SmartGen HMC6000A Diesel Engine Controller User Manual

: June 13, 2024
: SmartGen

SmartGen HMC6000A Diesel Engine Controller

SmartGen-HMC6000A-Diesel-Engine-Controller-PRODUCT

OVERVIEW

HMC6000A
diesel engine controller integrates digit al , intelligent and network technology which are used for genset automation and monitor control system of single unit to achieve automatic start/stop, data measure, alarm protection and “three remote s ” (remote control, remote measuring and remote communication). It fit with 132*64 liquid displ ay, optional Chinese/English languages interface, and it is reli able 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. Major parameters can be configured from front panel and can be configured by communication interface via PC. Due to its compact structure, simple connections and high reliability, HMC6000A can be widely used in marine emergency engines, main propulsion engines, main generator engines and pumping engines.
HMC6000A
diesel engine controller has an expansion CANBUS port that will be connected to a remote monitoring module or digital output expansion module and security module.

PERFORMANCE AND CHARACTERISTICS

32 bit ARM micro processor, 132*64 liquid displ ay , optional C hinese/English interface, push button operation
Connect with remote monitoring module via CANBUS (expand) port to realize remote monitoring and remote start/stop control;
RPU560A security module can be expanded via CANBUS (expand) port;
Dozens of engine s which is compatible with J1939 protocol, can be monitored via CANBUS (ECU) port;
RS485 communication ports enable data communication as well as remote control, remote measurement and remote communication;
Control and protection: remote/local start and sto p diesel engine, alarm protection;
Override mode, in which only overspeed and manual emergency shutdown can stop the engine;
Parameter setting: parameters can be modified by users and stored into internal FLASH memory and cannot be lost even in case of pow er outage;
Six sensor inputs for pressure, temperature, fuel level or other resistor type sensors; pressure sensor and f lexible sensor 1~3 also can be set to (4~20)mA input and (0~5)V input;
Real time clock, engine total run time accumulation, display the total start times;
Built in speed detection, which can accurately judge crank disconnect status, rated running and overspeed status
99 event logs can be saved circularly and can be inquired on the spot;
Digital regulation of all parameters , instead of an alog regulation using conventional potentiometer, therefore, higher reliability and stability;
Modular design, self extinguishing ABS plastic enclosure and embedded installation way; small size and compact structure with easy mounting

TECHNICAL PARAMETERS

Table 2 Technical Parameters

Items	Content
Working Voltage	DC8.0V to DC35.0V, uninterrupted power supply
Power Consumption	<3W (Standby mode: ≤2W)
Speed Sensor Voltage	1.0V to 24V (RMS)
Speed Sensor Frequency	Max 10,000 Hz
Start Relay Output	16A Connect to common output port
Stop Relay Output	16A Connect to common output port
Fuel Relay Output	16A Connect to common output port
Audio Alarm Output	7A Connect to common output port
Common Alarm Output	7A Connect to common output port
Flexible Relay Output 1-9	B+ DC supply, 0.5A output current
Flexible Relay Output 10-12	7A AC250V voltage free output
Case Dimension	197mm x 152mm x 47mm
Panel Cutout	186mm x 141mm
Working Temperature	(-25~+70)ºC
Working Humidity	(20~93)%RH
Storage Temperature	(-25~+70)ºC
Protection Level	IP65: when water proof gasket ring inserted between panel

and housing.
Weight| 0.70kg

CONTROLLER INF ORMATION DISPLAY
Table 3 Controller Information Display $SmartGen-HMC6000A-Diesel-Engine- Controller-FIG-1 $1$$

OPERATION

KEY FUNCTION DESCRIPTION
Table 4 Key Function Description $SmartGen-HMC6000A-Diesel-Engine- Controller-FIG-1 $2$$

CONTROLLER PANEL $SmartGen-HMC6000A-Diesel-Engine-Controller-FIG-1 $3$$

Fig.1 HMC6000A Front Panel

START/STOP OPERATION OF REMOTE CONTROL
ILLUSTRATION
Deploy any digital input port of HMC6000A to remote start input. After the “remote mode” is active, remote start/stop operation can be initiated.
REM OTE START SEQUENCE

When “Remote Start” input is active, “Start Delay” timer is initiated;
“Start Delay” countdown will be displayed on LCD;
After “Start Delay” expired, preheat relay energizes (if configured), “Preheat Delay XX s” information will be displ ayed on LCD;
After the above delay, the “Fuel Relay” is energized, and then one second later, the “Start Relay” is engaged. Engine is cranked for a pre set time. If engine fails to fire during this cranking attempt then the fuel relay and start relay are disengaged for the pre set rest period; “ C rank R est T ime” begins and wait for the next crank attempt;
Should this start sequence continue beyond the set number of attempts, the start sequence will beterminated, the first line of LCD display will be highli ghted with black and Fail to Start fault will be displayed;
In case of successful crank attempt, the “Safety On” timer is activated. As soon as this delay is over, “ S tart I dle” delay is initiated (if configured);
After the start idle, the generator enters into “Warming Up” status (if configured);
When “Warming Up” delay is expired, engine will normally run.
- NOTE If engine is started by remote monitoring module, there is no “Start Delay” step, and will jump to “Preheat Delay” directly.

REMOTE STOP SEQUENCE

When “Stop Input” signal is active, “Stop Delay” timer is
After “Stop Delay” expired, cooling will be started;
After cooling, idle relay is energized while “Stop Idle” (if configured) starts;
Once this “Stop Idle” has expired, the “ETS Solenoi d Hold” begins. ETS relay is energized while fuel relay is de energized;
Once this “ETS Solenoid Hold” has expired, the ” Wait Stop Time ” begins. Complete stop is detected automatically;
Engine is placed into its standby mode after its complete stop. Otherw ise, fail to stop alarm is initiated and the corresponding alarm information is displayed on LCD while entering into “Fail to Stop” status (If stop successfully after “Fail t o Stop” alarm has initiated, engine will enter into standby sta t us).

NOTE: If eng ine is stopped by remote monitoring module, there is no “Stop Delay” step, and will jump to cooling step directly.

AUTO MODE START/STOP OPERATION

ILLUSTRATION
Deploy any digital input port to auto mode input. After the “Auto Mode” is active, Start/Stop ope ration can be initiated.
AUTO START SEQUENCE

When “Auto Start” input is active or “Remote Start/Stop” input is active, “Preheat Delay” is initiated;
PPreheat 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. 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;
Should this start sequence continue beyond the set number of attempts, the start sequence will be terminated, the first line of LCD display will be highlighted with black and Fail to Start fault will be displayed;
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);
When the “Start Idle “delay is over, “Warming Up” delay is initiated (if configured);
When “Warming Up” delay is over, engine will enter into “Normal Running S tatus”.

AUTO STOP SEQ UENCE

When “Stop Input” is active or “Start/Stop” input open, cooling is started;
Once the “Cooling Delay” has expired, the “Stop Idle” delay is initiated (if configured). During “Stop Idle” Delay, idle relay is energized;
Once the “Stop Idle” delay has expired, “ETS Solenoid Hold” begins. ETS relay is energized while fuel relay is de energized;
Once this “ETS Solenoid Hold” has expi red, the Wait Stop Time begins. Complete stop is detected automatically;
Engine 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 while entering into “Fail to
Stop” status (If stop successfully after “Fail t o Stop” alarm has initiated, engine will enter into standby sta t us).

LOCAL START/STOP OPERATION

ILLUSTRATION

Deploy any digital input port to local mode input. After the “ L ocal M ode” is active, Start/Stopoperation will be doable by pressing buttons on the controller.
Under local mode, “Idle Output” is unavailable.

LOCAL START SEQUENCE

Press button to start the engine; 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. The genset is cranked for a pre-set time. If engine fails to fire during this cranking attempt then the fuel relay and start relay are disengaged for the pre-set rest period and engine enters “Energize to Stop” status;
In case of successful crank attempt, the “Safety On” timer is activated;
After the “Start Idle” delay expired, if the speed, temperature and oil pressure of controller are regular, engine will enter into “Normal Running” status directly.

LOCAL STOP SEQUENCE

Press to enter “Energize to Stop” status, ETS relay is energized while fuel relay is de energized;
Once the “ ETS Solenoid Hold ” delay has W ait Stop Time begins. Complete stop is detected automatically;
Engine 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 while entering into “Fail to
Stop” status (If stop successfully after “Fail to Stop” alarm has initiated, engine will enter into standby sta t us).

Table 5 HMC6000A Start/Stop Description

System Mode| Local Start| Local Stop| Remote Start

Input

| Stop Input| Remote Start/Stop

Input

| Auto Start

Input

| Remote Module

Start

| Remote Module

Stop

---|---|---|---|---|---|---|---|---
Local| ●| ●| –| –| –| –| –| –
Remote| –| –| ●| ●| –| –| ●| ●
Auto| –| –| –| ●| ●| ●| –| –

ALARMS

WARNING ALARM
When controller detects warning alarms, which does not lead to shutdown, the detailed alarm information will be d isplayed on LCD.
Table 6 Warning Alarm

No.	Type	Detection Range	Description

| ****

Over speed

| ****

Always active

| When the controller detects that the engine speed has exceeded the pre-set value, it will initiate a warning alarm and the corresponding alarm information will be

displayed on LCD.

| ****

Under speed

| From “Warming up” to “Cooling” delay| When the controller detects that the engine speed has fallen below the pre-set value, it will initiate a warning alarm and the corresponding alarm information will be

displayed on LCD.

| ****

Loss of Speed Signal

| From “Start Idle” delay to “Stop Idle” delay| When the controller detects that the engine speed is 0 and action select “Warning”, it will initiate a warning alarm and the corresponding alarm information will be

displayed on LCD.

| ****

Failed to start

| ****

Among set crank times, after “Start Completed”

| Among set crank times, if genset failed to start, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD.

Note: start attempt is forced as 1 time in local mode,

and no alarms if failed to crank.

| ****

Failed to stop

| After “Fail to Stop” Delay| After “Fail to Stop” delay, if engine still has speed signal, it

will initiate a warning alarm and the corresponding alarm information will be displayed on LCD.

| ****

Charge Alt Fail

| ****

When generator is normal running

| When the controller detects that charger voltage has fallen below the pre- set value, it will initiate a warning alarm and the corresponding alarm information will be

displayed on LCD.

| ****

Aux. Input 1-10

| ****

User defined

| When the controller detects that the auxiliary input 1-10 warning signals, it will initiate a warning alarm and the corresponding alarm information will be displayed on

LCD.

| ****

High Water Temperature

| ****

Bigger than set speed

| When the controller detects that the high water temperature warning signals, it will initiate a warning alarm and the corresponding alarm information will be

displayed on LCD.

| ****

High Oil Temperature

| ****

Bigger than set speed

| When the controller detects that the high oil temperature warning signals, it will initiate a warning alarm and the corresponding alarm information will be displayed on

LCD.

10.| Low Oil Pressure| Bigger than set| When the controller detects that the low oil pressure
No.| Type| Detection Range| Description
---|---|---|---
| | speed| warning signals, it will initiate a warning alarm and the

corresponding alarm information will be displayed on LCD.

| ****

Aux. Sensor 1-3 High

| ****

Bigger speed

| ****

than

| ****

set

| When the controller detects that the Flexible sensor 1-3 warning signals, it will initiate a warning alarm and the corresponding alarm information will be displayed on

LCD.

| ****

Aux. Sensor 1-3 Low

| ****

Bigger speed

| ****

than

| ****

set

| When the controller detects that the Flexible sensor 1-3 warning signals, it will initiate a warning alarm and the corresponding alarm information will be displayed on

LCD.

| ****

Water Temperature Open

| ****

Always active

| When the controller detects that the water temperature sensor open warning signals, it will initiate a warning alarm and the corresponding alarm information will be

displayed on LCD.

| ****

Oil Temperature Open

| ****

Always active

| When the controller detects that the oil temperature sensor open warning signals, it will initiate a warning alarm and the corresponding alarm information will be

displayed on LCD.

| ****

Oil Pressure Open

| ****

Always active

| When the controller detects that the oil pressure sensor open warning signals, it will initiate a warning alarm and the corresponding alarm information will be displayed

on LCD.

| ****

Aux. Sensor 1-3 Open

| ****

Always active

| When the controller detects that the flexible sensor 1-3 open warning signals, it will initiate a warning alarm and the corresponding alarm information will be displayed

on LCD.

| ****

Supply 1 Under Volt

| ****

Always active

| When the controller detects that the supply voltage has fallen below the pre-set value for more than 20s, it will initiate a warning alarm and the corresponding alarm

information will be displayed on LCD.

| ****

Supply 1 Over Volt

| ****

Always active

| When the controller detects that the supply voltage has exceeded the pre-set value, it will initiate a warning alarm and the corresponding alarm information will be

displayed on LCD.

| ****

Supply 2 Under Volt

| ****

Always active

| When the controller detects that the supply voltage has fallen below the pre-set value for more than 20s, it will initiate a warning alarm and the corresponding alarm

information will be displayed on LCD.

| ****

Supply 2 Over Volt

| ****

Always active

| When the controller detects that the supply voltage has exceeded the pre-set value, it will initiate a warning alarm and the corresponding alarm information will be

displayed on LCD.

21.| DOUT 16 Comm.

Fail

| Always active

(When DOUT16 is

| When the controller detects DOUT 16 module

communication failure, it will initiate a warning alarm

No.	Type	Detection Range	Description
		enabled)	and the corresponding alarm information will be

displayed on LCD.

| ****

HMC6000RM

Comm. Fail

| Always active (When HMC6000RM is

enabled)

| When the controller detects HMC6000RM module communication failure, it will initiate a warning alarm and the corresponding alarm information will be

displayed on LCD.

| ****

RPU560A Comm.

Fail

| Always active (When RPU560A is enabled)| When the controller detects RPU560A module communication failure, it will initiate a warning alarm and the corresponding alarm information will be

displayed on LCD.

| ****

HMP300 Comm.

Fail

| Always active (When HMP300 is enabled)| When the controller detects HMP300 module communication failure, it will initiate a warning alarm and the corresponding alarm information will be

displayed on LCD.

| ****

HMC9800RM

Comm. Fail

| Always active (When HMC9800

is enabled)

| When the controller detects HMC9800RM module communication failure, it will initiate a warning alarm and the corresponding alarm information will be

displayed on LCD.

| Fresh Water Pressure Low Input| ****

Always active

| When the input port defines this function, the controller

will initiate a warning alarm and the corresponding alarm information will be displayed on LCD.

| ****

Fresh Water Level Low Input

| ****

Always active

| When the input port defines this function and it is active, the controller will initiate a warning alarm and the corresponding alarm information will be displayed

on LCD.

| ****

Grease Level Low Input

| ****

Always active

| When the input port defines this function and it is active, the controller will initiate a warning alarm and the corresponding alarm information will be displayed

on LCD.

| ****

Fuel Leakage Input

| ****

Always active.

| When the input is active, the controller will initiate a

warning alarm and the corresponding alarm information will be displayed on LCD.

| ****

ECU Warning

| ****

Always active

| When there is ECU warning alarms, the corresponding alarm information and SPN and FMI will be displayed on LCD. Max.5 SPN codes of ECU alarm can be

displayed.

NO TE: The warning types of Auxiliary input are active only when they are configured by users.

NOTE: The aux. input port 1~10 are corresponding with the input port A~J on the back plate of the controller.

NOTE: The aux. sensor 1~3 are corresponding with the sensor A~C on the back plate of the controller.

DOUT16: 16-channel digital output expansion module.

RPU560A: security expansion module.

HMP300: power integrated protection expansion module.

HMC9800RM: remote monitoring expansion module.

SHUTDOWN ALARM
When controller detects shutdown alarms, controller will stop the genset and corresponding alarm information will display on the LCD.
Table 7 Shutdown Alarm

No.	Type	Detection Range	Description

| ****

Emergency Stop

| ****

Always active

| When the controller detects that the emergency stop is active, it will initiate a shutdown alarm and the corresponding alarm information will be displayed on

LCD.

| ****

Over speed

| ****

Always active

| When the controller detects that the engine speed has exceeded the pre-set value, it will initiate a shutdown alarm and the corresponding alarm information will be

displayed on LCD.

| ****

Aux. Input 1-10

| ****

User defined

| When the controller detects that the auxiliary input 1-10 shutdown signals, it will initiate a shutdown alarm and the corresponding alarm information will be displayed on

LCD.

| ****

High Water Temperature

| ****

Bigger speed

| ****

than

| ****

set

| When the controller detects that the high water temperature shutdown is active, it will initiate a shutdown alarm and the corresponding alarm

information will be displayed on LCD.

| ****

High Oil Temperature

| ****

Bigger speed

| ****

than

| ****

set

| When the controller detects that the high oil temperature shutdown is active, it will initiate a shutdown alarm and the corresponding alarm information will be displayed on

LCD.

| ****

Low Oil Pressure

| ****

Bigger speed

| ****

than

| ****

set

| When the controller detects that the low oil pressure shutdown is active, it will initiate a shutdown alarm and the corresponding alarm information will be displayed on

LCD.

| ****

Aux. Sensor 1-3 High

| ****

Bigger speed

| ****

than

| ****

set

| When the controller detects that the Flexible sensor 1-3 shutdown is active, it will initiate a shutdown alarm and the corresponding alarm information will be displayed

on LCD.

| ****

Aux. Sensor 1-3 Low

| ****

Bigger speed

| ****

than

| ****

set

| When the controller detects that the Flexible sensor 1-3 shutdown is active, it will initiate a shutdown alarm and the corresponding alarm information will be displayed

on LCD.

| ****

ECU Shutdown

| ****

Always active.

| When there is an ECU shutdown alarm, the corresponding alarm information and SPN and FMI will be displayed on LCD. Max.5 SPN codes of ECU alarm

can be displayed.

NOTE: The shutdown types of Auxiliary input are active only when they are configured by users.

NOTE: The aux. input port 1~10 are corresponding with the input port A~J on the back plate of the controller.

No.	Type	Detection Range	Description

NOTE: The aux. sensor 1~3 are corresponding with the sensor A~C on the back plate of the controller.

PARAMETER CONFIGURATION LIST
Hold and press for 1s to enter into paramet er configuration and controller info selection menu after input the correct password (Default password as 00318). Please contact the manufacturer if forget password or need sensor resistance/current calibration.
Table 8 Parameter Configuration Items

Parameter	Range	Default	Remarks

1. Start delay

| ****

(1-3600)s

| ****

1

| The time from remote start signal active to

complete start when the controller is in remote mode.

2. Stop delay

| ****

(1-3600)s

| ****

1

| The time from remote stop signal active to complete stop when the controller is in

remote mode.

3. Pre-heating delay| (0-3600)s| 0| The time of heater plug energized before

starter energized.

4. Cranking Time| (3-60)s| 8| Each starter energized time.
5. Crank Rest Time| (3-60)s| 10| The waiting time before second energizes

start when starter failed to start.

6. Safety on Time| (0-3600)s| 10| First running time after machine started.
7. Start Idle time| (0-3600)s| 0| Idle running time when genset start.
8. Warming Up Time| (0-3600)s| 10| Warming up time after genset enters into

hi-speed running.

9. Cooling Time| (0-3600)s| 10| Cooling time before stop.
10. Stop Idle Time| (0-3600)s| 0| Stop idle time when stop.
11. ETS Hold Time| (0-3600)s| 20| Stop magnet energized time when the

genset is to stop.

12. Wait Stop Time

| ****

(0-3600)s

| ****

0

| Time from idle delay finished to wait stop when “ETS Hold Time” is set to 0; time from ETS hold to wait stop when “ETS Hold

Time” isn’t set to 0.

13. Start Key Confirm

| ****

(0.2-5.0)s

| ****

0.2

| The time from pressing start button to start performance when the controller starts by

button-press.

14. Stop Key Confirm

| ****

(0.2-5.0)s

| ****

0.2

| The time from pressing stop button to stop performance when the controller stops by

button-press.

15. J1939 Enable

| (0-1)

0: Disabled

1: Enabled

| ****

0: Disabled

| After enabled, J1939 monitoring can be achieved via select related engine type.
16. Engine Type| (0-39)| 0:| Default: Conventional Genset. When
Parameter| Range| Default| Remarks
---|---|---|---
| | Conventional

Engine

| connect to J1939 genset, please select

related engine type.

17. SPN Version| (1-3)| 1| Alarm analysis type of SPN
18. ECU Shutdown Enable| (0-1)| 0: Disabled| After enabled, genset shuts down when

detected red lamp alarms.

19. Flywheel teeth

| ****

(1-300)

| ****

118

| The flywheel teeth installed in genset is used for judgment of separate conditions and detection of rotate speed. See 14

Installations.

20. Rated speed| (1-5999)r/min| 1500| Provide standard for judgment of over

speed and under speed.

21. Engine Idle Speed| (0-2000)r/min| 700| The target value of idle speed for relay

speed regulation.

22. Start Attempts

| ****

(1-30)

| ****

3

| The maximum of start attempts when genset failed to start. When it arrive pre-set value, the controller will send failed to start

signal.

23. Crank Disconnect Condition

| (0-2)

0: Speed

1: Oil Press.

2: Speed+ OP

| ****

0: Speed

| The three disconnection conditions of starter and engine, which can be used alone or simultaneously, are used to make starter motor disconnect with engine as soon as

possible.

24. Disconnect OP| (10-1000)kPa| 80| Disconnect when Oil Pressure exceeds

preset value.

25. Disconnect Speed

| ****

(0-200)%

| ****

25%

| Set value is percentage of rated rotate speed. When speed exceeds pre-set value,

starter will separate.

26. Under Speed Shutdown

| (0-1)

0 Disabled

1 Enabled

| ****

0 Disabled

| ****

Under speed shutdown setting.

27. Set Value| (0-200)%| 85%
28. Delay| (0-3600)s| 3

29. Under Speed Warn

| (0-1)

0 Disabled

1 Enabled

| ****

0 Disabled

| ****

Under speed warning setting.

30. Set Value| (0-200)%| 90%
31. Return Value| (0-200)%| 92%
32. Delay| (0-3600)s| 3

33. Over Speed Shutdown

| (0-1)

0 Disabled

1 Enabled

| ****

1 Enabled

| ****

Over speed shutdown setting.

34. Set Value| (0-200)%| 115%
35. Delay| (0-3600)s| 1
36. Over Speed Warn| (0-1)| 1 Enabled| Over speed warning setting.
Parameter| Range| Default| Remarks
---|---|---|---
| 0 Disabled

1 Enabled

| |
37. Set Value| (0-200)%| 110%
38. Return Value| (0-200)%| 108%
39. Delay| (0-3600)s| 3
40. Speed Signal Lose Delay| (0-3600) s| 3| The time from that detecting speed is 0 to

confirm action.

41. Speed Signal Lose Action

| (0-2)

0: Warn

1: Shutdown

2: No Action

| ****

1: Shutdown

| ****

The action after detecting loss of speed.

42. Charge Alt Fail

| ****

(0-60.0)V

| ****

16.0

| After engine is normal running, controller will initiate an alarm when voltage of

charger falls below this limit.

43. Bat Rated Volt| (0-60.0)V| 24.0| Provide standard for judgment of over

voltage and under voltage.

44. Power 1 Over Volt| (0-200)%| 125%| Set value is percentage of power supply

rated voltage.

45. Power 1 Under Volt| (0-200)%| 75%
46. Power 2 Over Volt| (0-200)%| 125%| Set value is percentage of power supply

rated voltage.

47. Power 2 Under Volt

| ****

(0-200)%

| ****

75%

| The main interface won’t display voltage of power supply A and B when this value is set as 0. Main interface icon will show battery 1

voltage.

48. Heating Up Limit

| ****

(0-100)℃

| ****

42

| Open when temperature of water temperature sensor larger than pre-set

value.

49. Heat Down Limit| (0-100)℃| 37| Close when temperature of water

temperature sensor less than pre-set value.

50. Pre-lubrication Cycle Enable| (0-1)

0 Disabled

1 Enabled

| ****

0 Disabled

| It can circulate pre-lubrication for genset after setting enabled.
51. Pre-lubrication Interval| (0-7200)min| 300| It can set circulate period after circulate

pre-lubrication.

52. Pre-lubrication Time| (0-7200)s| 300| The time of each pre-lubrication.

53. Idle Set

| ****

(0-2000)r/min

| ****

700

| When the controller is speed regulating automatically, the controller needs a stable

rotate speed value.

54. Dead Band| (0-10.0)%| 1.0| ****

Relay automatic speed regulation setting. NOTE: as rated idle percent (in no working area idle); as rated speed percent (in high speed ).

55. Gain| (0-100)%| 10
56. Response| 0.25-4.00| 0.50
57. Stability| (0.05-1.60)s| 1.0
58. Speed Wire Break| (0-1)

0 Disabled

| 0 Disabled| It can detect engine speed sensor wire

break if enabled.

Parameter	Range	Default	Remarks
	1 Enabled
59. Device ID	(1-254)	1	RS485 Comm. Address.

60. Language Select

| (0-1)

0: Simplified Chinese

1: English

| ****

0: Simplified Chinese

| ****

Language selections.

61. Password Set| (0-65535)| 00318| Password of parameter setting.
62. DOUT16 Enable| (0-1)| 0 Disabled| If DOUT16 module is needed to expand, this

setting enabled is needed.

63. HMC6000RM Module

Enable

| (0-1)| 0 Disabled| If HMC6000RM module is needed to

expand, this setting enabled is needed.

64. RPU560A Enable| (0-1)| 0: Disabled| If RPU560A module is needed to expand,

this setting enabled is needed.

65. Expand Baud Set

| (0-1)

0: 250kbps

1: 125kbps

| ****

0: 250kbps

| ****

CANBUS port communication Baud rate.

66. HMP300 Module Enable

| (0-1)

0 Disabled

1 Enabled

| ****

0 Disabled

| If HMP300 module is needed to expand, this setting enabled is needed.
67. HMC9800RM Module Enable| (0-1)

0 Disabled

1 Enabled

| ****

0 Disabled

| If HMC9800RM module is needed to expand, this setting enabled is needed.

68. Self-check Type

| ****

(0-1)

0: Self-Check

Mode 1

1: Self-check

Mode 2

| ****

0: Self-check

Mode 1

| When self-check is set as 1, it can test alarm by connecting with corresponding sensor with no rotated speed after self-check is active; when self-check is set as 2, it can test alarm with system auto- regulating the sensor after self-check

is active.

69. Date & Time| | | Date &Time setting.

70. Water Temp. Sensor Set (Resistance input)

| See 8.3. Sensor functional configuration

NOTE: Resistance input

measuring range is not applicable.

| ****

Water temperature sensor setting.

71. Oil Temp. Sensor Set (Resistance input)

| See 8.3. Sensor functional configuration

NOTE: R Resistance input measuring range is not

applicable.

| ****

Oil temperature sensor setting.

72. Oil Pressure Sensor Set (Resistance/voltage/current input)

| See 8.3. Sensor functional configuration

NOTE: Resistance input measuring range is not

applicable.

| ****

Oil pressure sensor setting.

Parameter	Range	Default	Remarks

73. Flexible sensor 1 Set (Resistance/voltage/current input)

| See 8.3. Sensor functional configuration

NOTE: Resistance input

measuring range is not applicable.

| ****

Flexible sensor1 setting.

74. Flexible sensor 2 Set (Resistance/voltage/current input)

| See 8.3. Sensor functional configuration

NOTE: Resistance input measuring range is not

applicable.

| ****

Flexible sensor2 setting.

75. Flexible sensor 3 Set (Resistance/voltage/current input)

| See 8.3. Sensor functional configuration

NOTE: Resistance input measuring range is not

applicable.

| ****

Flexible sensor3 setting.

76. Input 1 Set| (0-50)| 18: Local

Mode

| See table 8.1.2.
77. Active type| (0-1)| 0: Close

Activate

| Set up input port active of close or open.
78. Input 2 Set| (0-50)| 19: Remote

Mode

| See table 8.1.2.
79. Active type| (0-1)| 0: Close

Activate

Activate

Activate

Activate

Activate

| Set up input port active of close or open.
88. Input 7 Set| (0-50)| 20: Remote

Start Input

| See table 8.1.2.
89. Active type| (0-1)| 0: Close

Activate

Activate

| Set up input port active of close or open.
92. Input 9 Set| (0-50)| 23: Override

Mode

| See table 8.1.2.
Parameter| Range| Default| Remarks
---|---|---|---
93. Active type| (0-1)| 0: Close

Activate

| Set up input port active of close or open.
94. Input 10 Set| (0-50)| 11: Fuel

Leakage Input

| See table 8.1.2.
95. Active type| (0-1)| 0: Close

Activate

always close.

always close output.

always close output.

always close output.

always close output.

always close output.

always close output.

always close output.

always close output.

always close output.

always close output.

always close output.

NOTE: The aux. input port 1~10 are corresponding with the input port A~J on the back plate of the controller.

NOTE: The aux. output port 1~12 are corresponding with the output port A~L on the back plate of the controller.

Parameter	Range	Default	Remarks

NOTE: The Flexible sensor 1~3 are corresponding with the sensor A~C on the back plate of the controller.

INPUT/OUTPUT PORT CONFIGURATION

A UXILIARY INPUT 1~10 FUNCTIONAL CONFIGURATION DIGITAL INPUT PORT CONFIGURATION
Table 9 Digital Input Port Definition

No.	Settings	Contents	Description
1	Feature Set	(0- 50)	See 8.1.2 Input Port Functions
2	Active type	(0-1)	0: Close Activate 1: Open Activate
3	Active Range	(0-3)	0: From Safety on 1: From Crank

2: Always 3: Never

characters

INPUT PORT FUNCTIONS
Table 10 Input Ports Function Definition

No.	Function	Description
0.	Not Used	Not used.
1.	Custom	Users configured input port settings.
2.	Alarm Mute	Can prohibit “Audible Alarm” output when it is active.
3.	Reset Alarm	Can reset all alarms when input is active.
4.	Pre-lubricate	If output is set as pre-lubrication output, the relay

disconnects

after the set pre-lubrication delay.

5.| Reserved|

| ****

Panel Lock

| All keys in panel is inactive except and when input is active.
7.| Quick Start| Cranking will start directly (without preheating) when the input

is active.

| ****

Remote Start/Stop

| Genset starts when active and stops when inactive.

NOTE: Only one of two start/stop control ways (remote start/stop input, and remote starts input and remote stop input) can be selected, and

cannot select at the same time.

| ****

Auto Mode IN

| When the input is active, enter into auto mode, the local mode and remote mode is inactive and start/stop can only be

achieved via input port.

10.| Turning Chain| Start inhibition when the input is active.
11.| Fuel Leakage Input| When the input active, alarm initiate if fuel leak occurs.
12.| Water Press. Low| Connect to digital input of sensor.
13.| Water Level Low| Connect to digital input of sensor.
14.| Oil Level Low| Connect to digital input of sensor.
15.| Water Temp. High IN| Connect to digital input of sensor.
No.| Function| Description
---|---|---
16.| Oil Temp. High IN| Connect to digital input of sensor.
17.| Oil Pressure Low IN| Connect to digital input of sensor.
18.| Local Mode IN| The genset is in local mode when active.
19.| Remote Mode IN| The genset is in remote mode when active.
20.| Remote Start Input| When remote start input is active in Remote Control Mode,

controller initiate start command.

21.| Stop Input| When stop input is active in Remote Control Mode or Auto Mode, controller initiate stop command.
22.| Auto Start Input| When auto start input is active in Auto Mode, controller initiate

start command.

23.| Override Mode| When override mode input is active, only over speed stop and emergency stop are available.
24~50| Reserved|

NOTE The name of the input ports 1~10 only can be configured via PC software.

OUTPUT PORT DEFINITION DIGITAL OUTPUT DEFINITION CONTENTS
Table 11 Digital Output Port Definition Content

No.	Items	Contents	Note
1	Output Function Configuration	(0-100)
2	Effective ways	0 Open 1 Close

3

| ****

Effective duration

| Bit1: Standby Bit2: Preheat Bit3: Fuel Output Bit4: Start

Bit5: Crank Rest Time Bit6: Safety Delay Bit7: Start Idle

Bit8: High Speed Warm Up Bit9: Wait to Load

Bit10: Normally Working Bit11: Cooling

Bit12: Stop Idle Bit13: ETS

Bit14: Wait for Stop

Bit15: Fail to Stop

|
5| Delay output time| (0-100.0)s|
6| Output time| (0-3600)s|

OUTPUT PORT 1 12 FUNCTION DEFINITION
Table 12 Output Port 112 Function Definition

No.	Items	Description
0.	Not Used	This port is not used.
1.	Custom	See Table 11.
2.	Air Flap	Action when over speed shutdown and emergence stop. Air flap

can be closed.

No.	Items	Description

| ****

Audible Alarm

| Action when warning and shutdown. It can be connected

enunciator externally. When “alarm mute” configurable input port is active, it can remove the alarm.

4.| Crank Output| Action when genset is starting and disconnect when crank

success.

5.| Fuel Output| Action when genset is starting and disconnect when stop is

completed.

is 0.

10.| Pre-lubricate| The controller output when the engine is in standby mode

(user-defined output delay) if pre-lubrication input is active.

| ****

Idle Control

| Action from “crank delay” to “start idle delay” and from “stop idle delay” to “wait for stop delay”. When in local mode, idle control is

unavailable.

15.| Common Alarm| Action when genset common warning and common shutdown

alarms occur.

speed less than 100r.

25.| Normal Running Output| The engine outputs when the speed over 85% of rated

requirements, stops when less than 75% of rated requirements.

DOUT16. (3s overtime)

30.| Shutdown Output| The controller output when it is shutdown mode.
31.| Power 1 Under Volt| Action when the controller detects that the power 1 voltage has

fallen below the set value.

32.| Power 1 Over Volt| Action when the controller detects that the power 1 voltage has

exceeded the set value.

No.	Items	Description
33.	Under Speed Warn	Action when under speed warning.
34.	Under Speed Stop	Action when under speed shutdown alarm.
35.	Over Speed Warn	Action when over speed warning.
36.	Over Speed Stop	Action when over speed shutdown alarm.
37.	Emergency Stop	Action when emergency stop alarm.
38.	Charge Alt Fail	Action when charge failure warning.
39.	Failed to Start	Action when failed start alarm.
40.	Failed to Stop	Action when failed stop alarm.
41.	Reserved
42.	Water Temp. Open	Action when water temperature sensor is open circuit.
43.	Water Temp. High Warn	Action when high water temperature sensor warning

RPU560A safeguard module. (3s overtime)

59.| RPU560A Power 1 Fault| Security module output when power1 fault.
60.| RPU560A Power 2 Fault| Security module output when power2 fault.

| ****

Raise Speed

| When the controller is in idle mode, if speed doesn’t arrive at rated idle, it will output when speed is rising and auto disconnect when speed arrives at rated idle.

When the controller is hi-speed running, if speed doesn’t arrive at rated rotate speed, it will output when speed is rising and auto disconnect when speed arrives at rated speed.

NOTE: Active only when controller is in remote/auto mode.

| ****

Drop Speed

| When the controller is in idle mode, if speed exceeds rated idle, it will output when speed is dropping and auto disconnect when speed arrives at rated idle.

When the controller is hi-speed running, if speed exceeds rated rotate speed, it will output while speed is dropping and auto disconnect when speed arrives at rated speed.

NOTE: Active only when controller is in remote/auto mode.

63.| Sensor 3 Open| Action when Flexible sensor 3 is open circuit.
No.| Items| Description
---|---|---
64.| Sensor 3 Warn| Action when Flexible sensor 3 warning alarm.
65.| Sensor 3 Shutdown| Action when Flexible sensor 3 shutdown alarm.
66.| Fuel Leakage| Output when this alarm is active.
67.| Power 2 Under Volt| Output when the controller detects power 2 voltage is lower than

set value.

68.| Power 2 Over Volt| Output when the controller detects power 2 voltage is upper than

set value.

69.| Lamp Test Output| Output while lamp testing.
70.| Over Speed Shutdown

(Redundant Protection)

| Output after RPU560 module is over speed and shuts down.
71.| Input Port 1 Shutdown

(Redundant Protection)

| Output after input port 1 of RPU560 module is shutdown.
72.| Input Port 2 Shutdown

(Redundant Protection)

| Output after input port 2 of RPU560 module is shutdown.
73.| Input Port 3 Shutdown

(Redundant Protection)

| Output after input port 3 of RPU560 module is shutdown.
74.| Input Port 4 Shutdown

(Redundant Protection)

| Output after input port 4 of RPU560 module is shutdown.
75.| Alarm Flash| Output when there is alarm. When another alarm occurs, output

after alarm indicator flashing disconnected for 2s.

76.| Reserved| Reserved

| ****

Fault Shutdown

| In addition to “Emergency Shutdown Alarm” and “Redundant

Protection Emergency Shutdown Alarm”, output when there is other shutdown alarm.

| ****

Power Failure

| The power failure outputs when the voltage of Power 1 or Power 2 is lower than 5V. This alarm will not occur when the under voltage alarm of Power 1 or Power 2 is set as 0% and the voltage

is less than 5V.

79~

100

| Reserved| Reserved

SENSOR FUNCTIONAL CONFIGURATION SENSOR CONFIGURATION
Table 13 Controller Sensor Configuration

No.	Settings	Contents	Remarks

| ****

Sensor type

| (0-3)

0: Not Used

1: Oil Pressure Sensor 2: Temperature Sensor 3: Fuel Level Sensor

| Types such as “Water Temperature Sensor”, “Oil Temperature Sensor”, and “Oil Pressure Sensor” are not optional and are fixed temperature or

pressure.

has exceeded the set value.

No.	Settings	Contents	Remarks

| ****

Range

| ****

(0-6000)

| Active when current of sensor is between (4~20)mA. Corresponding unit of pressure sensor is kPa; Corresponding unit of level sensor

is %.

| ****

Display Units

| Temperature 0: ºC

1: ºF

Pressure 0: kPa

1: bar

2: psi

Fuel level unit fixed as “%”

| ****

The units displayed on LCD. After selection of units, the displayed data will automatically convert according to units.

| ****

High Shutdown Enable

| (0-1)

0: Enable

1: Disable

|
7.| Set Value| (0-6000)|
8.| Delay| (0-3600)s|

| ****

Low Shutdown Enable

| (0-1)

0: Enable

1: Disable

|
10.| Set Value| (0-4000)|
11.| Delay| (0-3600)s|

| ****

Sensor High Warn Enable

| (0-1)

0: Enable

1: Disable

|
13.| Set Value| (0-6000)|
14.| Return Value| (0-6000)|
15.| Delay| (0-3600)s|

| ****

Low Warn Enable

| (0-1)

0: Enable

1: Disable

|
17.| Set Value| (0-4000)|
18.| Return Value| (0-4000)|
19.| Delay| (0-3600)s|
20.| First Point X (Resistance)| Resistance type (not PT100)| ****

Sensor curve is user-defined X axis: 8

Y axis: 8.

21.| Second Point X

(Resistance)

| Resistance type (not PT100)
22.| Third Point X (Resistance)| Resistance type (not PT100)
23.| Fourth Point X

(Resistance)

(Resistance)

| Resistance type (not PT100)
27.| Eighth Point X| Resistance type (not PT100)
No.| Settings| Contents| Remarks
---|---|---|---
| (Resistance)| |
28.| First Point Y (Value)| Resistance type (not PT100)
29.| Second Point Y (Value)| Resistance type (not PT100)
30.| Third Point Y (Value)| Resistance type (not PT100)
31.| Fourth Point Y (Value)| Resistance type (not PT100)
32.| Fifth Point Y (Value)| Resistance type (not PT100)
33.| Sixth Point Y (Value)| Resistance type (not PT100)
34.| Seventh Point Y (Value)| Resistance type (not PT100)
35.| Eighth Point Y (Value)| Resistance type (not PT100)
36.| User-defined String| User-defined sensor names| Only can be set via upper computer

software.

TEMPERATURE CURVES
Table 14 Temperature Curve List

No.	Contents	Remarks
0	Not Used	****

The input range of user-defined resistance is between (0-1000)Ω. The factory defaults of water temperature sensor and oil temperature sensor are PT100 sensors.

1| PT100
2| Custom Resistance Curve
3| VDO
4| CURTIS
5| VOLVO-EC
6| DATCON
7| SGX
8| SGD
9| SGH
10| Reserved
11| Cu50
12| Reserved
13| Reserved
14| Reserved
15| Reserved

NOTE: PT100 Resistance type temperature sensor division value is fixed set as 0.385 (0.385Ω corresponds to 1ºC).
PRESSURE CURVES
Table 15 Pressure Curve List

No.	Contents	Remarks
0	Not Used	****

The input range of User-defined resistance is between (0-1000)Ω. The factory default of oil pressure sensor is (4-20)mA sensor.

FUEL LEVEL CURVES
Table 16 Fuel Level Curve List

No.	Contents	Remarks
0	Not Used	****

The default of sensor type doesn’t have fuel level sensor. Please chose one of Flexible sensor 1/2/3 to use if need to.

PARAMETER SETTING

MATTERS NEEDED ATTENTION

Press the button for 1 second after start the controller, and then enter into parameter configuration and controller info selection menu, in which enter parameter configuration menu needs to input correct password. The default password is 00318. Please contact with manufacturer when forgets the password or need to correct the resistance/current/voltage value.

Please modify the controller internal parameters in standby mode(such as starting successfully condition selections auxiliary inputs 、 output port configuration time delay, etc) otherwise the alarm stop or other abnor mal phenomena may occur.
High sensor alarm threshold value must be bigger than the low alarm threshold, otherwise they will both issue alarm simultaneously.
Over speed threshold value must be bigger than under speed threshold, otherwise there will be eithe r overspeed or underspeed simultaneously.
When setting the condition of successful start, the start speed threshold value is supposed to be set lower as possible for quick disconnection of starter.
Auxiliary input port 1 10 cannot be set to the same projec t, otherwise correct function cannot arrive. Auxiliary output port 1 12 can be set to the same project.

SENSOR SETTING CLARIFICATION

When reselect the sensors, the standard value of the selected sensor will be selected. If temperature sensor default is set to PT100, sensor curve will be the curve of PT100. If it is set to SGD (120ºC resistance), sensor curve will be the curve of SGD.
If standard sensor curve is mismatching with sensor in using, “User defined sensor “could be chosen, then input user defined sensor curve.
When inputting sensor curve, X (resistance) must be input in accordance with the order of growing up, otherwise mistakes will occur.
Can set ordinate of front several points or last several points to the same. As shown in below:

Table 17 Normal Pressure Unit Conversion

	N/m2 Pa	kgf/cm2	bar	psi
1Pa	1	1.02×10－5	1×10－5	1.45×10－4
1kgf/cm2	9.8×104	1	0.98	14.2
1bar	1×105	1.02	1	14.5
1psi	6.89×103	7.03×10－2	6.89×10－2	1

BACK PANEL

$SmartGen-HMC6000A-Diesel-Engine-Controller-FIG-1 $11$$

Fig.3 HMC6000A Controller Back Panel
Table 18 Terminal Connection Description $SmartGen-HMC6000A-Diesel- Engine-Controller-FIG-1 $12$$ $SmartGen-HMC6000A-Diesel-Engine-Controller-FIG-1 $13$$

Icon	No.	Function	Cable Size	Description
42.	Start (G)	0.5mm2	Digital input 7

Default Set: Remote start input

43.| Stop (H)| 0.5mm2| Digital input 8

Default Set: Stop input

44.| Aux. Input1 (A)| 0.5mm2| User configure

Default Set: Local Mode input

45.| Aux. Input2 (B)| 0.5mm2| User configure

Default Set: Remote Mode input

46.| Override (I)| 0.5mm2| Digital input 9

Default Set: Override input

47.| Fuel Leakage (J)| 0.5mm2| Digital input 10

Default Set: Fuel leakage input

inside

Power A

Input

| 53.| B1-| 1.0mm2| Power supply A negative pole
54.| B1+| 1.0mm2| Power supply A positive pole
Power B

Input

| 55.| B2-| 1.0mm2| Power supply B negative pole
56.| B2+| 1.0mm2| Power supply B positive pole

RS485

| 57.| RS485-(B)| 0.5mm2| PC programming and monitoring port (isolation type). Its single end earthed
58.| RS485+(A)| 0.5mm2
59.| RS485 Shield Ground| 0.5mm2

CANBUS (ECU)

| 60.| CAN(L)

(ECU)

| 0.5mm2| ****

Used for connect to ECU of engine with J1939 interface. If connect CAN(L) to 120Ω, then there is no need to external connect 120Ω resistor

61.| CAN(H)

(ECU)

| 0.5mm2
62.| 120Ω

(ECU)

software

NOTE: It is strictly prohibited to take out start battery when the engine is running. Failure to do so can create excessive DC input voltage and result in damage of destruction of equipment!

COMMUNICATION AND CONNECTION

RS485 AND LINK COMMUNICATION
HMC6000A genset controller has RS485 port and Link port which allows the controller to connect to op en type LAN. RS485 and Link applies ModBus communication protocol with the help of PC or DAS (Data Acquisition Systems) operational software provides easy to use marine engine monitoring system management scheme and enables remote control, remote measureme nt and remote communication.
CANBUS (EXPANSION) BUS COMMUNICATION
Various expansion modules can be connected to the controller via CANBUS (EXPANSION) port.

DOUT16 Digital output module : The module connects to the main controller via CANBUS port.
ain contr oller transfers the output condition data of digital output module to module to handle via CANBUS. All parameters of digital output port can be configured via main controller.
HMC6000RM Remote control module: Remote control module can achieve control oper ations such as starting engine, stopping engine, etc. All kinds of parameters and records of the engine real time display on remote controller.
RPU560A Security module: The module connects to the main controller via CANBUS port. If security module receive s 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.
- NOTE : Remote control module can only be used in remote mode of the engine; in local mode remote control module only can check parameters and records but not control the engine. $SmartGen-HMC6000A-Diesel-Engine-Controller-FIG-1 $15$$

CANBUS (EXU) COMMUNICATION
A large number of J1939 engines can be controlled by the controller via CANBUS ( ECU ) port. Besides, at the same time users also can connect expansion module which makes it convenient and su itable for different working environments.
CUMMINS ISB/ISBE
Table 19 Fuel Start Wiring Connection

Terminals of controller	Connector B	Remarks
Fuel relay output	39
Start relay output	–	Connect to starter coil directly.
Programmable output port 1	Expand 30A relay, battery voltage of

terminal 01, 07, 12,

13 are supplied by relay.

| ECU power; set programmable output 1 as “ECU power”.

Table 20 9 Pin Connector Wiring Connection

Terminals of controller	9 pin connector	Remarks
CAN(H) (ECU)	SAE J1939 signal	Impedance 120Ω connecting line is

recommended.

CAN(L) (ECU)| SAE J1939 return| Impedance 120Ω connecting line is

recommended.

Engine type: Cummins ISB
CUMMINS QSL9
Compatible with CM850 engine controller module.
Table 21 Fuel Start Wiring Connection

Terminals of controller	50 pin connector	Remark
Fuel relay output	39
Start relay output	–	Connect to starter coil directly.

Table 229 Pin Connector Wiring Connection

Terminals of controller	9 pin connector	Remark
CAN(H) (ECU)	SAE J1939 signal-C	Impedance 120Ω connecting line is

recommended.

CAN(L) (ECU)| SAE J1939 return-D| Impedance 120Ω connecting line is

recommended.

CUMMINS QSM11
Compatible with CM750 engine controller module. Engine types: QSM11 G1, QSM11 G2
Table 23 Fuel Sta rt Wiring Connection

Terminals of controller	C1 connector	Remark
Fuel relay output	5&8
Start relay output	–	Connect to starter coil directly.

Table 243 Pin Connector Wiring Connection

Terminals of controller	3 pin data link connector	Remark
CAN(H) (ECU)	A	Impedance 120Ω connecting line is

recommended.

CAN(L) (ECU)| B| Impedance 120Ω connecting line is

recommended.

Engine type: Cummins ISB
DETROIT DIESEL DDEC III/IV
Table 25 Engine Wiring Connection

Terminals of controller	Engine CAN port	Remark

Fuel relay output

| Expand 30A relay; battery

voltage of ECU is supplied by relay

recommended.

recommended.

| connecting| line| is

Engine type: Common J1939
DEUTZ EMR2
Table 26 Engine Wiring Connection

Terminals of controller	F connector	Remark

Fuel relay output

| Expand 30A relay, battery

voltage of terminal 14 is supplied by relay. Fuse is 16A.

|
Start relay output| –| Connect to starter coil directly.
–| 1| Connect to battery negative.
CAN(H) (ECU)| 12| Impedance 120Ω

recommended.

recommended.

| connecting| line| is

JOHN DEERE
Table 27 Engine Wiring Connection

Terminals of controller	21 pin connector	Remark
Fuel relay output	G, J
Start relay output	D
CAN(H) (ECU)	V	Impedance 120Ω connecting line is

recommended.

CAN(L) (ECU)| U| Impedance 120Ω connecting line is

recommended.

Engine type: John Deere
MTU MDEC
Compatible with MTU 2000 and 4000 series engines.
Table 28 Engine Wiring Connection

Terminals of controller	X1 connector	Remark
Fuel relay output	BE1
Start relay output	BE9
CAN(H)(ECU)	G	Impedance 120Ω connecting line is

recommended.

CAN(L)(ECU)| F| Impedance 120Ω connecting line is

recommended.

Engine type: MTU MDEC 303
PERKINS
Compatible with ADEM3/ ADEM4 engine control modules. Engine types: 2306, 2506, 1106, and 2806.
Table 29 Engine Wiring Connection

Terminals of controller	Connector	Remark
Fuel relay output	1, 10, 15, 33, 34
Start relay output	–	Connect to starter coil directly
CAN(H) (ECU)	31	Impedance 120Ω connecting line is

recommended.

CAN(L) (ECU)| 32| Impedance 120Ω connecting line is

recommended.

SCANIA
Compatible with S6 engine control module.
Engines: DC9, DC12, DC16.
Table 30 Engine Wiring Connection

Terminals of controller	B1 connector	Remark
Fuel relay output	3
Start relay output	–	Connect to starter coil directly.
CAN(H) (ECU)	9	Impedance 120Ω connecting line is

recommended.

CAN(L) (ECU)| 10| Impedance 120Ω connecting line is

recommended.

Engine type: Sca nia
VOLVO EDC3
Compatible with such engines as TAD1240, TAD1241, and TAD1242.
Table 31 Fuel Start Wiring Connection

Terminals of controller	“Stand alone” connector	Remark
Fuel relay output	H
Start relay output	E

Auxiliary output 1

| ****

P

| Set auxiliary output 1 as “Preheating until cranking” and set preheating time

as 5 seconds.

Table 32 CANBUS Wiring Connection

Terminals of controller	“Data bus” connector	Remark
CAN(H) (ECU)	1	Impedance 120Ω connecting line is

recommended.

CAN(L) (ECU)| 2| Impedance 120Ω connecting line is

recommended.

VOLVO EDC4
Compatible engine types are TD520, TAD520 (optional), TD720, TAD720 (optional), TAD721, and TAD722.
Table 33 Engi ne Wiring Connection

Terminals of controller	Connector	Remark

Fuel relay output

| Expand 30A relay, battery volt of terminal 14 is supplied by relay.

Fuse is 16A.

|
Start relay output| –| Connect to starter coil directly.
| 1| Connect to battery negative.
CAN(H) (ECU)| 12| Impedance 120Ω

recommended.

recommended.

| connecting| line| is

Engine type: Volvo EDC4
VOLVO EMS2
Compatible with the following Volvo engines: D9、D13、D16、EMS
Table 34 Engine Wiring Connection

Terminals of controller	Engine CAN port	Remark

Auxiliary output 2

| ****

5

| ECU power supply

Set auxiliary output 2 as “ECU Power Supply”.

CAN(H) (ECU)| 1(CAN H)| Impedance 120Ω

recommended.

recommended.

| connecting| line| is
Input ports can be set with speed control function, auxiliary input port 1 can be set as speed up input,

and auxiliary input port 2 can be set as speed down input. After the normal running, raise/drop speed functions can be achieved by digital input ports.

Engine type: Volvo EMS2
BOSCH
Compatible with BOSCH common rail electronic engines.
Table 35 Engine Wiring Connection

Terminals of controller	42 pin engine port	Remark
Fuel relay output	1.40	Connect to engine ignition switch.
Start relay output	–	Connect to starter coil directly.
CAN(H) (EXPANSION)	1.35	Impedance 120Ω connecting line is

recommended.

CAN(L) (EXPANSION)| 1.34| Impedance 120Ω connecting line is

recommended.

POWER WIRING CONNECTION
Table 36 Power Wiring Conne ction

Battery	2 pin engine port	Remark
Battery negative	1	Wire size: 2.5mm2
Battery positive	2	Wire size: 2.5mm2

Engine type: BOSCH
Please contact us if you have any questions about controller and ECU connection.
HMC6000A APPLICATION DIAGRAM $SmartGen-HMC6000A-Diesel-Engine-Controller- FIG-1 $16$$

COMMISSIONING

Doing the following check before the system starting to run formally is recommended:

Ensure all the connections are correct and wires diameter is suitable;
Ensure that the controller DC power has fuse, controller’s positive and negative c onnected to start battery are correct;
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;
Make the local mode active and then the controller enter s int o local mode. Press the Start button and the engine will start. If fail to start, genset will enter into ETS status automatically;
Recover the action to prevent engine to crank success e. g. Connect wire of fuel valve), press start button again, and the en gine will start. The engine will run from idle to formal if all works regularly.
During this time, please watch the running status. If abnormal, stop engine and check all wires connection according to this manual;
If there is any other question, please con tact SmartGen’s service.

INSTALLATION

FIXING CLIPS
Contr

is panel built in design; it is fixed by clips when installed.

Withdraw the fixing clip screw (turn anticlockwise) until it reaches proper position;
Pull the fixing clip backwards (towards the back of the module) ensuring four clips are inside their allotted slots;
Turn the fixing clip screws clockwise until they are fixed on the panel.
- NOTE: Care should be taken not to over tighten the screws of fixing clips.

OVERALL DIMENSIONS AND CUTOUT DIMENSIONS $SmartGen-HMC6000A-Diesel-Engine- Controller-FIG-1 $18$$

INSTALLATION CAUTIONS

BATTERY VOLTAGE INPUT
HMC6000A controller can suit for widely range of battery voltage DC (8~35) V. Negative of battery mus t be connected with the engine shell. The diameter of wire which is from power supply to battery must be over 2.5mm 2 . If floating charge configured, please firstly connect output wires of charger to battery’s positive and negative directly, then, connect w ires 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.
SPEED SENSOR INPUT
Speed sensor is magnetic equipment which is installed on engine body for t esting flywheel teeth number. 2 core shielding wire is used for the connection of the sensor and controller. The wire is supposed to be connected to terminal 32 of controller with one end and the other end hanging in the air. The other two signal lines con nect separately to terminal 31, 32 . Speed sensor output voltage is supposed to be at AC (1 24) V (virtual value) when it is in full speed range, and AC12V (when in rated rotate speed) is recommended. When install the speed sensor, screw it to contact the f lywheel firstly, inverse it with 1/3 circle, and then tighten the nut finally.
OUTPUT AND EXPANSION RELAY
All outputs of controller are relay contact output type. If expansion relays are needed, please addfreewheel diode to both ends of expansion relay’s coils (when coils of relay ha ve DC current) or add resistance capacitance return circuit (when coils of relay ha ve AC current), in order to prevent charge disturbing the controller or others equipment.
SENSOR INPUT
All oil pressure sensor, auxiliary sensor 1, auxiliary sensor2 and auxiliary sensor3 of HMC6000A can be configured to current/power/resistance sensor (jumper switch over is as below). Water temperature sensor and oil temperature sensor is fixed resistor sensor.

Table 37 Wire Jumper List

Sensors	Jumper Hat	Resistor (Jumper)	Voltage (Jumper)	Current (Jumper)
OP Sensor	J3, J7	Connect to term.1,2 of J3	Connect to J7	Connect to

WITHSTAND VOLTAGE TEST
When controller has been installed in control panel, if need the high voltage test, please disconnect controller’s all terminals in order to prevent high voltage into contr oller and damage it.

TROUBLESHOOTING

Table 38 Troubleshooting

Problem	Possible Solution
Controller no response with power.	Check starting batteries;

Check controller connection wirings;

Check DC fuse.

Genset shutdown| Check the water/cylinder temperature is too high or not.
Emergency shutdown| Check emergency shutdown button function.
Low oil pressure alarm after

engine has fired.

| Check oil pressure sensor and wiring.
High water temperature alarm

after engine has fired.

| Check water temperature sensor and its wiring.
Shutdown alarm when engine is running| Check relevant switch and its wiring according to the information on LCD;

Check auxiliary digital input port.

Fail to start

| Check fuel return circuit and its wiring; Check starting battery;

Check speed sensor and its wiring;

Consult engine manual.

Starter no respond| Check starter wiring;

Check start battery.

RS485 communication failure

| Check wiring;

Check if COM port setting is right;

Check if RS485 A and B wires are connected in the opposite way; Check if PC communication port is damaged;

Putting a 120Ω resistance between RS485 A and B is recommended.

CANBUS communication failure

| Check wiring;

Check if CANBUS CANH and CANL wires are connected in the opposite way;

Check if CANBUS CANH and CANL wires at both ends are connected in the opposite way;

Putting a 120Ω resistance between CANBUS CANH and CANL is

recommended.

HMC6000A Diesel Engine Controller User Manual

CONTACT

Registered trademark

No. 28 Xuemei Street , Zhengzhou, Henan China
Tel: +86-371-67988888/67981888/67992951
+86-371-67981000(overseas)
Fax: +86-371-67992952
Web: www.smartgen.com.cn
www.smartgen.cn
Email: sales smartgen.cn
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.
SmartGen reserves the right to change the contents of this document without prior notice.

Table 1 Version History

Date	Version	Content
2016-07-06	1.0	Original release;
2016-11-10	1.1	Change input port fixed function to programmable function;
2017-01-10	1.2	Add output port function-lamp test function;
2019-02-28	1.3	Add CANBUS Communication.
2019-05-25	1.4	Fix front foil drawing.
2020-05-14	1.5	Change module setting contents