Dual Inventive ZKL 3000 RC User manual

Manual for installing
ZKL 3000 Remote Control (RC) Line Blockage System
ZKL 3000 RC
May 2023

2
1. Introduction 3
2. Definitions & technical specifications 3
a. Application of ZKL 3000 RC 3
3. Conditions & safety instructions 4
a. Conditions of use 4
b. Instructions 4
4. Components 5
a. ZKL 3000 RC and Ancillaries 5
b. The ZKL 3000 RC Unit 6
c. Batteries and Chargers 6
5. Charging the batteries 7
a. Instructions prior to use 7
b. Charging a backup battery 7
c. Charging an external battery 7
6. Testing the ZKL 3000 RC 8
a. Preparations 8
b. The override key switch 8
c. Function test for installation 9
7. Installing the ZKL 3000 RC 10
a. Installing the ZKL 3000 RC in the track 10
b. Functional test in the track 11
c. LED Indications 13
d. Replacing external battery 13
e. Removing the ZKL 3000 RC from the track 14
8. Alerts 15
a. Status screen alerts 15
b. Error and alerts 16
c. Error and alerts - reminders 19
9. Transport & storage 20
a. Transport 20
b. Storage 20
10. Maintenance & service 20
a. Maintenance 20
b. Service 21
11. Environment & recycling 21
In conclusion 21
CONTENTS
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3
1. INTRODUCTION
This manual details the correct method for installing the ZKL 3000 Remote Control (RC) Line
Blockage System safely. The ZKL 3000 RC system protects a section of track efficiently and effectively
by producing and monitoring a short circuit in the track, simulating a train in the section. This causes
the track circuit to be ‘OCCUPIED’, thus placing the protecting signals danger. This section is
immediately closed to rail traffic, enabling rail workers to perform work on the infrastructure safely.
The ZKL 3000 RC can be operated using either the MTInfo 3000 app or through the web interface MTinfo 3000.
This manual describes how to operate the ZKL 3000 RC using the MTinfo 3000 version 5 webplatform
and MTinfo 3000 app. The Remote Switch (RS) 3000 cannot be used on MTinfo 3000 version 5 to
switch a ZKL 3000 RC.
This manual is part of a set that details the entire ZKL 3000 RC system: The web interface
(MTinfo 3000), the Line Blockage System (ZKL 3000 RC), and the MTinfo 3000 app.
2. DEFINITIONS & TECHNICAL SPECIFICATIONS
a. Application of ZKL 3000 RC
The ZKL 3000 RC can be applied in track types with a width of 1,435mm, such as:
• NP46 • 85 lb RBS
• UIC54 • 109 lb
• UIC60 • 110 lb
• 95 lb RBS • 113 lb
Additionally, the ZKL 3000 RC can be used for mains voltage of both 1500 V and 25kV.
The ZKL 3000 RC can be used with the following track circuit systems:
You must NOT use a ZKL 3000 RC in locations with any of the following:
• Level crossings and/or service roads (or alongside)
• Axle counters
• Switches and Points
• Within 3m of the Tuning Zone
• In track circuits which have a frequency of 16.kHz or above
To connect to the ZKL 3000 RC the MTinfo 3000 app uses Dual Inventive’s wireless 3G network.
ZKL 3000 RC
• Jeumont-Schneider Peak Voltage
track circuit section
• Classic track circuit: 12V alternating
voltage 75 Hz
• Siemens electronic ripple control track
circuits FTGS46 & FTGS917
• GRS Overlay Track Circuit (OTC)
• Alstom Jade system
• Bi-rail type CV50B3P
• High power pulses type CVTHBG
• EBI track 400 OL (open line)
• Aster SF 15 type track circuit
• FS2600,
• Reed,
• HVI
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4ZKL 3000 RC
3. CONDITIONS & SAFETY INSTRUCTIONS
WARNING!
Please read all safety instructions carefully before using the ZKL 3000 RC, ensuring you
fully understand the system and how it works. When precautionary measures and safety
instructions are not followed properly there is a risk of electric shock, entrapment, fire
or even death.
a. Conditions of use
You are only allowed to install the ZKL 3000 RC if:
• you hold the ZKL 3000 RC competencies, and they are in date
• you have been assigned the appropriate user rights on MTinfo 3000
• you have been authorised to install the ZKL 3000 RC
As a competent user you are responsible for:
• any relevant paperwork, user names and passwords (and any authorisation codes via text
message or PIN that you have been assigned)
• managing your password and your PIN. You must never share this
information with others
b. Instructions
Other important instructions
• There are certain situations where it is not possible to switch the ZKL 3000 RC.
Please see the “Troubleshooting” section for more information should you encounter any problems
• Never perform any repairs to a ZKL 3000 RC. Please contact Dual Inventive for maintenance
and repairs
• Override keys must only be handed out to those who hold the ZKL 3000 RC competency
• Please take good care of the ZKL 3000 RC override keys by organising proper key management
to ensure they are not lost, stolen or damaged
• If the track circuit has been tuned including ZKL 3000 RC, the track circuit must be
tuned again after removal of the ZKL 3000 RC.
The batteries of the ZKL 3000 RC, both back-up and main, are lithium batteries and therefore
considered ‘dangerous goods’. Please ensure you follow the local laws and regulations when
storing and transporting these batteries. In case of damaged batteries, please avoid exposure and
discharge the battery in its original package conform the local laws and regulations. When you
are no longer in the possession of the packaging, we can deliver new packaging if required.
Instructions for first use
• Check whether the ZKL 3000 RC has the correct certification. Please consult our website
for the required certificates: www.dualinventive.com
• Please check whether local restrictions, regulations or certification apply to the use of
the ZKL 3000 RC
• Always take care of your own safety within the railway environment using the most current
applicable legislation
• Always visually inspect the ZKL 3000 RC for damage and perform a function test
DO NOT USE any ZKL 3000 RC if any damage or defects are detected. Please apply a label,
quarantine and return to your stores to be sent to Dual Inventive
• Always use the installation procedure set out in this manual for the ZKL 3000 RC
• Always start the installation with two fully charged batteries
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5
ZKL 3000 RC
4. COMPONENTS
A complete ZKL 3000 RC set consists of the following:
• Case including ZKL 3000 RC and ancillaries
• Batteries for ZKL 3000 RC with chargers
a. ZKL 3000 RC and Ancillaries
A ZKL 3000 RC set contains:
1. The ZKL 3000 RC including bypass clamps and override keys
2. Transport case
3. Backup battery
4. Battery compartment key
5. Manual
6. Key ring
7. Carrying strap
8. Test-Tool
9. Backup battery charger
10. USB (contains manual)
11. ZKL Clamp
12. Padlock
13. External battery
14. Charger external battery
15. Connection cable external battery
11
4
7
8
9
10
131415
5
6
12
3
1 2
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6ZKL 3000 RC
4. CONTINUATION COMPONENTS
b. The ZKL 3000 RC Unit
1. A hinged frame
2. SWITCH 3000
3. Electronics casing (LEDs, GPS and black box recorder)
4. Battery compartment
5. Contact points
6. Locking mechanism
c. Batteries and Chargers
1. Backup battery
2. Charger backup battery
3. External battery
4. Charger external battery
1
1
3 4
2
6 3 425
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7
ZKL 3000 RC
5. CHARGING THE BATTERIES
The ZKL 3000 RC uses two types of batteries and chargers, which are displayed below
a. Instructions prior to use
• The chargers only have an IP20 protection level, so always charge the batteries in a dry,
indoor environment
• ALWAYS place the chargers at least 50mm apart for adequate cooling
• Always check the charger and cables for visible damage before use. DO NOT USE the charger
if any damage is detected
• Do not charge the batteries in an environment which is below 6°C
• The charger of both the backup battery and the external battery may only be repaired and
maintained by Dual Inventive
• Always transport and store the chargers in a dry environment
• Only use the charger that was supplied for that particular model
b. Charging a backup battery
• Plug the charger into a power socket. The green LED will illuminate to indicate mains power
• Connect the battery to the charger. The red LED on the charger will illuminate to indicate the
backup battery is being charged
• When the red LED switches off, the battery is fully charged
• The backup battery can stay connected to the charger without causing damage, although
after a period of time the red LED may illuminate again
c. Charging an external battery
• Connect the power cable to the battery and then connect the charger to the mains.
The two red LEDs on the charger will illuminate
• The fan in the charger should start at this point
• Both LEDs on the charger will remain red when the external battery is being charged
• When charged, one LED will turn green indicating this
• The external battery can stay connected to the charger, however it will not trickle charge
ATTENTION:
If you are to re-use the charger on another battery, please remove the charger from the
power before connecting the new battery.
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8ZKL 3000 RC
6. TESTING THE ZKL 3000 RC
a. Preparations
Before you start, check whether the ZKL 3000 RC system’s calibration is still in date.
You can find the “Next calibration date” sticker on the measuring unit.
Before installation, the user should check the ZKL 3000 RC for defects and perform a function test.
Testing the ZKL 3000 RC should always be done in a position of safety.
• Before testing, clean the contact points with a wire brush to ensure the best possible connection
• Before use, place two fully charged batteries into the ZKL 3000 RC
• Open the battery cover with the compartment key
• ALWAYS place the power cable on the notched side of the battery compartment
• Insert the batteries and pull the rubber fastener over the battery ends to lock them in position
• Close the battery cover and lock it with the compartment key
• Wait at least 10 seconds after installing the batteries to allow the ZKL 3000 RC to switch on
• Using the override key switch, switch the ZKL 3000 RC on
b. The override key switch
The override key switch has three positions:
Key up (fully clockwise) = ON
The ZKL 3000 RC is now set in an overruled manner
and will not produce a short circuit. The unit cannot
be operated remotely.
Key horizontal = OPERATIONAL
The ZKL 3000 RC is now operational and can be operated
remotely by either the MTinfo 3000 app or MTinfo 3000.
Key down (fully counter-clockwise) = OFF
The ZKL 3000 RC is now set in an overruled manner and
will not produce a short circuit. The unit cannot be
operated remotely.
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9
ZKL 3000 RC
6. CONTINUATION TESTING THE ZKL 3000 RC
The override key switches the ZKL 3000 RC ON or OFF without using either the MTinfo 3000 app or
MTinfo 3000. Use of the override key will overrule commands sent by both the MTinfo 3000 app and
MTinfo 3000 as the key switch always takes priority. Usually, the key switch would only be used
as a last resort.
Attention! The OPERATIONAL position has two settings.
OPERATIONAL - ON: When switched from the ON to OPERATIONAL (one turn to the left),
the ZKL 3000 RC remains activated creating a short circuit. However, it will now be possible to
remotely operate the ZKL 3000 RC using either the MTinfo 3000 app or MTinfo 3000.
OPERATIONAL - OFF: When switched from OFF to OPERATIONAL (one turn to the right), the ZKL
3000 RC remains deactivated. Again, it will now be possible to remotely operate the ZKL 3000 RC
using either the MTinfo 3000 app or MTinfo 3000.
Attention! Please wait a few seconds after operating the override key. If the override key is
switched through multiple positions too rapidly (such as from ON immediately to OFF),
the ZKL 3000 RC might not properly register this switch action.
c. Function test for installation
• Ensure that the contact points and the Test-Tool are clean
• With the Test-Tool present (as shown below), press the contact points together and switch
the ZKL 3000 RC ‘ON’ using the override key
• The green LED should start flashing (twice per second), indicating that a short circuit has
been detected. Check this status for at least five seconds
• If all is OK and the green LED continues to flash, switch the ZKL 3000 RC ‘OFF’ using the
override key. The LED should stop flashing. Again, check this for at least five seconds
• If the LED remains off, remove the Test-Tool. The ZKL 3000 RC is ready to be deployed
ATTENTION: If the ZKL 3000 RC does not pass the functional test before installation,
do NOT use the unit. Apply a label to the ZKL 3000 RC, quarantine it and return to your
depot/warehouse to be returned to Dual Inventive for repair.
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10 ZKL 3000 RC
7. INSTALLING THE ZKL 3000 RC
a. Installing the ZKL 3000 RC in the track
CAUTION, Please check whether local restrictions, regulations or certification apply to the use of
the ZKL 3000 RC.
After successfully testing the ZKL 3000 RC in a position of safety, the ZKL 3000 RC is then ready to
be installed in the track. Before doing so, ensure the rails are cleaned as thoroughly as possible
(to remove rust build up). This helps to create a good connection between the ZKL 3000 RC and
the track. A wire brush, connected to a power tool, is one such solution to clean the rails, as seen
in the images below:”
• Ensure that the distance between the bottom of the ZKL 3000 RC and any ballast is at least 3cm
• Set the override key switch of the ZKL 3000 RC to ‘ON’
• Unfold the ZKL 3000 RC and place the contact points on the web of the rail
• Partially insert and remove the ZKL 3000 RC during installation several times (being careful
to keep it in the same location) before the final placement of the ZKL 3000 RC. The contact
points will scrape the rust away from the rail web ensuring a better contact
• Using your hand or foot (and being careful to avoid trapping in the hinge), push the
ZKL 3000 RC down until it locks
• The green LED should start flashing (twice per second), indicating that a short circuit has
been detected. Check this status for at least five seconds
• Place the locking clamp over the hinge of the ZKL 3000 RC
• Insert the two metal locking plates in the base of the locking clamp
• Next, place the clamp around the two pins and lock with a padlock (as shown below)
• Place the external battery outside of the track in a safe location and secure it.
No padlocks or chains have been supplied for this purpose
• Pass the cable under the rail (on the side of the battery cover where possible) to the ZKL 3000 RC
• Open the battery cover and connect the plug of the external battery with the ZKL 3000 RC using
the connection cable to battery slot 2. Otherwise, the ZKL 3000 RC will not function properly
ATTENTION! You should always place the power cable to the side of the notch in the
battery compartment.
before after
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11
ZKL 3000 RC
7. CONTINUATION INSTALLING THE ZKL 3000 RC
• Carefully close the battery compartment, ensuring the cable stays within the specially cut
hole and lock it using the compartment key
• If you are not using an external battery, you must instead insert a secondary backup
battery. Please ensure you always use two batteries. If you use a second backup battery in
place of an external battery the power will only last around 24 hours and is therefore not
suited for long term deployment
• Apply the bypass clamps to the foot of the rails. The bypass clamps are linked to each contact
point of the ZKL 3000 RC. You connect these clamps to the rail by tapping them with a hammer
until they are fully placed on the base. This ensures below result.
• Next, test the ZKL 3000 RC for functionality to ensure the ZKL 3000 RC can be switched on
and off and is visible in MTinfo 3000. See chapter “Functional test in the track”
• In case of any problems, DO NOT use the ZKL 3000 RC
b. Functional test in the track
Ensure your own safety at all times during the functional test.
The ZKL 3000 RC is now installed in the track and should next be function tested. It is important
that you first read the other chapters before continuing.
ATTENTION! If you are applying a short circuit with the ZKL 3000 RC in the same section,
the distance to the ZKL 3000 RC should be at least 5 metres.
• Login on either MTinfo 3000 (https://MTinfo3000.com), or the
MTinfo 3000 app
• Find the ZKL 3000 RC using its ID in the real-time status
• Click on the ZKL 3000 RC to verify the status
• For more information, see the manual: Using MTinfo 3000, chapter “Real-time status”
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12 ZKL 3000 RC
7. CONTINUATION INSTALLING THE ZKL 3000 RC
If any of the steps below show a different result than expected, please
consult chapter 9, Troubleshooting.
The status is shown as:
• Ensure detection quality is at least 80% (if the detection quality hits 0% the detection is
NOT OK (NOK) meaning the device will not show a green blinking led). If this is not possible,
see the chapter “Placing ZKL 3000 RC in the track”.
• From the ‘ON’ position, rotate the override key back to ‘OPERATIONAL’
(see chapter 6b, The key switch for additional explanation) and check the real-time
status again.
The status is shown as:
• From the ‘OPERATIONAL’ position, switch the override key to ‘OFF’ and once again check
the real-time status.
The status is shown as:
The ‘detection quality date/time’ field reports the last time the ZKL 3000 RC was switched on and
detection was OK (this is only applicable when the switch status is ‘OFF’).
• From the position OFF, reset the key switch to OPERATIONAL and check the real-time status again.
The status is shown as:
• The function test is now complete.
• Finally, set the ZKL 3000 RC to OFF-OPERATIONAL by using the override key. This will ensure
the ZKL 3000 RC is ready for use remotely
• The OPERATIONAL position remembers the device’s last switch status and allows you to operate
the device remotely through MTinfo 3000 and the MTinfo 3000 app.
It is possible to use the ZKL 3000 RC as a regular ZKL 3000 by leaving it in the ON position.
Do not use the ZKL 3000 RC if you are not sure that the system is functioning properly.
Switch status Switched On
OK
88.21%
Operational
Detection OK
Detection quality
Key position
Switch status Switched OFF
88.21%
(2019-04-01 10:50:54)
Operational
Detection quality
Key position
Switch status Switched OFF
88.21%
(2019-04-01 10:50:54)
O
Detection quality
Key position
Switch status Switched ON
OK
88.21%
On
Detection OK
Detection quality
Key position
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13
ZKL 3000 RC
7. CONTINUATION INSTALLING THE ZKL 3000 RC
c. LED Indications
You may find the following situations on the ZKL 3000 RC:
• Green led is flashing  status safe
• Cause: ZKL 3000 RC has been switched on and is measuring a short circuit
• Green and red LED are off no detection
• Possible causes:
- ZKL 3000 RC has not been switched on
- ZKL 3000 RC does not have any power
- ZKL 3000 RC is defective. Remove the ZKL 3000 RC from the track, label, quarantine
and send it to Dual Inventive for repairs
- ZKL 3000 RC does not have a good connection with the rails
Use MTinfo 3000 (https://mtinfo3000.com), or the MTinfo 3000 app
to see the status. More information can be found in the chapter “Troubleshooting”
• If the red LED is permanently illuminated
• Cause: power supply is below desired level
• Solution: Replace the battery as soon as possible
d. Replacing external battery
When the ZKL 3000 RC indicates that the power supply is low, it must be replaced.
• Disconnect the power cable from the external battery
• Insert a fully charged, external battery and connect it to the power supply cable
• The backup battery will start charging automatically
• Report to the relevant person within your organisation that the external battery has been
replaced. This is because MTinfo 3000 will report that the battery was disconnected next time a
project is released
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14 ZKL 3000 RC
7. CONTINUATION INSTALLING THE ZKL 3000 RC
e. Removing the ZKL 3000 RC from the track
• Remove the external battery and connection cable
• Disconnect the bypass clamps
• Remove the locking clamp from the ZKL 3000 RC
• Open the locking mechanism cover
• Place your fingers in the open area behind the cover and press the palm of your hand on
top of the ZKL 3000 RC
• Put your other hand on the cover of the ZKL 3000 RC
• Using your fingers, squeeze open the locking mechanism
• In a controlled manner, pull the ZKL 3000 RC up
• Lift the ZKL 3000 RC out of the track and fold until it locks
Put your other hand on the
cover of the ZKL 3000 RC
Place your fingers in the open
area behind the cover and the
palm of your hand on top of
the ZKL 3000 RC
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15
ZKL 3000 RC
8. ALERTS
a. Status screen alerts
When you click the ‘plus’ symbol next to a ZKL 3000 RC on the realtime screen, you will see an
expanded status view for the ZKL 3000 RC.
Status Explanation
Device status: Online The ZKL 3000 RC is connected to MTinfo 3000.
Device status: Offline The ZKL 3000 RC is not connected to MTinfo 3000.
Last update The last time the device signaled to the MTinfo 3000 app and MTinfo 3000.
Switch status: Switched ON The ZKL 3000 RC is switched “ON”.
Switch status: Switched OFF The ZKL 3000 RC is switched “OFF”.
Detection: OK A short circuit has been detected.
Detection: NOK A short circuit has not been detected.
Key position: Operational The key switch is in the operational position.
Key position: On The ZKL 3000 RC is overruled by the key switch and is switched “ON”.
Key position: Off The ZKL 3000 RC is overruled by the key switch and is switched “OFF”.
Battery The battery is connected to the ZKL 3000 RC and is full.
Battery The battery is connected to the ZKL 3000 RC an has sufficient power.
Battery The battery is connected to the ZKL 3000 RC but is almost empty.
Battery The battery is empty.
Battery The battery is critical.
Battery The battery has been removed from the ZKL 3000 RC or is completely empty.
Battery volt Shows the voltage of the ZKL 3000 RC batteries.
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16
8. CONTINUATION ALERTS
b. Error and Alerts
Users with switching rights on a released project will automatically receive alerts via text messages
(SMS). Users’ mobile phone number is entered as alarm number within the user profile to enable
this. The notification service starts as soon as the ZKL 3000 RC has been assigned to a project and
the project is released. It is the responsibility of the recipient to act upon these alerts.
NOTE
A notification is a message or a reminder of a message send by MTinfo 3000 to a users’ mobile
device (tablet, phone). A reminder for a critical notification is an extra service to help the user
but it is explicitly not a mitigation of an identified risk.
WARNING
SMS messages will not be delivered to the user if a wrong telephone number is registered or
when the user blocks the sender’s phone number MTinfo 3000. Verify if you have entered your
correct telephone number and do not block the sender.
NOTE
When replacing batteries make sure you install the main battery and backup battery in the
correct slot indicated by the label on the ZKL.
The text message alerts that require action are:
Alert Explanation Action
ZKL 3000 RC “Serial
Number“ * Detection
NOT ok. Please check
manual for more infor-
mation
ZKL 3000 RC with ID “Serial Number” is no
longer creating a proper short circuit in the
track. The detection is not OK.
Remove contaminants and reinstall the device
to improve the detection. If this doesn’t solve
the issue replace the device with another
device and return for service.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ *
is offline. Please check
manual for more infor-
mation
ZKL 3000 RC with ID “Serial Number” is offli-
ne. The ZKL 3000 RC cannot make a connec-
tion to MTinfo 3000.
Restart the device by reconnecting the batte-
ries of the device, move the device 10 meters
or check the Status page for network outage.
If this doesn’t solve the issue contact Dual
inventive. See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ *
The backup battery is
CRITICAL, the main bat-
tery is CRITICAL. Please
check manual for more
information
Both batteries of ZKL 3000 RC with ID “Seri-
al Number” are critical. The system will send
a new alert as soon as one of the batteries is
getting depleted.
Replace the Main battery with a full main
battery as soon as possible.
See 7. INSTALLING THE ZKL 3000 RC.
8. CONTINUATION ALERTS
Alert Explanation Action
ZKL 3000 RC “Serial
Number“ *
The backup battery has
sufficient power, the
main battery is CRITI-
CAL. Please check manu-
al for more information
The main battery of the ZKL 3000 RC with ID
“Serial Number” is critical and the backup
battery is ok (either full or half full). The
system will send a new message as soon
as one of the batteries will reach the next
depletion level.
Replace the Main battery with a full main
battery as soon as possible.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ * The backup
battery is CRITICAL,
the main battery has
sufficient power. Please
check manual for more
information
The backup battery of the ZKL 3000 RC with
ID “Serial Number” is critical and the main
battery is ok (either full or half full). The
system will send a new message as soon
as one of the batteries will reach the next
depletion level.
Check the status of the backup battery in a few
hours. If after a few hours it is still not charged
then replace the battery.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ *
The backup battery has
sufficient power, the
main battery is DEPLE-
TED. Please check manu-
al for more information
The main battery of the ZKL 3000 RC with ID
“Serial Number” is depleted and the backup
battery is ok (either full or half full). The
system will send a new message as soon as
the ok battery reaches the next depletion
level.
Replace the Main battery with a full main
battery as soon as possible.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ * The backup
battery is DEPLETED,
the main battery has
sufficient power. Please
check manual for more
information
The backup battery of the ZKL 3000 RC with
ID “Serial Number” is depleted and the main
battery is ok (either full or half full). The
system will send a new message as soon as
the ok battery reaches the next depletion
level.
Check the status of the backup battery in a few
hours. If after a few hours it is still not charged
then replace the battery.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ *
The backup battery is
DEPLETED, the main bat-
tery is CRITICAL. Please
check manual for more
information
The backup battery of the ZKL 3000 RC with
ID “Serial Number” is depleted and the main
battery is critical. The system will send a
new alert as soon as the main battery is
depleted.
Replace the Main battery with a full main
battery as soon as possible.
Check the status of the backup battery in a few
hours. If after a few hours it is still not charged
then replace the battery.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ *
The backup battery is
CRITICAL, the main bat-
tery is DEPLETED. Please
check manual for more
information
The main battery of the ZKL 3000 RC with ID
“Serial Number” is depleted and the backup
battery is critical. The system will send a
new alert as soon as the backup battery is
depleted.
Replace the Main battery with a full main
battery as soon as possible.
Check the status of the backup battery in a few
hours. If after a few hours it is still not charged
then replace the battery.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ *
The backup battery is
DEPLETED, the main bat-
tery is DEPLETED. Please
check manual for more
information
Both batteries of ZKL 3000 RC with ID “Seri-
al Number” are depleted.
Replace the Main battery with a full main
battery as soon as possible.
Check the status of the backup battery in a few
hours. If after a few hours it is still not charged
then replace the battery.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC
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8. CONTINUATION ALERTS
Alert Explanation Action
ZKL 3000 RC “Serial
Number“ *
The backup battery has
sufficient power, the
main battery is CRITI-
CAL. Please check manu-
al for more information
The main battery of the ZKL 3000 RC with ID
“Serial Number” is critical and the backup
battery is ok (either full or half full). The
system will send a new message as soon
as one of the batteries will reach the next
depletion level.
Replace the Main battery with a full main
battery as soon as possible.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ * The backup
battery is CRITICAL,
the main battery has
sufficient power. Please
check manual for more
information
The backup battery of the ZKL 3000 RC with
ID “Serial Number” is critical and the main
battery is ok (either full or half full). The
system will send a new message as soon
as one of the batteries will reach the next
depletion level.
Check the status of the backup battery in a few
hours. If after a few hours it is still not charged
then replace the battery.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ *
The backup battery has
sufficient power, the
main battery is DEPLE-
TED. Please check manu-
al for more information
The main battery of the ZKL 3000 RC with ID
“Serial Number” is depleted and the backup
battery is ok (either full or half full). The
system will send a new message as soon as
the ok battery reaches the next depletion
level.
Replace the Main battery with a full main
battery as soon as possible.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ * The backup
battery is DEPLETED,
the main battery has
sufficient power. Please
check manual for more
information
The backup battery of the ZKL 3000 RC with
ID “Serial Number” is depleted and the main
battery is ok (either full or half full). The
system will send a new message as soon as
the ok battery reaches the next depletion
level.
Check the status of the backup battery in a few
hours. If after a few hours it is still not charged
then replace the battery.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ *
The backup battery is
DEPLETED, the main bat-
tery is CRITICAL. Please
check manual for more
information
The backup battery of the ZKL 3000 RC with
ID “Serial Number” is depleted and the main
battery is critical. The system will send a
new alert as soon as the main battery is
depleted.
Replace the Main battery with a full main
battery as soon as possible.
Check the status of the backup battery in a few
hours. If after a few hours it is still not charged
then replace the battery.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ *
The backup battery is
CRITICAL, the main bat-
tery is DEPLETED. Please
check manual for more
information
The main battery of the ZKL 3000 RC with ID
“Serial Number” is depleted and the backup
battery is critical. The system will send a
new alert as soon as the backup battery is
depleted.
Replace the Main battery with a full main
battery as soon as possible.
Check the status of the backup battery in a few
hours. If after a few hours it is still not charged
then replace the battery.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ *
The backup battery is
DEPLETED, the main bat-
tery is DEPLETED. Please
check manual for more
information
Both batteries of ZKL 3000 RC with ID “Seri-
al Number” are depleted.
Replace the Main battery with a full main
battery as soon as possible.
Check the status of the backup battery in a few
hours. If after a few hours it is still not charged
then replace the battery.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC
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8. CONTINUATION ALERTS
Alert Explanation Action
ZKL 3000 RC “Serial
Number“ * The backup
battery is CRITICAL, the
main battery has been
REMOVED. Please check
manual for more infor-
mation.
The backup battery of the ZKL 3000 RC with
ID “Serial Number” is critical and the main
battery has been removed, The system will
send a new alert as soon as the backup
battery is depleted.
Install a full main battery as soon as possible.
Check the status of the backup battery in a few
hours. If after a few hours it is still not charged
then replace the battery.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ * The backup
battery is DEPLETED,
the main battery has
been REMOVED. Please
check manual for more
information.
The backup battery of the ZKL 3000 RC with
ID “Serial Number” is depleted and the
main battery has been removed, The system
will send a new alert as soon as the backup
battery is removed.
Install a full main battery as soon as possible.
Check the status of the backup battery in a few
hours. If after a few hours it is still not charged
then replace the battery.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ * The back-
up battery has been
REMOVED, the external
battery is CRITICAL.
Please check manual for
more information.
The backup battery of the ZKL 3000 RC with
ID “Serial Number” has been removed and
the main battery is critical, The system will
send a new alert as soon as the main battery
is depleted.
Replace the Main battery with a full main bat-
tery as soon as possible.
Place a full backup battery.
See 7. INSTALLING THE ZKL 3000 RC.
ZKL 3000 RC “Serial
Number“ * The backup
battery has been REMO-
VED, the main battery
is DEPLETED. Please
check manual for more
information.
The backup battery of the ZKL 3000 RC with
ID “Serial Number” has been removed and
the main battery is depleted, The system
will send a new alert as soon as the backup
battery is depleted.
Replace the Main battery with a full main bat-
tery as soon as possible.
Place a full backup battery.
See 7. INSTALLING THE ZKL 3000 RC.
8. CONTINUATION ALERTS
c. Error and Alerts - reminders
For the offline and the detection critical events a reminder system is introduced. The reminders are
helping the user to remind that there is an unresolved issue with a specific ZKL 3000 RC.
Battery notifications already have an implicit reminder system as the user is notified when the main
or backup battery reaches critical and depleted levels.
NOTE
Reminders do not relieve the user of his responsibility to go immediately to the device to
inspect it when receiving the first alert massage!
Please, always consult the Real Time Status for the up-to-date situation.
A reminder is sent after a 15-minute interval. A maximum of 3 reminders are sent for one
continuously ‘not ok’-situation. Reminders are only sent when the device is in active state
(i.e. in an activated protection zone).
The reminder text messages are:
Alert Explanation Action
Reminder: ZKL 3000
RC “Serial Number“ *
Detection NOT ok. Please
check manual for more
information
Reminder message when the detection is
not ok and the device is in an activated
protection zone.
Remove contaminants and reinstall the device
to improve the detection. If this doesn’t solve
the issue replace the device with another
device and return for service.
Reminder: ZKL 3000
RC “Serial Number“ *
is offline. Please check
manual for more
information
Reminder message when the device is
offline and the device is in an activated
protection zone.
Restart the device by reconnecting the batte-
ries of the device, move the device 10 meters
or check the Status page for network outage.
If this doesn’t solve the issue contact Dual
inventive.
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8. CONTINUATION ALERTS
c. Error and Alerts - reminders
For the offline and the detection critical events a reminder system is introduced. The reminders are
helping the user to remind that there is an unresolved issue with a specific ZKL 3000 RC.
Battery notifications already have an implicit reminder system as the user is notified when the main
or backup battery reaches critical and depleted levels.
NOTE
Reminders do not relieve the user of his responsibility to go immediately to the device to
inspect it when receiving the first alert massage!
Please, always consult the Real Time Status for the up-to-date situation.
A reminder is sent after a 15-minute interval. A maximum of 3 reminders are sent for one
continuously ‘not ok’-situation. Reminders are only sent when the device is in active state
(i.e. in an activated protection zone).
The reminder text messages are:
Alert Explanation Action
Reminder: ZKL 3000
RC “Serial Number“ *
Detection NOT ok. Please
check manual for more
information
Reminder message when the detection is
not ok and the device is in an activated
protection zone.
Remove contaminants and reinstall the device
to improve the detection. If this doesn’t solve
the issue replace the device with another
device and return for service.
Reminder: ZKL 3000
RC “Serial Number“ *
is offline. Please check
manual for more
information
Reminder message when the device is
offline and the device is in an activated
protection zone.
Restart the device by reconnecting the batte-
ries of the device, move the device 10 meters
or check the Status page for network outage.
If this doesn’t solve the issue contact Dual
inventive.
ZKL 3000 RC
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9. TRANSPORT & STORAGEa. Transport
a. Transport
• Always use the transport case to transport the ZKL 3000 RC when possible. The ZKL 3000 RC
transport cases are equipped with wheels for use on solid ground and are horizontally stackable
• If you transport the ZKL 3000 RC without a case, carry it horizontally next to the body and
use the handle ensuring the contact points of the ZKL 3000 RC point forward
• Make sure the locking mechanism is latched shut
• During transport, ensure your own safety at all times
b. Storage
Careful maintenance and adequate storage of the ZKL 3000 RC prolongs its life span.
• Clean the ZKL 3000 RC every four months with a cloth and/or brush
• When frequently used, you should regularly clean the sprung contact legs and the contact
points. Debris can cause parts to wear faster
• Clean the contact points with a wire brush
• Use the transport case to store the ZKL 3000 RC and store it in a dry, well ventilated area.
• Do not store a wet ZKL 3000 RC in a closed case for a long period of time. This will cause mould
10. MAINTENANCE & SERVICE
a. Maintenance
It is possible that due to wear and tear, the ZKL 3000 RC’s ability to create and detect a short circuit
is decreased. This will be noticeable if you have to resend the ‘ON’ command multiple times, even
though the green LED is flashing. In this case, the contact points are probably worn, and they
should be replaced. These can be supplied by Dual Inventive. The ZKL 3000 RC does not need to
be recalibrated during this maintenance.
To replace the contact points, use a torx wrench T25 to loosen the bolts. After you have
completely removed the bolts, you can install the new contact points by reusing these.
When installing contact points, please tighten to a torque of 6.1 Nm.
10. CONTINUATION MAINTENANCE & SERVICE
b. Service
Once every four years, the ZKL 3000 RC needs to be recalibrated by Dual Inventive. At the same
time they will undertake any remedial maintenance that is required. The “next certification
date” stickers indicate when this is due. For more information, please contact us quoting the
ID number.
For service and repair please contact your local Dual Inventive representative.
11. ENVIRONMENT & RECYCLING
Equipment Disposal
The ZKL 3000 RC, the LI-ion batteries and peripherals, such as chargers, are not domestic waste.
For more detailed information about recycling the equipment, please contact the local authorities
or Dual Inventive.
IN CONCLUSION
If you encounter any problems when using our products or are unsure of anything in this manual,
please report this to us via [e-mail], or by phone. Ultimately, customer satisfaction
and your safety are our top priority and therefore we take all feedback very seriously. We use this to
improve the safety and design of our products. On behalf of the Dual Inventive team, we wish you
all the best.
For marketing materials, please visit our website where they have been made available by
Dual Inventive. Please visit www.dualinventive.com.
ZKL 3000 RC
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