WENZHOU ROCKWILL ELECTRICCO.,LTD.DC Battery Bank-GZDW48V Controller System InstructionChapter 1 overview1.1 System configurationTHJK002G-48V monitor and control system is composed of two parts, the host controller THJK002G-3S-48V and data acquisition module, including charger, general data acquisition module, battery detection module, switch module and etc. Shown in table 1-1NOTE :(40-60)VDC power supply only, charger module exception. Bus and battery can not be grouped.1.2 Function introduction 1.2.1 THJK002G-3S-48V host unitBlue color 240*64 pixels LCDOptional English language, key operation, easy for parameter settings andinformation inquiry.RS485, RS232 interface optional, communication protocol CDT, MODBUS The real-time clock demonstrated, after power failure clock normal operation. May save 200 alarm logs, 48 work logs, after the power failure the informationdoes not lose.Battery charge management function and integrated system use1.2.2 ZHCL-2-48V unitDetects 1 3-phases AC voltage input.Detects 3 DC voltage, 2 current,1 battery temperature. Detects 24 D/I, 8 D/ONameModelFunction summaryHOST unitTHJK002G-3S-48VBlue color 240*64 pixels LCD, key option ChargerAC-DC/ DC-ACAC-DC applicable for charging systemDC-AC applicable for integrated system OptionalGeneral data acquisition module (choose either)ZHCL-2-48VDetest 1 AC voltageDetects 3 DC voltage, 2 current,1 temperature Detects 24 DI, 8 DO ZHCL-3-48V Detects 2 AC voltageDetects 6 DC voltage, 4 current,2 temperature Detects 32 DI, 8 DOBattery detector (optional)DCXJ-24-48VDetects 24 batteries the voltages, 1 temperatureSwitch moduleKGL-64-48V Detects 64 DI, 8 DO, max 4 pcs in one system1.2.3 ZHCL-3-48V unitDetects 2 3-phases AC voltage input.Detects 6 DC voltage, 4 current, 2 battery temperature.Detects 32 D/I, 8 D/O1.2.4 DCXJ-24-48V unitDetect 24 batteries, detection range, 0-16VDetect 1 battery temperature1.2.5 KGL-64-48V unitDetects 64 DI, 8 DO1.3 Typical solution1.3.1 Battery management systemApplicable for 48V battery and charging system and application useSystem configuration: 48V charger module, ZHCL-2-48V/ ZHCL-3-48V,KGL-64-48V, DCXJ-24-48VThe sample signal gathered by ZHCL module, the charging curve and optional module (KGL-64-48V、DCXJ-24-48V), see the following instruction.1.3.2 Integrated systemApplicable for system without battery charging management function,System configuration: 48V charger module, ZHCL-2-48V/ ZHCL-3-48V, KGL-64-48V Sample signal gathered by ZHCL module, optional(KGL-64-48V), see following instruction.1.4 Working environment●The work ambient temperature is not lower than - 5℃, is not higher than +40℃, theequipment saves ambient temperature permission for - 10℃~+60℃.●The work environment maximum relative humidity does not ≤90% (ambienttemperature is 25℃).●The movement place non-electric conduction dust, does not have the dipping and thedestruction insulation gas or the steam.●In door use only●Remark when place order if any special request.Chapter 2 THJK002G-3S-48V2.1Features2.1.1 Human interfaceBlue color 240*64 pixels LCD,Optional English menu, key operation, easy for settings and information inquiry2.1.2 Alarm informationAlarm text display, identify fault, max 50 current alarm texts.200 history fault records, do not lose once power failureAlarm indication, when alarm occurs, the LCD screen light, the buzzer sound.The alarm threshold is settable2.1.3 Battery managementWhen AC power supply input, charge the battery automatically according to preset parameters.Can work with battery detector DCXJ to detect the battery cell voltage, 24 cells, 1 group Manage charging process of one battery bankPerfect charing and discharging protection function2.1.4 Switch DI/DO16 DI, which the user can choose to define.Choose the switch type (alarm or state) and define the initial number8 DO, which the user can choose to define.2.1.5 PC end communicationInterface: RS232 or RS485.Protocol: MODBUS.Baud rate: 2400、4800 or 9600.Address range 01~99.2.1.6 Others48 working logs, record running information every half an hour. the information does not lose once power failure.If there is no key-press operation within 4 minute, then runs screen protection.The real-time clock demonstrated, after power failure clock normal operation.2.2 THJK002G-3S-48V interfaceFig 2-1 THJK002G-3S-48V front panelFig 2-2 THJK002G-3S-48V rear panelMark DescriptionESC Function key在不同的显示界面下有不同的定义,……ENT Function keyRUN When power on,the green LED light on.ALM When there is fault, the red LED flashRST Reset key.COM2 RTU RS485 interface.COM1 PC end communication RS232 1-RXD 2-TXD 3-GNDRS485 4-485A 5-485BPower supply Input power, range 40~60VDC, power ≤15WTable 2-1 THJK002G-3S-48V interface definition2.3 Operation instructionTwo working mode: integrated working mode, and battery management mode, which set by through the host monitor (parameter set--input type)2.3.1 integrated system operation instructionSetting method: parameter set→special set→input type set “DC IN” . Menu display structure, easy operation.2.3.1.1 basic operationEnter host interface after powered on. Shoe the system time, bus voltage, load currentand current fault.Time:Jan 1st, 2013 12:12:12Bus:voltage 53.2 V Load:0.0AFault: NonePress “ENT”, come to main interfaceInformationPara SettingSys ControlPassword Setting2.3.1.2 InformationShow the information inquiry menu. Press “▲” “▼” to move cursor and “enter”and get the following menu .1 AC info 5 History fault2 Charger info 6 Current fault3 Switches info4 Running logAC infoShow the system input voltageDC input 220.0VCharger infoShow the output voltage, current, working state (RUN/OFF)01#:Voltage 48.0V Current 10A RUN02#:Voltage 48.0V Current 10A RUN03#:Voltage 48.0V Current 10A RUN04#:Voltage 48.0V Current 10A RUNSwitches infoCheck switches info of ZHCL module, KGL moduleThe state of user defined switchesUndefined:Normal Undefined:NormalUndefined:Normal Undefined:Normal#2 inlet switch:Normal #1 inlet switch:Normal#2 Arrestor:Normal #1 Arrestor:NormalShow the alarm switch infoK001:Normal K002:Normal K003:NormalK004:Normal K005:NormalShow the state switch infoK010:Open K011:Open K012:OpenK013:Open K014:OpenRunning logShow the bus voltage, load current, fault info and record every half an hour. Max 48 records and delete the earliest record. The records are not lost once power failure.History faultThe type, starting time, ending time of history fault. Max 200 records and delete the earliest record if more. The records are not lost once power failure.Current faultShow the current fault type, starting time. Pop up new fault if any and audible and visual alarm.2.3.1.3 Parameter settings instructionThe parameter setting menu is as follows: move and press “ENT”to next parameter settings menu1 System settings 5 Alarm settings2 Charger settings3 Switch settings4 Other settingsSystem settingsSystem settings is for setting the system configuration, is the foundation of other settings.1 Charger quantity 012 KGL quantity 003 Sensor range 100ACharger quantity:the quantity of charger, range 0~15(0-14 if EMERSON protocol)KGL quantity: range 0~4Sensor range: range 50,100,150,200 (800)Charger module settings1 Rated voltage 48V2 Rated current 10A3 Over voltage alarm 58.0V4 Under voltage alarm 42.0V5 Output voltage 53.2VRated voltage:48V moduleRated current:the max output current, 10A,20A,25A,30A,50A,100A Over voltage alarm:range: under voltage alarm ~60VUnder voltage alarm:range:40V~over voltage alarmOutput voltage:output voltage of charging module, range:40V~60VKGL settings1 KGL output settings1)KGL output settingsD/O settings :K1~K8, options :comprehensive fault, charger fault, DC inputfault, AC fault, battery fault, bus fault, feeder fault, battery float charge, battery boost charge, battery discharge, group #1 float charge, group #1 boost charge, group #1 discharge, group #2 boost charge, group #2 discharge, charger 1 fault, charger 2 fault, charger 3 fault, charger 4 fault, battery fuse, system OK, B1 primary power down, B1 secondary power down, B2 primary power down, B2 secondary power down. 2) D/I settingsTake ZHCL D/I for example, the menu is as followsSpecial switch quantity: max 16 user defined switches, normally open and willalarm.Alarm switch quantity :24 (ZHCL-2-48V), 32 (ZHCL-3-48V), KGL-64, normallyopen, display mode: alarm.Alarm initial number: the number of first alarm switch, max 500.State switch quantity: 24 (ZHCL-2-48V), 32 (ZHCL-3-48V), KGL-64, normally01 ZHCL special switch quantity 1602 ZHCL alarm switch quantity 5 03 ZHCL alarm initial number 001 04 ZHCL state switch quantity 3 05 ZHCL state initial number 01006 ZHCL other 01 No definition 07 ZHCL other 02 No definition08 ZHCL other 03 No definition 09 ZHCL other 04 No definition1 Output switch K1 comprehensive fault2 Output switch K2 Charger fault3 Output switchK3 Insulation fault4 Output switchK4 AC faultclose, display mode: open/close, no alarmState initial number: the number of first state switch, max 500.Special switch options: AC switch, DC switch, DC fuse, battery switch, battery fuse, discharge switch, inverter switch, feeder switch, 1# arrestor, 2# arrestor, inverter, DC converter, battery fault, battery fuse, 1# AC switch, 2# AC switch, 3# AC switch, 4# AC switch, 5# AC switch, 6# AC switch, 7# AC switch, 8# AC switch, 9# AC switch, 10# AC switch, 11# AC switch, 12# AC switch, 13# AC switch , 14# AC switch, 1# DC switch, 2# DC switch, 1# DC fuse , 2# DC fuse, 1# battery fuse, 2# battery fuse, 1# battery switch, 2# battery switch, 1# discharge switch, 2# discharge switch, 3# AC switch, 4# AC switch, 1# bus switch, 2# bus switch, charger input switch, 1# charger input switch, 2# charger input switch, 3# charger input switch, 4# charger input switch, charger output switch, 1# charger output switch, 2# charger output switch, 3# charger output switch, 4# charger output switch, 1# distribution panel switch, 2# distribution panel switch, 3# distribution panel switch, 4# distribution panel switch, 1 # feeder panel switch, 2 # feeder panel switch, 3 # feeder panel switch, 4 # feeder panel switch, #1 inlet switch, #2 inlet switch, interconnection switch, UPS input switch, UPS output switch, 5# charger in switch, 6# charger in switch, 5# charger out switch, 6# charger out switch, comprehensive fault, charger fault, input voltage fault, no definition.Other settings1 Communication settings2 Time settings3 Other settingsGet following menu after enter special password1 Communication settings 5 Version2 Time settings3 Other settings4 Special settings1)CommunicationSet communication add :001~099 Set communication baud rate :2400、4800、9600Communication protocol :Modbus Interface: RS4852) Time settings Set system time 3) Other settingsContrast control : Adjust screen display,10-60 Delete history fault :Delete history fault Delete running log :Delete running logDelete discharge record :delete discharge capacity, discharge time record 4) Special settingsMeasure calibration: ZHCL online calibration Special settings1 Communication add. 12 Baud rate 96003 Communication protocol ModBus4 Interface RS485 1 Measure calibration 2 Special settings5 Input type Three6 Input numbers 17 Charger protocol TH 1 Factory settings NO 2 Language English 3 ZHCL ZHCL-2-48V 4 Charger type LED1、Contrast control 452、Delete history fault No3、Delete running log No4、Delete discharge recordNoInput type :single phase, three phases, DC. The system is batterymanagement system when the input AC (single/three), and is integratedsystem if input DCInput numbers :1 if single and DC input, 2 if three phases input and workwithZHCL-3-48VCharger protocol :TH/AMS1/AMS2Bus section, battery group, charger group: only 1 Alarm settingsinput over voltage :range: under voltage~480V Input under voltage :range: 80V~input over voltage Bus over voltage :range: bus under voltage~60.0V Bus under voltage :range: 40.0 V ~bus over voltage2.3.1.4 system controlCharger control :charger on/off (disable this function temporarily )2.3.1.5 password settingsDefault factory password is 0000, the user can set new password2.3.2 Charging management system operation instructionSetting method :set the “input type ” under “parameter settings ” to “Three” or “Single”. Menu display and easy operation.Layer stepping structure, easy operation. It comes the main Interface after power on and9 Battery groups 1 TH10 Charger groups 1 1 input over voltage286V 2 input under voltage 198V 3 bus over voltage 58.0V4 bus under voltage 48.0V1、Charger control power ondisplay the system time, battery information, control busbar information, and current state.Press“ENT”button, enter main menu2.3.2.2 Info inquiryShown as belo w: the info inquiry menu, move the cursor and select by press “ENT ” , then enter the selected menuAC info inquiryDisplay the AC input voltageTwo AC input, the AC data are as follows:One AC input, the AC data are as follows :Charger infoSee 2.3.1.2, the state of charger: float/boost Switch infoSee 2.3.1.2 Running logDisplay the battery voltage, current, bus voltage, current, float/boost status and faults during the system operation process. Automatic record every half an hour. Max 48 history log record and the previous records will be deleted. The records will not loss if powerAC input 220.0VTime : October 19, 2012 14:58:41 Batt : Volt 53.2V Current : 0.0A Corl bus : Volt 53.2V Load : 0.0A State : Float charge Fault : No1:Info inquiry2:Parameter set3:System control4:Password set1:AC info 5:history fault 2:Charger info 6:current fault 3:Switch info 7:battery info 4:Running logAC I Switch off AC II Switch off AB : 380.0V AB : 380.0V AC : 380.0V AC : 380.0V BC : 380.0V BC : 380.0Vfailure.History faultSee 2.3.1.2Current faultSee 2.3.1.2Battery infoDisplay battery pack voltage, current, temperature, single cell voltage if there is DCXJ module in the system.2.3.2.3 Parameter set instructionInclude:System set menu, move the cursor and select by press “ENT” to enter the selected menu1、System set 5、alarm set2、Charger set 6、DXCJ3、switch set 7、battery management4、other setSystem settingsSystem settings is for setting the system configuration, is the foundation of other settings.1 Charger quantity 012 KGL quantity 003 Sensor range 100A4 DXCJ module quantity 00Charger quantity:the quantity of charger, range 0~15(0-14 if EMERSON protocol)KGL quantity: range 0~4Sensor range: range 50,100,150,200 (800)DXCJ quantity: 0-1Charger module settings1 Rated voltage 48V2 Rated current 10A3 Over voltage alarm 58.0V4 Under voltage alarm 42.0V5 float charge voltage 53.2VRated voltage:48V moduleRated current:the max output current, 10A,20A,25A,30A,50A,100A Over voltage alarm:range: under voltage alarm ~60VUnder voltage alarm:range:40V~over voltage alarmFloat charge voltage: range: under voltage threshold-boost charge voltage Boost charge voltage: range: float charge voltage-over voltage thresholdDI/DO settingSee 2.3.1.3Other settingsSee 2.3.1.3Alarm settings1 input over voltage 450V2 input under voltage 304V3 bus over voltage 58.0V4 bus under voltage 48.0V5 Battery over voltage 58.0V6 Battery under voltage 48.0V7 Battery over current 040A8 Backlash 05V9、LVDS primary power down 46.0V10、LVDS secondary power down 43.4Vinput over voltage:range: under voltage~480VInput under voltage:range: 80V~input over voltageBus over voltage:range: bus under voltage~60.0VBus under voltage:range: 40.0 V ~bus over voltageBattery over voltage:battery under voltage~60.0V。