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User Manual: HMC9000A/HMC9000S Diesel Engine Controller
User Manual: HMC9000A/HMC9000S 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.
CONTENTS
1 OVERVIEW ......................................................................................................................................... 5
2 PERFORMANCE AND CHARACTERISTICS .................................................................................... 6
3 MODEL COMPARISON ...................................................................................................................... 7
4 TECHNICAL PARAMETERS .............................................................................................................. 8
5 OPERATOR INTERFACE ................................................................................................................... 9
5.1 PUSHBUTTON DESCRIPTION .................................................................................................. 9
5.2 LCD DISPLAY............................................................................................................................ 10
5.2.1 MAIN SCREEN DISPLAY ............................................................................................... 10
5.2.2 MEASURED DATA DISPLAY.......................................................................................... 10
6 OPERATION ...................................................................................................................................... 11
6.1 REMOTE START/STOP OPERATION ....................................................................................... 11
6.1.1 CONFIGURATION REQUIREMENTS.............................................................................11
6.1.2 REMOTE START SEQUENCE ........................................................................................11
6.1.3 REMOTE STOP SEQUENCE .........................................................................................11
6.2 LOCAL START/STOP OPERATION.......................................................................................... 12
6.2.1 CONFIGURATION REQUIREMENTS ............................................................................ 12
6.2.2 LOCAL START SEQUENCE .......................................................................................... 12
6.2.3 LOCAL STOP SEQUENCE ............................................................................................ 12
7 PROTECTION ................................................................................................................................... 13
7.1 WARNING.................................................................................................................................. 13
7.2 SHUTDOWN ALARMS .............................................................................................................. 17
8 PANEL CONFIGURATION ................................................................................................................ 17
9 INPUT/OUTPUT PORTS CONFIGURATION ................................................................................... 25
9.1 AUXILIARY INPUTS 1~18 FUNCTIONAL DEFINITION ............................................................ 25
9.2 OUTPUT PORTS 1~14 FUNCTION DEFINITION...................................................................... 27
9.3 SENSOR FUNCTION DEFINITION ............................................................................................ 35
9.3.1 SENSOR CONFIGURATION LIST ................................................................................... 35
9.3.2 TEMPERATURE CURVES ............................................................................................... 36
9.3.3 PRESSURE CURVES ...................................................................................................... 36
9.3.4 LIQUID LEVEL CURVES.................................................................................................. 37
10 BACK PANEL .................................................................................................................................. 37
11 TYPICAL WIRING DIAGRAM ......................................................................................................... 41
12 COMMUNICATION CONFIGURATION AND CONNECTION ........................................................ 43
13 CONTROLLER AND ENGINES EXPANSION (CANBUS) CONNECTION .................................... 44
13.1 CUMMINS ISB/ISBE ................................................................................................................. 44
13.2 CUMMINS QSL9 ....................................................................................................................... 44
13.3 CUMMINS QSM11..................................................................................................................... 44
13.4 DETROIT DIESEL DDEC III / IV ............................................................................................... 45
13.5 DEUTZ EMR2 ............................................................................................................................ 45
13.6 JOHN DEERE............................................................................................................................ 46
13.7 MTU MDEC ............................................................................................................................... 46
─ Core of 32-bit ARM micro-processor, 4.3-inch LCD display with backlight, optional Chinese/English
language, tuch-button operation.
─ Ability of controlling and communicating with dozens of electrical injection engines with J1939
interface. It can also connect with digital output module, security module, electric quantity protection
module, analog input module etc. for users’ convenience and needs.
─ Realizing the function of remote-distance monitoring the engine via REMOTE (CANBUS) interface.
Under the remote monitoring mode, other buttons on the controller do not work except Stop button.
It is safe and convenient.
─ Equipped with RS485 and USB communication interfaces. It can realize the functions of data
communication and “three-remotes” by installing monitoring software on PC and MODBUS
protocol.
─ Protection control function: it can realize the Start/Stop, Alarm protection function under remote or
local control mode.
─ Override mode function: under this mode only over speed shutdown and emergency shutdown can
stop the engine.
─ Parameter setting function: it allows users to change and set the parameters and meanwhile they
shall be stored in the FLASH memorizer so that they will not disappear in case of power outage.
─ Four 4-20mA inputs: it can put in pressure or liquid level messages.
─ Four resistance sensor inputs: it can put in pressure signal, PT100 temperature signal, liquid level
signal or other signals.
─ Two K-type thermocouple inputs: it can put in exhaust temperature signals.
─ Real-time calendar, real-time clock, and total running time accumulation function.
─ Displaying the total start accumulation times.
─ Built-in speed detection equipment: it can precisely judge successful start status, normal running
status and over speed status.
─ Circularly 99 event logs preservation function: users can search the documentation on the spot.
─ Double power supply monitoring and transferring function: power supply switchover can be
performed through external interface by setting switchover voltage value.
─ All parameters are done by digitalized modification: it gets rid of the analog adjustment methods of
ordinary potentiometers and improves the reliability and stability of the whole genset.
─ Break wire detection function for some Input/output ports.
─ Modular structure design, and embedded installation way: Structure compact; size small; and
operation easy and convenient.
Protection Class IP65: adding a waterproof gasket between controller and screen
Weight 0.90kg
Lamp Test Test panel LED indicators and the display screen.
WARNING: Default password is 01234. It can be changed by users to prevent others randomly altering the settings.
Please clearly remember the password after the change. If it is forgotten, please contact SmartGen service department and
feedback all the information on the “ABOUT” page of the controller.
The main screen displays a tachometer (range: 0~3000 r/min), a thermometer (range: 0~150 ºC;
connected sensor is user-configurable, for example: default-configured sensor 1), an oil manometer
(range: 0~1000 kpa; connected sensor is user-configurable, for example: default-configured sensor 5),
and two powers’ voltage display. The main screen displays as follows:
The main screen is divided into two separate display areas: the right and left parts. Left displays status
data steadfast and cannot turn over, and the right can turn over by using button.
a) Status page includes the following contents:
engine working and running status and power status;
b) Engine page includes the following contents:
engine speed, sensor 1-4 (resistance), sensor 5-8 (current), sensor 9~10(K-type thermocouple),
main power voltage, spare power voltage, charger voltage, accumulated running time and total start
times.
Note: sensor names can be users-defined.
c) If J1939 is enabled, ECU data display shall appear on the main screen. ECU data includes: cooling
liquid pressure, coolant level, engine oil temperature, fuel temperature, fuel pressure, air inlet
temperature, air outlet temperature, turbine pressure, fuel consumption, total fuel consumption etc.
(Different engines include different parameters).
d) Alarm page.
It displays all kinds of warning alarms and shutdown alarms. It displays at most 5 SPN and
corresponding FMI at the same time when ECU alarms happen.
NOTE: About ECU alarms and shutdown alarms if it displays the detailed alarm contents, please check the engine
according to them, otherwise please check the engine manual according to SPN alarm code.
e) Event log page.
It records all shutdown events and the time when they occur.
f) Other information about the module includes the following contents:
Module date and time, input and output interface status.
g) About page includes the following contents:
HMC9000A/HMC9000S Diesel Engine Controller 2018-12-25 Version 1.3 Page 10 of 51
HMC9000A/HMC9000S DIESEL ENGINE CONTROLLER USER MANUAL
Release software version, and hardware version.
6 OPERATION
Any one of the auxiliary input ports can be configured to remote mode input. When the input port is
active, the controller shall be in remote control mode.
a) When the “Remote Stop” input is active, the “Stop Delay” is initiated.
HMC9000A/HMC9000S Diesel Engine Controller 2018-12-25 Version 1.3 Page 11 of 51
HMC9000A/HMC9000S DIESEL ENGINE CONTROLLER USER MANUAL
b) Once the “Stop Delay” has expired, “High Speed Cooling Delay” is energized.
c) When “Stop Idle Delay” (if configured) starts, idling relay is energized and outputs.
d) When “ETS Solenoid Hold” begins, ETS relay is energized and outputs and meanwhile fuel relay
and is de-energized and automatically judges whether stop is completed.
e) When "Fail to Stop Delay" begins, complete stop is detected automatically.
f) When the generator stops completely, it enters standby mode. Otherwise, it enters stop failure
mode and has Stop Failure Alarm (If it stops completely after the alarm, then it enters standby mode
and press Alarm Reset key, and it shall remove the failure alarm.).
NOTE: If remote monitoring controller is used to stop the genset, press the Stop key and there is not stopping delay, and
other processes are the same as the above stop input.
Any one of the input ports can be configured to machine side mode input. After machine side mode
input is active, the controller shall be in machine side mode.
a) Press and preheating relay outputs (if configured). LCD status screen displays “Preheat
Delay XX”.
b) After the preheating delay time ends, fuel relay outputs for 1 second, and starter relay outputs. If the
generator does not start during “Cranking Time”, fuel relay and starter relay stop outputting and enter
“Crank Rest Time”, waiting for another starting.
c) In the starting times set, if the generator does not start, the controller initiates starting failure shutdown
and meanwhile LCD alarm screen displays starting failure alarm.
d) Among the starting times, if the generator starts, it shall enter “Safety On Time”, in which low oil
pressure, high water temperature, under speed, charging failure etc. alarm data are all inactive. After
“Safety On Time”, it enters “Start Idle Delay” (if configured).
e) During “Start Idle Delay” time, under speed alarm is active. After “Start Idle Delay” it enters high-speed
“Warming up Delay” (if configured).
f) After high speed warming up delay, if the oil pressure and speed of the generator are normal, then it
works normally. If they are abnormal, then the controller shall operate alarm and shutdown (LCD alarm
screen displays shutdown alarm data.).
When controller detects shutdown alarm, it stops immediately and displays alarm type.
Table 6 Shutdown alarms
No. Type Detection range Description
When the controller detects an emergency stop
Emergency Stop alarm signal, it will initiate a shutdown alarm and
1 Always active
Alarm 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 Overspeed Alarm Always active
initiate a shutdown alarm and the corresponding
alarm information will be displayed on LCD.
When the controller detects that the generator
“Waiting For Load”→ speed has fallen below the pre-set value, it will
3 Underspeed Alarm
“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 “Start Idle Delay”→ “Stop speed is 0, it will initiate a shutdown alarm and
4
Signal Alarm Idle Delay” the corresponding alarm information will be
displayed on LCD.
When the controller detects that the auxiliary
Auxiliary Input 1-18 input 1-18 shutdown alarm input, it will initiate a
5 User-defined
Alarm shutdown alarm and the corresponding alarm
information will be displayed on LCD.
When the controller detects ECU shutdown alarm
signal, it will initiate a shutdown alarm and the
6 ECU Alarm Always active
corresponding alarm information will be
displayed on LCD.
ECU If the module cannot detect CAN signal, it will
Do not detect in stop or
7 Communication initiate a shutdown alarm and the corresponding
standby mode
Failure Alarm alarm information will be displayed on LCD.
When the controller detects sensor 1-10 active
Sensor 1~10 High shutdown alarm signal, it will initiate a shutdown
8 >preset warning speed
Alarm alarm and the corresponding alarm information
will be displayed on LCD.
When the controller detects sensor 1-10 active
Sensor 1~10 Low shutdown alarm signal, it will initiate a shutdown
9 >preset warning speed
Alarm alarm and the corresponding alarm information
will be displayed on LCD.
CAUTION: The alarm types of auxiliary inputs are active only when they are configured by users. If the controller is
in override mode, only “Emergency Shutdown” and “Overspeed Shutdown” can work.
NOTE1: ECU shutdown happens when “ECU Shutdown” is enabled and ECU shutdown alarm signal is detected.
8 PANEL CONFIGURATION
Press for over 3 seconds and the controller enters configuration interface by which all
parameters can be set for the controller. For details please see below.
>Start Delay
Interface 4:
>Stop Delay 00008
>Preheat Delay Press to enter settings (Interface 5),
>Cranking Time
to return to the previous screen
>Crank Rest Time
>Safety On Time (Interface 6).
>Start Idle Time
>Warming Up Time
>Cooling Time
>Stop Idle Time
>ETS Hold Time
>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
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.
10 BACK PANEL
NOTE: It is strictly prohibited to take out the starting battery when the engine is running, otherwise the control system
will be burned because of the over high DC input voltage! Failure to do so can create excessive DC input voltage and
Users can control a large number of ECU engines by controller expansion ports. Besides, various
expansion modules can be connected to the controller for user to adapt different working environments
at the same time.
It is suited for CM750 engine controller module. Engine types: QSM11 G1, QSM11 G2.
The engine types suitable for MTU engines are 2000 series, 4000 series.
13.8 PERKINS
It is suited for ADEM3/ADEM4 Engine Control Module. Engine types: 2306; 2506; 1106; 2806.
Table 28 Engine Wiring
Controller Terminals Connector Remark
Fuel relay output 1,10,15,33,34
Start relay output - connected to starter coil directly
CAN communication shielding line
SCR (EXPANSION) -
(connected 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.
NOTE: Engine type of the testing software chooses: Perkins.
It is suited for S6 Engine Control Module. Engine types: DC9, DC12, DC16.
The suitable engine types are TD520, TAD520 (optional), TD720, TAD720 (optional), TAD721, and
TAD722.
Table 32 Engine Wiring
Controller Terminals Connector Remark
Expansion 30A relay,
providing power voltage for
Fuel relay output
Terminal 14. The fuse is
16A.
Start relay output - Connected to starter coil directly.
1 Connected to battery negative.
CAN communication shielding line
SCR (EXPANSION) -
(connected to controller’s terminal only)
13.12 VOLVO-EMS2
13.13 BOSCH
By EXPANSION communication ports users can develop different application modules. For details
please see as follows:
─ RPU560A Safeguard Module: It is used with the main controller together via CANBUS port. If
safeguard module does not receive signals from the main controller for more than 1 second, and
the main controller has faults and inputs are inactive, it will take over engine control; until stop input
This expansion port is a CANBUS port for connecting remote control module.
HRM3300 Remote Control Module: It is used with the main controller together via CANBUS port. It
can realize start, stop, alarm mute etc. operations on the engine from remote-distance. All parameters
and records are all displayed on the remote monitoring controller.
NOTE: Only in remote mode can the remote control module control the engine; in local mode, except Stop, other
15 INSTALLATION
HMC9000A/HMC9000S has embedded panel structure. It is fixed with the help of fixing clips. Overall
dimensions and cutout sizes can be seen below.
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