YK-6 On-load voltage regulating

controller

Operation Instruction

Guizhou Changzheng Electric Co.,Ltd

Welcome to use On Load Tap Changer of Guizhou Changzheng!
Please read the operating instructions of this product before you put the on load tap

changer into service. Please pay special attention to the following items:

1. Check and accept the products according to the packing list when receiving

products. Keep the evidence if there are any damages during transportation in

order to claim compensation from the responsible party and protect your rights.

2. The tap changer only can be used with the transformer which specified in the

order. You need to consult with our company in advance if you want to change the

purpose of this product.

3. The installation, put into operation, maintenance and repair of the product should

be complied with the operating instructions and relevant provisions of security.

All data in this manual may be different in details from the tap-changer that we
delivered. We reserve the right to change without notice.
 Content

1. General introduction………………………………………………1

2. Main technical parameters…………………………………………1

3. Panel drawings……………………………………………………2

4. Outline and installation method………………………………3

5. Controller wiring…………………………………………………4

6. Controller interface and parameter settings…………………6

7. Operation and maintenance………………………………………15

8. File and spare parts………………………………………………15

9. Notice to customer…………………………………………………15

10. Appendix: MODBUS communication protocol…………………15

2019.5.10
1. General introduction
1.1. Safety instructions
Personnel engaged in the installation, commissioning, operation, maintenance and
repair of this unit must:
- Qualified professional qualifications
- Strict compliance with the operating instructions of this manual
Illegal operation or misuse may result in:
- serious personal injury
- Damage to the device and the user's equipment
- Reduce the efficiency of this unit.
This instruction emphasized some important matters of safety instruction in four
ways.
Warning
Give the word of “Warning” when ignoring a requirement will cause the life damage
of operator. This is a warning of danger to life and health, disregarding this warning
can lead to the serious or fatal injury.
Careful
Give the word of “Careful” when ignoring a requirement will lead to the damage to
the equipments. This information indicates particular danger to this device or other
equipment of the user, but the serious or fatal injury can’t be excluded.
Caution
In order to emphasize at any time, the word of “Caution” will be used, remind it
should be careful when operating according to the requirements of “Warning” and
“Caution”.
Note
These are additional explanations for a certain subject.

1.2. Application
YK-6 On-load voltage regulating controller (Hereinafter referred to as the
controller) application for remote to tap changer.
This controller main use for ZD motor driver unit, controller’s main faction is
make local controller communicate with local ZD motor driver unit by
communication line or optical fiber.

2. Main technical parameter

table 1
No. Specification Technical parameter Note
1 Work power AC 85 ～ 265V ,50/60Hz
2 Power loss Above7W
1 set RS485 communicate port; The above two are used to
Connection 1 set optical fiber: multimode ,62.5/125μm,ST communicate with the local
3 method with Contact, wave length 820nm, maximum control module ZDK controller,
MDU transmission distance 1kM。 mutually standby, follow the
MODBUS protocol.
 Sampling AC 0-500V
voltage
Automatic Set voltage Range: AC 85-460V, step 1V
pressure Voltage Range: 0.1-9.9%, step 0.1%
4
regulating regulation
function accuracy
Delay time Range: 5-180s, step 1s
Actual voltage Range: 0-500V
Passive normally open contact
1 group BCD code
output (contact load capacity:
5 Switch output 1 group status signal
1A / 240V AC, 0.5A / 24V
1 group alarm signal
DC, 0.3A / 220V DC)
Passive normally open contact
6 Switch input 1→ N, N → 1, STOP instruction input
(Input by external device)
Communication 1 group RS485 (A, B) communication port
7
Interface 1 group TCP / IP 100M network port (RJ45)
8 Display method 4.3-inch touch screen
1. Tap position, tap position action status
2. various parameter settings
9 3. Parameter display: various status signals,
Display content
local body failure, temperature, the number of
operations
4. Log records query
Working Indoor, 0 ℃ ~ +40 ℃, relative humidity ≤
11
environment RH95% non-condensing.
Installation
12 Screen cabinet installation
method

3. Panel drawing
3.1 Front panel diagram (Figure 1)

Touch screen Button

3.2 Back panel diagram (Figure 2)

4. Outline and installation

4.1 Outline as show as Figure 3
 7107
4.2 Installation method can be used screws to install fixed for the front panel,also can
be used on both sides of the bracket locking installation. (Figure 4)

Figure 4 (both sides of the bracket locking installation method diagram)

4.3 Hole Size: 151×76

Caution: When the front panel screws are fixed, you need to drill 4 Φ5 holes on
the cabinet.

5.Controller wiring

Figure 5 (Circuit block diagram)

5.1 Working power connection
Working power AC 85 ~ 265V, 50 / 60Hz.

Note
When using DC power access special order, and +, - can
not be confused.

5.2 Controller and motor drive unit connection

The connection between controller and electric mechanism is provided with
RS485 communication port and optical fiber interface. These two ports are used for
communication with ZDK controller of local ZD motor control unit and are mutually
standby. Routine recommended RS485 communication port, the use of optical
interface to be special orders.
X3 terminal shown in Table 2
Table 2
Terminal Terminal Terminal Signal
Note
number labeling meaning type
X3-1 A
Communication Follow the MODBUS protocol
X3-2 B RS485
Interface G for the shield connection
X3-3 G

Note
When operating with the YK-6, the local ZD motor-internal change-over switch
must be placed in the "remote controlled state."

5.3 X1 input, output terminals shown in Table 3

Table 3
Terminal Terminal
Terminal meaning Signal type Note
number labeling
X1-1 A Follow the
Communication Interface RS485 MODBUS
X1-2 B
protocol
X1-3 D-COM Tap position BCD code COM
Passive normally
X1-4 D01 Tap position bit BCD code 20
open contact
X1-5 D02 Tap position bit BCD code 21 BCD
2 (Contact load
X1-6 D04 Tap position bit BCD code 2 code
capacity: 1A /
X1-7 D08 Tap position bit BCD code 23 output
240V AC, 0.5A /
X1-8 D10 Tap position bit BCD code20
24V DC, 0.3A /
X1-9 D20 Tap position tens BCD code21
220V DC)
X1-10 S-COM Limit output common Status signal
X1-11 LMT1 Min. position limit output output
X1-12 LMTN Max. position limit output
X1-13 RUN Run signal output
X1-14 I-R Remote command state
X1-15 I-D Motor drive command status
X1-16 I-L Local (controller) instruction status
X1-17 I-A Automatic control instructions state
X1-18 W-COM Alarm signal common
STEP-OU Alarm signal
X1-19 Out of step alarm
T output
X1-20 FAULT Fault alarm
X1-21 1→N Remote command input (1 → N) Passive normally
X1-22 STOP Remote command input (stop) open contact
Remote input
X1-23 N→1 Remote command input (N → 1) (Input by external
X1-24 R-COM Remote command input common device)

Prompt：
1. Communication Interface RS485 transmission tap position, operation instructions
signal, a variety of status signals, alarm signals, etc;
2. Parallel control can also be used to connect with other YK-6 controller to achieve
parallel operation function;
3. Use RS485 interface to participate in parallel the number of controllers up to 4 units.

5.4 TCP / IP (RJ45) network port to transmit the tap position, operation command
signals, various status signals, alarm signals, etc., for connection with other intelligent
devices (LED). The network port can also be used with another YK-6 controller port
to connect to run in parallel functions.

Prompt：
The maximum number of controllers that can parallel
connection and using network ports is 2.
5.5 When sampling the voltage input, connect the potential transformer PT, the access
range is AC 0-500V.

Prompt：
Only the realization of automatic voltage regulator control
access to the sampling voltage.

5.6 Ground mark " " must be reliably grounded.

6.Controller interface and parameter settings

The controller uses 4.3-inch LCD touch .
6.1 Turn on the main interface
Power on the controller after the main interface appears

Setting
Search

Alone
Manual

System fault: When controller detects a fault in local electric mechanism,

mark is displayed and flashes, otherwise the mark is not displayed on the interface.

Communication failure: When controller has a problem with local electric mechanism

communication connection, the mark is displayed and flashes, otherwise

the interface does not display this mark.

Prompt:

In all the settings and query interface are blocked 1 → N, N → 1, STOP

instruction operation, only in the main interface can be instruction operation.
6.2 User interface

Setting

Search

Alone
Manual

Run ID: Displayed while the tap switch is running. Displayed when 1→N,
displayed when N→1.

6.3 Query Interface

After touching the mark on the home screen, the query interface is displayed.

Prohibit operation

Parameter

Log

Prohibit
operation

6.4 Real-time parameter display interface

When the “Parameter” icon is touched on the query interface, the real-time
parameter display interface is displayed.
 参数 Parameter
工作状态 Working status 远方 Remote 锁定状态 Lock state 解锁 unlock
指令选择 Instruction selection 手动 Manual 运行状态 Running status 到位 in place
操作次数 Number of operations 58118 控制状态 Control status 就绪 ready
最小分接 Min tap 1 故障形式 Fault type
最大分接 Max tap 17 就地温度 Local temp 31℃
通讯地址 2 实际电压 Actual voltage 217.2V
Communication address
连动位置 9a、9c

This interface reflects various real-time parameters of the local motor driver unit and
the YK-6 controller.
Working status: There are three kinds of status: local, stop, and remote.
Instruction selection: There are three states: manual, automatic, and remote.
Lock state: There are two states, unlock and lock. (For external access blocking signal
detection)
Running status: There are two kinds of status, they are in place and running.
Control status: There are two kinds of status: ready and fault.
Fault type: There are three types of status, namely, open/closed, power failure, and
self-test failure.
Communication address: The communication address between this controller and the
local ZDK controller. It is set to "1" at the factory.

6.5 Log Display Interface

When the "Log" icon is touched on the query interface, the log display interface
is displayed. Log display Time Event

NO.

10 step
Page up

Page down

There are a maximum of 10,000 log records. Users can query records of
operations or failures for a long time as needed.
 6.6 Parameter Setting Interface

After to touching the on the home screen, the parameter setting interface is
displayed.
Parameter Setting

Working model
Instruction selection
Time setting
Net parameter

Prohibit
operation

Disable operation identification: " " mark appears during all parameter
setting, and latch 1 → N, N → 1, STOP instruction operation.

6.7 Working Mode Selection Interface

The operating mode selection interface is displayed after touching the "operation
mode" mark under the parameter setting interface.

Working Mode Selection

Alone

Parallel master

Parallel slave
Prohibit
Confirm
operation

In this interface, the "Alone" mode is the default setting of the controller. When
parallel control is required, "parallel master" or "parallel slave" is selected.

6.8 Communication Address Setting Interface

When the “parallel slave” icon is touched under the operation mode selection
interface, the communication address setting interface is displayed.
 Communication
address

Prohibit
Confirm
operation

In parallel operation, when the controller is set to "parallel master", the controller
communication address defaults to 01; when the controller is set to "parallel slave",
the communication address needs to be reset, and all slave address codes participating
in the parallel connection must not be repeated. .

6.9 instruction selection interface

When the “Instruction Select” icon is touched under the parameter setting
interface, the command selection interface is displayed.

Instruction selection

Manual

Auto

Remote

Prohibit operation Confirm

The "Manual" mode under this interface is the controller default setting.

6.10 Automatic Mode Parameter Setting Interface

The automatic mode parameter setting interface is displayed after touching the
"automatic" mark on the instruction selection interface
 Setting value Setting parameter Range Step size
Unit

Content

Setting voltage

Precision of voltage
regulation

Delay

Prohibit operation

Only the setting value field needs to be set in this interface.

Delay time setting: Set according to the required operating frequency of the
switch in the range of 5-180S; set the delay time, it must be more than 10 seconds.
Under the premise of guaranteeing the power supply quality, set the delay time as long
as possible. This can avoid frequent tap changer operation and extend the life of the
switch.
Setting voltage and voltage regulation accuracy settings:
Connect a sampling voltage of 100V; adjust the output voltage of the regulator so
that the output voltage deviates from the ±2.5% voltage value of the 100V sampling
voltage, that is:
Lower limit voltage = setting voltage - setting voltage × pressure regulation
accuracy;
The upper limit voltage = setting voltage + setting voltage × precision of voltage
regulation;
Example: setting voltage is 100V, voltage regulation accuracy is set to 2.5%;
Then: the lower limit voltage = 100V-100V × 2.5% = 97.5V;
The upper limit voltage = 100V + 100V × 2.5% = 102.5V;
When the sampling voltage is lower than the set lower limit voltage, the
controller itself issues a "1→N" command;
When the sampling voltage is higher than the set upper limit voltage, the
controller itself issues an "N→1" command;
After the delay time set by the controller is delayed (for example, 10 seconds
delay), the switch shall switch to the corresponding 1→N or N→1 direction
synchronously, and adjust the voltage to “set voltage”=“actual” The output voltage"
realizes the automatic control of the output voltage of the transformer system.
 6.11 Auto-adjusting the main interface

Setting

Search

Alone
Actual
Auto
voltage
Setting voltage

When the YK-6 controller operates in the auto-regulation mode, a real-time

histogram will appear below the number of tap positions. Both sides of the histogram
display the real-time values of the setting voltage and the actual voltage when the
sampling voltage is within the setting range. The bar graph is green when there is no
need to regulate the voltage, and it is red when it is out of the setting range. When the
sampling voltage exceeds the setting range and the corresponding delay time is
performed, the pressure adjustment command is automatically issued.
6.12 Parallel Voltage Regulator Main Interface

Setting

Search
Parallel unit

Parallel master
Manual
Out of step

When the YK-6 controller is operating in the shunt regulator mode, the
mark is displayed on the left side of the screen.

When the controller participating in the parallel connection loses

 synchronization, the mark is displayed at the bottom right of the interface.

Prompt:

After the mark is displayed, all 1 → N, N → 1, and STOP

instructions are operated, and the controller sends an out-of-step alarm signal.
Synchronization corrections need to be set up to be manually corrected
individually.

6.13 Participate in parallel interface

After touching the mark on the main interface of the parallel voltage
regulator, the participating parallel interface is displayed.

参与并联控制器 Participating in parallel control

从机 1 Slave 1
通讯地址 Communication address 2
通讯状态 Communication state 故障 Faulf
分接位置 Tap position 00
并联状态 Parallel state 失步 Out of step

This screen shows all slaves participating in parallel control.

 Prompt:
Working mode selection "parallel main" also need to participate in the parallel
number of slaves to choose from.

Prompt:
It is also necessary to reset the command selection after returning from
the "slave slave" operation mode to other operating modes.

6.14 Time setting interface

Year Month Day

Time

Prohibit Confirm
operation

6.15 Network Parameters Interface

Prohibit
operation

In the TCP / IP settings, the IP address is the IP address of the controller. If you need
to access the unit by IP address, set the corresponding address.
7. Operating and maintenance
7.1 The user to install the correct wiring and the corresponding parameter settings can
be put into use after the controller.
7.2 controller in use, should always be kept clean, there should be no conductive dust
covering the body and the terminal.

8. Documents and spare parts

 Product Certificate: One
 Manual: One
 1-24 plug: a group (factory installed in the X1 socket)
 1-5 Plug: a group (factory installed in the X2 socket)
 1-3 Plug: a group (factory installed in the X3 socket)
 Mounting bracket: two

9. User notes
9.1 When ordering, it is necessary to provide the type of tap changer, voltage
regulation series, middle position, required input / output interface.
9.2 Users under the custody and use of the rules, from the installation of the use of 12
months, and shipped from the manufacturer to the user within 18 months deadline, the
product due to the quality of the cause of damage or does not work properly, the
manufacture The factory can be replaced or repaired for users without compensation.

10. Appendix: MODBUS protocol

YK-6 controller using MODBUS RTU protocol
YK-6 controller communication physical layer using optical or RS485, baud rate
4800, the data format for the 1 start bit, 8 data bits, no parity, a stop bit.
The YK-6 controller opens 03, 05, and 06 function codes to make it easier for the
user to read information about the controller, and to perform operations of raising,
lowering, and stopping the controller, and modifying the communication address of
the machine.

Read data (function code 03H)

An example of the following table is an example of reading the current tap position
(register 03) from the No. 01 slave.
The data frame received by the slave (YK-6 controller)
Slave Function Start Start Read data Read data CRC16 CRC16
address code address address number high number low low high
high Low
01H 03H 00H 03H 00H 01H 74 0AH

The data frame returned by slave (YK-6 controller) (the current tap position is 06)
Slave Function Data length Data segment CRC16 low CRC16
address code (2 bytes) high
 01H 03H 02H 00H, 06 H 38H 46H

YK-6 controller data call address table:

Address Parameter Data Type Property Remark
0001H Max. tap position Uint16 R
0002H Min. tap position Uint16 R
If high 8 position are 10, 11, 12,
corresponding to a, b, c, the low 8
0003H Current tap position Uint16 R position for the step(e.g: 22a, data is
0x0a16)
High position number
0004H Uint16 R
of operations
Low position number
0005H Uint16 R
of operations
0006H Temperature value Uint16 R
0007H Humidity value Uint16 R
0008H State quantity Uint16 R
0009H Linkage position 1 Uint16 R Format with register 3
000AH Linkage position 2 Uint16 R
000BH Linkage position 3 Uint16 R
000CH Linkage position 4 Uint16 R
000DH Linkage position 5 Uint16 R
000EH Linkage position 6 Uint16 R

Status Description
SN Bit address Description
1 Bit1～bit2 Operating modes: 00-Stop, 01-Local, 10-Remote
2 Bit3 Operating status: 0-Switch to position, 1-switching
3 Bit4 Locked state: 0-Unlock, 1-Lock
4 Bit5 Fault status: 0-Ready, 1-Air switch open
5 Bit6 Fault Status: 0-Ready, 1-Power Failure
6 Bit7 Fault Status: 0-Ready, 1-Self-test fault
7 Bit8 Minimum limit: 0-Normal, 1-Minimum limit
8 Bit9 Maximum limit: 0-Normal, 1-Maximum limit
9 Bit14 Action direction: 0-No action, 1-N→1
10 Bit15 Action direction: 0-No action, 1-1→N
Remote control format (function code 05H)
Remote control upper
 Slave function Remote Remote Remote Remote CRC16 CRC16
address code control control command command low high
address high address low high low
01H 05H 00H 01H FFH 00H DDH FAH
Remote control lower
Slave function Remote Remote Remote Remote CRC16 CRC16
address code control control command command low high
address high address low high low
01H 05H 00H 02H FFH 00H 6cH 0aH
Remote control stop
Slave function Remote Remote Remote Remote CRC16 CRC16
address code control control command command low high
address high address low high low
01H 05H 00H 03H FFH 00H 3DH CAH

Remote address description

Address Parameter Data Type Property Remarks
0001H Remote control upper Uint16 S
0002H Remote control lower Uint16 S
0003H Remote control stop Uint16 S