GYDCG-UBCH2 Series Dual DC Channels Insulation Monitoring Device

GYDCG-UBCH2 Series User Manual

Product Information

The GYDCG-UBCH2 Series is a DC insulation monitoring device that
is based on the MODBUS protocol. It is designed for online
monitoring of the insulation resistance of the DC floating system,
where two DC systems share one ground. This product has two
independent DC channels that are controlled separately, ensuring
non-interference between the two channels. Users can enable or
disable the insulation monitoring function of each DC channel and
acquire insulation resistance values by RS485 communication. The
product can monitor positive and negative symmetrical and
asymmetrical insulation resistance, and it has the following
features:

• High reliability
• Easy installation
• Convenient use
• Remote monitoring and management
• Monitor positive and negative poles
• Ground insulation resistance
• DC voltage monitoring
• Vehicle side DC voltage monitoring
• Voltage reverse polarity alarm

The GYDCG-UBCH2 Series is an important equipment to ensure the
safe and stable operation of automobile charging piles.

Product Usage Instructions

1. Before turning on the power supply, make sure that the power
   supply is within the provisions of the instrument.
2. During installation, ensure that the current input terminal is
   non-open, and the voltage input terminals are non-short
   circuit.
3. Strictly prohibit imposing high pressure on the communication
   terminal (RS485).
4. Ensure that the instrument wiring is consistent with the
   internal system settings.
5. When communicating with the PC, ensure that the instrument
   communication parameters are consistent with the PC.
6. To enable or disable the insulation monitoring function of each
   DC channel, refer to the user manual.
7. Use RS485 communication to acquire insulation resistance
   values.
8. The product can monitor positive and negative symmetrical and
   asymmetrical insulation resistance in real-time.
9. After turning off the product, the high-voltage switch is
   disconnected, and the product is completely separated from the DC
   and the earth.

GYDCG-UBCH2 Series
(Dual DC channels)
User Manual

Version1.13

Revision 2023.04

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Read me
When you use GYDCG-UBCH2 Series, be sure to read this user manual carefully, and be able to fully understand the implications, the correct guidance of operations in accordance with user manual, which will help you make better use of GYDCG-UBCH2 Series, and help to solve the various problems at the scene.
1. Before turning on the power supply, be sure that the power supply within the provisions of the instrument;
2. When installation, the current input terminal must non-open, voltage input terminals must Nonshort circuit;
3. Communication terminal (RS485) is strictly prohibited to impose on high pressure;
4. Be sure the instrument wiring consistent with the internal system settings;
5. When communicating with the PC, instrument communication parameters must be consistent with the PC.

Please read this user manual carefully Please save this document

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Directory
1. – SUMMARIZE ………………………………………………………………………………………………………………………. – 3 2. – TECHNICAL PARAMETERS ……………………………………………………………………………………………….. – 4 3. – INSTALLATION …………………………………………………………………………………………………………………… – 5 –
3.1. – MOUNTING…………………………………………………………………………………………………………………………- 5 3.2. – CONNECTION TERMINAL……………………………………………………………………………………………………….- 6 4. – COMMUNICATION INTERFACE ………………………………………………………………………………………… – 8 4.1. – CONNECTION FOR RS485………………………………………………………………………………………………………- 8 4.2. – MODBUS © PROTOCOL ……………………………………………………………………………………………………….- 9 –
4.2.1 – Modbus RTU Frame Format: ………………………………………………………………………………………… – 9 4.3.1 – Communication protocol RS485 …………………………………………………………………………………… – 10 5 – REGISTER MAP …………………………………………………………………………………………………………………. – 16 6. – MODEL SELECTION SHEET …………………………………………………………………………………………….. – 19 7. – SAFETY CONSIDERATIONS ……………………………………………………………………………………………… – 20 8. – MAINTENANCE ………………………………………………………………………………………………………………… – 20 9. – FAQS………………………………………………………………………………………………………………………………….. – 21 –

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1. – SUMMARIZE
GYDCG-UBCH2 Series model is based on MODBUS protocol of DC insulation monitoring device, is used in on-line monitoring insulation resistance of the DC floating system (two DC system shared one ground). two DC channels are controlled independently, two DC insulation monitoring noninterference in each other. Users can enable or disable the insulation monitoring function of each DC channel and acquire insulation resistance values by RS485 communication.
This product has the characteristics of high reliability, easy installation, and convenient use. It is one of the important equipment to ensure the safe and stable operation of automobile charging piles.
This product can monitor positive and negative symmetrical and asymmetrical insulation resistance, when the product is turned on, it can real-time monitor the insulation resistance, and user can read the current insulation resistance value at any time. After the product is turned off, the high-voltage switch is disconnected, and the product is completely separated from the DC and the earth.

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
DC capacitor discharge Guarantee the safety and stability of charging Improvement of the efficiency and charging quality Personnel and equipment security
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2. – TECHNICAL PARAMETERS
Basic parameters

Parameter

Value

Power supply

9~30VDC, power 6w

DC voltage range

0V~1000V

Vehicle side voltage measurement range 0V~1000V

Off-line pressure test

<2mA

Standard

IEC 61851-23 (2014-03):2014-11

Humidity

85%

Storage temperature

– 40°C ~125°C

Operating temperature

– 40°C ~70°C

DC voltage at pile side accuracy

2V+0.3%

Insulation monitoring accuracy

3K+5%s

Insulation resistance measurement range 1K~10M

Other parameters
Pressure point D+/D- TO GND Power supply +/- TO GND RS485 A/B TO GND

Maximum voltage rating 4200VDC/3000VAC 3500VDC/2500VAC 4000VDC/2800VAC

Time 1min 1min 1min

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3. – INSTALLATION
3.1. – Mounting
The module can be installed by guide rail or screw fixation. Guide rail using standard width 36mm. External dimensions are shown as follows: (Unit: mm)

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3.2. – Connection Terminal

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Upper Lower

Interface DC1+ DC1DC2+ DC2Vin 0V GND RG A

Connection mode
Positive pole of DC 1 Negative pole of DC 1 Positive pole of DC 2
Negative pole of DC 2
Positive pole of power supply Negative pole of power supply
Grounding point 485 Communication Ground port
(can leave it unwired) 485A

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4. – COMMUNICATION INTERFACE
4.1. – Connection for RS485
In RS485 communication system, this IMD module works in slave mode. Baud rate, communication address, parity check mode, can be set by DIP switch, default stop bit 1, data bit 8. The interval between each byte in the sent frame must not exceed 20ms, otherwise the frame will be cleared.
4.1.1 – Communication Parameter configuration bit Two Dip switch configuration bit ‘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 check sum, simply dial the corresponding position to “ON”. If E and O are set to no, indicates NONE parity. See Figure 2.
4.1.2 – Initializing Module Communication Parameters Dip switch configuration bit ‘CONFIG’second function can be used to initialize communication parameters. When E and O of CONFIG are dialed to ON at the same time foat 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 on. Thetotal number of times for modifying the baud rate, changing the communication address, andinitializing the baud rate must be less than 1 million. See Figure 3

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4.2. – MODBUS © protocol
Standard MODBUS RTU protocol, initial address: A0H, initial baud rate: 9600bps, parity: (parity can be set through CONFIG), stop bit 1, data bit 8. The interval between each byte in the sent frame must not exceed 20ms, otherwise the frame will be cleared.
4.2.1 – Modbus RTU Frame Format:

Address code Function code Data code Error Check code

1 BYTE 1 BYTE 4 BYTE 2 BYTE

Slave device address 1-247
Indicates the function codes like read coils / inputs
Starting address, high byte Starting address, low byte Length of registers, high byte Length of registers, low byte
Cyclical Redundancy Check ( CRC )

MODBUS FUNCTIONS: Code

Meaning

FUNCTION 01

Read Coil Status

Description Only valid when equipped DO port

FUNCTION 02 FUNCTION 03 FUNCTION 05 FUNCTION 06

Read Input Status Read holding register Write Single coil Write single register

Only valid when equipped DI port
This function permits to read all the electrical parameters
When DO in remote control mode can work
This function permits to write a value into a single holding register.

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4.3.1 – Communication protocol RS485 4.3.2 – Dc DC1 input relay control instructions
Instruction 1 Input relay closed Host inquiry: Addr. 97 00 00 00 00 00 00 CRC CRC Slave response: Addr. 97 00 00 00 00 00 00 CRC CRC
Instruction 2 Input relay is disconnected
Host inquiry: Addr. 90 00 00 00 00 00 00 CRC CRC Slave response: Addr. 90 00 00 00 00 00 00 CRC CRC

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4.3.3 – Dc DC2 input relay control instructions Instruction 1 Input relay closed Host inquiry: Addr. 9A 00 00 00 00 00 00 CRC CRC Slave response: Addr. 9A 00 00 00 00 00 00 CRC CRC
Instruction 2 Input relay is disconnected
Host inquiry: Addr. 95 00 00 00 00 00 00 CRC CRC Slave response: Addr. 95 00 00 00 00 00 00 CRC CRC

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4.3.4 – Dc DC1 data reading instruction

Host inquiry: Slave response:

Addr. 01 00 00 00 00 00 00 CRC CRC
Addr. 01 00(H): Dc voltage high bytes 00(L): Dc voltage high bytes 00(H): Positive insulation resistance high bytes 00(L): Positive insulation resistance low bytes 00(H): Negative insulation resistance high bytes 00(L): Negative insulation resistance low bytes CRC: According to actual calculation CRC: According to actual calculation

Slave response: (reverse connection state
> 160 VDC)

Addr. 70 00 00 00 00 00 00 CRC CRC

Command example:
Host inquiry:
Slave response:
Slave response: (reverse connection state)

A0 01 00 00 00 00 00 00 5A B3 A0 01 01 A4 01 F4 00 78 6A 97 A0 70 00 00 00 00 00 78 3B B4

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4.3.5 – Dc DC2 data reading instruction

Host inquiry: Slave response:

Addr. 03 00 00 00 00 00 00 CRC CRC
Addr. 03 00(H): Dc voltage high bytes 00(L): Dc voltage high bytes 00(H): Positive insulation resistance high bytes 00(L): Positive insulation resistance low bytes 00(H): Negative insulation resistance high bytes 00(L): Negative insulation resistance low bytes CRC: According to actual calculation CRC: According to actual calculation

Slave response: (reverse connection state
> 160 VDC)

Addr. 80 00 00 00 00 00 00 CRC CRC

Command example:
Host inquiry:
Slave response:
Slave response: (reverse connection state)

A0 03 00 00 00 00 00 00 00 5A B3 A0 03 01 A4 01 F4 00 78 6A 97 A0 07 00 00 00 00 00 00 78 3B B4

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4.3.6 ­ Do.1 Vehicle Side Voltage Data Reading Instruction

Host inquiry: Slave response:

Addr. 02 00 00 00 00 00 00 CRC CRC
Addr. 02 00(H): Auto mobile voltage 1 high 8bits 00(L): Car voltage 1 low 8bits 00 00 00 00 CRC CRC

Slave response: (reverse connection state
> 20 VDC)

Addr. 07 00 00 00 00 00 00 CRC CRC

Command example:
Host inquiry:
Slave response: (voltage 420V)
Slave response: (reverse connection state)

A0 02 00 00 00 00 00 00 69 B3 A0 02 01 A4 00 00 00 00 19 BB
A0 07 00 00 00 00 00 00 78 3C B3

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4.3.7 ­ Do.2 Vehicle Side Voltage Data Reading Instruction

Host inquiry: Slave response:

Addr. 05 00 00 00 00 00 00 CRC CRC
Addr. 05 00(H): Auto mobile voltage 2 high 8bits 00(L): Car voltage 2 low 8bits 00 00 00 00 CRC CRC

Slave response: (reverse connection state
> 20 VDC)

Addr. 08 00 00 00 00 00 00 CRC CRC

Command example:
Host inquiry:
Slave response: (voltage 420V)
Slave response: (reverse connection state)

A0 05 00 00 00 00 00 00 1F 73 A0 05 01 A4 00 00 00 00 6F 7B
A0 08 00 00 00 00 00 00 C3 B3

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5 – Register map

Register

Data

Byte mode

Instruction

0x0010 Bus voltage

0x0012 0x0013

DC1 Positive insulation resistance
DC2 Positive insulation resistance DC1 Negative insulation Resistance
DC2 Negative insulation Resistance

float

Unit:0.1V,voltage between positive and

negative poles of DC bus

float 1 The unit is K, an integer

float 1 The unit is K, an integer

0x001A

Read version number

float

0x001B IO state

float

Insulation

monitoring control

0x0102

float

Insulation

monitoring control

0x0103 Modify the address float

0x0104

Modify the baud rate

float

0x66

The host broadcast

reads the slave

float

address

1
Bit1: Whether the current insulation resistance monitoring results are valid. Bit2: Whether the insulation monitoring is 1 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)
Enable DC1 insulation monitoring. 1 Enable DC2 insulation monitoring.
Disable DC1 insulation monitoring. Disable DC2 insulation monitoring. 1 Change the address from 01H to 02H; Change the address from 02H to 03H; 1 Change the baud rate to 9600; Change baud rate to 19200 Example of reply from machine 1 FF 66 01 02 50 7E The slave addresses are0x01 and 0x02

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The samples:

Sample1 Start insulation monitoring

Host inquiry: 01 06 01 02 00 11 E9 FA Slave response: 01 06 02 00 11 78 84

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(600K), the positive insulation resistance 0xEA60 (infinite), the negative insulation resistance 0X0258 (600K).
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.

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Sample5

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. 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.

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6. – Model Selection Sheet

DC Insulation Monitor (Dual DC channels)

GYDCG-UBCH2 GYDCG-UBCH2 MV

Dual insulation monitoring DC voltage detection
Can monitor two DC voltages at the same time
Dual-circuit insulation monitoring DC voltage detection
Vehicle side voltage measurement Can monitor two DC voltages at the same time

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7. – SAFETY CONSIDERATIONS
All installation specification described at the previous chapters named: INSTALLATION AND STARTUP, INSTALLATION MODES and SPECIFICATIONS.
Please note that with the instrument powered on, the terminals could be dangerous to touching and cover opening actions or elements removal may allow accessing dangerous parts. This instrument is factory-shipped at proper operation condition.
The device must have a professional installation and maintenance Any operation of the device, you must cut off the input signal and power;
8. – MAINTENANCE
The GYDCG-UBCH2 does not require any special maintenance. No adjustment, maintenance or repairing action should be done when the instrument is open and powered on, should those actions are essential, high-qualified operators must perform them.
Before any adjustment, replacement, maintenance or repairing 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.

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9. – 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)

Question 3:

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 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.

For any inquiry about the instrument performance or any failure, contact to Blue Jay’s technical service.
Blue Jay – After-sales service
E-mail: [email protected]

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References

• Blue Jay - Development, production and sales of power automation monitoring products and energy metering instruments.