Data Download HGM4010N HGM4020N HGM4010NC HGM4020NC HGM4010CAN HGM4020CAN V1.0 en - 1
Data Download HGM4010N HGM4020N HGM4010NC HGM4020NC HGM4010CAN HGM4020CAN V1.0 en - 1
GENSET CONTROLLER
USER MANUAL
CONTENTS
1 OVERVIEW .............................................................................................................................................. 5
2 PERFORMANCE AND CHARACTERISTICS ........................................................................................ 5
3 SPECIFICATION OPERATION ............................................................................................................... 7
4 OPERATION ............................................................................................................................................ 8
4.1 KEY FUNCTION ............................................................................................................................ 8
4.2 CONTROLLER PANEL .................................................................................................................. 9
4.3 AUTO START/STOP OPERATION.............................................................................................. 10
4.4 MANUAL START/STOP OPERATION.......................................................................................... 11
4.5 EMERGENCY START UP ............................................................................................................ 11
5 PROTECTION ....................................................................................................................................... 12
5.1 WARNINGS ................................................................................................................................. 12
5.2 SHUTDOWN ALARM .................................................................................................................. 15
6 WIRINGS CONNECTION ...................................................................................................................... 18
7 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS .............................................. 21
7.1 CONTENTS AND SCOPES OF PARAMETERS......................................................................... 21
7.2 ENABLE DEFINITION OF PROGRAMMABLE OUTPUT PORTS ............................................. 29
7.3 DEFINED CONTENTS OF CONFIGURABLE INPUT PORTS ................................................... 30
7.4 SELECTION OF SENSORS ........................................................................................................ 31
7.5 CONDITIONS OF CRANK DISCONNECT SELECTION ............................................................ 32
8 PARAMETERS SETTING ..................................................................................................................... 33
8.1 CONTROLLER PARAMETER SETTING .................................................................................... 33
8.2 CONTROLLER INFORMATION .................................................................................................. 34
8.3 LANGUAGE SELECTION ........................................................................................................... 34
8.4 EVENT LOG ................................................................................................................................ 34
8.5 MAINTENANCE ........................................................................................................................... 34
9 SENSOR SETTING ............................................................................................................................... 35
10 COMMISSIONING ................................................................................................................................. 36
11 TYPICAL APPLICATION....................................................................................................................... 37
12 INSTALLATION ..................................................................................................................................... 40
12.1 FIXING CLIPS.............................................................................................................................. 40
12.2 OVERALL DIMENSION ............................................................................................................... 40
13 CONNECTIONS OF CONTROLLER WITH J1939 ENGINE................................................................ 42
13.1 CUMMINS ISB/ISBE .................................................................................................................... 42
13.2 CUMMINS QSL9.......................................................................................................................... 42
13.3 CUMMINS QSM11 (import) ......................................................................................................... 43
13.4 CUMMINS QSX15-CM570 .......................................................................................................... 43
13.5 CUMMINS GCS-MODBUS .......................................................................................................... 43
13.6 CUMMINS QSM11 ....................................................................................................................... 44
13.7 CUMMINS QSZ13 ....................................................................................................................... 44
13.8 DETROIT DIESEL DDEC III / IV .................................................................................................. 45
13.9 DEUTZ EMR2 .............................................................................................................................. 45
13.10JOHN DEERE.............................................................................................................................. 45
13.11MTU MDEC.................................................................................................................................. 46
13.12MTU ADEC(SMART MODULE)................................................................................................... 46
Chinese trademark
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: http://www.smartgen.com.cn
http://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.
HGM4000N series genset controllers integrate 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 etc. functions. It fit with LCD display, optional
languages interface (Chinese, English, Spanish, Russian, Turkish, French, Portugal, and Polish), and
it is reliable and easy to use.
HGM4000N series genset controllers adopt micro-processor technology with precision parameters
measuring, fixed value adjustment, time setting and set value adjusting and etc. All parameters can be
configured from front panel or through programmable interface (USB or RS485 interface) via PC. It
can be widely used in all types of automatic genset control system with compact structure, advanced
circuits, simple connections and high reliability.
Items Contents
Manual Pressing this key will set the module into manual mode.
Auto Pressing this key will set the module into auto mode.
1) HGM4020: Manual mode is selected by pressing the button; a LED besides the button will
illuminate to confirm the operation; press button to start the genset, it can automatically judge
crank success and accelerate to high speed running. If high temperature, low oil pressure, over speed
and abnormal voltage occur during genset running, controller can effectively protect genset to stop
(detail procedures please refer to No.4~9 of Auto start sequence). Under Manual Mode, load breaker
won’t transfer automatically and C/O key should be pushed to enter into the C/O interface.
Through key to control mains switch open/close and key to control generator switch
open/close.
2) HGM4010: Manual mode is selected by pressing the button; a LED besides the button will
illuminate to confirm the operation; Then press button to start the generator, it can automatically
judge crank success and accelerate to high speed running. If high temperature, low oil pressure, over
speed and abnormal voltage occur during genset running, controller can effectively protect genset to
stop (detail procedures please refer to No.4~9 of Auto start sequence). After genset high speed
normal running, press the key to enter into the Close/Open interface. Through key to
control generator switch close and key to control generator switch open.
3) Manual stop: pressing key can stop the running genset. (detail procedures please refer to
No.3~7 of Auto stop sequence)
Simultaneously press and in manual mode will force generator to crank. Successful start
will not be judged according to crank disconnect conditions, operator will have to crank the starter
motor manually; when operator decides that the engine has fired, he/she should release the button
and start output will be deactivated, safety on delay will be initiated.
5.1 WARNINGS
When controllers detects the warning signals, alarm only and not stop the genset, besides, the LCD
displays the warning information.
When the controller detects that the fuel level has fallen below the pre-set
value while shutdown is prohibited, or detects that the Aux. input low fuel
5 Low Fuel Level
level while shutdown is prohibited, it will initiate a warning alarm and the
corresponding alarm information will 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.
When the controller detects that battery voltage has fallen below the
7 Battery Under Volt pre-set 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 exceeded the pre-set
8 Battery Over Volt value, it will initiate a warning alarm and the corresponding alarm
information will be displayed on LCD.
When the controller detects that the auxiliary input warning signals, it will
9 Auxiliary Input 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
10 will initiate a warning alarm and the corresponding alarm information will
Signal
be displayed on LCD.
When the controller detects the low coolant level input is active, it will
11 Low Coolant Level initiate a warning alarm and the corresponding alarm information will be
displayed on LCD.
When the controller detects that the temperature sensor is open circuit and
Temp. Sensor
12 the action select “Warn”, it will initiate a warning alarm and the
Open
corresponding alarm information will be displayed on LCD.
When the controller detects that the oil pressure sensor is open circuit and
Oil Pressure
13 the action select “Warn”, it will initiate a warning alarm and the
Sensor Open
corresponding alarm information will be displayed on LCD.
When the controller detects that the level sensor is open circuit and the
14 Level Sensor Open action select “Warn”, it will initiate a warning alarm and the corresponding
alarm information will be displayed on LCD.
If the config. sensor set as temperature sensor, When the controller
Temp. Sensor 2 detects that the temperature sensor is open circuit and the action select
15
Open “Warn”, it will initiate a warning alarm and the corresponding alarm
information will be displayed on LCD.
If the config. sensor set as oil pressure sensor, When the controller detects
Oil Pressure that the oil pressure sensor is open circuit and the action select “Warn”, it
16
Sensor 2 Open will initiate a warning alarm and the corresponding alarm information will
be displayed on LCD.
If the config. sensor set as level sensor, When the controller detects that
Level Sensor 2 the level sensor is open circuit and the action select “Warn”, it will initiate a
17
Open warning alarm and the corresponding alarm information will be displayed
on LCD.
When the controller detects that config. sensor temperature (sensor type:
High temperature sensor) has exceeded the pre-set value while shutdown is
18
Temperature 2 prohibited, it will initiate a warning alarm and the corresponding alarm
information will be displayed on LCD.
When the controller detects that config. sensor oil pressure (sensor type:
oil pressure sensor) has fallen below the pre-set value while shutdown is
19 Low Oil Pressure 2
prohibited, it will initiate a warning alarm and the corresponding alarm
information will be displayed on LCD.
When the controller detects that config. sensor coolant level (sensor
type: level sensor) has fallen below the pre-set value while shutdown is
20 Low Coolant Level prohibited, it will initiate a warning alarm and the corresponding alarm
information will be displayed on LCD.
When genset running time has exceeded the user setting maintenance
time and the action select “Warn”, it will initiate a warning alarm and the
21 Maintenance Due
corresponding alarm information will be displayed on LCD. The
maintenance alarm will reset if the action select “Inactive”.
When controller detects the voltage is higher than the set value, it will send
22 Gen Over Voltage warn signals and the corresponding alarm information will be displayed on
LCD.
When controller detects the voltage is lower than the set value, it will send
Gen Under
23 warn signals and the corresponding alarm information will be displayed on
Voltage
LCD.
When controller detects the frequency is higher than the set value, it will
Gen Over
24 send warn signals and the corresponding alarm information will be
Frequency
displayed on LCD.
When controller detects the frequency is lower than the set value, it will
Gen Under
25 send warn signals and the corresponding alarm information will be
Frequency
displayed on LCD.
When controller detects the charger alt fail warn input is active, it will send
26 Charge Alt Fail alarm signals and the corresponding alarm information will be displayed on
LCD.
When controller detects the power value (power is positive) is higher than
27 Over Power the set value and the action select warn, it will send warn signals and the
corresponding alarm information will be displayed on LCD.
When controller gets the warn signals from engine via J1939, it will send
28 ECU Warn warn 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.
NOTE: ECU warns 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.
Compared with HGM4020, HGM4010 missing one mains voltage three-phase input terminal. HGM4020
controller back panel is as follows:
NOTE: USB ports in controller rear panel are programmable parameter ports, user can directly configure
controller via PC.
disconnected.
When generator oil pressure higher than
Oil Pressure of Crank
68 (0-400)kPa 200 the set value, starter will be
Disconnected
disconnected.
Factory default: when high temperature
High Temperature
69 (0-1) 0 occurs, shutdown alarm is initiated.
Inhibit
Detail to see NOTE 2
Factory default: when low oil pressure
Low Oil Pressure
70 (0-1) 0 occurs, shutdown alarm is initiated.
Inhibit
Detail to see NOTE 3
Factory default: when low fuel level
71 Low Fuel Level Inhibit (0-1) 1 occurs, shutdown alarm is initiated.
Detail to see NOTE 4
Factory default: when config. sensor
value higher/lower than the set value
72 Config. Sensor Inhibit (0-1) 1 (particular case depends on the sensor
type), shutdown alarm is initiated.
Detail to see 69,70,71 Setting Items
0: 3P4W; 1: 2P3W
73 AC System (0-3) 0
2: 1P2W; 3: 3P3W
74 Temp. Sensor Curve (0-12) 8 SGX Detail to see Table 10
Pressure Sensor
75 (0-12) 8 SGX Detail to see Table 10
Curve
0: Aux. Input 4 Configuration
Multiplex Input Liquid
76 (0-1) 0 1: Liquid Level Sensor
Level Sensor
Detail to see NOTE 5
77 Level Sensor Curve (0-7) 3 SGD Detail to see Table 10
0: Aux. Input 5 Configuration
1: Temperature Sensor
Multiplex Input
78 (0-3) 0 2: Pressure Sensor
Programmable Sensor
3: Liquid Level Sensor
Detail to see NOTE 5
(0-9) 8 SGX
Config. Sensor
79 (0-9) 8 SGX
Curve
(0-5) 3 SGD
Numbers of generator poles, which can
80 Poles (2-64) 4 be used to calculate generator speed
(generator with no speed sensor).
81 Temp. Sensor Open (0-2) 1
Oil Pressure Sensor
82 (0-2) 1 0: Indication (temperature sensor will
Open
show “+++”);
1:Warn; 2:Shutdown
83 Level Sensor Open (0-2) 1
Cooling Blower.
When the liquid level of the external
sensor falls below the set value, “Low
Fuel Level” timer is initiated. (this only
87 Low Fuel Level Warn (0-100)% 20
concerns fuel level sensor and does not
concern low fuel level warning signal via
configurable input port)
When generator voltage exceeds pre-set
value, gen over voltage warning alarm
88 Gen Over Volt Warn (30-620)V 253
will be sent. (No detection for over volt
signal if the value set as 620V)
When generator voltage below pre-set
value, gen under voltage warning alarm
89 Gen Under Volt Warn (30-620)V 193
will be sent. (No detection for under volt
signal if the value set as 30V)
When generator frequency exceeds the
90 Gen Over Freq Warn (0-75.0)Hz 55.0 pre-set value, gen over frequency
warning signals will be sent.
When generator frequency below the
91 Gen Under Freq Warn (0-75.0)Hz 42.0 pre-set value, gen under frequency
warning signals will be sent.
When generator current exceeds the
Gen Over Current pre-set value, gen over current warning
92 (50-130)% 110
Percentage Warn signals will be sent. (No warning alarms
been sent if the value set as 0)
When the value of external temperature
sensor exceeds the pre-set value, which
only be functional for external temp.
sensor after safety delay, over high temp.
93 High Water Temp. Warn (80-140)℃ 95
signals will be sent. No warning alarms
been sent if the value set as 140 (only
suit for temp. sensor, and digital inputs
are not included).
When the value of external pressure
sensor below the pre-set value, which
only be functional after safety delay, low
94 Low Oil Pressure Warn (0-400)kPa 124 oil pressure delay timer will be initiated.
No warning alarms been sent if the value
set as 0 (only suit for pressure sensor,
and digital inputs are not included).
(80-140)ºC Respectively correspond to
Programmable Sensor 93(Temperature Sensor set),
95 (0-400)kPa 95
Warn 94(Pressure Sensor set), 87(Level
(0-100)%
Sensor set) in this table.
When generator volt higher than the
pre-set shutdown value and the “over
96 Gen Over Volt Delay (0-20.0)s 10.0
volt” delay has expired, then it can be
considered as gen over volt shutdown.
97 Gen Over Frequency (0-20.0)s 2.0 When generator frequency higher than
No Items Description
0 Not Used Output port is deactivated when “Not Used” is selected.
Include all shutdown alarms and warning alarms. When there is
1 Common Alarm warning alarm only, it is not self-lock; when a shutdown alarm
occurs, it is self-lock until the alarm is reset.
Suitable for genset with electromagnet and will active after “stop idle
2 Energized to Stop
delay”. It is deactivated when the “ETS Solenoid delay” expires.
Used for engine which has idles. Close before starting and open in
3 Idle Control warming up delay; Close during stop idle delay and open when stop
is completed.
4 Preheat Control Close before starting and open before power up;
5 Close Generator When close time is 0, it’s continuous output.
6 Mains Closed HGM4010 without this function.
7 Open ATS When close time is 0, it’s disabled.
Close when the generator enters into Warming Up delay (close
8 Raise Speed
time: warming up delay) while open when Aux.
Close when the generator enters into Stop Idle delay/ Energized to
9 Drop Speed
Stop delay (close time: Stop Idle delay) while open when Aux.
Action when genset is normal running while deactivated when
10 Generator Run
engine speed is lower than the “crank disconnect speed”.
Close when fuel level is lower than the “Fuel Pump On” value or
when low fuel level warning input is active; Open when fuel level is
11 Fuel Pump Control
higher than the “Fuel Pump Off” and low fuel level warning input is
deactivated;
Close when the generator enters into Warming Up delay while open
12 High Speed Control
after cooling delay.
13 In Auto Mode The controller is in automatic mode.
14 Fuel Relay Output Action when generator start; disconnect when wait for stop.
Output in start period. If there is no generator frequency during
15 Generator Excite
safety running, output for 2 seconds.
16 Air Cooler Output Control air cooler to start\stop according to cooler temperature.
Action in genset starting and disconnect when genset stopped
17 Louver Control
completely.
18 Shutdown Alarm Output Output when shutdown alarms appeared.
When warning and shutdown alarms appear, audible alarm output is
19 Audible Alarm fixed as 300s. When “alarm mute” or any keys on the panel
configurable input port is active, it can remove the alarm.
Coolant Liquid Heating
20 Controlled by the upper or lower limit of temperature sensor.
Control
21 Reserved
22 Start Output Output when in start status; disconnected in other status.
No Items Description
23 ECU Stop Used for ECU engine and control its stop.
24 ECU Power Supply Used for ECU engine and control its power.
25 ECU Warning Indicate ECU sends a warning signal.
26 ECU Shutdown Indicate ECU sends a shutdown signal.
ECU Communication Indicate controller not communicates with ECU.
27
Failure
28 Reserved
29 Reserved
30 Reserved
31 Reserved
No Items Description
0 Not Used
1 High Temperature Input If these signals are active after safety on delay, shutdown alarm will
Low Oil Pressure be immediately initiated.
2
Warning Input
3 Auxiliary Warning Only warning and not stops if this input is active.
4 Emergency Stop Input Shutdown alarm will be immediately initiated if this input is active.
When the gen-set is running normally and this signal is activated, if
there is a high temperature situation, the controller will first cool
High Temperature Stop
5 down the generator and then stop it; if the signal is deactivated and
Input
a high temperature situation occurs, the controller will shut down the
gen-set without cooling down.
6 Generator Closed Input Connected to the auxiliary switch of the generator on load.
7 Mains Closed Input Connected to the auxiliary switch of the mains on load.
Inhibit High Temperature When it is active, prohibit stopping when high temperature occurs.
8
Stop Details to see NOTE 2
Inhibit Low Oil Pressure When it is active, prohibit stopping when low oil pressure occurs.
9
Stop Details to see NOTE 3
When this input is active in auto mode, genset start automatically
10 Remote Start and on load after running. Otherwise, genset will stop automatically
if it is deactive.
11 Low Fuel Level Warn Connected to digital input port of sensor, if this input is active,
12 Low Coolant Level Warn controller will send warn alarm signal.
No Items Description
generator is normal running, stop command won’t be executed.
When this input is deactivated, genset will automatically start or stop
according to the mains status (normal or abnormal).
When the input is active, keys on the panel are locked except for
keys and remote mode will displayed on the LCD.
16 Remote Control Input
Remote module pattern and start/stop operation can be switched by
the keys on the panel.
17 Charge Alt Failure Warn Connected to charge alt failure output port.
When input is active, all keys expect the buttons are
18 Panel Lock
inactive.
When input is active, enter into auto mode automatically, panel
19 Manual/Auto Switch buttons and local operation are inactive; When input is inactive,
enter into manual mode automatically, remote operation is inhibited.
20 Alarm Mute When input is active, “Audible Alarm” output can be inhibited.
21 Idle Input Idle control output when input is active.
22 Speed Raise Impulse Input Used for genset with CANBUS interface.
23 Speed Drop Impulse Input Used for genset with CANBUS interface.
24 Return Idle Impulse Input Used for genset with CANBUS interface.
Used for genset with CANBUS interface. When it is active,
25 60Hz Option
frequency is 60Hz.
26 External Shutdown Alarm Genset will warn and shutdown immediately if the signal is active.
27 Reserved
28 Reserved
29 Reserved
30 Reserved
31 Reserved
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 genset without speed sensor please don’t select corresponding items, otherwise, “start fail” or “loss speed
signal” maybe caused.
5) If genset 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
8 PARAMETERS SETTING
Start the controller, then press to enter into the parameters setting menu, menu items as follows:
1Set Parameters
2Information
3Language
4Eventlog
5Maintennance
When entered password interface, inputting “0318” can set all parameter items in Table 7. 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) For HGM4010, there are no items from 1 to 5 in Table 7; there are no mains items in auxiliary output 1-5.
b) 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.
c) Over voltage set value must be higher than under voltage set value, otherwise over voltage and under
voltage condition may occur simultaneously.
d) Over speed set value must be higher than under speed set value, otherwise over speed and under speed
condition may occur simultaneously.
e) 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.
f) 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.
g) Programmable sensor 1 input port can be set as fuel level sensor or digital input port 4; programmable
sensor 2 input port can be set as temperature sensor, pressure sensor, coolant level sensor or digital input
port 5. Choose either sensor or digital input port, if digital input port be selected, corresponding set
parameters be functional and sensor parameters are deactive and reserved; otherwise, if sensor be
selected, corresponding sensor parameters be functional and digital input port parameters are deactive
and reserved.
h) 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”
Note: In this interface, press will display the auxiliary inputs and outputs status.
Press and or and simultaneously to adjust LCD contrast ratio and make
LCD character display more clearly. Contrast ratio adjustment range: 0-7.
Chinese, English, Spanish, Russian, Turkish, French, Portuguese and Polish can be optional.
View event log from this interface, including start/stop information and shutdown alarm
information log. It can record and display up to 99 pieces.
8.5 MAINTENANCE
Password need to be input when enter into the maintenance interface, default as 0(if change this
password, please contact with SmartGen service personnel or sales personnel). Setting
maintenance parameters will refresh maintenance time.
Note: Refresh maintenance time and enter into the next maintenance period in maintenance interface
when Maintenance Due Alarm.
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 adjust it in
“curve type”.
3) When input the sensor curve, X value (resistor) must be input from small to large, otherwise,
mistake occurs.
4) If there is no oil pressure sensor, but there is low oil pressure alarm switch, user must set the oil
pressure sensor as “None”, otherwise, maybe low oil pressure shutdown occurs.
5) 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) Emergency stop input is connected to the positive pole of starter battery via emergency stop button’s
normally closed point and fuse.
4) 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.
5) Set controller under manual 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.
6) 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.
7) Select the AUTO mode from controller’s panel, connect mains signal. After the mains normal delay,
controller will transfer ATS (if fitted) into mains load. After cooling time, controller will stop genset and
make it into “at rest” mode until there is mains abnormal situation.
8) When mains is abnormal again, genset will be started automatically and enter into normal running,
then controller send signal to making generator switch on, and control the ATS transfer into generator
load. If not like this, please check ATS’ wires connection according to this manual.
9) If there is any other question, please contact SmartGen’s service.
Note: Expand relay with high capacity in start and fuel output is recommend.
NOTE:
2) When there is load current, transformer’s secondary side prohibit open circuit.
Table 13 Connector B
Table 26 F Connector
13.14 PERKINS
It is suitable for ADEM3/ ADEM4 engine control module. Engine type is 2306, 2506, 1106, and 2806.
Table 33 Connector
13.15 SCANIA
It is suitable for S6 engine control module. Engine type is DC9, DC12, and DC16.
Table 34 B1 Connector
Table 37 Connector
13.18 VOLVO-EMS2
Volvo Engine types are TAD734, TAD940, TAD941, TAD1640, TAD1641, and TAD1642.
13.19 YUCHAI
It is suitable for BOSCH common rail pump engine.
13.20 WEICHAI
It is suitable for Weichai BOSCH common rail pump engine.