SmartGen RPU560A Marine Engine Controller User Manual

SmartGen RPU560A Marine Engine Controller User Manual

Brand Information

SmartGen — make your generator smart

SmartGen Technology Co., Ltd.

No.28 Jinsuo Road, Zhengzhou, Henan Province, China Tel: +86-371-67988888/67981888/67992951

+86-371-67981000(overseas)

Fax: +86-371-67992952

Email:sales@smartgen.cn

Web:www.smartgen.com.cn www.smartgen.cn

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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.

Table 1 – Software Version

voltage input description of power supply.

This manual is suitable for RPU560A redundant protection unit only.

Table 2 – Clarification of notation used within this publication.

correctness.

CAUTION!

| Indicates  a  procedure  or  practice,  which,  if  not  strictly observed,  could

result in damage or destruction of equipment.

WARNING!

| Indicates a procedure or practice, which could result in injury to personnel or loss of life if not followed correctly.

OVERVIEW

RPU560A Redundant Protection Unit is a redundant protection unit that can autonomously maintain the engine running and protect it in the case of master control fault. The module is connected to HMC9000/HMC6000 via CONBUS port. All parameters and alarm types can be checked on the master controller. It can be widely used in marine emergency units, main propulsion units, main generator units and pumping units.

PERFORMANCE AND CHARACTERISTICS

• Speed sensor enables accurate control and protection of the running engine;
• Optional working mode; one is synchronized with master controller to protect engine normal running; the other is protect engine automatically when master controller failure occurs.
• 4 digital shutdown inputs;
• 5 relay outputs: shutdown output, fuel output, common warning output, common shutdown output, auxiliary output;
• Emergency shutdown input port: after emergency shutdown is initiated, regardless of whether main controller failure occurred or not, shutdown signal will still be sent;
• Remote mode, in which only overspeed shutdown and emergency shutdown signals will be able to stop the unit;
• Modular design, compactness structure, small size, easy use.

TECHNICAL PARAMETERS

Table 3 – Technical Parameters

OPERATION

MAIN PROTECTED MOD

In this mode, RPU560A redundant protection unit will detect engine parameters and shutdown inputs automatically to protect the engine in real time whether the main module is active or not.
If overspeed shutdown or other shutdown alarm input is occurred, the stop relay is energized while the fuel relay is disengaged, then the common shutdown relay is engaged. When the engine is stop successfully, users can reset the alarm by pressing reset button mounted on the HMC9000/HMC6000 panel or by pressing the reset button contained within the RPU560A module.

STANDBY PROTECTED MODE

1. When main control is active (CANBUS communication is normal), if the engine speed has exceeded the fuel output speed, the fuel relay is energized. Only the active shutdown input and overspeed signal will be able to stop the generator.
2. When main control is deactivated (CANBUS communication is failed), if overspeed shutdown or other shutdown signal is detected, the stop relay is energized while the fuel relay is disengaged, then the common shutdown relay is engaged. When the engine is stop  successfully, users can reset the alarm by pressing reset button.
3. In override mode, if main control is deactivated, only overspeed shutdown and emergency shutdown signals will be able to stop the unit.

PROTECTION

WARNINGS

Table 4 – Warnings

below the pre-set threshold and last for 20s. Then lamp BAT.1, BAT.2 will blink and the common warn relay outputs at the same time.
2| Bat 2 over volt
3| Bat 1 under volt
4| Bat 2 under volt
5| Input 1 BW Warn| When the controller detects wire disconnection, the disconnection indicators begin to blink and the common warn relay outputs, and the corresponding information will displayed on the LCD screen.
6| Input 2 BW Warn
7| Input 3 BW Warn
8| Input 4 BW Warn
9| Override input BW Warn
10| Shutdown output BW Warn
11| Fuel BW Warn
12| Speed BW Warn
13| EM. STOP Wire Break Warn

SHUTDOWN ALARM

**** If shutdown alarm signal is detected, shutdown relay and common shutdown relay activates while fuel relay deactivates.

Table 5 – Shutdown Alarms

initiated, shutdown relay and common shutdown relay are activated while fuel relay deactivates. When failure shutdown is active, the corresponding lamp will be always initiated.
2| Input 1 shutdown| Always active| When failure shutdown input is active and engine speed has exceeded or been equal with pre-set value, shutdown relay and common shutdown relay are activated while fuel relay deactivates. When failure shutdown is active, the corresponding lamp will be always initiated, and the controller possesses with break wire detection function (it can be defined by users).
3| Input 2 shutdown
4| Input 3 shutdown
5| Input 4 shutdown

PARAMETER CONFIGURATION

RPU560A Redundant protection unit parameters can only be configured via PC software (the LINK port of RPU560A must be connected with SG72 transfer module and then connect with PC).

Table 6 – Parameter Configuration

14. EM. Stop Wire Break

Detection Enable

| (0-1)| 0: Do not detect
15. Output 1 Set| (0-10)| 1: Main Control Fail
16. Output 1 Type| (0-1)| 0: Normally open
17. Flywheel Teeth| (1-300)| 118
18. Rated Speed| (0-5999) r/min| 1500 r/min
19. Fuel Output| (0-200)%| 25% The fuel relay is active when the speed has exceeded the default value while deactivated when the speed has fallen below

the default value.

20. Over Speed Shut| (0-200)%| 115%
21. Over Speed Delay| (0-3600)s| 1s
22. Over Speed Warn| (0-200)%| 110%
23. Over Speed Return| (0-200)%| 108%
24. Bat Rated Volt| (0-60.0)V| 24.0V
25. Bat 1 Over Volt Warn| (0-200)%| 125%
26. Bat 2 Over Volt Warn| (0-200)%| 125%
27. Bat 1 Under Volt Warn| (0-200)%| 80%
28. Bat 2 Under Volt Warn| (0-200)%| 80%
29. Work Mode| (0-1)| 0: Main protected mode

The RPU560A module will detect engine parameters and alarm information automatically to protect the engine in real time whether the main module is active or not.

1: Standby protected mode
The RPU560A module will protect engine automatically when the main module is deactivated.

OUTPUT PORT FUNCTION DEFINITION

Table 7 – Output Port Function Definition

TERMINAL CONNECTIONS

Table 8 – Terminal Description

Impedance-120Ω shielded wire with its one end connected to SCR is recommended.
8.| CAN(H)
(CANBUS)| 0.5mm2
9.| CAN(L)
(CANBUS)| 0.5mm2
10| 120Ω| 0.5mm2
11.| COM1| 2.5mm2| Common output port
12.| FUEL| 1.0mm2| Output as working indication when the module detects engine speed exceeded preset “fuel output speed”,  deactivate  when  shutdown,  and possess break wire detection function.
13.| STOP| 1.0mm2| Output when the module detects a warning alarm, connect to shutdown electromagnet, and possess break wire detection function.
14.| SHUTDOWN| 1.0mm2| Output when the module detects a warning alarm, alarm status will be locked to save, and it can be reset by pressing reset button.
15.| WARN| 1.0mm2| Output when the module detects a warning alarm, the status will not be locked to save.
16.| OUT1| 1.0mm2| It can be configured by users; output after it is energized.
17.| MAGNETIC PICKUP| 0.5mm2| Speed sensor input with break wire detection function.
18.| 0.5mm2
19.| 0.5mm2
20.| EM.STOP| 0.5mm2| Emergency   shutdown   input   port   (connect   to COM2(-) to activate)
Note: Break wire detection function can be configured; it need to connect COM2(-) port with a 10kΩ resistance.
21.| SD1| 0.5mm2| Failure shutdown input port (connect to COM2(-) to activate); It can control engine to stop when it is active.
Note: Break wire detection function can be configured; it need to connect COM2(-) port with a 10kΩ resistance
22.| SD2| 0.5mm2
23.| SD3| 0.5mm2
24.| SD4| 0.5mm2
25.| OVERRIDE| 0.5mm2| Override mode (connect to COM2(-) to activate); In this mode, only Emergency shutdown and Over speed shutdown can stop the engine in case of main controller deactivate.
26.| COM2(-)| 0.5mm2| Common input port
| ALARM RESET| | Pressing this button can reset the alarm.
Note: When the communication of CAN and HMC9000/HMC6000 is normal, then CAN indicator will blink, otherwise it will be distinguished.

SYSTEM CONNECTION DIAGRAM

APPLICATION DIAGRAM

INSTALLATION

TROUBLESHOOTING

Check controller connection wirings;
CANBUS communication failure| Check if CANBUS wires are connected in the opposite way;
Check if 120Ω resistance is connected;
Check if Baud rate of the dial switch is correct.

References

• 众智科技
• smartgen.cn/
• 众智科技

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