voltage (if the voltage is not stable, adjust STAB button on AVR.)

3Low frequency adjust (U/F). Adjust alternator frequency at 45Hz, and then adjust to LEC lighting, turn back

a little.

4Stabilize adjust (STAB): Slowly adjust STAB to configure variable AVR and alternator electromagnetic value,

too large adjust will make voltage unstable. Suggest using finger type voltage meter to monitor F+, F-, and keep

STAB meter at the min range.

5DROOP may replenish 0-5% rated voltage at 0.8 P.F.

6If alternator loses excitation, 12v battery should be connected to charging excitation. Release at least one

cable of F+, F- and stops genset (charging time about 3-5s).

Attention: Dont use 24V excitation loop in order to avoid any damages.

24
 Dismantle AVR cable before measuring by megger or puncture tester to avoid high voltage damages.

Warning: exceed excitation may hurt AVR or alternator excitation loop..

4.3.4 Take load step by step

In order to grinding-in, genset should take load step by step for the first time running, load capacity will be 20%,

50%, 75% and 100%. Each period cant be less than 30min before taking 75% rated load. According to genset

type, 110% load can be carried for testing power mover.

4.3.5 Genset stop

Transfer load to other power sources or stop load before genset stops, then open genset output switch at

STOP keeping genset non-load running about 1-3m to make engine parts at good lubricated and cooling

condition, finally put controller button at STOP.

If genset cant stop or at idle running, there will be some stop valve or controller fault. At this time, push fuel pump

valve at min position manually or knock stop valve to open fuel supply. If no reflection, may turn off fuel pipes to

stop genset, and then find experienced engineer to test and settle troubles.

Examine genset cooling system, fuel system, lubricated system to avoid any leakage, if there is any, find

experienced engineer to dismantle.

After genset stops, recheck cooling system, fuel system, lubricated system and other system the same as

examinations before start to make sure genset is at normal ready condition. If genset need auto start, put controller

start button at AUTO.

4.3.6 Examine genset self protect functions

Common self protect functions include: low oil pressure, high coolant temp, high speed, adjust or simulate above 3

conditions to examine genset protection and stop function.

4.3.7 Test other functions

For auto system, genset-Mains system, dual system, test and debugging according to relevant requirements to

meet authorized power supply demand. Put genset controller, ATS controller at AUTO position, simulate Mains

fault, and then observe whether genset can start within regulated time, whether ATS can transfer to Mains within

regulated time after Mains recovery, and whether genset can stop within regulated time.

25
5. Maintenance and Repair Instruction

5.1 General
A good maintenance programmed is the key to long generating set life. Qualified technicians should only carry out
maintenance and service. Records of this work should be kept to aid in developing an efficient maintenance
programmed.

In general, the generating set should be kept clean. Do not permit liquids such as fuel or oil film to accumulate on any
internal or external surfaces or on, under or around any acoustic material, if fitted. Wipe down surfaces using an
aqueous industrial cleaner. Do not use flammable solvents for cleaning purposes.

Any acoustic material with a protective covering that has been torn or punctured should be replaced immediately to
prevent accumulation of liquids or oil film within the material.

5.2 Common maintenance classification and period

Depending on the application of the generating set, requirement for preventative maintenance will vary. The preventative
maintenance requirements associated with the engine are detailed in the Engine Manual, which should be reviewed in
conjunction with this section. Maintenance intervals for the engine may be more frequent than those shown in this
section.

Class Aevery time startup or every week or every month

Class B every 250h running or one year

Class C every 1500h running or two years

Class D every 5000h running or four years

Seasonal maintenance

Notice: new DEG should replace oil and oil filter after the first 50h running.

5.3 Maintenance content

5.3.1 Class A maintenance

Definition: to check every time startup or every week or every month

Examine whether there is any loose bolt or loose vibration damper, and fasten if any.

Check whether there is any water, fuel, oil leakage.

Check whether belt is loose and fasten if any.

Check whether fuel capacity is enough and refill if any deficiency.

Check whether oil capacity is enough and refill to the top limit if deficiency.

Check any circuit is loose and fasten if any.

Check any loose or damaged fuse in control panel and replace if any (the red indicator will illuminate

when the fuse damaged)

Check any loose or damaged fuse in ATS and replace if any

Check the indicator status and the switches, buttons position

Check whether the battery vol. is abnormal and connection is loose, and fasten if any

Check whether battery electrolyte is enough and refill if needed

26
 Check battery charger whether abnormal

If the battery charger is not intelligent type, it should be float type.

5.3.2 Class B maintenance

Definition: to check every 250h running or one year

Repeat the maintenance content of class A

Replace oil

Replace filters: oil filter, fuel filter, air filter or water filter if any

Release water and sediment in water-fuel separator

Add lubricant crease to fan bearing (large capacity DEG)

Check alternator terminals

Check control system, fasten circuit and clear dust

5.3.3 Class C maintenance

Definition: to check every 1500h running or two years

Repeat the maintenance content of class A and class B

Check and adjust gun clearance

Check and adjust injection time

Check fan, water pump, and static charger belt status, replace if any one worn out

Check and clean cooling system including radiator and watercourse cleaning

5.3.4 Class D maintenance

Definition: to check every 5000h running or four years

Repeat the maintenance content of class A and class B

Clean and adjust injector mouth and fuel pump

Inspect, replace or repair turbo-charger

Inspect, replace or repair water pump

Check and add lubricant to alternator bearing

5.3.5 Seasonal maintenance

Fill anti frozen liquid in winter and start water heater

Keep cooling system clean in summer

27
5.4 Maintenance procedures
Every day or Every Every year or every
System Maintenance Content
week month 250h
Any leakage
Examine
Oil level
Lubricant Oil filter
Replace
Oil
Clean Crankcase breather
Any leakage
Radiator block
Tubes and tie-ins
Coolant capacity
Anti frozen/anti rusty

Examine liquid
Cooling Belt tightness
Refill coolant
Fan and belt wheel
Belt pulley and water

pump
Replace Coolant
Clean Cooling system
Any leakage
Air cleaner resistance
Inspect
Air intake indicator
Pipe fittings and tie-ins
Replace Filter element
Any leakage
Fuel capacity
Inspect
Fuel pipes and tie-ins
Fuel pump
Fuel
Release Deposit
Replace Fuel filter
Injection capacity and
Adjust
speed
Any leakage
Air outlet Inspect
Exhaust resistance
Belt tightness
Electrolyte level
Electrolyte ratio
Electronic
Inspect Switch and warners
control
Pet cock and tie-ins
Alternator winding

insulation
Abnormal vibration
Inspect
Others Tightness to base frame
Clean Engine surface

5.5 Maintenance measures

5.5.1 Air filter
Clean air filter by air compressor for every 50h running; replace for every 500h running or warn device becomes red to keep
enough space to filter air. Warn device becoming red means filter core has blocked by contamination, and need to be replaced.
Open the filter cover, and return warn device to normal position after replacement.

28
 Filter core

5.5.2 Oil filter

Preheat DEG for 10m and stop in winter;

Open oil release piston and release oil;

Clean seat after screwing off replaced oil filter by filter spanner;

Coat thin lubricant oil on filter gasket;

Rotate new oil filter clockwise

Then fasten the filter by spanner about 2/3 winding (Screw down moment 2023Nm);

Fasten oil release piston after oil empty. Refill oil from inlet till meter scale;

Start DEG for 5m and check if there is any leakage;

Check oil level after 10m stop and add to top level.

5.5.3 Fuel filter

Fuel filter shall be replaced after first 50H running or every 250hrs running periodically.

Users shall replace as following process:

Close fuel tank switch, release fuel filter and clean filter seat;

Replace filter core, and install original filter;

Open fuel tank switch and eject air in fuel pipe

5.5.4 Coolant filter replacement (if configured)

Coolant filter shall be replaced after the first 250 hrs running or 3 months running. And then replace for every

500 hrs running or 1 year running.

*Find trial filter on engine, close water inlet valve

*Screw the valve by belt wrench

29
 *Examine whether seal ring is on new filter, clean section

*Install new filter at original position and wrench to the end plus 2/3 round

*Open water inlet valve.

5.5.5 Lubricant oil replacement

Oil shall be replaced after the first 50 hrs running or after 3 months for new DEG, then replace for every 250hrs

running.

Oil type: API CF-4, CG-4, CH-4, or ACEA E2, E3 or CCMC D4 series, different type cant mix together. If lubricant

sulfur content is more than 0.5%, 50% maintenance interval has to be shortened.

5.5.6 Coolant replacement and water tank clean

Coolant shall be replaced every 500 hrs running or 1 year running. The maintenance interval may length for

those gensets filled with anti-frozen liquid.

Clean procedure:

*Fill anti rusty liquid to water tank and make genset running for 15m

*Remove water tank cover; open the bottom water outlet valve

*Clean cooling system by fresh water

*Close water outlet valve, fill coolant to full, and cover

Attention:

*Dont open cover within 15m after genset stops to avoid any vapor damages
*Wash water tank cooling fin vertically with reasonable distance.

5.5.7 Battery maintenance

Battery maintenance is very important for battery problem occupied 30% among DEG fault problems.

Standard electrolyte (10-15mm higher than pole board) should be filled to the new acid-lead battery.

Electrolyte should be refilled at times for it is easily absorbed by the pole board.

30
 After electrolyte filling, users should put the battery aside for 6~8h until the temp. reaches 35 and then

charge for the battery. The charging has to be within 24h from electrolyte filling.

Pay attention to the correct connection while charging.

Battery should be recharged in the shortest time after discharging in order to avoid pole board acidification.

Charged battery without discharging should be recharged at least one time per month.

Battery should keep clean

Reinforce distilling water to standard level and inspect whether the electrolyte proportion is between

1.27~1.28
5.5.8 Alternator maintenance

Alternator need to be cleaned periodically.

Process:

Open power sources and clean dust, water, ordure and liquid on the surface and enclosure.

Dust and ordure need to use cleaner rather than air blower or high pressure water.

Low insulation resistance arising by alternator reversion need to be dried. Drying may refer to Alternator

Operation and Maintenance Manual.

5.6 Genset common fault troubleshooting

Phenomenon Reason Troubleshooting
No power Fuse breakoff Replace fuse after examining circuit
generation or Voltage meter damage Test alternator voltage by multimeter
abnormal Incorrect volt meter Checkout volt meter periodically, and replace if any incorrect
voltage Booster plug connect not fine Inspect booster 50Hz, 60Hz and plugs whether loose
Pulse volt restrictor short circuit Inspect selenium to make sure no touch
Remove cable, and test diode by multimeter, replace if
Diode damage
damaged.
Excitation stator loop by 12V battery, anode to F+, cathode to
Lose remanence F- (15-20min). Attention: while excitation, alternator must be
at stop mode.
Wrong circuit connection Inspect and connect according to circuit diagram
Excitation loop short circuit Reconnect and tin, wrapped by insulation materials
Plugs loose or connect not fine Clean plugs and re connect
Alternator armature coil short
Find the short place and weld it
circuit
Alternator armature coil short Short circuit may cause extreme heat phenomenon, should
circuit be replaced.

Exciter armature coil break or Find fault place and replace loops
31
 short circuit
Abnormal speed Test alternator speed by frequency meter or speed meter
Booster protect circuit action Adjust booster according to booster instruction
Invalid booster Replace
AC armature coil short circuit Remove and replace damaged coil
Air flue block Clean alternator interior
Exciter armature coil short
Replace coil
circuit
Incorrect speed Test alternator speed by current meter, voltage meter
Unstable speed Inspect booster whether stable
Unstable booster Adjust booster stability according to booster instruction
Unstable Connection faulty or loose Inspect connection whether loose or bad contact
alternator Diode, pulse voltage restrictor
Make alternator excitation experimentby 12V battery
voltage faulty
Booster faulty Replace booster according to booster instruction
Imbalanced air gap caused by Replace old bearing, examine bearing worn condition and
bad bearing replace if necesary
Over load Keep load at reasonable capacity
AC armature coil short circuit Replace coil
Hot alternator Air flue block Clean alternator interior by blower
Exciter armature coil short
Replace coil
circuit

32
6. ZK3201 Control panel manual

6.1 general
ZK3201 generator intelligent controller is mainly composed of ZK320B,internal intelligent charger and auxiliary
wires etc. then add lightning protection module,reach to automatic control and three remote funtions and so on.
ZK320B controler adopts high performance computer chip, can modify control procedure and protection parameters of
the generator, which incorporating measure, control, protection and three remote functions and so on, The controller
measure and display all output digital parameters for generator, and rpm, oil pressure, water temperature, DC voltage
and runtime for engine. And the voltage and current use real virtual value measure to make sure the data more
exacter.Chinese/English menu for your choice, large LCD display,.Keys on control panel are used for selecting control
mode, startup running procedure, data display and modify the protection parameter. LED indicator is used for
indicating the controller running mode and Gen set running status, and LCD display measuring parameter and status.
Auxiliary wires have control and protection,effectively improve the using time of the controller
The internal intelligent charger with auxiliary wires control and protect starting battery,automatic choose (12V/24V),
Floating charge over a long period time,when the genset is running,the main charger stop working,then the genset
charger which mounted on the genset is start working,The box of the control panel is produced follow IEC
standards,with steel plate, Plastics ejection on the surface,its very beautiful and durable.Internal wire connections are
treaded in Unified,as a pin type connection,all the wires are very durable, easy maintenance and replacement.lightning
protection module is supplied to protect the equipment, with world famous product Iskra Zascite d.o.o , excellent
quality, safe and reliable.

33
 205.0 mm
156.0 mm

58.5 mm
9.0 mm

Technical Specifications
Voltage range: 12V/24V 8~35VContinued
Max working current@12V 0.4A, @24V 0.2A
AC input voltagephase voltage15~300VAC RMSAC frequency26 Hz
AC current input0.055A real valid value.
AC measure precision0.5 level
AC input frequency3~70Hzvoltage15V
Oil-gate/start control relay output 10A/30VDC
Aux. relay output 3A/30VDC
Running ambient temperature -20~50
Storage ambient temperature -40~80
Humidity(20%75%)RH no condensation
Air pressure: (86106)kPa
IEC shell defend levelIP54B SEN60529 IEC529, BS5490
Vibration standardISO10816-11995GB/T6075.1-1999

6.2 Connection Port

No. Function Single Line
A1 A-phase voltage input 0-300VAC 1mm line
A2 B-phase voltage input 0-300VAC 1mm line
A3 C-phase voltage input 0-300VAC 1mm line
A4 N zero line 1mm line

B5 A-phase current input{S1} 0-5A(AC) 1mm line

B6 B-phase current input{S1} 0-5A(AC) 1mm line
B7 C-phase current input{S1} 0-5A(AC) 1mm line
34
B8 Current input com. port{S2} 0-5A(AC) 1mm line

C9 Relay output com. point 1.5mm line

C10 Fuel electromagnetism valve N.O. dry contact, 10A/30VDC 1.5mm line
relay output
C11 Start relay output N.O. dry contact, 10A/30VDC 1.5mm line
C12 Charger excitation source If not use, forbid connected 1mm line
output to cathode
C13 Gen set running output N.O. dry contact, 3A/30VDC 1mm line
C14 Custom output 1# N.O. dry contact, 3A/30VDC 1mm line
C15 Custom output 2# N.O. dry contact, 3A/30VDC 1mm line
C16 Custom output 3# N.O. dry contact, 3A/30VDC 1mm line

D17 Oil pressure test Pressure sensor 1mm line

(<2K)
D18 Water temperature test Temperature sensor 1mm line
(<2K)
D19 Oil position test Oil position sensor (<2K) 1mm line
D20 Oil pressure signal Low potential valid 1mm line
D21 Water temperature signal Low potential valid 1mm line
D22 Emergency stop signal Low potential valid 1mm line
D23 Start {external control }signal Low potential valid 1mm line
D24 Aux. on-off input Low potential valid 1mm line
D25 Magnetic sensor signal{} 1~70Vac 2 core shield
D26 Magnetic sensor signal{} Internal connect to DC source line
cathode
D27 Working source anode {+} 12V/24V (8~35VDC 1mm line
D28 Working source cathode {-} continued) 1mm line
D29 Protection ground wire 1.5mm line

Remark: D19 pin is standby analog measure input, can measure 0-5VDC or 0-20mA or resistance signal, preset to resistance signal,
if need change should change the hardware first.

35
 36
1 2 3 4 5 6 7 8
L1 L4 A
A L2
P1
S1
P2
S2
L5
P1 P2
G S1 S2
L3 P1 P2 L6
S1 S2
N1 N1
E E
FUSES LOCATED 104 103 102 101
EARTH STUD
ON ALTERNATOR
TERMINAL BOX
104 103 102 101 C10 C30 C50 C90
B F4 F5 F6 B
132
AUXILIARY F3
A.C. SUPPLY 131 (6A)
136
:4
108 109 110 101 C10 C30 C50 C90
CR/1 AC
:1 1 2 3 4 5 6 7 8
CAR/1
:3 :4
Genset Controller :1
C 81 82 83
C
CHARGE FAIL(
137 FAIL TO START(
LOW OIL PRESSURE(
HIGH TEMPERATURE(
COMMON ALARM
OVERSPEED( VOLT FREE CONTACT
REMOTE START EMERGENCY STOP(
5 24 23 REMOTE START
5 28_
137 131 AUTO MAN TEST START
STOP L.TEST
RESET
5 AMP BATTERY (12/24Vdc) MUTE
CONSTANT 2 27+
VOLTAGE - +
CHARGER
D 5 31 D
PROGRAMMABLE FAULT CHANNELS
FUEL RUNING PRE IDLE EMERG ENGINE ENGINE
3 REF. CRANK FAULT ALARM STOP TEMP TEMP
E04 MAG
OIL OIL
PICKUP
RL1 RL2 RL3 RL4 RL5
4 REF. PRESS PRESS (0-5Vdc) I/P + -
E04 F2 DC 9 10 11 13 14 15 16 12 22 20 21 17 18 19 24 25 26 29
(10A)
7 3 4 14 17 15 16 OP ET RED BLACK
SSR + + F1 2 2
yellow/green
(16A)
2 EMER REF.
2 STOP F02
SSR 7
51
+
E
E 24V SS W/L
1 AMP E
CHARGING :2 :2
M ALTERNATOR CR CAR
:7 3 4 :7
REF. REF. FL 26
3 D02 D02 5
FCS RED BLACK NET
5 15 16 OP ET
REF. + -
E07 RS485
P S1 S2
MAGNETIC
PICK-UP
F F
REMARKS Power
OUTGOING/INCOMING PANEL TERMINAL D.C. CONNECTOR FROM ENGINE BREAKER BOX TERMINAL
Title: Z3203
CUSTOMER POWER CONNECTION NO A.C. CONNECTOR FROM ALTERNATOR Corporation
INTERNAL PANEL TERMINAL TERMINALS TO CHANGEOVER SYSTEM THIS DRWING IS COPRRIGHRED AND MAY BE COPIED ONLY FOR THE Drawn by: Audit: Drawing NO: Sheet of:
BREAKER BOX TERMINAL SPADE PIN CONNECTION ON ENGINE PURPOSES OF MAINTAINING THE PURCHASED EQUIPMENT BY THE
PURCHASER ZCK3203105 1
1 2 3 4 5 6 7 8
 L1

L2

G L3 (3P&N)

F1 F2 F3

1 2 3 4 5 6 7 8

ZK320B
+CI485=RS485
+CI232=RS232

RS-CONNECTOR

12/24VDC RL1 RL2 RL3 RL4 RL5 RL6
WL
27 28 29 9 12 10 11 13 14 15 16 20 21 22 23 24 17 18 19 25 26

F4 F5
(2A) (16A)

DCV

37
6.3 Operation Panel

6.3.1 Preparations before operation

Make sure controller is fixed well and its install ambient meet requirement.
Confirm controller all control connection meet electric specification and corresponding to typical wiring diagram 2.3.
Especially need confirm DC supply source has added fusing element to protect, and correct polarity. Otherwise, it maybe
damage controller.
Controller must be ground well.
We suggest install E- stop key in external, connecting E-stop signal input terminal to E- stop key N. O. contact, and
another contact connected to the cathode of battery power source
Switch on DC working source, make sure default parameter meet practical condition, such as current ratio, speed sensor
mode, pressure sensor mode, temp sensor mode, etc.
If speed sensor is electromagnetism type sensor, then must according to below steps to correct speed measuring
parameter:

6.3.2 The whole operation panel includes 3 sections: measuring parameter display by LED, operation switch
and running status LED indication.
Function Description Tag

Entering submenu/modify/confirming modification

Scroll up menu/ value ascend

Scroll down menu/ value descend

Function Description Tag

AUTO/LED
The key is used for setting auto-operation mode. When
controller is running in this mode, the LED above the
button will illuminate. According to the remote control
start input signal, the controller control generator start
and stop.

MAN/LED
The key is used for setting manual-operation mode.
When controller is running in this mode, the LED above
the button will illuminate. The controller control generator
start and stop by pressing START and STOP key.

TEST/LED
The key is used for setting test-operation mode. When
controller is running in this mode, the LED above the
button will illuminate. According to the valid of analog
remote control start input signal, the controller control
generator start. When switch to Auto operation mode
and analog remote control start input signal is disabled,
generator stop.

38
START/LED
The key is used for Gen set manual startup. When the
controller is running in manual-operation mode, press
this key to start the generator. During controller
performing start procedure to Gen set in normal running,
the LED above the key on, and continuously on when the
Gen set in normal running.
STOP/RESET/LED
The key is used for generator manual stop, when the
controller set in MAN mode, this key can stop the Gen
set. Press this key more than 2 seconds can release the
fault stop lock if there is a fault output. (When the
controller performing stop procedure LED on; When stop
failure, LED flash)
MUTE/LAMP TEST
It is alarm mute and lamp test key. Press the key more
than 2 seconds, all LED on the panel will illuminate. This
function used to test all LED on the panel. When warning
or fault alarm occur, press this key can mute the buzzer
and the lamp above the key illuminate. Press it again will
cancel mute function. If controller held on fault status, the
buzzer keeping alarm.

6.3.3 LCD Display and Control Keys:

Adopting 12864 lattice LCD can display multi-lines data information at the same time. And LCD has background-light function,
after pressing any key the background-light can auto turn off in a certain time. Set a different parameter in every page and

control by the setting, each item load electrical parameter displayed in main page, press and scroll to display each

electrical parameter and oil machine measuring data. If no failure occurs, LCD keep stay at current page, when failure occurs,
LCD display failure information in status file immediately, when not only one failure, LCD just display one of them.

For parameter setting and modify by gradually increase and decrease, when continuously press increase or decrease key, the
single digit cnahge one by one, then the tens digit changed after ten single digit changed, follow this logic, and the hundreds
digit changed after ten. In any page continuously press 2s to enter setting status, then can use and scroll in
the same grade menu. Press again can enter into next submenu, select need modify item, press enter into
modify. When prompt enter password, enter (221313)continuously press 2s to
quit setting status after finishing modify.
Static LCD display:
WHEN CONTROLLER STANDBY
Operation Description

U=0V I=0A

When controller has not tested engine data P=0kW F=0.0Hz

such as running speed, oil pressure, water
SP=0rpm OP=0.0kPa
temp, etc. the related data display at 0, LCD
display: TEMP=0 Bat=24V

READY

When controller set without HP-sensor

39
 Operation Description

U=0V I=0A

When controller has not tested engine data P=0kW F=0Hz

such as running speed, oil pressure, water
SP=0rpm OP= - - -
temp, etc. On standby or running the related
data all display at ---, LCD display: TEMP= - - - Bat=24V

READY

When controller normal running

Operation Description

This page display voltage/current value at the average

P=0kW F=0Hz
of three-phase . Press or can switch display SP=1500rpm OP=475kPa
TEMP=70 Bat=25.4V
page
RUN
V1=220V U12=380V
I1=0A A1=0kVA
Press can switch display page P1=0kW PF1=1.00
Q1=0kVAr

V2=220V U23=380V
I2=0A A2=0kVA
Press can switch display page P2=0kW PF2=1.00
Q2=0kVAr

V3=220V U31=380V
I3=0A A3=0kVA
Press can switch display page P3=0kW PF3=1.00
Q3=0kVAr

Relay Outputs
---- ----
Press can switch display page Digital Inputs
---- ----
RUN
P=0KW
A=1000KVA
Press can switch display page Q=KVAr

RUN

40
6.3.4 Measuring data
Electric section

Generator phase voltage V L1-N L2-N L3-N

Generator line voltage V L1-L2 L2-L3 L3-L1
Generator current A L1 L2 L3
Generator frequency Hz HZ
Generator apparent power kVA L1 L2 L3 three phase and their sum
Generator active power kW L1 L2 L3 three phase and their sum
Generator power factor PF L1 L2 L3 three phase
Generator reactive power kVAr L1 L2 L3 three phase and their sum
Generator active energy kWh
Generator reactive energy kVArh

Engine section

Engine oil pressurekPa This data from an external sensor

Cooling water temperature
Oil position measuring (%)
RPMRPM
Running hoursRUN Hour
Battery voltage (V)
This data from an external sensor
This data from an external sensor
This data from speed sensor
Precise to 0.1hour
Adopt working source voltage

6.4 System Parameter

Name Explanation on View Menu

Menu Name EXPLANATION Menu Name EXPLANATION

0.QUIT Quit 1.SYSTEM System Parameter
2.GENERATOR Generator Parameter 3.ENGINE Engine Parameter

NO. Item Default Value Range

1.0 Quit
1.1 Current Transformer 100 1~5000
1.2 Voltage Ratio 1 1~100
1.3 Voltage Input Type 1 1~5
1.4 Communication Address 1 1~255
1.5 Recover Default
1.6 Language >English
1.7 Firmware update
1.8 Firmware update

Remark: After changing communication address only restart working source can become effective.

Generator Parameter

NO. Item Default Value Range

2.0 Quit
2.1 Gen. Low Voltage Failure Value 0V AC45~20000V / 0 (no set)
2.2 Gen. Low Voltage Warning 198V AC45~20000V / 0 (no set)
2.3 Gen. High Voltage Warning 253V AC45~20000V /29999(no set)

41
2.4 Gen. High Voltage Failure Value 29999V AC45~20000V /29999(no set)
2.5 High Current Warning 9999A 1~9999A / 9999 (no set)
2.6 High Current Failure Value 9999A 1~9999A / 9999 (no set)
2.7 Failure Delay 10S 0~600S

Engine Parameter

NO. Item Default Value Range

3.0 Quit
3.1 Engine Running Speed 1500 99-9999 RPM
3.2 Sensor Frequency Input Value 3000 1-9999 Hz
3.3 Setting Sensor Frequency
3.4 Pair of Poles 2 1~4
3.5 Fuel Valve Type 0 0 N.C. Type / 1 N.O. Type
3.6 T-sensor Type 1 0~8 / 0 (no use)
3.7 P-sensor Type 1 0~9 / 0 (no use)
3.8 Speed Sensor Type 0 0~1 / 0 (no use) / 1(use)
3.9 Start Delay 10S 0~300 S
3.10 Start Times 3Times 1~10 Times
3.11 Crank Time 8S 0~30 S
3.12 Crank rest 15S 0~300 S
3.13 Crank Cut Off Speed 300rpm 1-9999 RPM
3.14 Idle Delay 0S 0~9999S
3.15 Preheat Delay 0S 0~9999S
3.16 Safety-on Delay 60S 0~600S
3.17 Cooling Delay 300S 0~600 S
3.18 Stop Failure Delay 20S 0~60S
3.19 Low Speed Failure Value 0 RPM 0-9999 RPM / 0 (no set)
3.20 Low Speed Warning 1440rpm 0-9999 RPM / 0 (no set)
3.21 Over Speed Warning 1600rpm 1-9999 RPM / 9999 (no set)
3.22 Over Speed Failure Value 1710rpm 1-9999 RPM / 9999 (no set)
3.23 Low Oil Pressure Failure Value 140kPa 5~300 kPa / 0 (no set)
3.24 Low Oil Pressure Warning 220kPa 5~300 kPa / 0 (no set)
3.25 High Water Temp Warning 95 70~320 / 9999 (no set)
3.26 High Water Temp Failure Value 105 70~320/ 9999 (no set)
3.27 Low Battery Warning 8V 1~25V / 0 (no set)
3.28 High Battery Warning 35.0V 1~35V / 99.9 (no set)
3.29 Switch Aux. Input 0 0 (warning) /1(stop)
0 no use
3.30 Oil Position Sensor Input 2 1 unit is % according to resistance type data
2 Custom Input
3.31 Oil Pressure Stop (On-Off) 1 0~1 / 0 (warning) / 1 (stop)
3.32 Water Temp Stop (On-Off) 1 0~1 / 0 (warning) / 1 (stop)
3.33 Fuel pump On Level Value 20% 0~100%
3.34 Fuel pump Off Level Value 70% 0~100%
3.35 Relay Custom 1 2 0~80
3.36 Relay Custom 2 3 0~80
3.37 Relay Custom 3 4 0~80
3.38 Low Charging Warning 8.0V 1~25V / 0 (no set)

AppendixRelay can custom content

Code Define Failure Type Code Define Failure Type

0 No Use 1 Over Current Output
2 Failure Alarm Output 3 Warning Output
4 Idle Output (N. C.) 5 Preheat Output
6 Reserved 7 Reserved
8 Fuel pump Control 9 Running
10 System in Auto Mode 11 System in Test Mode
42
 12 System in Man. Mode 13 Reserved
14 Idle Output (N. O.) 15 Reserved
16 Reserved 17 Start Failure
Voltage Input Type: use different winding connect type, on behalf of different winding by selecting menu.

1. Series parallel start, three-phase four-line 2. Series parallel angle, three-phase three-line
3. Island angle, three-phase four-line 4. Biangle, one-phase two-line
5. Biangle, one-phase three-line
Remark:
When menu 3.8 set at 0 and not using speed sensor, generator running speed set by 3.4 pole logarithm, when pole
logarithm at 2 running speed is 1500 rpm, when pole logarithm at 1 running speed is 3000 rpm.
When menu 3.8 set at 1 and using speed sensor, through manual setting 3.2 frequency input value, generator running
speed display by setting menu 3.1.
When menu 3.8 set at 1 and using speed sensor, through below 11.6 showing method auto setting frequency input value,
then menu 3.4 pole logarithm and 3.1 generator running speed should be correctly setting.
PT-Sensor Explanation
According to below table difference sensor type of oil pressure sensor and water temp sensor express by difference number, if
the using sensor not listed in the table, can through software logging into controller base on sensor offered data parameter, and
the sensor type should select the last custom type listed in the type at parameter setting.
No. Pressure Sensor Type Temp Sensor Type
0 NOT USE NOT USE
1 VDO 10 bar VDO 120 degrees C
2 KD 10 bar KD KD 120 dc KD
3 YG962 1J1M ZJ WGJ 900131 ZJ
4 KP 6 barKP KP 130 dc KP
5 3846 N-010-B2 DX 21YB054 DX
6 3967251KL 3967250 KL
7 MHI 10 bar SL MHI 98 dc SL
8 Datcon 10 bar Custom (Base on sensor data)
9 Custom (Base on sensor data)

Example: (setting current transformer rate at 1000 /5, then CT should be set at 200)

Operation Description

<<SETTING >>
Continuously press 2s, enter into parameter setting menu, then
LCD display:
0QUIT

1. CT/current transformer
Press and , and then press again, then LCD display:

=1000

Press and then press , prompt enter password, key in password

1. CT/current transformer rate Password:******

Press or change parameter, change at 200, then LCD display: 1. CT/current transformer rate 200

<<SETTING >>
Press confirm after changingthen press and , then LCD
display:
1. System parameter

43
Press and again for quit, or continuously press more that
2s also can quitthen LCD display: READY

6.5 Alarm and Stop failure

6.5.1 Alarm
(NOTE: Warning is a very serious failure status, it will not damage generator system for the moment, only remind operator the
improper condition and need solve to make sure system continuous running. When warning occurs, the status indicator
illuminate, the buzzer alarm but failure will not be locked and the unit non stop. Once failure has been eliminated alarm lamp
auto turn off.)
Charge Failure Controller has tested voltage lower than low charge warning setting value from excitation contact
of auxiliary AC charge, LCD status file display WARN: CHARGE FAILURE or ALARM: CHARGE FAILURE, buzzer
alarm.

Battery Voltage Too Low Controller has tested voltage lower than low charge warning setting value, LCD status file
display WARN: BATTERY LOW or ALARM: LOW VOLTAGE, buzzer alarm.

Battery Voltage Too High Controller has tested voltage lower than low charge warning setting value, LCD status file
display WARN: BATTERY HIGH or ALARM: HIGH VOLTAGE, buzzer alarm.

Low Oil Pressure After safety-on delay timing over, controller has tested engine oil pressure reduced to oil
pressure setting alarm value, LCD status file display WARN: LOW OIL PRESSURE or ALARM: LOW OIL PRESSURE,
buzzer alarm.

Engine High Temp Controller has tested engine coolant temp over than high temp setting alarm value, LCD status file
display WARN: COOLANT TEMP or ALARM: HIGH WATER TEMP, buzzer alarm.

Over Speed If engine rpm over than setting alarm value, LCD status file display WARN: OVER SPEED or
ALARM: OVER SPEED, buzzer alarm.

Low Speed If engine rpm lower than setting alarm value, LCD status file display WARN: LOW SPEED or
ALARM: LOW SPEED, buzzer alarm.

Gen. High Voltage Alarm If controller has tested generator output voltage over than setting alarm value, LCD status file
display WARN: GEN. V HIGH or ALARM: GEN. V HIGH, buzzer alarm.

Gen. Low Voltage Alarm If controller has tested generator output voltage reduced tosetting alarm value, LCD status file
display WARN: GEN. V LOW or ALARM: GEN. V LOW, buzzer alarm.

Over Current Alarm If controller has tested generator output current over than setting alarm value, LCD status file
display WARN: OVER CURRENT or ALARM: OVER CURRENT, buzzer alarm.
Standby Input If standby auxiliary input set as alarm input for use, when input signal valid, LCD status file display WARN:
AUX ALARM or ALARM: AUX SWITCH INPUT, buzzer ala

6.5.2 Stop Failure

Note: Stop failure locks system immediately and generator stop running, it only can operated controller again after eliminating
failure and press reset key to release failure locked
Start Failure If engine start times over desired setting value and still can not run, that is start failure, LCD status file
display WARN: START FAILURE or ALARM: START FAILURE, failure indicator illuminate FAIL TO START,
buzzer alarm, failure relay close output.
Stop Failure If after stop time delay over engine can not stop, then buzzer alarm, LCD status file display WARN: STOP
FAILURE or ALARM: STOP FAILURE, failure relay close output.

Emergency Stop When emergency stop input signal valid, control immediately stop all relay control output except alarm,
LCD status file display WARN: E. STOP or ALARM: E. STOP, failure indicator illuminate EMERGENCY STOP,
buzzer alarm, failure relay close output.

Low Oil Pressure After safety-on delay timing over, controller has tested engine oil pressure still lower than oil pressure
failure value or oil pressure switch in close status, engine stop immediately, then LCD status file display WARN: LOW OIL
PRESSURE or FAILURE: LOW OIL PRESSURE, failure indicator illuminate LOW OIL PRESSURE, buzzer alarm,
failure relay close output.

High Water Temp Controller has tested engine coolant temp over than high water failure value or temp switch in close
status, engine stop immediately, LCD status file display WARN: COOLANT TEMP or FAILURE: HIGH WATER TEMP,
failure indicator illuminate HIGH TEMP, buzzer alarm, failure relay close output.

Over Speed Controller has tested engine rpm over than over speed failure value, engine stop immediately, LCD status
file display WARN: LOW SPEED or FAILURE: LOW SPEED, buzzer alarm, failure relay close output.

44
Low Speed Controller has tested engine rpm lower than low speed failure value, engine stop immediately, LCD
status file display WARN: LOW SPEED or FAILURE: LOW SPEED, buzzer alarm, failure relay close output.

High Voltage Failure If controller has tested generator output voltage over than Gen. high voltage failure, after delay
engine confirmed stop, LCD status file display WARN: GEN. V HIGH or FAILURE: GEN. V HIGH, buzzer alarm, failure
relay close output.

Low Voltage Failure After safety-on delay timing over, controller has tested generator output voltage low than Gen. low
voltage failure, after delay engine confirmed stop, LCD status file display WARN: GEN. V LOW or FAILURE: GEN. V
LOW, buzzer alarm, failure relay close output.

Over Current Failure Controller has tested generator output current over than Gen. high current failure value, after delay
engine confirmed stop, LCD status file display WARN: OVER CURRENT or FAILURE: OVER CURRENT, buzzer
alarm,
failure relay close output.

Standby Input If standby auxiliary input set as failure stop for use, when input signal valid, engine stop immediately, LCD
status file display WARN: AUX ALARM or FAILURE: AUX SWITCH INPUT, buzzer alarm, failure relay close output.

Remark:

Oil pressure and water temp on-off warning or failure stop, we can through setting 3.29 and 3.30 menu realizing, the data
from oil pressure and water temp sensor on-off status(on or off) test.
Oil pressure and water temp analog warning or failure stop, we can through setting parameter range on 3.22, 3.23, 3.24
and 3.25 menu realizing warning or failure stop request, the data from oil pressure and water temp sensor on-off status(on
or off) test.
Engine rpm normal from flywheel speed sensor frequency which mounted on engine, if system not mounted speed sensor,
controller will auto use generator output voltage frequency as control and failure protection parameter, for user
convenience, some data expressed by rpm, RPM=HZ*30.
Generator failure during generator running: after high water temp, low oil pressure, over speed and low speed occurred,
stop immediately no delay, and non idle function only play protection function by set idle delay at 0 during cooling delay,
low speed, low oil pressure, or will not play.

6.6 Communication Function

6.6.1 Brief Introduction

The controller has a RS CONNECTOR communication port , this port need to match use with CI485ACI232A
communication interface module, then controller has RS485/RS232 industrial standard COM. This COM adopt photoelectricity
seclusion design and has circuit protection function to prevent common mode Voltage interfere and damage by error connection,
and adopt 9600 baud rate. The controller that has communication function has following features:

z 100% remote signaling, including running and failure status.

z 100% remote regulating, including all settable parameters in controller.
z 100% telemetering data, including all measuring data in controller.
z 100% remote control, including all panel control function.
6.6.2 CI485 Communication Connection
Controller has RS485 COM after add CI485
accessory, following typical wiring diagram:

ZK320B Controller

45
Controller has RS232 COM after add CI232A accessory, following typical wiring diagram:

ZK320B Controller

The communication interface offers user a route: from which you can get more information that can not get from the panel, can
display all measured parameter and status information by matching software and possible to setting all parameters. The
controller that has RS485 COM allow 1 communication bus can most connect 247 same series of controllers by line type
connection mode, each device has one and only ID NO., only can connect to PC or MODEM by matching with another
RS485/RS232 shifter in that time. Following typical wiring diagram:

46


RS485/232

R
ZK320B Controller

ZK320B Controller

ZK320B Controller

NoteCommunication cable use high quality shielded twisted-pair cable, and its amount length must not exceed 1000m.
RS485 anode and cathode port in each controller must be properly connected, and the cable shield only can be connected to
the earth at one side.

6.6.3 Communication Protocol

When working controller adopts 9600 baud rate and MODBUS-RTU communication protocol, when it is working, computer will
send out a string of instruction to controller and then waiting for the return data string. Modbus protocol is one kinds of universal
language that applied in electronics controller. Using this protocol, controllers can communication with each other, the controller
can communication with other device through network (such as Ethernet). It has become a universal industry standard. Using it,
the control device that manufactured by different manufacturer can connect to industry network, processing concentration
monitor.

This protocol defined a message construction that controller can identify, no matter which network it used to communication. If
response request from other device it describes the process that a controller request to access other device and how to detect
error and make a record. It has set up message structure and content common format.

When communicating in Modbus network, this protocol decides each controller must know their device address, and identify
message that send out from address, and according it to decide take which action. If need respond, controller will create return
massage and send out by Modbus protocol. In other network, the message that including Modbus protocol will be translated into
frame or package structure that used in network.

Data frames format

Address Function Code Data Quantity Data 1 Data n CRC High Bit CRC Low Bit

47
Communication Agreement

Use RTU mode, sending message at least using 3.5 characters interval to start, which is easy to realize under network baud
rate with multi character interval (showed as following figure T1-T2-T3-T4). The first transferred field is device address, can use
transfer characters are hexadecimal 09, AF. The network device continued to detect network bus, including in the interval.
When received the first field (address field), each device decode it to judge whether it is sent to itself. After the last character be
transferred, an interval at least 3.5 characters decide finish the whole message. After this a new message may be start.

The entire message frame must transfer as a continuous flow. Receiver will refresh uncompleted message and assume the next
byte is address field of a new message if over 1.5 characters interval before finishing frame. Likewise, if another new message
follows the last message sent out less than 3.5 characters interval, receiver will identify it as the continuous of the last message.
That will cause an error, because the value in the final CRC field impossible correct. Typical message frame as following:
Start Bit Device Address Function Code Data CRC Parity Stop Bit
T1-T2-T3-T4 8Bit 8Bit n*8Bit 16Bit T1-T2-T3-T4

Address code

Message frame address field including two characters: ASCII or 8 bit RTU. The possible slave device address is
0247(algorism). Single device address range is 1247. Master device select slave device by putting salve address which to
be contacted into address filed in message. When slave device send out response message, it will put itself address into
response address field, in order to master device know which device send out response.

Address 0 used to be broadcast address, so that all slave devices can identify. When Modbus protocol used in higher level
network, broadcast maybe not allow or use other mode to replace.

Function Code

1. Read register command code 03Hread the maximum words is (word) 40

2. Write register command code10Hwrite the maximum words is 38

Data Field

Data field is structured by two hex number set, range 00...FF. According network transfer mode, it can be structured by 1 pair
ASCII or RTU characters.

The message data field sent out from master device to slave device including additional message: slave device must use this
message to implement action that defined by function code. This including discontinuous register address, the quantity of items
will to be handled, really data bytes in the field.

For example, if master device need slave device read a set of hold register (function code 03), the start register and the quantity
of register to be read is specified by data field. If master device write a set of slave device register (function code 10 hex), then
data field specify start register and the quantity of register to be wrote. Data bytes in data field need to write into register data.

If no error, data field return from slave device including request data. If occur error, this field will including an exception code,
master device application can use it to judge the next action.

In some message, data field can be inexistent (0 length). For example, master device requires slave device response
communication event record (function code 0B, hex), slave device no need any additional message.

Error Correction CodeCRC

Standard Modbus network has two error test methods. Content in test field depend on selected test method.
When select RTU mode as character frame, error test field including a 16 bits value (realized by two 8 bits character). Content in
error test field has test out by message content processing CRC. CRC field append at the end of the message, add from low
byte to high byte. So the high byte of CRC is the last byte in send out message.
Use RTU mode, message including an error test field which based on CRC method. CRC field has test the entire message
content.
CRC field is two bytes including a 16 bits binary value, which added into message after calculated by transmission device.
Receiver recalculates CRC that received message and compared with the value in CRC field. If any difference, there must be
some error.
CRC first fold in a 16 bit register which all value at 1, and then transfer a process, compare the continuous 8 bits byte in a
message with value in currently register. Only 8 bit data in each character is valid for CRC, start bit, stop bit and parity are not
valid.
During CRC produce, each 8 bit character will OR with register content respectively, result moving to the low valid bit, use 0 fill
out the highest valid bit. LSB is pick out for testing, if LSB is 1, register OR with default respectively, if LSB is 0, no action. The
whole process need repeat 8 times. After finishing the last bit (the eighth bit), the next 8 bit byte will OR with the register default
respectively. At last, the value in register is CRC value after all bytes in message are processing.

48
Information frame format example
Example on Using RTU Mode Read Entire Data

Master Device Request

Function High address of the Low address of the High bit on the Low bit on the Error
Address
Code first register first register register quantity register quantity Correction

01 03 00 38 00 01 XX

Slave Device Request

Address Function Code Byte quantity Data high byte Data low byte Error Correction

01 03 2 41 24 XX

Hex number 4124 is express algorism integer 16676, error correction value decided by transmission mode.

49
Controller Data Cell Address

Address Byte Content Unit

$1000 1 L3-N Voltage C-phase phase voltage Unit: V
$1001 1 L2-N Voltage B-phase phase voltage Unit: V
$1002 1 L1-N Voltage A-phase phase voltage Unit: V
$1003 1 L3-L1 Voltage AC-phase line voltage Unit: V
$1004 1 L2-L3 Voltage BC-phase line-voltage Unit: V
$1005 1 L1-L2 Voltage AB-phase line voltage Unit: V
$1006 1 L3 Current C-phase phase current Unit: A
$1007 1 L2 Current B-phase phase current Unit: A
$1008 1 L1 Current A-phase phase current Unit: A
$1009 1 L3 PF C-phase power factor
$100A 1 L2 PF B-phase power factor
$100B 1 L1 PF A-phase power factor
$100C 1 Frequency Gen. frequency Unit: 0.1Hz
$100D 1 L3 VA C-phase apparent power Unit: kVA
$100E 1 L2 VA B-phase apparent power Unit: kVA
$100F 1 L1 VA A-phase apparent power Unit: kVA
$1010 1 L3 W C-phase active power Unit: kW
$1011 1 L2 W B-phase active power Unit: kW
$1012 1 L1 W A-phase active power Unit: kW
$1013 1 L3 VAr C-phase Reactive power Unit: kVAr
$1014 1 L2 Var B-phase Reactive power Unit: kVAr
$1015 1 L1 VAr A-phase Reactive power Unit: kVAr
$1016 1 Tacho speed sensor rpm Unit: RPM
$1017 1 Oil Pressure Oil Pressure sensor value Unit: kPa
$1018 1 Coolant Water temp sensor value Unit:
$1019 1 VBAT Battery voltage Unit: V
$101A 1 VALT Charging excitation voltage Unit: V
$101B 1 AI Standby input voltage Unit: mV
Bit0Oil Pressure
Bit1Water temp
$101C 1 Bit2Emergency stop
Bit3Remote start signal
Bit4Standby on-off signal
Bit0
Bit1
Bit2Custom 3 output
Bit3Custom 2 output
$101D 1
Bit4Custom 1 output
Bit5Unit normal running status
Bit6Oil machine start
Bit7Oil machine oil-gate
$101E 1 Bit0
Bit1
Bit2STARTLED
Bit3TEST LED

50
 Bit4AUTO LED
Bit5MAN LED
Bit6
Bit7STOP LED
Bit8
Bit9
Bit10Charge failure LED
Bit11Start failure LED
Bit12Low oil pressure LED
Bit13High water temp LED
Bit14Over speed LED
Bit15E stop LED
$101F 1 Warn Warning Code Refer to attached
$1020 1 Alarm Alarm Code failure code
03Oil machine stop
04Oil machine start
05 Enter test status
$1021 1
06 Enter Man status
07 Enter Auto status
08Reset
$1022 1 SN Series number
$2001 1 Com. Address Communication Address
$2002 1 Language Language select
$2003 1 CT Current transformer rate
$2004 1 GEN-V Low Alarm Gen. low voltage failure Unit: V
$2005 1 GEN-V Low Warning Gen. low voltage warning Unit: V
$2006 1 GEN-V High Warning Gen. high voltage warning Unit: V
$2007 1 GEN-V High Alarm Gen. high voltage failure value Unit: V
$2008 1 I High Warning High current warning Unit: A
$2009 1 I High Alarm High current failure value Unit: A
$200A 1 GEN-HZ Low Alarm Gen. low frequency failure Unit: Hz

$200B 1 Standby
$200C 1 Standby
$200D 1 GEN-HZ High Alarm Gen. high frequency failure Unit: Hz
$200E 1 Standby
$200F 1 Standby
$2010 1 Standby
$2011 1 Alarm delay Failure delay Unit: S
$2012 2 KWH active energy Unit: kWh
$2014 2 KVArH Reactive energy Unit: kVArh
$2016 1 VT voltage transfer rate
$2017 1 Pair of Poles
$2018 1 Rated speed engine running speed Unit: RPM
$2019 1 Pickup frequency sensor frequency input value Unit: RPM
$201A 1 Fuel mode Fuel valve mode
$201B 1 T-sensor mode Water temp sensor mode
$201C 1 P-sensor mode Oil pressure sensor mode

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 $201D 1 H-sensor mode speed sensor mode
$201E 1 Start delay Unit: S
$201F 1 Crank attempt Start times
$2020 1 Crank time Unit: S
$2021 1 Crank rest Crank intermission time Unit: S
$2022 1 Crank disconnect Crank disconnect speed Unit: RPM
$2023 1 Idle delay Unit: S
$2024 1 Safety-on delay Unit: S
$2025 1 Cooling delay Unit: S
$2026 1 Stop delay Stop failure delay Unit: S
$2027 1 Low SP Alarm Low speed failure value Unit: RPM
$2028 1 Low SP Warning Low speed warning Unit: RPM
$2029 1 Over SP Warning Over speed warning Unit: RPM
$202A 1 Over SP Alarm Over speed failure value Unit: RPM
$202B 1 Oil-P Low Alarm Low oil pressure Failure Unit: kPa
$202C 1 Oil-P Low Warning Low oil pressure warning Unit: kPa
$202D 1 Coolant Warning High water temp warning Unit:
$202E 1 Coolant Alarm High water temp failure Unit:
$202F 1 Batt Low Warning Low battery warning Unit: V
$2030 1 RUNHr Running time Unit: HOUR
$2031 1 External Alarm On-off aux. input
$2032 1 Fuel level input Oil pressure sensor input Unit: 0: V / 1 2: %
$2033 1 Oil-P Stop Oil pressure stop
$2034 1 Coolant Stop Water temp stop
$2035 1 Pre-Heat delay Unit: S
$2036 1 Fuel pump on level Unit: %
$2037 1 Fuel pump off level Unit: %
$2038 1 Custom Relay 1
$2039 1 Custom Relay 2
$203A 1 Custom Relay 3
$203B 1 Batt High Warning High battery warning Unit: V
$203C 1 ALT. Low Warning Low charging warning Unit: V
$203D 1 Voltage Type Voltage input type
$203E 1 Preset AUTO
$2040 1 V1 Correction
$2041 1 V2 Correction
$2042 1 V3 Correction
$2043 1 I1 Correction
$2044 1 I2 Correction
$2045 1 I3 Correction
$2046 1 Oil pressure Correction
$2047 1 Water temp Correction
$2048 1 Battery voltage Correction
$2049 1 Excitation charging voltage Correction
$204A 1 Aux. input voltage Correction
$204B $205E P-sensor data table, ordered according to resistance(0.1) from small to big and
resistance-corresponding value-resistance.

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 $205F $2072 T-sensor data table, ordered according to resistance(0.1) from small to big and resistance-
corresponding value-resistance
$2073 $2086 Oil position sensor data table, ordered according to resistance(0.1) from small to big and
resistance- corresponding value-resistance

Appendix: Failure Code

Code Failure Type Remark Code Failure Type Remark

0 NO ERROR No failure
BATTERY Low battery
10
1 NO PICKUP No speed signal LOW voltage alarm

2 OVER SPEED Over speed failure CHARGE Charging failure

12
FAILURE alarm
3 LOW SPEED Low speed failure

Oil pressure sensor Low voltage

4 P-SENSOR OPEN 13 V LOW
open alarm
High voltage
5 LOW OILPRESS Low oil pressure failure 14 V HIGH
failure
High current
6 T-SENSOR OPEN Water temp sensor open 15 I HIGH
failure

7 COOLANT TEMP High water temp failure

8 START FAIL Start failure

9 STOP FAIL Stop failure

6.7 Troubleshooting

Failure Phenomenon Failure Eliminate

In MAN mode 1. Check failure LED, or check LCD display to confirm if failure display.
pressSTART key 2. Check DC voltage on controller C9 terminal, if no voltage, check related circuitry fuse.
or in AUTO mode, Such as low voltage, use charger charging battery, after battery fully charging, start again.
Gen set no remote control 3. Check DC voltage on controller C10 and C11 terminal before start, if no voltage, need change
start action start, input signal is controller.
valid. Or in Test 4. Use DC voltage meter cathode measure contact upon magnet of start motor, if have
mode no start voltage, it is magnet failure, must change, if no voltage, check controller panel connection to
action. confirm if loose or short.

Controller LCD 1. Check fuel oil position.

display start 2. Check DC voltage on controller C10 terminal, if no voltage need change controller.
failure: START 3. Check connection and voltage on fuel control magnet.
FAILURE, diesel 4. Check fuse on one side of alternator.
Diesel start
rotating but can not 5. Check fuel manifold and filter if jam.
failure
start or diesel stop 6. If has white smoke release from exhaust system, that means fuel has gone into engine,
after start, start but diesel not start. Please refer to Engine manual for further check.
failure LED 7. If ambient temp low and has heat start function, please use it.
illuminate. 8. Once failure eliminate, press RESET key, let control system reset.

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 1. Check controller temp sensor modes T-sensor mode correct or not, if error need reset.
2. Check diesel over or not.
Controller LCD
3. Check radiator jam or not.
display high water
Diesel 4. Check fan belt loose or tighten.
temp failure
hight 5. Check ambient temperature if meet generator usage range.
HIGH
temp 6. After diesel cooling, check cool position, do not add a great deal of cooling water into diesel
TEMPERATURE,
stop before it is not cooling, or will cause serious damage to it.
high water temp
7. Refer to Engine manual
LED illuminate.
8. Once failure eliminate, press RESET key, let control system reset.
9. Run Gen set 10 minutes under unload condition let it cooling and then load.

1. Check controller pressure sensor modes P-sensor mode correct or not, if error need
Controller LCD
Low oil reset.
display: LOW OIL
pressure 2. Check oil position, if oil not enough, add oil.
PRESSURE, low
failure 3. Refer to Engine Manual
oil pressure failure
stop 4. Check oil pressure switch by test meter, if any problem change it.
LED illuminate.
5. Once failure eliminate, press RESET key, let control system reset.
1. Check frequency input value of speed sensor in controller correct or not, if error need
Diesel Controller LCD
reset.
over display OVER
2. Check if governor speed level shaft moved, if yes correct it.
speed SPEED, over
3. If installed electronics governor check level shaft if can freely move, correct it if necessary.
failure speed LED
4. Refer to Engine Manual
stop illuminate.
5. Once failure eliminate, press RESET key, let control system reset.

1. Check frequency input value of speed sensor in controller correct or not, if error need
reset.
Speed
2. Check if supply fuels enough.
not LCD display low
3. Check if governor moved, if yes correct it.
satisfy frequency failure
If installed electronics governor check level shaft if can freely move, correct it if necessary.
stop
4. Correct diesel speed when it is running.
5. Refer to Engine Manual

1. Switch off load on alternator, eliminate failure after stop and restart Gen set.
Too low 2. Check setting value of generator low voltage failure, make sure data correction.
LCD display low
voltage 3. If voltage still low, adjust generator outpur voltage setting potentiometer, recover to normal
voltage failure
stop value.
4. Refer to Alternator Manual

1. Switch off load on alternator, eliminate failure after stop and restart Gen set.
2. Check setting value of generator high voltage failure, make sure data correction.
Too high LCD display high 3. Check controller measuring voltage, if voltage normal, check load and make sure it is non
voltage voltage failure capacitive, (power factor compensation device will casual cause a capacitive load).
stop 4. If voltage still high, adjust generator output voltage setting potentiometer recover to normal
value.
5. Refer to Alternator Manual

Generator still
Engine 1. Check oil-gate electromagnetic valve in diesel (or level shaft), make sure completely close
running after stop,
can not oil channel under close status.
LCD display stop
stop 2. Check oil-gate control electromagnetic valve, change it if necessary.
failure

54