BLUE JAY GYDCG-UBCH2-LZ DC Insulation Monitor Device User Manual

BLUE JAY GYDCG-UBCH2-LZ DC Insulation Monitor Device

Specifications

• Product Name: GYDCG-UBCH2-LZ DC Insulation Monitor Device (Dual Channels)
• User Manual Version: 1.15
• Manufacturer Contact:
• Tel: +0086-023-67628702,
• Email: tech@cqbluejay.com
• Manufacturer Address: 1802, Building 2, No.88, Jianxin East Road, Chongqing, 400020, China
• Revision: 2023.12

Product Usage Instructions

Important Guidelines

1. Before turning on the power supply, ensure it is within the instrument’s specified range.
2. During installation, keep the current input terminal non-open and the voltage input terminals non-short-circuited.
3. Avoid high pressure on the communication terminal (RS485).
4. Ensure the instrument wiring matches the internal system settings.
5. For communication with a PC, ensure communication parameters are consistent with the PC.

Product Summary

The GYDCG-UBCH2-LZ is a DC insulation monitoring device based on the MODBUS protocol. It is designed for online monitoring of insulation resistance in DC floating systems with two DC channels controlled independently. Users can enable or disable insulation monitoring for each channel and retrieve insulation resistance values through RS485 communication.

Features

• Two independent control channels
• Remote monitoring and management capabilities
• Monitoring of positive and negative poles
• Ground insulation resistance monitoring
• DC voltage monitoring
• Vehicle-side DC voltage monitoring
• Voltage reverse polarity alarm functionality

Applications

• Ensuring the safety and stability of charging processes
• Improving efficiency and charging quality
• Enhancing personnel and equipment security
• Electric vehicle safety testing

When you use GYDCG-UBCH2-LZ, be sure to read this user manual carefully, and be able to fully understand the implications, and the correct guidance of the operations user manual, which will help you make better use of GYDCG-UBCH2-LZ, and help to solve the various problems at the scene.

1. Before turning on the power supply, be sure that the power supply is within the provisions of the instrument;
2. When installation, the current input terminal must be non-open, voltage input terminals must be Non-short circuit;
3. The communication terminal (RS485) is strictly prohibited from imposing high pressure;
4. Be sure the instrument wiring is consistent with the internal system settings;
5. When communicating with the PC, instrument communication parameters must be consistent with the PC.
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SUMMARIZE

GYDCG-UBCH2-LZ is based on the MODBUS protocol of the DC insulation monitoring device and is used in online monitoring insulation resistance of the DC floating system (two DC systems shared one ground). two DC channels are controlled independently, and two DC insulators monitor non-interference in each other. Users can enable or disable the insulation monitoring function of each DC channel and acquire insulation resistance values by RS485 communication.

The IMD can measure the insulation resistance value in the DC system of 100~1000V, the resistance ranges of 1KΩ~10MΩ, read unit by KΩ. When the insulation resistance value is greater than 10 MΩ, the insulation resistance data read value is 60000 (0xEA60), indicating infinity. If the read insulation resistance data is 65535 (0xFFFF), means the data is invalid. The invalid data (0xFFFF) indicates that the insulation monitoring function is not fully started is in the closed state, or the DC voltage is less than 100V.

This IMD adopts a dual-DC channels independent control scheme. Its schematic diagram is shown in the following figure. Users can control dual-channel startup, shutdown, and data reading respectively according to the content of the communication protocol. Take the DC1 channel as an example. When the insulation monitoring function is disabled, the positive and negative extreme relays K1 and K2 are disconnected, and the DC voltage and insulation resistance monitoring will not be provided at this time. When the host computer of the user sends the DC1 open instruction to IMD, K1, and K2 relays are closed, the DC1 voltage is collected and insulation resistance is calculated immediately. The user can read the corresponding DC1 voltage and insulation resistance value. The application and principle of DC2 are the same as DC1. Dual independent control. When the two insulation monitoring functions are closed, the K5 relay is disconnected and the IMD disconnects from the ground.

FEATURES

• Two independent control
• Remote monitoring and management
• Monitor positive and negative poles
• Ground insulation resistance
• DC voltage monitoring
• Vehicle-side DC voltage monitoring
• Voltage reverse polarity alarm

APPLICATIONS

• Guarantee the safety and stability of charging
• Improvement of the efficiency and charging quality
• Personnel and equipment security
• Electric vehicle safety testing

TECHNICAL PARAMETERS

Basic parameters

Notes

1. When facing the ground insulation resistance RISO+ and negative insulation resistance to ground RISO-, The difference is too large, Multiplier of difference>10 times, RISO+ and RISO- Large resistors may not be typical values.
2. CY Refers to the positive and negative Y capacitance values of the system bus to the ground.

Other parameters

INSTALLATION

Mounting
The module can be installed by guide rail or screw fixation. Guide rail using standard width 35mm. External dimensions are shown as follows: (Unit: mm)

Connection Terminal

DC1 interface 1

DC1-| The negative pole of DC 1
DC2+| The positive pole of DC 2| ****

DC2 interface 2

DC2-

| ****

The negative pole of DC 2

Vin| The positive pole of power supply| ****

9-30VDC

0V| The negative pole of power supply
GND| Grounding point|
RG| 485 Communication Ground port (can leave it unwired)| Reserved, communication shielded line access point
A| 485A|
B| 485B|

COMMUNICATION INTERFACE

Connection for RS485
In the RS485 communication system, this IMD module works in slave mode. Baud rate, communication address, and parity check mode, can be set by the DIP switch, default stop bit 1, and data bit 8. The interval between each byte in the sent frame must not exceed 20, otherwise the frame will be cleared.

Communication Parameter configuration bit
Two Dip switch configuration bits ‘CONFIG’, one of which can be used to configure the communication verification mode. E stands for EVEN parity and O stands for ODD parity. Touse the corresponding checkchecksumply dial the corresponding position to “ON”. If E and O are set to no, indicates NONE parity. See Figure 2.

Initializing Module Communication Parameters
Dip switch configuration bit ‘CONFIG’， the second function can be used to initialize communication parameters. When E and O of CONFIG are dialed to ON at the same time for at least 3 seconds, the baud rate is restored to 9600bps, and the communication address is restored to 01H and 02H. The system can be initialized only once after each power is on. The total number of times to modify the baud rate, change the communication address, and initialize the baud rate must be less than 1 million. See Figure 3

MODBUS © Protocol
The device provides the Modbus RTU protocol interface and uses the Modbus RTU 0x03/0x06 command. The default device addresses are 0x01 and 0x02. Baud rate The default baud rate is 9600 bps. The data bit is 8 and the stop bit is 1. The IMD works in slave mode and supports 9600bps and 19200bps baud rates.

Modbus RTU Frame Format:

Address code

| ****

1 BYTE

| ****

Slave device address 1-247

---|---|---

Function code

| ****

1 BYTE

| Indicates the function codes like read coils/inputs

Data code

| ****

4 BYTE

| Starting address, high byte Starting address, low byte Length of registers, high byte Length of registers, low byte
Error Check code| 2 BYTE| Cyclical Redundancy Check ( CRC )

MODBUS FUNCTIONS

Code

| ****

Meaning

| ****

Description

---|---|---

FUNCTION 01

| ****

Read Coil Status

| ****

Only valid when equipped with DO port

FUNCTION 02

| ****

Read Input Status

| ****

Only valid when equipped DI port

FUNCTION 03

| ****

Read holding register

| ****

This function permits to reading of all the electrical parameters

FUNCTION 05

| ****

Write Single coil

| When DO in remote control mode can work

FUNCTION 06

| ****

Write single register

| This function permits to write a value into a single holding register.

Register map

0x0010

| ****

Bus voltage

| ****

float

| | Unit:0.1V, voltage between positive and negative poles of DC bus

0x0012

| DC1 Positive insulation resistance

DC2 Positive insulation resistance

| ****

float

| ****

1

| ****

The unit is KΩ, an integer

0x0013

| DC1 Negative Insulation Resistance

DC2 Negative Insulation Resistance

| ****

float

| ****

1

| ****

The unit is KΩ, an integer

0x001A

| Read version number| ****

float

| ****

1

|

0x001B

| ****

IO state

| ****

float

| ****

1

| Bit1: **** Whether the current insulation resistance monitoring results are valid.

Bit2: **** Whether the insulation monitoring is on and the high voltage switch is closed.

Bit7: Bus voltage back connection alarm (when the back connection voltage is above

170V, this position 1)

0x0102

| Insulation monitoring control| ****

float

| ****

1

| Enable DC1 insulation monitoring.

Enable DC2 insulation monitoring.

Insulation monitoring control| Disable DC1 insulation monitoring. Disable DC2 insulation monitoring.

0x0103

| ****

Modify the address

| ****

float

| ****

1

| Change the address from 01H to 02H; Change the address from 02H to 03H; (Turn the 2-bit DIP switch to the ON position

after power-on to modify it)

0x0104

| ****

Modify the baud rate

| ****

float

| ****

1

| Change the baud rate to 9600;

Change baud rate to 19200

(Turn the 2-bit DIP switch to the ON position after power-on to modify it)

0x66

| The host broadcast reads the slave address| ****

float

| ****

1

| Example of reply from machine FF 66 01 02 50 7E

The slave addresses are0x01 and 0x02

---|---|---|---|---

Notes:

• Only when the DC voltage is between 100V~1000V, Insulation resistance monitoring can be realized. If the DC voltage is lower than 100V, or it is turned on within a short time, the insulation resistance read is 0xFFFF (means an invalid number).
• If the read insulation resistance value is a valid number, the insulation resistance value monitoring range is between 1KΩ~10MΩ. When the measured value is greater than 10MΩ, the value received by the communication is 0xEA60 (means infinity).

Command samples

Sample1
Start insulation monitoring

• Host inquiry:
  • 01 06 01 02 00 11 E9 FA (Enable CH-1 insulation monitoring)
  • 02 06 01 02 00 12 A9 C8 (Enable CH-2 insulation monitoring)
• Slave response:
  • 01 06 02 00 11 78 84
  • 02 06 01 02 00 12 CRC CRC

Sample2
Turn off insulation monitoring

Host inquiry:
01 06 01 02 00 00 29 F6

Slave response:
01 06 02 00 00 B8 88

Sample3
Read the DC bus voltage and positive and negative electrode resistance to the ground (read 4 registers)

Host inquiry:
01 03 00 10 00 04 45 CC

Slave response:
01 03 08 03 E8 02 58 EA 60 02 58 A9 7F

Definition: Read the DC voltage 0X03E8(100V), the total insulation resistance 0X0258(600KΩ), the positive insulation resistance 0xEA60 (infinite), the negative insulation resistance 0X0258 (600KΩ).

Sample4
Read IO status:

Host inquiry:
01 03 00 1B 00 01 F4 0D

Slave response:
01 03 02 00 84 B8 27

Definition : Bus voltage reverse connection, insulation monitoring is enabled (ground relay is closed), insulation resistance monitoring is invalid.

Slave response:
01 03 02 00 06 38 46

Definition: There is no reverse connection of bus voltage, insulation monitoring is enabled (ground relay is closed), and insulation resistance monitoring is effective

Sample5
Read version number

Host inquiry:
01 03 00 1A 00 01 A5 CD

Slave response:
01 03 02 22 01 61 24

Definition: The version number is V2201.

SAFETY CONSIDERATIONS

All installation specifications described in the previous chapters are named: INSTALLATION AND STARTUP, INSTALLATION MODES, and SPECIFICATIONS.
Please note that with the instrument powered on, the terminals could be dangerous to touch, and cover opening actions or elements removal may allow accessing dangerous parts. This instrument is factory-shipped in proper operation condition.

• The device must have professional installation and maintenance
• For any operation of the device, you must cut off the input signal and power;

MAINTENANCE

• The GYDCG-UBCH2-LZ does not require any special maintenance. No adjustment, maintenance, or repair action should be done when the instrument is open and powered on, should those actions be essential, high-qualified operators must perform them.
• Before any adjustment, replacement, maintenance, or repair operation is carried out, the instrument must be disconnected from any power supply source.
• When any protection failure is suspected to exist, the instrument must be immediately put out of service. The instrument’s design allows a quick replacement in case of any failure.

FAQS

Question 1: The power indicator LED is off
Check whether the power supply terminal of the module is improperly connected, or the hot swap overcurrent causes the fuse to burn, try to avoid hot plug.

Question 2: Communication failure

• Do not use USB-232-485 bipolar interface for communication,
• If the communication fails again, use the CONFIG mode to restore the factory Settings parameters. (chapter4.1.2)

The insulation monitoring resistance is infinite after the simulation of insulation resistance
Check whether the ground cable is connected reliably at GND port.

Question 4 : The insulation monitoring resistance is much smaller than the actual value
The DC ground capacitance may be too large. Check the DC ground capacitance.

Question 5 : Communication initialization is invalid
The system can be initialized only once by CONFIG during each power-on.

CONTACT

• For any inquiry about the instrument’s performance or any failure, contact Blue Jay’s technical service.
• Blue Jay – After-sales service
• E-mail: tech@cqbluejay.com
• Tel: + 0086-023-67628702
• www.cqbluejay.com
• Add: 1802, Building 2, No.88, Jianxin East Road, Chongqing,400020, China
• Email: tech@cqbluejay.com

Frequently Asked Questions

• Q: How do I check the insulation resistance values for each DC channel?
  • A: You can acquire insulation resistance values by using RS485 communication as per the user manual instructions.
• Q: What should I do if I encounter a voltage reverse polarity alarm?
  • A: When facing a voltage reverse polarity alarm, please refer to the user manual for troubleshooting steps or contact the manufacturer for assistance.

References

• Blue Jay - Industrial Electric Automation Manufacturer - Power & Energy Meters, Automatic protection relay etc.

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