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User Manual: HMC9000A Diesel Engine Controller
User Manual: HMC9000A Diesel Engine Controller
English trademark
SmartGen — make your generator smart
SmartGen Technology Co., Ltd.
No.28 Jinsuo Road
Zhengzhou
Henan Province
P. R. China
Tel: 0086-371-67988888/67981888
0086-371-67991553/67992951
0086-371-67981000(overseas)
Fax: 0086-371-67992952
Web: www.smartgen.com.cn
www.smartgen.cn
Email: [email protected]
All rights reserved. No part of this publication may be reproduced in any material form (including
photocopying or storing in any medium by electronic means or other) without the written permission of
the copyright holder.
Applications for the copyright holder’s written permission to reproduce any part of this publication should
be addressed to Smartgen Technology at the address above.
Any reference to trademarked product names used within this publication is owned by their respective
companies.
SmartGen Technology reserves the right to change the contents of this document without prior notice.
Software Version
Date Version Content
2016-08-08 1.0 Original release.
2017-03-26 1.1 Modified Volvo-EMS2 wiring connection mode.
2017-11-25 1.2 Added Enabled ECU Shutdown function and ECU alarms display mode.
HMC9000A DIESEL ENGINE CONTROLLER USER MANUAL
CONTENTS
1 OVERVIEW ....................................................................................................................................... 5
2 PERFORMANCE AND CHARACTERISTICS ................................................................................... 6
3 TECHNICAL PARAMETERS ............................................................................................................ 7
4 OPERATOR INTERFACE ................................................................................................................. 8
4.1 PUSHBUTTONS DESCRIPTION .............................................................................................. 8
4.2 LCD DISPLAY ............................................................................................................................ 9
4.2.1 MAIN SCREEN ............................................................................................................ 9
4.2.2 MEASURED DATA DISPLAY ....................................................................................... 9
5 OPERATION ................................................................................................................................... 11
5.1 START/STOP OPERATION OF EMERGENCY UNIT.............................................................. 11
5.1.1 CONFIGURATION REQUIREMENTS ............................................................................ 11
5.1.2 REMOTE START SEQUENCE ....................................................................................... 11
5.1.3 REMOTE STOP SEQUENCE ......................................................................................... 11
5.2 LOCAL START/STOP OPERATION ........................................................................................ 12
5.2.1 CONFIGURATION REQUIREMENTS ............................................................................ 12
5.2.2 LOCAL START SEQUENCE ........................................................................................... 12
5.2.3 LOCAL STOP SEQUENCE ............................................................................................. 12
6 PROTECTION................................................................................................................................. 13
6.1 WARNING................................................................................................................................ 13
6.2 SHUTDOWN ALARMS ............................................................................................................ 16
7 PANEL CONFIGURATION .............................................................................................................. 17
8 INPUT/OUTPUT PORTS CONFIGURATION .................................................................................. 24
8.1 AUXILIARY INPUTS 1~18 FUNCTIONAL CONFIGURATION ................................................ 24
8.2 OUTPUT PORTS 1~14 FUNCTIONAL CONFIGURATION ..................................................... 26
8.3 SENSOR FUNCTIONAL CONFIGURATION ........................................................................... 32
8.3.1 SENSOR CONFIGURATION ..................................................................................... 32
8.3.2 TEMPERATURE CURVES ........................................................................................ 33
8.3.3 RESISTANCE SENSORS PRESSURE CURVES ..................................................... 33
8.3.4 LIQUID LEVEL CURVES ........................................................................................... 34
9 BACK PANEL .................................................................................................................................. 35
10 TYPICAL WIRING DIAGRAM ......................................................................................................... 38
11 RS485 COMMUNICATION AND CONNECTION ............................................................................ 39
12 CONTROLLER AND ENGINES CONNECTION (EXPANSION CANBUS) ..................................... 40
12.1 CUMMINS ISB/ISBE ................................................................................................................ 40
12.2 CUMMINS QSL9 ..................................................................................................................... 40
12.3 CUMMINS QSM11 ................................................................................................................... 41
12.4 DETROIT DIESEL DDEC III / IV .............................................................................................. 41
12.5 DEUTZ EMR2 .......................................................................................................................... 41
12.6 JOHN DEERE .......................................................................................................................... 42
12.7 MTU MDEC ............................................................................................................................. 42
12.8 PERKINS ................................................................................................................................. 42
HMC9000A diesel engine controller integrates digitization, intelligentization and network technology
which are used for genset automation and monitor control system of single unit to achieve automatic
start/stop, data measurement, alarm protection and “three remote” (remote control, remote measuring
and remote communication). It fits with TFT-LCD display, optional Chinese/English languages interface,
and it is reliable and easy to use.
The powerful 32-bit ARM processor contained within the module allows for precision parameters
measuring, fixed value adjustment, time setting and set value adjusting and etc. Majority parameters can
be configured from front panel or by communication interface via PC. Due to its compact structure,
simple connections and high reliability, HMC9000A enjoys wide application in all types of diesel engine
automation systems. It can be widely used in marine emergency units, main propulsion units, main
generator units and pump units.
SAE J1939 interface of HMC9000A diesel engine controller allows its communication with ECU
engines. Multiple parameters such as engine speed, water temperature, oil temperature, oil pressure
can be transmitted via this communication interface and displayed on LCD, so there is no need to install
additional sensors and complicated wiring is avoided. This port also enables all kinds of module
expansion; it combines fast data transmission, simple connections and high reliability.
HMC9000A diesel engine controller can be connected to a remote control module that will perform
remote start, remote stop and other functions.
32-bit ARM micro-processor, 4.3 inches LCD display with backlight, optional Chinese/English
interface, push-button operation.
Ability to control and communicate with dozens of ECU engines via J1939 interface which can also
be connected to digital output module and security module to meet modules expanding needs of
user.
Remote monitoring and remote control via REMOTE (CANBUS) port; HMC9000A panel lock in
remote mode (except for 'stop’ button), making work safe and convenient.
RS485 and USB communication ports enable data transmission as well as remote control, remote
measurement and remote communication to be performed with the help of PC monitoring software
via MODBUS protocol;
Control and protection: remote/local start and stop, alarm protection.
Override mode, in which only overspeed shutdown and emergency shutdown will be able to stop
the engine;
Parameter setting: parameters can be modified and stored into internal FLASH memory and cannot
be lost even in case of power outage;
Four 4-20mA inputs for pressure or liquid level sensors;
Four resistance sensor inputs for pressure, PT100 temperature, liquid level or other sensors;
Two K-type thermocouple inputs exhaust temperature sensors;
Real-time calendar, real-time clock, engine total run-time accumulation;
Display the total start times;
Built-in speed detection that accurately estimates starter disconnect speed, rated speed and over
speed.
99 event logs can be saved circularly and can be inquired on the spot.
Double power supply monitoring and transfer function; performed via external port according to the
set switchover voltage value;
Digitization regulation of all parameters - instead of analog regulation using conventional
potentiometer - and, therefore, higher reliability and stability;
Some Input/output ports have break wire detection function;
Modular design, and embedded installation way; small size and compact structure with easy
mounting
Parameter Details
Weight 0.90kg
If alarm occurs, pressing this button will reset it. All alarm only can
Alarm Reset
be removed after reset.
System enters self-check mode after pressing this button. All kinds of
Self-Check
alarms can be detected without starting genset.
Pressing this button will test panel LED indicators and display
Lamp Test
screen.
Screen scroll.
Up/Increase
Up cursor and increase value in setting menu.
Screen scroll.
Down/Decrease
Down cursor and decrease value in setting menu.
Screen scroll.
Left
Left move cursor in setting menu.
Screen scroll.
Right
Right move cursor in setting menu.
WARNING: Factory default password is 01234. Operator can change the password to prevent others from free altering of
the settings. Please clearly remember the password after changing. In case of password loss, please contact SmartGen
service department enclosing all the information from the “ABOUT” page of the controller.
The main screen displays revolution meter (0~3000r/min), thermograph (0~150 ºC; related sensor is
user-configurable, for example: HMC9000A sensor 1), oil manometer (0~1000kpa; related sensor is
user-configurable, for example: HMC9000A sensor 5) and two batteries voltage. The main screen
displays as follows:
The main screen is divided into two separate viewing areas: right and left. Left area display status and
Controller under remote control mode if any programmable input port configured as remote control
(is active).
a) When the “Remote Start” signal is removed, the Stop Delay is initiated.
b) Once this “stop delay” has expired, “cooling delay” is energized.
c) During “Stop Idle” Delay (if configured), idle relay is energized.
d) “ETS Solenoid Hold” begins, ETS relay is energized while fuel relay is de-energized and complete
stop is detected automatically
e) "Fail to Stop Delay" begins, complete stop is detected automatically.
f) Generator is placed into its standby mode after its complete stop. Otherwise, fail to stop alarm is
initiated and the corresponding alarm information is displayed on LCD (If generator is stop
successfully after “fail to stop” alarm has initiated, generator is placed into its standby mode and the
alarm will be removed after pressed Reset button.
NOTE: if use remote monitoring controller to stop the genset, there is no stop delay time after pressing stop key, and other
processes are the same as above remote stop sequence.
Controller is under local mode if configured one input port as local mode (is active).
a) Press button to start the gen-set; preheat relay energizes (if configured), “preheat delay XX
s” information will be displayed on LCD;
b) After the above delay, the Fuel Relay is energized, and then one second later, the Start Relay is
engaged. The engine is cranked for a pre-set time. If the engine fails to fire during this cranking attempt
then the fuel relay and start relay are disengaged for the pre-set rest period; “crank rest time” begins
and wait for the next crank attempt.
c) Should this start sequence continue beyond the set number of attempts, the start sequence will be
terminated, Fail to Start fault will be displayed on LCD.
d) In case of successful crank attempt, the “Safety On” timer is activated, allowing Low Oil Pressure, High
Temperature, Under Speed and Charge Alternator Failure inputs to stabilize without triggering the fault.
As soon as this delay is over, “start idle” delay is initiated (if configured).
e) During “start idle” delay, under speed alarm is inhibited. When this delay is over, “warming up” delay is
initiated (if configured).
f) When “warming up” delay is over, generator will enter into Normal Running status if engine speed and
oil pressure are normal; if engine speed or oil pressure is abnormal, the controller will initiate shutdown
alarm (alarm information will be displayed on LCD);
a) Press button to stop the gen-set and the “Cooling Delay” is then initiated.
b) The “Stop Idle” delay is initiated (if configured). During “Stop Idle” Delay, idle relay is energized.
c) “ETS Solenoid Hold” begins, ETS relay is energized while fuel relay is de-energized.
d) "Fail to Stop Delay" begins, complete stop is detected automatically.
e) Generator is placed into its standby mode after its complete stop. Otherwise, fail to stop alarm is
initiated and the corresponding alarm information is displayed on LCD (If generator is stop
successfully after “fail to stop” alarm has initiated, generator is placed into its standby mode and the
alarm will be removed after pressed Reset button.)
When controller detects shutdown alarm, it will send signal to open breaker and shuts down generator
and the detailed alarm information will be displayed on LCD.
Shutdown alarms as following:
No. Type Detection range Description
When the controller detects an emergency stop
alarm signal, it will initiate a shutdown alarm and
1 Emergency Stop Always active
the corresponding alarm information will be
displayed on LCD.
When the controller detects that the generator
speed has exceeded the pre-set value, it will
2 Over speed Always active
initiate a shutdown alarm and the corresponding
alarm information will be displayed on LCD.
When the controller detects that the generator
From “Waiting for load” speed has fallen below the pre-set value, it will
3 Under speed
delay to “Cooling” delay initiate a shutdown alarm and the corresponding
alarm information will be displayed on LCD.
When the controller detects that the genset
Loss of Speed From “Start Idle” delay to speed is 0, it will initiate a shutdown alarm and
4
Signal “Stop Idle” delay the corresponding alarm information will be
displayed on LCD.
When the controller detects that the auxiliary
input 1-18 shutdown alarm, it will initiate a
5 Auxiliary Input 1-18 User defined
shutdown alarm and the corresponding alarm
information will be displayed on LCD.
When the controller detects ECU shutdown
alarm, it will initiate a shutdown alarm and the
6 ECU Shutdown Always active
corresponding alarm information will be
displayed on LCD.
If the module detects that there is no CAN data, it
Do not detect in stop or will initiate a shutdown alarm and the
7 ECU Com Fail
standby mode corresponding alarm information will be
displayed on LCD.
When the controller detects that the sensor 1-10
Exceed preset warning shutdown alarm, it will initiate a shutdown alarm
8 Sensor 1~10 High
speed and the corresponding alarm information will be
displayed on LCD.
When the controller detects that the sensor 1-10
Exceed preset warning shutdown alarm, it will initiate a shutdown alarm
9 Sensor 1~10 Low
speed and the corresponding alarm information will be
displayed on LCD.
NOTE: The warning types of Auxiliary input are active only when they are configured by users. If controller in
override mode, only “Emergency Shutdown” and “Over Speed Shutdown” can work.
NOTE: ECU shutdown occurred only when “ECU Shutdown Enabled” is active and controller detects ECU
shutdown alarms.
Pressing and holding button for more than 3 seconds will enter the configuration menu, which
allows users to set all kinds of parameters, as follows:
Return >Start Delay
Interface 1:
Module Set >Stop Delay
Timers Set > >Preheat Delay Use to scroll settings, to
Engine Set >Cranking Time
Sensor Set >Crank Rest Time enter settings (Interface 2), to exit
Digital Inputs >Safety On Time
settings menu.
Relay Outputs >Start Idle Time
>Warming Up Time
>Cooling Time
>Stop Idle Time
>ETS Hold Time
>Fail to Stop
>Start Delay
Interface 5:
>Stop Delay 00008
>Preheat Delay Press to change cursor position,
>Cranking Time
>Crank Rest Time are used for changing cursor value,
>Safety On Time Confirm setting (Interface 4), exit
>Start Idle Time
>Warming Up Time setting (Interface 4).
>Cooling Time
>Stop Idle Time
>ETS Hold Time
>Fail to Stop
>Start Delay
Interface 6:
>Stop Delay 00008
>Preheat Delay are used for changing the setting
>Cranking Time
>Crank Rest Time contents. to enter settings (Interface 4),
>Safety On Time to return to the previous screen (return
>Start Idle Time
>Warming Up Time to Interface 1).
>Cooling Time
>Stop Idle Time
>ETS Hold Time
>Fail to Stop
Parameter Contents
Resistance sensor 1 settings User-defined sensor curve settings
Resistance sensor 2 settings User-defined sensor curve settings
Resistance sensor 3 settings User-defined sensor curve settings
Resistance sensor 4 settings User-defined sensor curve settings
Sensor 1~10 name settings User-defined sensor name
Output 1 custom settings Name / Button/ Active period /Output delay / Output time
Output 2 custom settings Name / Button/ Active period /Output delay / Output time
Output 3 custom settings Name / Button/ Active period /Output delay / Output time
Output 4 custom settings Name / Button/ Active period /Output delay / Output time
Output 5 custom settings Name / Button/ Active period /Output delay / Output time
Output 6 custom settings Name / Button/ Active period /Output delay / Output time
Output 7 custom settings Name / Button/ Active period /Output delay / Output time
Output 8 custom settings Name / Button/ Active period /Output delay / Output time
Output 9 custom settings Name / Button/ Active period /Output delay / Output time
Output 10 custom settings Name / Button/ Active period /Output delay / Output time
Output 11 custom settings Name / Button/ Active period /Output delay / Output time
Output 12 custom settings Name / Button/ Active period /Output delay / Output time
Output 13 custom settings Name / Button/ Active period /Output delay / Output time
Output 14 custom settings Name / Button/ Active period /Output delay / Output time
NOTE: The name of the input ports 1~18 only can be configured via PC software.
NOTE: The name of the output ports 1~14 only can be configured via PC software.
NOTE: PT100 Resistance type temperature sensor division value is set as 0.385 (0.385Ω corresponds to 1°C).
NOTE: There is no need to set curve type if the pressure sensor is current type.
NOTE: It is strictly prohibited to take out start battery when the engine is running. Failure to do so can create excessive
HMC9000A gen-set controller has RS485 port and USB port which allows the controller to connect
to open-type LAN. RS485 and USB applies ModBus communication protocol with the help of PC or DAS
(Data Acquisition Systems) operational software provides a simple and useful marine engine monitoring
system management scheme and enables remote control, remote measurement and remote
communication.
For more information about communication protocols please to see SmartGen document "HMC9000
communication protocols".
RS485 Communication parameters
Module address 1 (Range: 1~254, user-defined, default: 1)
Baud rate 9600 bps
Data bit 8 bit
Parity check bit None
Stop bit 2 bit
PC connects to the module’s USB as shown below.
A large number of ECU engines can be connected to the EXPANSION port of the controller. Besides, at
the same time users can connect expansion module which makes it convenient and suitable for different
working environments.
Compatible with CM750 engine controller module. Engine types: QSM11 G1, QSM11 G2
Terminals of controller C1 connector Remark
Fuel relay output 5&8
Start relay output - Connect to starter coil directly.
12.8 PERKINS
Compatible with ADEM3/ ADEM4 engine control modules. Engine types: 2306, 2506, 1106, and 2806.
Terminals of controller Connector Remark
Fuel relay output 1,10,15,33,34
Start relay output - Connect to starter coil directly
CAN communication shielding line (connect
SCR (EXPANSION) -
to controller’s terminal only)
CAN(H) (EXPANSION) 31 Impedance 120Ω connecting line is
recommended.
CAN(L) (EXPANSION) 32 Impedance 120Ω connecting line is
recommended.
Engine type: Perkins
Compatible engine types are TD520, TAD520 (optional), TD720, TAD720 (optional), TAD721, and TAD722.
Terminals of controller Connector Remark
Expand 30A relay, battery
voltage of terminal 14 is
Fuel relay output
supplied by relay. Fuse is
16A.
Start relay output - Connect to starter coil directly.
1 Connect to battery negative.
CAN communication shielding line (connect
SCR (EXPANSION) -
to controller’s terminal only)
CAN(H) (EXPANSION) 12 Impedance 120Ω connecting line is
recommended.
CAN(L) (EXPANSION) 13 Impedance 120Ω connecting line is
recommended.
Engine type: Volvo EDC4
12.13 BOSCH
Various expansion modules can be connected to the controller via EXPANSION port.
RPU560A Security module: The module connects to the main controller via CANBUS port. If
security module receives no signal from the main controller for more than 1 second and the main
controller failure input deactivates, security module will take over engine control; after that the
engine will be stopped only by shutdown input or in case of overspeed. Module input function,
output function and overspeed alarm threshold are user-set.
DOUT16 Digital Output Module: The module is connected to main controller via CANBUS port. The
module has 16 output channels, each of which can be set via HMC9000 controller. The set
parameters can be saved in internal HMC9000A controller and cannot be lost in case of power
outage.
NOTE: Only in remote mode can remote control module control the engine; in local mode, it can only monitoring the
engine, but not control.
13 CONTROL PORT
This expansion port is a CANBUS port for connecting remote control module.
HRM3300 Remote control module: HRM330, connected with main controller via CANBUS interface,
enables start, stop, alarm mute and other functions to be performed on the distance. All engine
parameters and real-time events are displayed on the remote control module.
NOTE: Remote control module can only be used in remote mode of the engine; in local mode only shutdown button
14 INSTALLATION
The front panel of HMC9000A has embedded structure; the module is fixed with the help of fixing clips.
Overall dimensions and cutout dimensions can be seen below.
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