User Manual: HMC4000 Marine Genset Controller
User Manual: HMC4000 Marine Genset Controller
USER MANUAL
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
CONTENTS
1 OVERVIEW .............................................................................................................................................. 5
2 MODEL COMPARISON ........................................................................................................................... 5
3 PERFORMANCE AND CHARACTERISTICS ......................................................................................... 5
4 SPECIFICATION OPERATION ............................................................................................................... 7
5 OPERATION ............................................................................................................................................ 8
6 SCREENS DISPLAY................................................................................................................................ 9
7 CONTROLLER PANEL AND OPERATION ........................................................................................... 10
7.1 CONTROLLER PANEL ................................................................................................................ 10
7.2 REMOTE START/STOP OPERATION ......................................................................................... 11
7.2.1. ILLUSTRATION ................................................................................................................... 11
7.2.2. REMOTE START SEQUENCE ........................................................................................... 11
7.2.3. REMOTE STOP SEQUENCE ............................................................................................. 11
7.3 AUTO START/STOP .................................................................................................................... 12
7.3.1. ILLUSTRATION .................................................................................................................. 12
7.3.2. AUTO START SEQUENCE ................................................................................................ 12
7.3.3. AUTO STOP SEQUENCE .................................................................................................. 12
7.4 LOCAL START/STOP SEQUENCE............................................................................................. 13
7.4.1. ILLUSTRATION .................................................................................................................. 13
7.4.2. LOCAL START SEQUENCE .............................................................................................. 13
7.4.3. LOCAL STOP SEQUENCE ................................................................................................ 13
8 PROTECTION ....................................................................................................................................... 14
8.1 WARNINGS ................................................................................................................................. 14
8.2 SHUTDOWN ALARM .................................................................................................................. 17
9 WIRINGS CONNECTION ...................................................................................................................... 19
10 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS ............................................... 21
9.1 CONTENTS AND SCOPES OF PARAMETERS......................................................................... 21
9.2 ENABLE DEFINITION OF PROGRAMMABLE OUTPUT PORTS 1~5 ...................................... 28
9.2.1. DEFINITION OF OUTPUT PORTS SETTING CONTENT ................................................ 28
9.2.2. DEFINITION OF OUTPUT PORTS 1-5 FUNCTION .......................................................... 28
9.3 DEFINED CONTENTS OF CONFIGURABLE INPUT PORTS 1-5............................................. 31
9.3.1. DEFINITION OF INPUT PORTS SETTING CONTENT .................................................... 31
9.3.2. DEFINITION OF INPUT PORTS 1-5 FUNCTION .............................................................. 31
9.4 SELECTION OF SENSORS ........................................................................................................ 33
9.4.1. SENSORS SELECTION .................................................................................................... 33
9.4.2. TEMPERATURE CURVE LIST .......................................................................................... 34
9.4.3. PRESSURE CURVE LIST ................................................................................................. 35
9.4.4. LIQUID LEVEL CURVE LIST ............................................................................................. 35
9.5 CRANK DISCONNECT CONDITIONS........................................................................................ 36
11 PARAMETERS SETTING ...................................................................................................................... 37
10.1 CONTROLLER PARAMETER SETTING .................................................................................... 37
10.2 CONTROLLER INFORMATION .................................................................................................. 37
10.3 EVENT LOG ................................................................................................................................ 37
2 MODEL COMPARISON
FUNCTION
MODEL
INPUT OUTPUT SENSOR GEN RS485 HEAD CANBUS REMARK
HMC4000MPU 3 6 4 ● ● ●
HMC4000CAN 3 6 4 ● ● ●
HMC4000RM 0 0 0 - ● ●
Note:
HMC4000MPU speed is collected by head sensor.
HMC4000CAN speed is collected by J1939 CANBUS.
HMC4000RM is remote monitoring control module, and it is can remotely control HMC4000MPU or
HMC4000CAN
Technical Parameters
Items Contents
Engine status
Generator is at rest screen display
Engine status
Remark: if there is no electric parameters display, the 3rd, 4th, and 5th screen will be shielded
automatically.
7.2.1. ILLUSTRATION
Press , its indicator lights, controller enters Remote Control Mode. After remote control mode is
active, users can remotely start/stop engine by operating the controller HMC4000RM or via inputs
(remote start input and remote stop input) to control engine start/stop.
─ When remote start command is active or “Remote Start” input is active, “Start Delay” timer is
initiated;
─ “Start Delay” countdown will be displayed on LCD;
─ When start delay is over, preheat relay energizes (if configured), “preheat delay XX s” information will
be displayed on LCD;
─ After the above delay, the Fuel Relay is energized, and then one second later, the Start Relay is
engaged. Genset is cranked for a pre-set time. If genset 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.
─ Should this start sequence continue beyond the set number of attempts, the start sequence will be
terminated, and Fail to Start fault alarm will be displayed on the alarm page of LCD.
─ In case of successful crank attempt, the “Safety On” timer is activated. As soon as this delay is over,
“start idle” delay is initiated (if configured).
─ After the start idle, the controller will enter into hi-speed “Warming Up” delay (if configured).
─ When the remote stop command is active or “Remote Stop” input signal is active, the Stop Delay is
initiated.
─ Once this “stop delay” has expired, controller hi-speed “Cooling” delay is energized.
─ Once “Cooling” delay has expired, the “Stop Idle” is initiated (if configured). During “Stop Idle” Delay,
idle relay is energized.
─ Once this “Stop Idle” has expired, the “ETS Solenoid Hold” begins. ETS relay is energized while
fuel relay is de-energized.
─ Once this “ETS Solenoid Hold” has expired, the "Fail to Stop Delay" begins. Complete stop is
detected automatically.
─ 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, it will enter into engine standby status).
NOTE: there is no stop delay while stopping the remote monitoring controller.
7.3.1. ILLUSTRATION
Set any programmable input as “Auto Mode Input”, after it is active, controller will enter into auto mode.
7.4.1. ILLUSTRATION
If controller currently stays in remote control status, press will enter into local mode, and
after local mode is active, users can start/stop engine according to the buttons on the front panel of the
controller.
─ Pressing to make preheat relay energized (if configured), “preheat delay XX s” information
will be displayed on LCD;
─ After the above delay, the Fuel Relay is energized, and then one second later, the Start Relay is
engaged. If the genset 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.
─ Should this start sequence continue beyond the set number of attempts, the start sequence will be
terminated, and Fail to Start fault alarm will be displayed on the alarm page of LCD.
─ In case of successful crank attempt, the “Safety On” timer is activated. As soon as this delay is
over, generator will enter into Normal Running status if speed, water temperature, and oil
pressure are normal.
1) Pressing to make “ETS Solenoid Hold” begins. ETS relay is energized while fuel relay is
de-energized.
2) Once this “ETS Solenoid Hold” has expired, the "Wait for Stop" begins. Complete stop is detected
automatically.
3) 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, it will enter into engine standby status).
8.1 WARNINGS
When controller detects the warning signals, alarm only and not stops the genset, the LCD displays
the warning information.
No. Type Description
When the controller detects that engine temperature has exceeded the
1 High Temperature pre-set value, it will initiate a warning alarm and the corresponding alarm
information will be displayed on LCD.
When the controller detects that the oil pressure has fallen below the
2 Low Oil Pressure pre-set value, it will initiate a warning alarm and the corresponding alarm
information will be displayed on LCD.
When the speed collected by the speed sensor has exceeded the pre-set
3 Over Speed value, it will initiate a warning alarm and the corresponding alarm
information will be displayed on LCD.
When the speed collected by the speed sensor has fallen below the
4 Under Speed pre-set value, it will initiate a warning alarm and the corresponding alarm
information will be displayed on LCD.
When the controller detects that the engine speed is 0 and the delay is 0, it
Loss Of Speed
5 will initiate a warning alarm and the corresponding alarm information will
Signal
be displayed on LCD.
When the controller detects that charger voltage has fallen below the
battery voltage and the difference value exceed pre-set charging voltage
6 Charge Alt Failure
difference value, it will initiate a warning alarm and the corresponding
alarm information will be displayed on LCD.
Engine failed to start if start attempts have been beyond pre-set start
7 Fail to Start times, it will initiate a warning alarm and the corresponding alarm
information will be displayed on LCD.
After “fail to stop” delay/ ETS delay has expired, if gen-set does not stop
8 Fail to Stop completely, it will initiate a warning alarm and the corresponding alarm
information will be displayed on LCD.
When the controller detects that battery voltage has exceeded the pre-set
9 Power Over Voltage value, it will initiate a warning alarm and the corresponding alarm
information will be displayed on LCD.
When the controller detects that battery voltage has fallen below the
Power Under
10 pre-set value, it will initiate a warning alarm and the corresponding alarm
Voltage
information will be displayed on LCD.
When the controller detects that fail to communication with HMC4000RM,
HMC4000RM
11 it will initiate a warning alarm and the corresponding alarm information will
Communication Fail
be displayed on LCD.
When controller gets the warning signals from engine via J1939, it will
12 ECU Warning send warning signals and the corresponding alarm information will be
displayed on LCD.
When controller detects shutdown alarm, it will send signals to stop the generator and the corresponding
alarm information will be displayed on LCD.
No. Type Description
When controller detects emergency stop signals, it will send stop signals and
1 Emergency Stop
the corresponding alarm information will be displayed on LCD.
When controller detects the speed value is higher than the set value, it will
2 Over Speed send stop signals and the corresponding alarm information will be displayed
on LCD.
When controller detects the speed value is lower than the set value, it will
3 Under Speed send stop signals and the corresponding alarm information will be displayed
on LCD.
When controller detects speed value equals to 0, and delay value isn’t 0
Loss Of Speed
4 (action select “Shutdown”), it will send stop signals and the corresponding
Signal
alarm information will be displayed on LCD.
When controller detects the frequency value is higher than the set value, it
5 Over Frequency will send stop signals and the corresponding alarm information will be
displayed on LCD.
When controller detects the frequency value is lower than the set value, it will
Under
6 send stop signals and the corresponding alarm information will be displayed
Frequency
on LCD.
When controller detects the voltage value is higher than the set value, it will
7 Over Voltage send stop signals and the corresponding alarm information will be displayed
on LCD.
When controller detects the voltage value is lower than the set value, it will
8 Under Voltage send stop signals and the corresponding alarm information will be displayed
on LCD.
When controller detects the current value of genset is higher than the set
9 Over Current value and the delay value is not 0, it will send stop signals and the
corresponding alarm information will be displayed on LCD.
When any one input set as high water temperature shutdown and the input is
High Temp.
10 active, it will send stop signals and the corresponding alarm information will
Shutdown Input
be displayed on LCD.
When any one input set as low oil pressure shutdown and the input is active,
Low Oil
11 it will send stop signals and the corresponding alarm information will be
Pressure Input
displayed on LCD.
When temperature value collected by the temperature sensor is higher than
High Temp.
12 the set value, it will send stop signals and the corresponding alarm
Shutdown
information will be displayed on LCD.
When oil pressure value collected by the oil pressure sensor is lower than the
Low Oil
13 set value, it will send stop signals and the corresponding alarm information
Pressure
will be displayed on LCD.
When the data collected by the sensor 1 has exceeded the pre-set value, it
14 Sensor 1 High will send stop signals and the corresponding alarm information will be
displayed on LCD. (the name of “Senor 1” can be changed on PC software,
NOTE: ECU warning and shutdown alarms illustration, if there are detailed alarms display, controller will check
engine based on the content. Otherwise, please look up engine Manuel to get the information based on the SPN
code.
NOTE: USB ports in controller rear panel are programmable parameter ports, user can directly configure
controller via PC.
No Items Description
0 Not Used Input port is inactive when select “Not Used”
1 Custom
2 Water Temperature High If input is active, shutdown alarm will be immediately initiated.
3 Oil Pressure Low If input is active, shutdown alarm will be immediately initiated.
4 Reserved Reserved
5 Emergency Stop Emergency stop alarm will be initiated if this input is active.
6 Remote Mode Controller enters remote control mode after this input is active.
7 Local Mode Controller enters local mode after this input is active.
If input is active, all shutdown alarms except over speed shutdown
8 Override Mode
alarm and emergency shutdown alarm are all unavailable.
9 Auto Mode Controller enters auto mode after this input is active.
When this input is active in auto mode, generator-set start
10 Remote Start/Stop automatically and on load after running. Otherwise, generator-set
will stop automatically if it is disconnect.
11 Reserved Reserved
12 Water Pressure Low Controller displayed “Low Water Pressure” after this input is active.
13 Water Level Low Controller displayed “Low Water Level” after this input is active.
14 Lub Oil Level Low Controller displayed “Low Oil Level” after this input is active.
15 Reserved Reserved
16 Reserved Reserved
17 Reserved Reserved
18 Panel Lock When input is active, all keys expect the buttons are
No Items Description
deactivated and right of last line of home page on LCD displayed .
Controller displayed “Fuel Leakage Warning” after this input is
19 Fuel Leak Warning
active.
20 Alarm Mute When input is active, “Audible Alarm” output is disconnecting.
21 Speed Up Rise speed output port of controller outputs when this input is active.
Drop speed output port of controller outputs when this input is
22 Speed Down
active.
23 Reserved Reserved
24 Reserved Reserved
Used for EFI engine with CANBUS interface. When it is active,
25 60Hz Select
frequency is 60Hz.
26 Reserved Reserved
When controller in remote control mode, generator-set starts up
27 Remote Start Input
when this input is active.
When controller in remote control mode, generator-set stops when
28 Stop Input
this input is active.
29 Reserved
30 Turning Chain Engine start is inhibiting after “Turning Chain” input is active.
31 Reserved Reserved
Note: PT100 division value of resistor type temperature sensor is fixed as 0.385 (0.385Ω correspond to 1℃)
Note: if pressure signal is current-type, there is no need to set the curve and only need to set range.
Note: if pressure signal is current-type, there is no need to set the curve and only need to set range.
NOTE:
1) There are 3 conditions to make starter separate with engine; speed, generator frequency and oil pressure can
be used separately while oil pressure suggest be used together with speed and generator frequency. The aim
is to disconnect the starter motor as soon as possible.
2) Speed stands for the real rotation speed detected by the speed sensor. Speed sensor is the magnetic
equipment which be installed in starter for detecting flywheel teeth.
3) When set as speed, must ensure that the number of flywheel teeth is as same as setting, otherwise, “over
speed shutdown” or “under speed shutdown” may be caused.
4) If generator-set without speed sensor please don’t select corresponding items, otherwise, “start fail” or “loss
speed signal” maybe caused.
5) If generator-set without oil pressure sensor, please don’t select corresponding items.
6) If not select generator frequency in crank disconnect setting, controller will not collect and display the
relative power quantity (can be used in water pump set); if not select speed in crank disconnect setting, the
engine speed displayed in controller is calculated by generator signal.
Start the controller, then press to enter into the parameters setting menu, menu items as
follows:
1Return
2Set Parameters
3Information
4Eventlog
When entered password interface, inputting correct password (default password is “0318”) can set
parameters. If the password is changed, only input the password same as controllers’, can the
parameter be set via PC software. If there is need to set more parameters (e.g. voltage calibration;
current calibration), please contact the factory.
NOTES:
a) Please change the controller parameters when generator is in standby mode only (e. g. Crank disconnect
conditions selection, auxiliary input, auxiliary output, various delay), otherwise, shutdown and other
abnormal conditions may occurs.
b) Over voltage set value must be higher than under voltage set value, otherwise over voltage and under
voltage condition may occur simultaneously.
c) Over speed set value must be higher than under speed set value, otherwise over speed and under speed
condition may occur simultaneously.
d) Please set the generator frequency value as low as possible when cranking, in order to make the starter be
separated quickly as soon as possible.
e) Auxiliary input 1~5 could not be set as same items; otherwise, there are abnormal functions. However, the
auxiliary output 1~5 can be set as same items.
f) Programmable sensor 1 input port can be set as temperature sensor, pressure sensor, coolant level sensor
or discrete input port 4; programmable sensor 2 input port can be set as temperature sensor, pressure
sensor, coolant level sensor or discrete input port 5. Choose either sensor or discrete input port, if discrete
input port be selected, corresponding set parameters be functional and sensor parameters are deactivated
and reserved; otherwise, if sensor be selected, corresponding sensor parameters be functional and
discrete input port parameters are deactivated and reserved.
g) If need to shut down after cooling, please set any auxiliary input as “High Temperature Stop Input”, then
connect this input port to GND or set “High Temperature Stop Input” action as “Cooling Stop”
LCD will display develop information like software version, issue date and present date of the
controller.
View event log from this interface, including start/stop information and shutdown alarm
information log. It can record and display up to 99 pieces.
Event Log Title
Shutdown Alarm Record Type
Over Speed Shutdown Name of Alarm
2017-08-08 15:30:25 Alarm Occurred Time
1) When reselect sensors, the sensor curve will be transferred into the standard value. For example,
if temperature sensor is SGH (120°C resistor type), its sensor curve is SGH (120°C resistor type);
if select the SGD (120°C resistor type), the temperature sensor curve is SGD curve.
2) When there is difference between standard sensor curves and using sensor, user can entry into
“Custom Sensors” page to define sensor curve.
3) When input the sensor curve, X value (resistor) must be input from small to large, otherwise,
mistake occurs.
4) The headmost or backmost values in the vertical coordinates can be set as same as below,
Please make sure the following checks are made before commissioning,
1) Ensure all the connections are correct and wires diameter is suitable.
2) Ensure that the controller DC power has fuse, controller’s positive and negative connected to start
battery are correct.
3) Take proper action to prevent engine to crank success (e. g. Remove the connection wire of fuel
valve). If checking is OK, make the start battery power on; choose manual mode and controller will
executive routine.
4) Set controller under local mode, press “start” button, genset will start. After the cranking times as
setting, controller will send signal of Start Failure; then press “stop” to reset controller.
5) Recover the action to prevent engine to crank success (e. g. Connect wire of fuel valve), press start
button again, genset will start. If everything goes well, genset will normal running after idle running (if
idle run be set). During this time, please watch for engine’s running situations and AC generator’s
voltage and frequency. If abnormal, stop genset and check all wires connection according to this
manual.
6) If there is any other question, please contact SmartGen’s service.
Note: Expand relay with high capacity in start and fuel output is recommend.
HMC4000 series controller can suit for widely range of battery voltage DC (8~35) V. Negative of
battery must be connected with the engine shell. Diameter of wire that connects from power supply to
battery must be over 2.5mm2. If floating charge configured, please firstly connect output wires of charger
to battery’s positive and negative directly, then, connect wires from battery’s positive and negative to
controller’s positive and negative input ports in order to prevent charge disturbing the controller’s normal
working.
NOTE:
2) When there is load current, transformer’s secondary side prohibit open circuit.
It is suitable for CM570 engine control mode. Engine type is QSM11 G1, QSM11 G2.
Terminals of controller C1 connector Remark
Set configurable output 1 as “Fuel Output”.
Outside expand relay, when fuel output,
Auxiliary output port 1 5&8
making make port 5 and port 8 of C1 be
connected
Start relay output - Connect to starter coil directly
It is suitable for GCS engine control module. Use RS485-MODBUS to read information of engine.
16.12 PERKINS
It is suitable for ADEM3/ ADEM4 engine control module. Engine type is 2306, 2506, 1106, and 2806.
Terminals of controller Connector Remark
Auxiliary output port 1 1,10,15,33,34 Set configurable output 1 as “Fuel Output”.
Start relay output - Connect to starter coil directly
CAN_SCR - CAN communication shielding line
CAN(H) 31 Using impedance 120Ω connecting line
CAN(L) 32 Using impedance 120Ω connecting line
16.13 SCANIA
It is suitable for S6 engine control mode. Engine type is DC9, DC12, and DC16.
Terminals of controller B1 connector Remark
Auxiliary output port 1 3 Set configurable output 1 as “Fuel Output”.
Start relay output - Connect to starter coil directly
CAN GND - CAN communication shielding line
CAN(H) 9 Using impedance 120Ω connecting line
CAN(L) 10 Using impedance 120Ω connecting line
Engine type: Scania
NOTE: When this engine type is selected, preheating time should be set to at least 3 seconds.
Suitable engine types are TD520, TAD520 (optional), TD720, TAD720 (optional), TAD721, TAD722,
and TAD732.
Terminals of controller Connector Remark
Expanded 30A relay, and
relay offers battery
Auxiliary output port 1 Set configurable output 1 as “Fuel Output”.
voltage to terminal 14.
Fuse is 16A
Start relay output - Connect to starter coil directly
1 Connected to negative of battery
CAN_SCR - CAN communication shielding line
CAN(H) 12 Using impedance 120Ω connecting line
CAN(L) 13 Using impedance 120Ω connecting line
Engine type: VolvoEDC4
16.16 VOLVO-EMS2
Volvo Engine types are TAD734, TAD940, TAD941, TAD1640, TAD1641, and TAD1642.
Terminals of controller Engine’s CAN port Remark
ECU stop
Auxiliary output port 1 6
Configurable output 1 “ECU stop”
ECU power
Auxiliary output port 2 5
Configurable output 2 “ECU power”
3 Negative power
4 Positive power
CAN_SCR - CAN communication shielding line
CAN(H) 1(Hi) Using impedance 120Ω connecting line
CAN(L) 2(Lo) Using impedance 120Ω connecting line
Engine type: Volvo-EMS2
NOTE: When this engine type is selected, preheating time should be set to at least 3 seconds.
16.17 Yuchai
16.18 Weichai
_________________________________