SmartGen HMC4000 Marine Genset Control Module User Manual

HMC4000 Marine Genset Control Module

Specifications

• Model: HMC4000 Marine Genset Controller

• Input: 3

• Output: 6

• Sensor: 4

• Functions: Genset automation and monitor control system, remote
  start/stop, data measurement, alarm protection

• Interface: LCD display, optional languages interface (Chinese
  and English)

Product Usage Instructions

1. Overview

The HMC4000 marine genset controller integrates digitization,
intelligentization, and network technology for genset automation
and monitor control system of a single unit. It enables remote
start/stop, data measurement, alarm protection, and other
functions. The controller features an LCD display with optional
languages, making it reliable and easy to use.

2. Model Comparison

The HMC4000 is available in different models:

• HMC4000MPU: Speed collected by head sensor
• HMC4000CAN: Speed collected by J1939 CANBUS
• HMC4000RM: Remote monitoring control module to control MPU or
  CAN models remotely

3. Performance and Characteristics

• 132×64 LCD with backlight and selectable language interface
  (Chinese and English)

• Hard-screen acrylic material for screen protection

• Silicone panel and pushbuttons suitable for extreme temperature
  environments

• CANBUS port for communication with J1939 gen-set

• RS485 communication interface for connecting remote control
  modules

• Override mode for over speed shutdown and emergency
  shutdown

FAQ

Q: Can I configure all parameters from the front panel?

A: Yes, all parameters can be configured from the front panel or
through a USB interface via PC.

Q: What languages are available in the interface?

A: The interface supports Chinese and English languages.

Q: How can I remotely control engine start/stop?

A: You can use the remote control modules connected through the
RS485 communication interface for easy and convenient remote
control of engine start/stop.

HMC4000 MARINE GENSET CONTROLLER
USER MANUAL

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.

Date 2017-08-29 2021-10-13 2022-10-14
2023-12-05

Table 1 Software Version

Version 1.0 1.1 1.2
1.3

Note Original release. Modify the IP protection level. Update company logo and manual format. Add RS485 baud rate and stop bit in contents and ranges of parameter setting.

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CONTENTS

1 OVERVIEW………………………………………………………………………………………………………………………………….5 2 MODEL COMPARISON ………………………………………………………………………………………………………………..5 3 PERFORMANCE AND CHARACTERISTICS ……………………………………………………………………………………5 4 SPECIFICATION ………………………………………………………………………………………………………………………….7 5 OPERATION ……………………………………………………………………………………………………………………………….8 6 SCREENS DISPLAY……………………………………………………………………………………………………………………..9 7 CONTROLLER PANEL AND OPERATION …………………………………………………………………………………… 10
7.1 CONTROLLER PANEL ……………………………………………………………………………………………………….. 10 7.2 REMOTE START/STOP OPERATION…………………………………………………………………………………… 11
7.2.1. ILLUSTRATION…………………………………………………………………………………………………………… 11 7.2.2. REMOTE START SEQUENCE……………………………………………………………………………………….. 11 7.2.3. REMOTE STOP SEQUENCE…………………………………………………………………………………………. 11 7.3 AUTO START/STOP ………………………………………………………………………………………………………….. 12 7.3.1. ILLUSTRATION…………………………………………………………………………………………………………… 12 7.3.2. AUTO START SEQUENCE……………………………………………………………………………………………. 12 7.3.3. AUTO STOP SEQUENCE ……………………………………………………………………………………………… 12 7.4 LOCAL START/STOP SEQUENCE……………………………………………………………………………………….. 13 7.4.1. ILLUSTRATION…………………………………………………………………………………………………………… 13 7.4.2. LOCAL START SEQUENCE ………………………………………………………………………………………….. 13 7.4.3. LOCAL STOP SEQUENCE ……………………………………………………………………………………………. 13 8 PROTECTION ………………………………………………………………………………………………………………………….. 14 8.1 WARNINGS ………………………………………………………………………………………………………………………. 14 8.2 SHUTDOWN ALARM …………………………………………………………………………………………………………. 16 9 WIRINGS CONNECTION …………………………………………………………………………………………………………… 19 10 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS…………………………………………….. 21 10.1 CONTENTS AND SCOPES OF PARAMETERS………………………………………………………………………. 21 10.2 DEFINED CONTENTS OF DIGITAL OUTPUT PORTS 1~5………………………………………………………. 29 10.2.1. DEFINED CONTENTS OF DIGITAL OUTPUT PORTS…………………………………………………….. 29 10.2.2. FUNCTION DEFINITION OF OUTPUT PORTS 1-5 ………………………………………………………… 29 10.3 DEFINED CONTENTS OF DIGITAL INPUT PORTS 1-5…………………………………………………………… 32 10.3.1. DEFINED CONTENTS OF DIGITAL INPUT PORTS ……………………………………………………….. 32 10.3.2. DEFINED CONTENTS OF DIGITAL INPUT PORTS 1-5 ………………………………………………….. 32 10.4 SELECTION OF SENSORS ………………………………………………………………………………………………….. 34 10.4.1. SENSORS SETTING ………………………………………………………………………………………………….. 34 10.4.2. TEMPERATURE CURVE LIST …………………………………………………………………………………….. 35 10.4.3. PRESSURE CURVE LIST ……………………………………………………………………………………………. 36 10.4.4. LEVEL CURVE LIST …………………………………………………………………………………………………… 36 10.5 SELECTION OF CRANK DISCONNECT CONDITIONS……………………………………………………………. 37 11 PARAMETERS SETTING ………………………………………………………………………………………………………… 38 11.1 CONTROLLER PARAMETER SETTING ………………………………………………………………………………… 38 11.2 CONTROLLER INFORMATION ……………………………………………………………………………………………. 38 11.3 EVENT LOG ………………………………………………………………………………………………………………………. 38

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12 SENSOR SETTING …………………………………………………………………………………………………………………. 39 13 COMMISSIONING ………………………………………………………………………………………………………………….. 40 14 TYPICAL APPLICATION …………………………………………………………………………………………………………. 41 15 INSTALLATION ……………………………………………………………………………………………………………………… 43
15.1 FIXING CLIPS ……………………………………………………………………………………………………………………. 43 15.2 OVERALL AND CUTOUT DIMENSIONS ……………………………………………………………………………….. 43 15.3 WIRE CONNECTION INSTRUCTION ……………………………………………………………………………………. 43 16 CONNECTIONS OF CONTROLLER WITH J1939 ENGINE ………………………………………………………….. 44 16.1 CUMMINS ISB/ISBE ………………………………………………………………………………………………………….. 44 16.2 CUMMINS QSL9 ……………………………………………………………………………………………………………….. 44 16.3 CUMMINS QSM11 (IMPORT) …………………………………………………………………………………………….. 45 16.4 CUMMINS QSX15-CM570………………………………………………………………………………………………….. 45 16.5 CUMMINS GCS-MODBUS ………………………………………………………………………………………………….. 46 16.6 CUMMINS QSM11…………………………………………………………………………………………………………….. 46 16.7 CUMMINS QSZ13 ……………………………………………………………………………………………………………… 47 16.8 DETROIT DIESEL DDEC III/IV ……………………………………………………………………………………………… 47 16.9 DEUTZ EMR2 ……………………………………………………………………………………………………………………. 47 16.10 JOHN DEERE ………………………………………………………………………………………………………………….. 48 16.11 MTU ADEC (SAM MODULE) …………………………………………………………………………………………….. 48 16.12 PERKINS ………………………………………………………………………………………………………………………… 48 16.13 SCANIA ………………………………………………………………………………………………………………………….. 49 16.14 VOLVO EDC3 ………………………………………………………………………………………………………………….. 49 16.15 VOLVO EDC4 ………………………………………………………………………………………………………………….. 49 16.16 VOLVO- EMS2………………………………………………………………………………………………………………….. 50 16.17 YUCHAI ………………………………………………………………………………………………………………………….. 50 16.18 WEICHAI…………………………………………………………………………………………………………………………. 51 17 FAULT FINDING …………………………………………………………………………………………………………………….. 51

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1 OVERVIEW

HMC4000 marine genset controller integrate digitization, intelligentization and network technology which are used for genset automation and monitor control system of single unit to achieve remote start/stop, data measurement, alarm protection and other functions. It fit with LCD display, optional languages interface (Chinese and English), and it is reliable and easy to use.
HMC4000 marine genset controller adopts 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 USB interface via PC. It can be widely used in all types of marine genset control automation system with compact structure, advanced circuits, simple connections and high reliability.

2 MODEL COMPARISON

Table 2 Model Comparison

Model

Input Output

Sensor

Function Gen RS485 Head CANBUS

Remark

HMC4000MPU

3

6

4

HMC4000CAN

3

6

4

HMC4000RM

0

0

0

–

NOTE:

HMC4000MPU speed is collected by head sensor.

HMC4000CAN speed is collected by J1939 CANBUS.

HMC4000RM is remote monitoring control module, and it is can remotely control HMC4000MPU or HMC4000CAN.

3 PERFORMANCE AND CHARACTERISTICS

Main features as follows:

132×64 LCD with backlight, selectable language interface (Chinese and English), push-button

operation.

Hard-screen acrylic material been used to protect screen with great wear- resisting and

scratch-resisting functions.

Silicone panel and pushbuttons can be used in extreme temperature environment.

Equipped with CANBUS port and can communicate with J1939 gen-set.

RS485 communication interface can connect with remote control modules. In remote control mode,

it is easy and convenient to remote control engine start/stop (local start/stop keys are deactivated).

With override mode: in this mode, only over speed shutdown and emergency shutdown can stop the

engine.

Suitable for 3-phase 4-wire, 3-phase 3-wire, single phase 2-wire, and 2-phase 3-wire systems with

voltage 120V/240V and frequency 50Hz/60Hz;

Collects and shows 3-phase voltage, 3-phase current, power parameter and frequency of generator.

Generator

Line voltage (Uab, Ubc, and Uca)

Phase voltage (Ua, Ub, and Uc)

Frequency Hz

Load

Current Ia, Ib, Ic

A (unit)

Each phase and total active power P

kW (unit)

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Each phase and reactive power Q

kvar (unit)

Each phase and average power factor PF

Precision measure and display parameters about Engine.

Temp. (WT)

°C/°F both be displayed

Oil Pressure (OP)

kPa/psi/bar all be displayed

Fuel Temp

°C/°F

Speed (RPM)

r/min (RPM)

Voltage of Battery

V (unit)

Voltage of Charger V (unit)

Hour count accumulation

Start times accumulation

Electric energy accumulation

Protection: real-time monitor and control diesel generator-set running status, and any faults occur it

will shutdown in time and record alarms.

Parameter setting: parameters can be modified and stored in internal FLASH memory and cannot

be lost even in case of power outage; most of them can be adjusted using front panel of the

controller and also can be modified using PC via USB port.

With multiplex input port 4 and 5. Input port 4 can be configured as discrete input port or sensor

input (default as oil temperature sensor); input port 5 can be set as discrete input port or

programmable sensor. It can be flexibly used in different occasions.

With two programmable sensors can be configured as temperature, pressure or liquid level sensor.

Multiple crank disconnect conditions (speed sensor, oil pressure and generator frequency) are

optional.

Widely power supply range DC(8~35)V, suitable to different starting battery voltage environment.

All parameters used digital adjustment, instead of conventional analog modulation with normal

potentiometer, more reliability and stability.

Event log and maximum 99 event logs can be memorized.

Waterproof security level IP65 due to rubber seal installed between the controller enclosure and

panel fascia.

Metal fixing clips enable perfect in high temperature environment.

Modular design, anti-flaming ABS plastic enclosure, pluggable connection terminals and embedded

installation way; compact structure with easy mounting.

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4 SPECIFICATION

Table 3 Technical Parameters

Item Operating Voltage Power Consumption Alternator Volt Input Range 3Phase 4Wire 3Phase 3Wire Single Phase 2Wire 2Phase 3Wire Alternator Frequency Speed sensor voltage Speed sensor Frequency Start Relay Output Fuel Relay Output Programmable Relay Output (1) Programmable Relay Output (2) Programmable Relay Output (3) Programmable Relay Output (4) Case Dimension Panel Cutout CT Secondary Current Working Temperature Working Humidity Storage Temperature Protection Level
Insulating Intensity
Weight

Content DC8.0V to DC35.0V, Continuous Power Supply. <3W (standby 2W)
AC15V – AC360V (ph-N) AC30V – AC620V (ph-ph) AC15V – AC360V (ph-N) AC15V – AC360V (ph-N) 50 Hz /60Hz 1.0V to 24.0V (RMS) 10,000 Hz (max.) 5A DC28V at supply output 5A DC28V at supply output 1A DC28V at supply output 1A DC28V at supply output 1A DC28V at supply output 1A DC28V at supply output 135mm x 110mm x 44mm 116mm x 90mm 5A rated (-25~+70)°C (20~93)%H (-25~+70)°C Front panel IP65 Apply AC2.2kV voltage between high voltage terminal and low voltage terminal; The leakage current is not more than 3mA within 1min. 0.32kg

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5 OPERATION

Table 4 Key Function Description

Icons

Function

Stop

Description Stop running generator in local mode; During stopping process, press this button again to stop generator immediately. When generator-set is at rest, pressing and holding the button for 3s will test indicator lights (lamp test).

Start

In local mode, press this key will start genset.

Remote Control Self-Check

After power up, controller enters local mode as default, and press this key will set the module into remote control mode (indicator beside the key lights on). Re-press this key to back to local mode (indicator besides the key lights off). Pressing this key when genset is at rest, LCD will auto scroll the screen to display sensor data and alarm information, and test alarms on an occasion of no speed.

Alarm Reset

Press this key to reset alarms.

Set/Confirm Up/Increase Down/Decrease

Pressing this key will enter into Main Menu; In setting parameter status, press this key will shift cursor or confirm setting value. Scrolls the screen up; Shift the cursor up or increase the set value in parameter setting menu. Scrolls the screen down; Shift the cursor down or decrease the set value in parameter setting menu.

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6 SCREENS DISPLAY

Table 5 Screen Display

1st Screen

Description

Generator is running screen display

Engine speed, genset UA/UAB voltage

Oil pressure, load power

Engine status

Generator is at rest screen display Engine speed, water temperature Oil pressure, power supply voltage

Engine status

2nd Screen Temp 35 Power 24.5V Oil Temp 20 D+ 24.5V

Description Engine water temperature, controller power supply Engine oil temperature, charger voltage

Total Running Time 10.2h

Total Start Times 5 Local Mode 3rd Screen

UL-L 400 400 400 V

UL-N 230 230 230 V

I

500 500 500 A

P 345 kW Q 0 kvar

Pf 1.00 50.0 Hz 4th Screen

P(kW) A: 115 B: 115 C: 115 PF 1.00

Q(kvar) S(kvA)

0

115

0

115

0

115

1.00 1.00

5th Screen

Total kWh:

0kWh

Total kvarh

0kvarh 6th Screen

I: 1 2 3 4 5

Engine total running time
Engine start attempts, controller current mode
Description Wire voltage: Uab, Ubc, Uca Phase voltage: Ua, Ub, Uc Load current: IA, IB, IC Load active power, load reactive power
Power facter, frequency
Description Active power, reactive power, apparent power display A-phase kW, A-phase kvar, A-phase kVA B-phase kW, B-phase kvar, B-phase kVA C-phase kW, C-phase kvar, C-phase kVA A-phase power factor, A-phase power factor, A-phase power factor
Description Accumalated active electric energy

Accumulated reactive electric energy

Input port name Input port status Output port name

Description

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O: C 1 2 3 4 5
2017-07-15 10:10:10 7th Screen
Warning Alarm Generator Under Volt.

Output port status System present time
Alarm type Alarm name

Description

NOTE: If there is no electric parameters display, the 3rd, 4th, and 5th screen will be shielded automatically.
7 CONTROLLER PANEL AND OPERATION 7.1 CONTROLLER PANEL

Fig.1 HMC4000 Front Panel Indication
NOTE: Part of indicator lights illustration: Alarm Indicators: Slowly flash when warning alarms occurred; fast flash when shutdown alarms occurred; light is off when there are no alarms. Status Indicators: Light is off when genset is standby; flash once per second during start up or shut down; always on when normal running.

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7.2 REMOTE START/STOP OPERATION 7.2.1. ILLUSTRATION

Press , its indicator lights, controller enters Remote Control Mode. After remote control mode is active, users can remotely start/stop engine by operating the controller HMC4000RM or via inputs (remote start input and remote stop input) to control engine start/stop.
7.2.2. REMOTE START SEQUENCE
When remote start command is active or “Remote Start” input is active, “Start Delay” timer is
initiated.
“Start Delay” countdown will be displayed on LCD. When start delay is over, preheat relay energizes (if configured), “Preheat Delay XX s” information will
be displayed on LCD.
After the above delay, the Fuel Relay is energized, and then one second later, the Start Relay is
engaged. Genset is cranked for a pre-set time. If genset fails to fire during this cranking attempt then the fuel relay and start relay are disengaged for the pre-set rest period; “Crank Rest Time” begins and wait for the next crank attempt.
Should this start sequence continue beyond the set number of attempts, the start sequence will be
terminated, and Fail to Start fault alarm will be displayed on the alarm page of LCD.
In case of successful crank attempt, the “Safety On” timer is activated. As soon as this delay is over,
“Start Idle” delay is initiated (if configured).
After the start idle, the controller will enter into hi-speed “Warming Up” delay (if configured). After warming up, engine runs normally.
7.2.3. REMOTE STOP SEQUENCE
When the remote stop command is active or “Remote Stop” input signal is active, the Stop Delay is
initiated.
Once this “stop delay” has expired, controller hi-speed “Cooling” delay is energized. Once “Cooling” delay has expired, the “Stop Idle” is initiated (if configured). During “Stop Idle” Delay,
idle relay is energized.
Once this “Stop Idle” has expired, the “ETS Solenoid Hold” begins. ETS relay is energized while fuel
relay is de-energized.
Once this “ETS Solenoid Hold” has expired, the “Fail to Stop Delay” begins. Complete stop is
detected automatically.
It is placed into standby mode after complete stop. Otherwise, fail to stop alarm is initiated and the
corresponding alarm information is displayed on LCD (If engine stops successfully after “fail to stop” alarm has initiated, it will enter into engine standby status).

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NOTE: There is no stop delay while stopping the remote monitoring controller.
7.3 AUTO START/STOP
7.3.1. ILLUSTRATION
Set any programmable input as “Auto Mode Input”, after it is active, controller will enter into auto mode.
7.3.2. AUTO START SEQUENCE
When “Start/Stop” input is active, “Start Delay” is initiated. “Start Delay” countdown information will be displayed on LCD. After the “Start Delay” has expired, 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. If the genset fails to fire during this cranking attempt then the fuel relay and start relay are disengaged for the pre-set rest period; “Crank Rest Time” begins and wait for the next crank attempt.
Should this start sequence continue beyond the set number of attempts, the start sequence will be
terminated, and Fail to Start fault alarm will be displayed on the alarm page of LCD.
In case of successful crank attempt, the “Safety On” timer is activated. As soon as this delay is
over, “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 status.
7.3.3. AUTO STOP SEQUENCE
When “Start/Stop” input is deactivated, the “Stop Delay” is initiated. Once the “Stop Delay” has expired, the “Cooling Delay” is then initiated. 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 expired, the “Fail to Stop Delay” begins. Complete stop is
detected automatically.
It is placed into standby mode after complete stop. Otherwise, fail to stop alarm is initiated and the
corresponding alarm information is displayed on LCD (If engine stops successfully after “fail to stop” alarm has initiated, “After stop” delay will be initiated and the alarm will be removed).

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7.4 LOCAL START/STOP SEQUENCE 7.4.1. ILLUSTRATION

If controller currently stays in remote control status, press

will enter into local mode, and

after local mode is active, users can start/stop engine according to the buttons on the front panel of the controller.

7.4.2. LOCAL START SEQUENCE

Pressing

to make preheat relay energized (if configured), “Preheat Delay XX s” information

will be displayed on LCD.

After the above delay, the Fuel Relay is energized, and then one second later, the Start Relay is

engaged. If the genset fails to fire during this cranking attempt then the fuel relay and start relay

are disengaged for the pre-set rest period; “Crank Rest Time” begins and wait for the next crank

attempt.
Should this start sequence continue beyond the set number of attempts, the start sequence will be

terminated, and Fail to Start fault alarm will be displayed on the alarm page of LCD.
In case of successful crank attempt, the “Safety On” timer is activated. As soon as this delay is

over, controller will enter into Normal Running status if speed, water temperature, and oil pressure

are normal.

7.4.3. LOCAL STOP SEQUENCE

Pressing

to make “ETS Solenoid Hold” begins. ETS relay is energized while fuel relay is

de-energized.

Once this “ETS Solenoid Hold” has expired, the “Wait for Stop” begins. Complete stop is detected

automatically.

It is placed into standby mode after complete stop. Otherwise, fail to stop alarm is initiated and the

corresponding alarm information is displayed on LCD (If engine stops successfully after “fail to

stop” alarm has initiated, it will enter into engine standby status).

Table 6 HMC4000 Start/Stop Illustration

System Mode Input Start Input Stop Input Start/Stop Remote Start Remote Stop

Local Mode

–

–

–

Remote Control

Mode

–

Auto Mode

–

–

–

–

–

–

Start Key

–
–

Stop Key

–
–

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8 PROTECTION

8.1 WARNINGS

When controller detects the warning signals, alarm only and not stops the genset, the LCD displays the warning information.

Table 7 Controller Warnings

No.

Type

Description

When the controller detects that engine temperature has exceeded the

1 High Temperature pre-set value, it will initiate a warning alarm and the corresponding alarm

information will be displayed on LCD.

When the controller detects that the oil pressure has fallen below the

2 Low Oil Pressure pre-set value, it will initiate a warning alarm and the corresponding alarm

information will be displayed on LCD.

When the speed collected by the speed sensor has exceeded the pre-set

3 Over Speed

value, it will initiate a warning alarm and the corresponding alarm

information will be displayed on LCD.

When the speed collected by the speed sensor has fallen below the

4 Under Speed

pre-set value, it will initiate a warning alarm and the corresponding alarm

information will be displayed on LCD.

Loss of Speed When the controller detects that the engine speed is 0 and the delay is 0, it

5

will initiate a warning alarm and the corresponding alarm information will

Signal

be displayed on LCD.

When the controller detects that charger voltage has fallen below the

6

Charge Alt Failure

battery voltage and the difference value exceed pre-set charging voltage difference value, it will initiate a warning alarm and the corresponding

alarm information will be displayed on LCD.

Engine failed to start if start attempts have been beyond pre-set start

7 Fail to Start

times, it will initiate a warning alarm and the corresponding alarm

information will be displayed on LCD.

After “fail to stop” delay/ ETS delay has expired, if gen-set does not stop

8 Fail to Stop

completely, it will initiate a warning alarm and the corresponding alarm

information will be displayed on LCD.

When the controller detects that battery voltage has exceeded the pre-set

9 Power Over Voltage value, it will initiate a warning alarm and the corresponding alarm

information will be displayed on LCD.

10

Power Voltage

When the controller detects that battery voltage has fallen below the Under pre-set value, it will initiate a warning alarm and the corresponding alarm
information will be displayed on LCD.

11 HMC4000RM

When the controller detects that fail to communication with HMC4000RM, it will initiate a warning alarm and the corresponding alarm information

Communication Fail will be displayed on LCD.

When controller gets the warning signals from engine via J1939, it will

12 ECU Warning

send warning signals and the corresponding alarm information will be

displayed on LCD.

13 Low Water Pressure When any one input set as Low Water Pressure Input and after this input

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No.

Type

Description

is active, it will send warning signals and the corresponding alarm

information will be displayed on LCD.

When any one input set as Low Water Level Input and after this input is

14 Low Water Level

active, it will send warning signals and the corresponding alarm

information will be displayed on LCD.

When any one input set as Low Oil Level Input and after this input is

15 Low Lub Oil Level active, it will send warning signals and the corresponding alarm

information will be displayed on LCD.

When any one input set as Fuel leakage Input and after this input is active,

16 Fuel Leakage

it will send warning signals and the corresponding alarm information will

be displayed on LCD.

Temp. Sensor Open After water temperature sensor is open circuit, it will send warning signals

17 Circuit

and the corresponding alarm information will be displayed on LCD.

18 Oil Pressure Sensor After oil pressure sensor is open circuit, it will send warning signals and

Open Circuit

the corresponding alarm information will be displayed on LCD.

Sensor 1 Open 19 Circuit

When sensor1 is open circuit, it will send warning signals and the corresponding alarm information will be displayed on LCD.(the name of “Senor 1” can be changed on PC software, default as “Oil Temperature”)

When the data collected by the sensor 1 has exceeded the pre-set

20 Sensor 1 High

sensor1 high warning alarm value, it will send warning signals and the corresponding alarm information will be displayed on LCD. (the name of

“Senor 1” can be changed on PC software, default as “Oil Temperature”)

When the data collected by the sensor 1 has fallen below the pre-set

21 Sensor 1 Low

sensor1 low warning alarm value, it will send warning signals and the corresponding alarm information will be displayed on LCD. (the name of

“Senor 1” can be changed on PC software, default as “Oil Temperature”)

22

Sensor 2 Open Circuit

When sensor 2 is open circuit, it will send warning signals and the corresponding alarm information will be displayed on LCD.(the name of “Senor 2” can be changed on PC software)

When the data collected by the sensor 2 has exceeded the pre-set

23 Sensor 2 High

sensor2 high warning alarm value, it will send warning signals and the corresponding alarm information will be displayed on LCD. (the name of

“Senor 2” can be changed on PC software)

When the data collected by the sensor 2 has fallen below the pre-set

24 Sensor 2 Low

sensor 2 low warning alarm value, it will send warning signals and the corresponding alarm information will be displayed on LCD. (the name of

“Senor 2” can be changed on PC software)

When input 1 configured as warning input and input is active, it will send

25 Input 1 Warning

warning signals and the corresponding alarm information will be

displayed on LCD. (the name of “Input 1” can be changed on PC software)

When input 2 configured as warning input and input is active, it will send

26 Input 2 Warning

warning signals and the corresponding alarm information will be

displayed on LCD. (the name of “Input 2” can be changed on PC software)

27 Input 3 Warning

When input 3 configured as warning input and input is active, it will send warning signals and the corresponding alarm information will be

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No.

Type

28 Input 4 Warning

29 Input 5 Warning

30

Generator Over Voltage

Generator Under 31
Voltage

Generator Over 32 Frequency

33

Generator Under Frequency

Generator Over 34
Current

35 Over Power

Description displayed on LCD. (the name of “Input 3” can be changed on PC software) When input 4 configured as warning input and input is active, it will send warning signals and the corresponding alarm information will be displayed on LCD. (the name of “Input 4” can be changed on PC software) When input 5 configured as warning input and input is active, it will send warning signals and the corresponding alarm information will be displayed on LCD. (the name of “Input 5” can be changed on PC software) When the controller detects that the genset voltage has exceeded the pre-set value, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. When the controller detects that the genset voltage has fallen below the pre-set value, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. When the controller detects that the genset frequency has exceeded the pre-set value, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. When the controller detects that the genset frequency has fallen below the pre-set value, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. When the controller detects that the genset current has exceeded the pre-set value, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD. When the controller detects that the power (power is positive) has exceeded the pre-set value and action selected “Warning”, it will initiate a warning alarm and the corresponding alarm information will be displayed on LCD.

8.2 SHUTDOWN ALARM

When controller detects shutdown alarm, it will send signals to stop the generator and the corresponding alarm information will be displayed on LCD.

Table 8 Shutdown Alarm

No.

Type

Description

When controller detects emergency stop signals, it will send stop signals

1

Emergency Stop and the corresponding alarm information will be displayed on LCD.

When controller detects the speed value is higher than the set value, it will

2

Over Speed

send stop signals and the corresponding alarm information will be

displayed on LCD.

When controller detects the speed value is lower than the set value, it will

3

Under Speed

send stop signals and the corresponding alarm information will be

displayed on LCD.

4

Loss of Signal

Speed

When controller detects speed value equals to 0, and delay value isn’t 0 (action select “Shutdown”), it will send stop signals and the corresponding alarm information will be displayed on LCD.

5

Over Frequency When controller detects the frequency value is higher than the set value, it

HMC4000 Marine Genset Controller User Manual

Page 16 of 52

No.

Type

Description

will send stop signals and the corresponding alarm information will be

displayed on LCD.

When controller detects the frequency value is lower than the set value, it

6

Under Frequency will send stop signals and the corresponding alarm information will be

displayed on LCD.

When controller detects the voltage value is higher than the set value, it will

7

Over Voltage

send stop signals and the corresponding alarm information will be

displayed on LCD.

When controller detects the voltage value is lower than the set value, it will

8

Under Voltage

send stop signals and the corresponding alarm information will be

displayed on LCD.

When controller detects the current value of genset is higher than the set

9

Over Current

value and the delay value is not 0, it will send stop signals and the

corresponding alarm information will be displayed on LCD.

10

High

Temp.

Shutdown Input

When any one input set as high water temperature shutdown and the input is active, it will send stop signals and the corresponding alarm information

will be displayed on LCD.

Low Oil Pressure When any one input set as low oil pressure shutdown and the input is

11

active, it will send stop signals and the corresponding alarm information

Input

will be displayed on LCD.

When temperature value collected by the temperature sensor is higher

12

High Shutdown

Temp.

than the set value, it will send stop signals and the corresponding alarm

information will be displayed on LCD.

When oil pressure value collected by the oil pressure sensor is lower than

13 Low Oil Pressure the set value, it will send stop signals and the corresponding alarm

information will be displayed on LCD.

When the data collected by the sensor 1 has exceeded the pre-set value, it

14 Sensor 1 High

will send stop signals and the corresponding alarm information will be displayed on LCD. (the name of “Senor 1” can be changed on PC software,

default as “Water Temperature)

When the data collected by the sensor 1 has fallen below the pre-set value,

15 Sensor 1 Low

it will send stop signals and the corresponding alarm information will be displayed on LCD. (the name of “Senor 1” can be changed on PC software,

default as “Water Temperature)

When the data collected by the sensor 2 has exceeded the pre-set value, it

16 Sensor 2 High

will send stop signals and the corresponding alarm information will be

displayed on LCD. (the name of “Senor 2” can be changed on PC software)

When the data collected by the sensor 2 has fallen below the pre-set value,

17 Sensor 2 Low

it will send stop signals and the corresponding alarm information will be

displayed on LCD. (the name of “Senor 2” can be changed on PC software)

When input 1 configured as shutdown input and input is active, it will send

18 Input 1 Shutdown stop signals and the corresponding alarm information will be displayed on

LCD. (the name of “Input 1” can be changed on PC software)

When input 2 configured as shutdown input and input is active, it will send 19 Input 2 Shutdown
stop signals and the corresponding alarm information will be displayed on

HMC4000 Marine Genset Controller User Manual

Page 17 of 52

No.

Type

Description

LCD. (the name of “Input 2” can be changed on PC software)

When input 3 configured as shutdown input and input is active, it will send

20 Input 3 Shutdown stop signals and the corresponding alarm information will be displayed on

LCD. (the name of “Input 3” can be changed on PC software)

When input 4 configured as shutdown input and input is active, it will send

21 Input 4 Shutdown stop signals and the corresponding alarm information will be displayed on

LCD. (the name of “Input 4” can be changed on PC software)

When input 5 configured as shutdown input and input is active, it will send

22 Input 5 Shutdown stop signals and the corresponding alarm information will be displayed on

LCD. (the name of “Input 5” can be changed on PC software)

When the controller detects that the power (power is positive) has

23 Over Power

exceeded the pre-set value and action selected “Shutdown”, it will initiate a stop alarm and the corresponding alarm information will be displayed on

LCD.

When controller gets the shutdown signals from engine via J1939, it will

24 ECU Shutdown

send stop signals and the corresponding alarm information will be

displayed on LCD.

ECU

After controller engine started up, it doesn’t receive any data via J1939,

25 Communication and then it will send stop signals and the corresponding alarm information

Fail

will be displayed on LCD.

NOTE: ECU warning and shutdown alarms illustration, if there are detailed alarms display, controller will check engine based on the content. Otherwise, please look up engine Manuel to get the information based on the SPN code.

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9 WIRINGS CONNECTION HMC4000 controller back panel is as follows:

Fig.2 HMC4000 Back Panel

Table 9 Terminal Wiring Connection

No. 1 B-
2 B+

Function

3 Fuel relay output 4 Start relay output 5 Charger(D+) 6 Common ground 7 Aux. Output 1
8 Aux. Output 2
9 Aux. Output 3
10 Aux. Output 4 11 Aux. Input 1 12 Aux. Input 2 13 Temperature sensor

Cable Size 2.5mm2
2.5mm2
1.5mm2 1.5mm2 1.0mm2 1.5 mm2 1.0mm2
1.0mm2
1.0mm2
1.0 mm2 1.0mm2 1.0mm2 1.0mm2

Remarks

Connected with negative of starter battery

Connected with positive of starter battery. If wire

length is over 30m, better to double wires in parallel.

Max. 20A fuse is recommended.

B+ is supplied by 2 terminal, rated 5A

Parameter set as “programmable relay output 5”.

B+ is supplied by 2 terminal, rated 5A

Connected with charger starter’s D+ (WL) terminals.

Being hang up If there is no this terminal.

Inside connect to B-.

B+ is supplied by No.2

terminal, rated 1A

B+ is supplied by No.2

terminal, rated 1A

Details see 10.2.2

B+ is supplied by No.2

terminal, rated 1A

B+ is supplied by No.2

terminal, rated 1A

Used as liquid level sensor or digital input port 4

Used as programmable sensor or digital input port 5

Connected

with

water Details see 10.4.2

temperature or cylinder

HMC4000 Marine Genset Controller User Manual

Page 19 of 52

No.

Function

Cable Size

Remarks

temperature resistor type

sensor.

14 Oil pressure sensor

1.0mm2 Connected with oil pressure Details see 10.4.3 resistor type sensor.

15 CAN H

0.5mm2 Controller connected with CAN BUS (if with CAN BUS

16 CAN L

0.5mm2 function);

Controller connected with speed sensor (if with no

17 CAN Common ground

0.5mm2 CAN BUS function);

Shielding line is recommended.

18 RS485 Common ground

/

Impedance-120 shielding wire is recommended, its

19 RS485+

0.5mm2 single-end earthed. These ports are used for

20 RS485-

0.5mm2

connecting with HMC4000RM remote monitoring controller.

21 Aux. input 1

1.0mm2 Ground connected is active (B-)

22 Aux. input 2

1.0mm2 Ground connected is active (B-) Details see 10.3.2

23 Aux. input 3

1.0mm2 Ground connected is active (B-)

24 Input common port

1.0mm2 Inside connected to B-

25 Genset U-phase voltage 1.0mm2 Connected to U-phase output of genset (2A fuse

monitoring input

recommended).

26 Genset V-phase voltage 1.0mm2 Connected to V-phase output of genset (2A fuse

monitoring input

recommended).

27 Genset W-phase voltage 1.0mm2 Connected to W-phase output of genset (2A fuse

monitoring input

recommended).

28 Genset line N input

1.0mm2 Connected to N-wire output of genset.

29 CT A-phase monitoring 1.5mm2 Outside connected to secondary coil of CT (5A rated). input

30 CT B-phase monitoring 1.5mm2 Outside connected to secondary coil of CT (5A rated). input

31 CT C-phase monitoring 1.5mm2 Outside connected to secondary coil of CT (5A rated). input

32 CT common port

1.5mm2 Reference to Installation Instruction

NOTE: USB ports in controller rear panel are programmable parameter ports, user can directly configure controller via PC.

HMC4000 Marine Genset Controller User Manual

Page 20 of 52

10 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS

10.1 CONTENTS AND SCOPES OF PARAMETERS

Table 10 Parameters Setting Contents and Scopes

No Timers

Items

1 Start Delay

Range (0-3600)s

2 Stop Delay

(0-3600)s

3 Pre-heating Delay (0-300)s

4 Crank Time

(3-60)s

5 Crank Rest Time (3-60)s

6 Safe Time

(1-3600)s

7 Start Idle Time 8 Warm Up Time
9 Cool Time 10 Stop Idle Time 11 ETS Hold Time

(0-3600)s (0-3600)s
(0-3600)s (0-3600)s (0-3600)s

12 Wait Stop Time

(0-3600)s

13 Start Key Confirm (0.2-5.0) s

14 Stop Key Confirm
Engine 1 Engine Options

(0.2-5.0) s (0-39)

2 Flywheel Teeth

(1-300)

3 Rated Speed

(1-5999)rpm

Default

Description

1

Time from remote start signal is active to genset start.

1

Time from remote stop signal is active to genset stop.

0

Power-on time of heater plug before starter is powered up.

8

Power-on time of starter

10

The waiting time before second power up when engine start fail.

Alarms for low oil pressure, high

temperature, under speed, under

10

frequency/voltage, charge alt failure are

inactive.

0

Idle running time of genset when starting.

Warming time between genset switch on

10

and high speed running.

Radiating time before genset stop, after it

10

unloads.

0

Idle running time when genset stop.

20

Stop electromagnet’s power on time when genset is stopping.

Time between ending of genset idle delay

and stopped when “ETS Hold Time” is set

0

as 0;

Time between ending of ETS hold delay

and stopped when “ETS time” is not 0.

0.2

Time duration from press start button to

engine execute start process.

0.2

Time duration from press stop button to

engine execute stop process.

0 118 1500

Conventional Generator-set Flywheel tooth number of the engine is used for judging of starter crank disconnect conditions and inspecting of engine speed. See the installation instructions. Provide standard for judging over speed, under speed and speed on load.

HMC4000 Marine Genset Controller User Manual

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No

Items

Range

Default

4 Start Times

(1-30)

3

(0-6)

0: Speed

1: Oil pressure

2: Speed + OP

5

Crank Disconnect Condition

3: Speed + Gen 4: Gen + OP

0: Speed

5: Speed + Gen +

OP

6: Gen

6 Oil Pressure of (10-1000)kPa

80

Crank Disconnect

7 Speed of Starting (0-200)%

25%

Motor Disconnect

Under

Speed (0-1)

8

Shutdown Enabled

0: Disabled 1: Enabled

0: Disabled

Under Speed Set

9 Value

(0-200)%

85%

Under

Speed

10

(0-3600)s

1

Warning Delay

(0-1)

Under

Speed

11 Warning Enabled

0: Disabled 1: Enabled

1: Enabled

12

Under Speed Set Value

(0-200)%

90%

13

Under

Speed

Warning Delay

(0-3600)s

1

14 Over

Speed

(0-1) 0: Disabled

Shutdown Enabled

1: Enabled

1: Enabled

15

Over Speed Value

Set (0-200)%

115%

16

Over

Speed

Warning Delay

(0-3600)s

1

17 Over

Speed

(0-1) 0: Disabled

Warning Enabled 1: Enabled

1: Enabled

Over Speed Set

18 Value

(0-200)%

110%

Over

Speed

19 Warning Delay

(0-3600)s

1

Description The maximum start attempts if engine fail to start. When the set number of starts is reached, the controller will send the start failure signal.
There are 3 conditions of disconnecting starter with engine, which can be used separately or together. Aiming at to separating the start motor and engine as soon as possible.
When oil pressure is higher than the set value, starter will be disconnected. When engine speed is higher than the set value, starter will be disconnected.
Under speed shutdown settings.
Under speed warning settings.
Over speed shutdown settings
Over speed warning settings

HMC4000 Marine Genset Controller User Manual

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No

Items

Range

20 Loss of Speed (0-3600)s Delay

(0-2)

21

Loss of Action

Speed 0: Warning 1: Shutdown

2: Indication

Charge 22
Voltage

Fail (0-60.0)V

Battery 23 Voltage

Rated (1-60.0)V

Battery

Over

24 Voltage Warning (0-200)%

25 Battery

Under (0-200)%

Voltage Warning

26 Upper Limit Temp (0-100)°C of Water Heating

27 Lower Limit Temp (0-100)°C of Water Heating

28 Generator Poles (2-64)

29 Frequency

of (10.0-30.0)Hz

Crank Disconnect

30 Fuel Pump On

(10.0-30.0)Hz

31 Fuel Pump Off

(0-100)%

Module Configuration 1 Language
2 Password 3 HMC4000RM
Module Enabled 4 Power On Mode 5 Date & Time 6 Baud Rate

(0-1) 0: Chinese 1: English (0-65535)
(0-1) (0-1) 0: Local Mode 1: Remote Mode
(0-1)

Default 3

Description Time duration from speed was detected as 0 to action was confirmed.

1: Shutdown

Action that controller executed detecting speed signal is lost.

after

16.0 24.0 125% 75% 42°C 37°C 4
14.0
20 30

When the voltage difference of B+ and charger D+ (WL) is exceed the setting value, it will initiate “Fail to Charge” alarm. Provide standard for judging battery over/under voltage.
Setting values are percentage of rated voltage.
Open when water temperature sensor’ temp is higher than the setting value. Close when water temperature sensor’s temp is lower than the setting value. The poles number of generator, which can be used in generator that without speed sensor to calculate engine speed. If generator frequency exceeds this setting value during start process, generator-set crank successfully and starter will disconnect. Fuel pump will open when the value of fuel level sensor falls below the setting point. Fuel pump will close when the value of fuel level sensor exceeds the setting point.

0: Chinese

Language selection displayed on the LCD of controller.

00318 0: Disabled

Password to enter into parameter settings page. Choose “Enabled” if HMC4000RM module is need to be extended.

Operation mode after controller 0: Local Mode power-on.

Controller time settings. 0: 250kbps CANBUS baud rate settings.

HMC4000 Marine Genset Controller User Manual

Page 23 of 52

No

Items

Range

Default

Description

0: 250kbps

1: 125kbps

7 Module Address (0-254)

1

Communication address of controller.

8 RS485 Baud Rate (0-4)

0

0:9600bps 1:2400bps 2:4800bps 3:19200bps 438400bps

9 Stop Bit

(0-1)

0

0: 2 Bits

1: 1 Bit.

Sensor

Water

Temp.

1 Sensor (resistance Details to see 10.4.

Water temperature sensor setting.

input)

2 OP Sensor

Details to see 10.4.

(resistance input)

Oil pressure sensor setting.

3

Oil Temp. Sensor (resistance input)

Details to see 10.4.

Flexible sensor 1 setting.

4

Flexible Sensor 1 (resistance input)

Details to see 10.4.

Flexible sensor 2 setting.

Inputs Setting

1 Input 1 Function (0-31)

0: Not used Details to see 10.3

2

Input Type

1

Active (0-1)

0: Close to Configure input port is close to activate or

activate

open to activate.

3 Input 2 Function (0-31)

0: Not used Details to see 10.3

Input 2 Active

4

(0-1)

Type

0: Close to Configure input port is close to activate or

activate

open to activate.

5 Input 3 Function (0-31)

0: Not used Details to see 10.3

6

Input Type

3

Active (0-1)

0: Close to Configure input port is close to activate or

activate

open to activate.

Details to see 10.3

7 Input 4 Function (0-31)

0: Not used Remark: This input only can be used when

flexible sensor 1 is configured as input port 4.

8 Input 4 Active (0-1) Type

0: Close to Configure input port is close to activate or

activate

open to activate.

Details to see 10.3

9 Input 5 Function (0-31)

0: Not used Remark: This input only can be used when

flexible sensor 2 is configured as input port 5.

Input 5 Active

10 Type

(0-1)

0: Close to Configure input port is close to activate or

activate

open to activate.

Outputs Setting

1 Output 1 Function (0-100)

0: Not used Details to see 10.2

2 Output Type

(0-1)

0: Open

Configure output port is normally open output or normally close output.

3 Output 2 Function (0-100)

0: Not used Details to see 10.2

4 Output Type

(0-1)

0: Open

Configure output port is normally open output or normally close output.

5 Output 3 Function (0-100)

0: Not used Details to see 10.2

HMC4000 Marine Genset Controller User Manual

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No

Items

Range

6 Output Type

(0-1)

7 Output 4 Function (0-100)

8 Output Type

(0-1)

9 Output 5 Function (0-100)

10 Output Type Generator

(0-1)

11 AC System

(0-3)

12 Rated Voltage

(30-30000)V

Voltage

(0-1)

13 Transformer

0: Disabled

Enabled

1: Enabled

14 PT

Primary (30-30000)V

Voltage

15 PT

Secondary (30-1000)V

Voltage

16

Over Volt Warning

(0-1) 0: Disabled

Enabled

1: Enabled

17

Over Volt Warning Set Value

(0-200)%

18 Over Volt Warning (0-3600)s Delay

Over

Volt (0-1)

19

Shutdown Enabled

0: Disabled 1: Enabled

Over 20 Shutdown
Value

Volt Set (0-200)%

Over

Volt

21 Shutdown Delay (0-3600)s

Default

Description

0: Open

Configure output port is normally open output or normally close output.

0: Not used Details to see 10.2

0: Open

Configure output port is normally open output or normally close output.

15:

Fuel Details to see 10.2

output

Note: this output port is fuel output

0: Open

Configure output port is normally open output or normally close output.

0 230 0: Disabled

0: 3P4W 1: 3P3W 2: 2P3W 3: 1P2W Provide standard for generator over/under voltage, and voltage on load (this value is transformer primary voltage). When AC supply mode is selected 3P3W, this value is line voltage; and for other selections, this value is phase voltage. After PT enabled, voltage calculation based on the ratio of primary voltage and secondary voltage.

100

PT primary input voltage.

100

PT secondary output voltage.

Enabled 110% 3s Enabled 120% 2s

When enabled, the module begins to detect overvoltage warnings.
When generator voltage exceeds pre-set value and warning delay is expired, generator over voltage warning alarm will be sent. Time duration from alarms been detected to initiate alarms.
When enabled, the module begins to detect overvoltage shutdown alarms.
When generator voltage exceeds pre-set value and over voltage shutdown delay is expired, generator over voltage shutdown alarms will be sent. Time duration from alarms been detected to initiate alarms.

HMC4000 Marine Genset Controller User Manual

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No

Items

Range

Under

Volt (0-1)

22 Warning Enabled

0: Disabled 1: Enabled

23 Under

Volt (0-200)%

Warning Set Value

Under

Volt

24 Warning Delay

(0-3600)s

(0-1)

25

Under

Volt

Shutdown Enabled

0: Disabled 1: Enabled

Under 26 Shutdown
Value

Volt Set (0-200)%

Under

Volt

27 Shutdown Delay (0-3600)s

(0-1)

28

Loss of Phase Detection Enabled

0: Disabled

1: Enabled

(0-1)

29 Action

0: Warning

1: Shutdown

30 Delay

(0-3600)s

Phase Sequence (0-1)

31 Wrong Detection 0: Disabled

Enabled

1: Enabled

(0-1)

32 Action

0: Warning

1: Shutdown

33 Delay

(0-3600)s

34 Rated Frequency

(10.0-75.0) Hz

35 Over

Frequency

(0-1) 0: Disabled

Warning Enabled 1: Enabled

36

Over Frequency Warning Set Value

(0-200)%

Default Enabled
84% 3s Enabled
80% 2s Disabled Warning 2 Disabled Warning 2 50.0 Enabled
110%

HMC4000 Marine Genset Controller User Manual

Description
When enabled, the module begins to detect under voltage warnings.
When generator voltage falls below pre-set value and warning delay is expired, generator under voltage warning alarm will be sent. Time duration from alarms been detected to initiate alarms.
When enabled, the module begins to detect under voltage shutdown alarms.
When generator voltage falls below pre-set value and shutdown delay is expired, generator under voltage shutdown alarms will be sent. Time duration from alarms been detected to initiate alarms.
Loss of phase detection starts after it is enabled.
Alarm actions after phase loss.
When controller detects phase loss, it will initiate corresponding alarms after alarm delay is expired.
Negative phase sequence detection starts after it is enabled.
Alarm actions after negative phase sequence alarm initiated.
When negative phase sequence been detected and alarm delay is expired, corresponding alarms will be sent. Provided standard for over/under frequency and frequency on load.
When enabled, the module begins to detect over frequency warnings.
When generator frequency exceeds pre-set value and warning delay is expired, generator over frequency warning alarms will be sent.
Page 26 of 52

No

Items

Range

37 Over Frequency (0-3600)s Warning Delay

Over Frequency (0-1)

38

Shutdown Enabled

0: Disabled 1: Enabled

Over Frequency 39 Shutdown Set (0-200)%
Value

Over Frequency 40 Shutdown Delay (0-3600)s

(0-1)

41

Under Frequency Warning Enabled

0: Disabled 1: Enabled

Default 3s Enabled
114% 2s Enabled

42 Under Frequency (0-200)%

84%

Warning Set Value

Under Frequency

43 Warning Delay

(0-3600)s

(0-1)

44

Under Frequency Shutdown Enabled

0: Disabled

1: Enabled

Under Frequency 45 Shutdown Set (0-200)%
Value

46

Under Frequency Shutdown Delay

(0-3600)s

47 Rated Current

(5-6000)A

3s Enabled
80% 2s 500

48 Transform

(5-6000)/5

500

49 Rated Power

(0-6000)kW

50

Over

Current

Warning Enabled

(0-1) 0: Disabled

1: Enabled

276 Enabled

Over

Current

51 Warning Set Value (0-200)%

110%

52 Over

Current (0-3600)s

Warning Delay

53 Over

Current (0-1)

10s Enabled

HMC4000 Marine Genset Controller User Manual

Description Time duration from alarms been detected to initiate alarms.
When enabled, the module begins to detect over frequency shutdown alarms.
When generator frequency exceeds pre-set value and shutdown delay is expired, generator over frequency shutdown alarms will be sent. Time duration from alarms been detected to initiate alarms.
When enabled, the module begins to detect under frequency warnings.
When generator frequency falls below pre-set value and warning delay is expired, generator under frequency warning alarms will be sent. Time duration from alarms been detected to initiate alarms.
When enabled, the module begins to detect under frequency shutdown alarms.
When generator frequency falls below pre-set value and trip delay is expired, generator under frequency trip alarms will be sent. Time duration from alarms been detected to initiate alarms. It is rated current of generator, which used as the standard for current with load. External connected current transformer ratio. It is rated power of generator, which used as the standard for power inspection.
When enabled, the module begins to detect over current warning alarms.
When generator current exceeds pre-set value and warning delay is expired, generator over current warning alarms will be sent. Time duration from alarms been detected to initiate alarms. When enabled, the module begins to
Page 27 of 52

No

Items

Range

Shutdown Enabled 0: Disabled

1: Enabled

Over

Current

54 Shutdown Set (0-200)%

Value

55

Over

Current

Shutdown Delay

(0-3600)s

56

Over

Power

Warning Enabled

(0-1) 0: Disabled

1: Enabled

Over

Power

57 Warning Set Value (0-200)%

58

Over

Power

Warning Delay

(0-3600)s

59

Over

Power

Shutdown Enabled

(0-1) 0: Disabled

1: Enabled

Over

Power

60 Shutdown Set (0-200)%

Value

61 Over

Power (0-3600)s

Shutdown Delay

Default

Description detect over current shutdown alarms.

114% 3s Enabled
110% 3s Enabled
114% 2s

When generator current exceeds pre-set value and trip delay is expired, generator over current trip alarms will be sent. Time duration from alarms been detected to initiate alarms.
When enabled, the module begins to detect over power warning alarms.
When generator current exceeds pre-set value and warning delay is expired, generator over power warning alarms will be sent. Time duration from alarms been detected to initiate alarms.
When enabled, the module begins to detect over power shutdown alarms.
When generator current exceeds pre-set value and warning delay is expired, generator over power trip alarms will be sent. Time duration from alarms been detected to initiate alarms.

HMC4000 Marine Genset Controller User Manual

Page 28 of 52

10.2 DEFINED CONTENTS OF DIGITAL OUTPUT PORTS 1~5

10.2.1. DEFINED CONTENTS OF DIGITAL OUTPUT PORTS

Table 11 Output Ports Setting

No. 1 2
3
5 6

Item Outputs Function Settings Active Selection
Active Period
Delay Output Time Output Time

Setting Content (0-100) 0: Normally Open 1: Normally Close Bit0: Not used Bit1: Standby Bit2: Pre-heat Bit3: Fuel Output Bit4: Crank Bit5: Crank Rest Bit6: Safety On Delay Bit7: Start Idle Bit8: Warming Up Bit9: Waiting for Loading Bit10: Normal Running Bit11: Cooling Bit12: Stop Idle Bit13: ETS Bit14: Wait for Stop Bit15: Fail to Stop (0-100.0)s (0-3600)s

Remark

10.2.2. FUNCTION DEFINITION OF OUTPUT PORTS 1-5

Table 12 Defined Contents of Digital Output Ports 1-5

No.

Items

0 Not Used

1 Custom

2 Common Alarm

3 ETS Hold

4 Idle Control

5 Preheat Control 6 Override Output

7 Engine Standby

8 Reserved 9 Raise Speed 10 Drop Speed 11 Crank Success

Description Output port is deactivated when “Not Used” is selected. Details to see 10.2.1. Output when alarms occurred. Output when energize to stop. Output when controller idle running and open in high speed running. Close before starting and open before power up. Output when controller in override mode. Output when controller in standby mode and without sensor break wire alarms. Reserved Output when raise speed input is active. Output when drop speed input is active. Output after controller crank disconnected.

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No.

Items

Description

12 Fuel Pump Control

Reserved

13 Reserved

Reserved

14 Local Mode Output

Output when controller in local mode.

15 Fuel Output

Close when generator starts up and open when in stop process.

16 Excite Generator

Output while generator is cranking, and output for 2s if there is no frequency during safety on period.

17 Fuel Leak Output

Output when controller fuel leakage warning.

18 Reserved

Reserved

19 Common Shutdown

Output when controller shutdown alarms occurred.

20 Audible Alarm

Output when controller alarms occurred and press any key to mute alarms. Then disconnect after alarms mute.

Controller controls heater working based on “Heating

21 Heater Control

Temperature Upper Limit” and “Heating Temperature Lower

Limit”

22 Reserved

Reserved

23 Crank Output

Close when generator is cranking and open when crank disconnect.

24 ECU Stop

Used for ECU engine and control its shutdown.

25 ECU Power

Used for ECU engine and control its power.

26 ECU Warning

Indicate ECU sends a warning alarm signal.

27 ECU Shutdown

Indicate ECU sends a shutdown alarm signal.

28 ECU Communication Fail Indicate controller not communicates with ECU.

29 Normal Running

Output after engine normally running.

30 Remote Mode Output

Output when controller in remote control mode.

31 Reserved

Reserved

32 Reserved

Reserved

33

Water Temp Sensor Output when controller open circuit alarms of temperature sensor

Open Circuit Warning

occurred.

34

Water Temp High Output when water temperature is high (action select warning).

Warning

35

Water Temp Shutdown

High Output when water temperature is high (action select shutdown).

36

Oil Pressure Sensor Output when controller open circuit alarms of oil pressure sensor

Open Circuit Warning

occurred.

37

Oil Pressure Warning

Low Output when oil pressure is low (action select warning).

38

Oil Pressure Shutdown

Low Output when oil pressure is low (action select shutdown).

39

Flexible Sensor 1 Open Output when controller open circuit alarms of flexible sensor 1

Circuit Warning

occurred.

40

Flexible Warning

Sensor

1 Output when flexible sensor 1 is warning.

Flexible Sensor 1

41

Shutdown

Output when flexible sensor 1 is shutdown.

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No.
42
43
44
45 46 47 48 49
50
51 52 53 54 55 56 57 58 59 60
61
62
63 64 65 66 67 68~100

Items

Flexible Sensor 2 Open

Circuit Warning

Flexible Sensor 2

Warning

Flexible Sensor 2

Shutdown

Over Volt Warning

Over Volt Shutdown

Under Volt Warning

Under Volt Shutdown

Over Frequency Warning

Over

Frequency

Shutdown

Over Current Warning

Over Current Shutdown

Over Power Warning

Over Power Shutdown

Over Speed Warning

Over Speed Shutdown

Battery Under Volt

Failed to Start

Failed to Stop

Emergency Stop Alarm

Under

Frequency

Warning

Under

Frequency

Shutdown

Input 1 Active

Input 2 Active

Input 3 Active

Input 4 Active

Input 5 Active

Reserved

Description Output when controller open circuit alarms of flexible sensor 2 occurred.
Output when flexible sensor 2 is warning.
Output when flexible sensor 2 is shutdown.
Output when controller is over voltage warning. Output when controller is over voltage shutdown. Output when controller is under voltage warning. Output when controller is under voltage shutdown. Output when controller is over frequency warning.
Output when controller is over frequency shutdown.
Output when controller is over current warning. Output when controller is over current shutdown. Output when controller is over power warning. Output when controller is over power shutdown. Output when controller is over speed warning. Output when controller is over speed shutdown. Output when controller power supply voltage is low warning. Output when controller fails to start warning. Output when controller fails to stop warning. Output when controller is emergency stop alarm occurred.
Output when controller is under frequency warning.
Output when controller is under frequency shutdown.
Output when controller input 1 is active. Output when controller input 2 is active. Output when controller input 3 is active. Output when controller input 4 is active. Output when controller input 5 is active.

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10.3 DEFINED CONTENTS OF DIGITAL INPUT PORTS 1-5

10.3.1. DEFINED CONTENTS OF DIGITAL INPUT PORTS

Table 13 Input Ports Setting

No. 1 2
3
4 5 6

Item Inputs Function Settings Active Selection
Active Period
Active Action Input Delay String Display

Setting Content

Remark

(0- 31)

Detail to see 10.3.2

(0-1)

0: Close to Active 1: Open to Active

0: After Safety On Delay

(0-3)

1: From Start 2: Always

3: Inactive

0: Warning

(0-2)

1: Alarm Shutdown

2: Indication

(0-20.0)s

Name of input port can 20 English characters or 10

be user-defined

Chinese characters

10.3.2. DEFINED CONTENTS OF DIGITAL INPUT PORTS 1-5

Table 14 Defined Contents of Digital Input Ports 1~5 (All GND(B-) Active)

No

Items

0 Not Used

1 Custom

2 Water Temp. High Shut

3 Oil Pressure Low Shut

4 Reserved

5 Emergency Stop

6 Remote Mode

7 Local Mode

8 Override Mode

9 Auto Mode

10 Remote Start/Stop

11 Reserved 12 Water Pressure Low 13 Water Level Low 14 Lub Oil Level Low 15 Reserved 16 Reserved 17 Reserved 18 Panel Lock

Description Input port is inactive when select “Not Used”.

If input is active, shutdown alarm will be immediately initiated.

If input is active, shutdown alarm will be immediately initiated.

Reserved

Emergency stop alarm will be initiated if this input is active.

Controller enters remote control mode after this input is active.

Controller enters local mode after this input is active.

If input is active, all shutdown alarms except over speed shutdown

alarm and emergency shutdown alarm are all unavailable.

Controller enters auto mode after this input is active.

When this input is active in auto mode, generator-set start

automatically and on load after running. Otherwise, generator-set

will stop automatically if it is disconnected.

Reserved.

Controller displayed “Low Water Pressure” after this input is active.

Controller displayed “Low Water Level” after this input is active.

Controller displayed “Low Oil Level” after this input is active.

Reserved

Reserved

Reserved

When input is active, all keys expect

are deactivated and

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No

Items

19 Fuel Leak Warning 20 Alarm Mute 21 Speed Up
22 Speed Down 23 Reserved 24 Reserved 25 60Hz Select 26 Reserved 27 Remote Start Input
28 Stop Input 29 Reserved 30 Turning Chain 31 Reserved

Description right of last line of home page on LCD displayed . Controller displayed “Fuel Leakage Warning” after this input is active. When input is active, “Audible Alarm” output is disconnecting. Rise speed output port of controller outputs when this input is active. Drop speed output port of controller outputs when this input is active. Reserved Reserved Used for EFI engine with CANBUS interface. When it is active, frequency is 60Hz. Reserved When controller in remote control mode, generator-set starts up when this input is active. When controller in remote control mode, generator-set stops when this input is active.
Engine start is inhibiting after “Turning Chain” input is active. Reserved

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10.4 SELECTION OF SENSORS

10.4.1. SENSORS SE TTING

Table 15 Sensor Setting Items

No.

Items

Description

Remark

(0-3)

0: Not used

1 Sensor Types

1: Pressure sensor

2: Temperature sensor

3: Fuel Level sensor

2 Sensor Curve Types

Details to see the following Details

to

see

curve type lists.

10.4.2/10.4.3/10.4.4.

3 Speed Warning

(0-200)%

Alarm detection start when this speed is exceeded.

4~20mA sensor is active

4 Range

(0-6000)

Pressure sensor unit is kPa and liquid level sensor unit

is %.

5 Display Unit

Unit displayed on the LCD of

Temp 0: °C 1: °F Pressure 0: kPa 1: Psi

2:

controller. Data automatically

will be converted

bar

according to the unit.

Sensor Upper Limit Shutdown (0-1)

6

0: Enabled

Enabled

1: Disabled

7 Upper Limit Shutdown Value (0-6000)

8 Shutdown Delay

(0-3600)s

(0-1)

9

Sensor Lower Limit Shutdown Enabled

0: Enabled

1: Disabled

10 Lower Limit Shutdown Value (0-4000)

11 Shutdown Delay

(0-3600)s

12

Sensor Upper Limit Warning

(0-1) 0: Enabled

Enabled

1: Disabled

13 Upper Limit Warning Value

(0-6000)

14

Upper Limit Warning Return Value

(0-6000)

15 Upper Limit Warning Delay

(0-3600)s

(0-1)

16

Sensor Lower Limit Warning Enabled

0: Enabled 1: Disabled

17 Lower Limit Warning Value

(0-4000)

18 Lower Limit Warning Return (0-4000) Value

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No.

Items

19 Lower Limit Warning Delay

20 1st Point of X (resistor)

21 2nd Point of X (resistor)

22 3rd Point of X (resistor)

23 4th Point of X (resistor)

24 5th Point of X (resistor)

25 6th Point of X (resistor)

26 7th Point of X (resistor)

27 8th Point of X (resistor)

28 1st Point of Y (value)

29 2nd Point of Y (value)

30 3rd Point of Y (value)

31 4th Point of Y (value)

32 5th Point of Y (value)

33 6th Point of Y (value)

34 7th Point of Y (value)

35 8th Point of Y (value)

36 User-defined Strings

Description (0-3600)s Resistor type (Non-PT100) Resistor type (Non-PT100) Resistor type (Non-PT100) Resistor type (Non-PT100) Resistor type (Non-PT100) Resistor type (Non-PT100) Resistor type (Non-PT100) Resistor type (Non-PT100) Resistor type (Non-PT100) Resistor type (Non-PT100) Resistor type (Non-PT100) Resistor type (Non-PT100) Resistor type (Non-PT100) Resistor type (Non-PT100) Resistor type (Non-PT100) Resistor type (Non-PT100) User can define name of sensors

Remark
User can define sensor curves. (X-axial and Y-axial are both contain 8 points.)
Set only by PC software.

10.4.2. TEMPERATURE CURVE LIST

Table 16 Temperature Curves Description

No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Name Not Used PT100 Custom Resistance Curve VDO CURTIS VOLVO-EC DATCON SGX SGD (Dongkang Sensor) SGH (Huanghe Sensor) Reserved Cu50 Reserved Reserved Reserved Reserved

Remark
Defined resistance’s range is (0~6)K, default is SGX sensor (water temperature sensor and oil temperature are all PT100 sensors).

NOTE: PT100 division value of resistor type temperature sensor is fixed as 0.385 (0.385 correspond to 1°C).

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10.4.3. PRESSURE CURVE LIST

Table 17 Pressure Curves Description

No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Name Not Used 4~20mA Custom Curve VDO 10bar CURTIS Reserved DATCON 10Bar SGX SGD (Dongkang Sensor) SGH (Huanghe Sensor) Reserved Reserved Reserved Reserved Reserved Reserved

Remark
Defined resistance’s range is (0~6)K, default oil pressure sensor is VDO- 10bar.

NOTE: If pressure signal is current-type, there is no need to set the curve and only need to set range.

10.4.4. LEVEL CURVE LIST

Table 18 Level Curves Description

No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Name Not Used 4~20mA Custom Resistance Curve SGD (Dongkang Sensor) SGH (Huanghe Sensor) Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved

Remark
There is no liquid level sensor in HMC4000 default sensor types. If this type is need to be used, please choose one between flexible sensor 1 and flexible sensor 2.

NOTE: If pressure signal is current-type, there is no need to set the curve and only need to set range.

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10.5 SELECTION OF CRANK DISCONNECT CONDITIONS

Table 19 Crank Disconnect Conditions election

No.

0

Speed

1

Oil pressure

2

Speed + Oil pressure

3

Speed +Generator

4

Gen + Oil pressure

5

Speed + Gen + Oil pressure

6

Generator

Setting Description

NOTE: 1) There are 3 conditions to make starter separate with engine; speed, generator frequency and oil pressure can be used
separately while oil pressure suggest be used together with speed and generator frequency. The aim is to disconnect the starter motor as soon as possible. 2) Speed stands for the real rotation speed detected by the speed sensor. Speed sensor is the magnetic equipment which be installed in starter for detecting flywheel teeth. 3) When set as speed, must ensure that the number of flywheel teeth is as same as setting, otherwise, “over speed shutdown” or “under speed shutdown” may be caused. 4) If generator-set without speed sensor please don’t select corresponding items, otherwise, “start fail” or “loss speed signal” maybe caused. 5) If generator-set without oil pressure sensor, please don’t select corresponding items. 6) If not select generator frequency in crank disconnect setting, controller will not collect and display the relative power quantity (can be used in water pump set); if not select speed in crank disconnect setting, the engine speed displayed in controller is calculated by generator signal.

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11 PARAMETERS SETTING
11.1 CONTROLLER PARAMETER SETTING
Start the controller, then press to enter into the parameters setting menu, menu items as
follows: 1 Return 2 Set Parameters 3 Information 4 Eventlog
When entered password interface, inputting correct password (default password is “0318”) can set parameters. If the password is changed, only input the password same as controllers’, can the parameter be set via PC software. If there is need to set more parameters (e.g. voltage calibration; current calibration), please contact the factory. NOTES:
a) Please change the controller parameters when generator is in standby mode only (e. g. Crank disconnect conditions selection, auxiliary input, auxiliary output, various delay), otherwise, shutdown and other abnormal conditions may occurs.
b) Over voltage set value must be higher than under voltage set value, otherwise over voltage and under voltage condition may occur simultaneously.
c) Over speed set value must be higher than under speed set value, otherwise over speed and under speed condition may occur simultaneously.
d) Please set the generator frequency value as low as possible when cranking, in order to make the starter be separated quickly as soon as possible.
e) Digital input 1~5 could not be set as same items; otherwise, there are abnormal functions. However, the digital output 1~5 can be set as same items.
f) Programmable sensor 1 input port can be set as temperature sensor, pressure sensor, coolant level sensor or 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 discrete input port, if digital input port be selected, corresponding set parameters be functional and sensor parameters are deactivated and reserved; otherwise, if sensor be selected, corresponding sensor parameters be functional and discrete input port parameters are deactivated and reserved.
g) If need to shut down after cooling, please set any auxiliary input as “High Temperature Stop Input”, then connect this input port to GND or set “High Temperature Stop Input” action as “Cooling Stop”.
11.2 CONTROLLER INFORMATION
LCD will display develop information like software version, issue date and present date of the controller.
11.3 EVENT LOG
View event log from this interface, including start/stop information and shutdown alarm information log. It can record and display up to 99 pieces.

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Table 20 Event Log Display

Event Log Shutdown Alarm Over Speed Shutdown 2017-08-08 15:30:25

Title Record Type Name of Alarm Alarm Occurred Time

12 SENSOR SETTING

1. When reselect sensors, the sensor curve will be transferred into the standard value. For example, if temperature sensor is SGH (120°C resistor type), its sensor curve is SGH (120°C resistor type); if select the SGD (120°C resistor type), the temperature sensor curve is SGD curve.
2. When there is difference between standard sensor curves and using sensor, user can entry into “Custom Sensors” page to define sensor curve.
3. When input the sensor curve, X value (resistor) must be input from small to large, otherwise, mistake occurs.
4. The headmost or backmost values in the vertical coordinates can be set as same as below,

Items 1Pa 1kgf/cm2 1bar 1psi

Fig.3 Sensor Curve

Table 21 Common Unit Conversion

N/m2 (pa) 1
9.8×104 1×105 6.89×103

kgf/cm2 1.02×105
1 1.02 7.03×102

bar 1×105
0.98 1
6.89×102

(p/in2.psi) 1.45×104
14.2 14.5
1

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13 COMMISSIONING
Please make sure the following checks are made before commissioning, 1) Ensure all the connections are correct and wires diameter is suitable. 2) Ensure that the controller DC power has fuse, controller’s positive and negative connected to start
battery are correct. 3) Take proper action to prevent engine to crank success (e. g. Remove the connection wire of fuel valve).
If checking is OK, make the start battery power on; choose manual mode and controller will executive routine. 4) Set controller under local mode, press “start” button, genset will start. After the cranking times as setting, controller will send signal of Start Failure; then press “stop” to reset controller. 5) Recover the action to prevent engine to crank success (e. g. Connect wire of fuel valve), press start button again, genset will start. If everything goes well, genset will normally run after idle running (if idle run be set). During this time, please watch for engine’s running situations and AC generator’s voltage and frequency. If abnormal, stop genset and check all wires connection according to this manual. 6) If there is any other question, please contact SmartGen’s service.

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14 TYPICAL APPLICATION

Fig.4 HMC4000 with Generator Typical Application (J1939 Interface)

Fig.5 HMC4000 Monitor Typical Application (J1939 Interface)

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Fig.6 Single Phase 2-Wire Wiring Connection Diagram
Fig.7 2-Phase 3-Wire Connection Diagram
NOTE: Expand relay with high capacity in start and fuel output is recommended.

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15 INSTALLATION
15.1 FIXING CLIPS

1. Controller is panel built-in design; it is fixed by clips when installed.
2. Withdraw the fixing clip screw (turn anticlockwise) until it reaches proper position. 3) Pull the fixing clip backwards (towards the back of the module) ensuring two clips are inside their
   allotted slots. 4) 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.
   15.2 OVERALL AND CUTOUT DIMENSIONS

Fig.8 Overall and Cutout Dimensions
HMC4000 series controller can suit for widely range of battery voltage DC (8~35) V. Negative of battery must be connected with the engine shell. Diameter of wire that connects from power supply to battery must be over 2.5mm2. If floating charge configured, please firstly connect output wires of charger to battery’s positive and negative directly, then, connect wires from battery’s positive and negative to controller’s positive and negative input ports in order to prevent charge disturbing the controller’s normal working.
15.3 WIRE CONNECTION INSTRUCTION

SPEED SENSOR INPUT
Speed sensor is the magnetic equipment which be installed in starter and for detecting flywheel teeth. Its connection wires to controller should apply for 2 cores shielding line. The shielding layer should connect to No. 17 terminal in controller while another side is hanging in air. The else two signal wires are connected to No.1 and No.17 terminals in controller. The output voltage of speed sensor should be within AC (1~24) V (effective value) during the full speed. AC12V is recommended (in rated speed). When install the speed sensor, let the sensor is spun to contacting flywheel first, then, port out 1/3 lap, and lock the nuts of sensor at last.

OUTPUT AND EXPAND RELAYS
All outputs of controller are relay contact output type. If need to expand the relays, please add freewheel diode to both ends of expand relay’s coils (when coils of relay have DC current) or, increase resistance-capacitance return circuit (when coils of relay have AC current), in order to prevent disturbance to controller or others equipment.

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AC INPUT
Current input of controller must be connected to outside current transformer. And the current transformer’s secondary side current must be 5A. At the same time, the phases of current transformer and input voltage must correct. Otherwise, the current of collecting and active power maybe not correct.
NOTE: 1) ICOM port must be connected to negative pole of battery. 2) When there is load current, transformer’s secondary side prohibit open circuit.

16 CONNECTIONS OF CONTROLLER WITH J1939 ENGINE

16.1 CUMMINS ISB/ISBE

Table 22 Connector B

Terminals of controller Auxiliary output 1 Start relay output
Auxiliary output 2

Connector B

Remark

39

Set Aux. output 1 as “Fuel Output”.

–

Connect with starter coil directly.

Expand 30A relay, battery

voltage of 01, 07, 12, 13 is supplied by relay.

ECU power; Set configurable output 2 as “ECU power”.

Table 23 9-pin Connector

Terminals of controller
CAN_SCR CAN(H) CAN(L)

9 pins connector
SAE J1939 shield SAE J1939 signal SAE J1939 return

Remark CAN communication shielding line (connect to ECU terminal only). Using impedance 120 connecting line. Using impedance 120 connecting line.

Engine type: Cummins ISB.

16.2 CUMMINS QSL9

Suitable for CM850 engine control module.

Table 24 50-pin Connector

Terminals of controller Auxiliary output 1 Start relay output

50 pins connector 39 –

Remark Set Aux. output 1 as “Fuel Output”. Connect to 34 starter coil directly.

Table 25 9-pin Connector

Terminals of controller
CAN_SCR
CAN(H) CAN(L)

9 pins connector
SAE J1939 shield-E
SAE J1939 signal-C SAE J1939 return-D

Remark CAN communication shielding line (connect to ECU terminal only). Using impedance 120 connecting line. Using impedance 120 connecting line.

Engine type: Cummins-CM850.

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16.3 CUMMINS QSM11 (IMPORT)

It is suitable for CM570 engine control mode. Engine type is QSM11 G1, QSM11 G2.

Table 26 C1 Connector

Terminals of controller

C1 connector

Auxiliary output 1

5&8

Start relay output

–

Remark Set configurable output 1 as “Fuel Output”. Outside expand relay, when fuel output, making make port 5 and port 8 of C1 be connected. Connect to starter coil directly.

Table 27 3-pin Data Link Connector

Terminals of controller CAN_SCR
CAN(H) CAN(L)

3 pins data link connector C
A B

Remark CAN communication shielding line (connect to ECU terminal only). Using impedance 120 connecting line. Using impedance 120 connecting line.

Engine type: Cummins ISB.

16.4 CUMMINS QSX15-CM570

It is suitable for CM570 engine control module. Engine type is QSX15.

Table 28 50-pin Connector

Terminals of controller Auxiliary output 1 Start relay output

50 pins connector 38 –

Remark Oil spout switch; Set Aux. output 1 as “Fuel Output”. Connect to starter coil directly.

Table 29 9-pin Connector

Terminals of controller CAN_SCR CAN(H) CAN(L)

9 pins connector SAE J1939 shield-E SAE J1939 signal-C SAE J1939 return-D

Remark CAN communication shielding line (connect to ECU terminal only). Using impedance 120 connecting line. Using impedance 120 connecting line.

Engine type: Cummins QSX15-CM570.

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16.5 CUMMINS GCS-MODBUS

It is suitable for GCS engine control module. Use RS485-MODBUS to read information of engine. Engine types are QSX15, QST30, QSK23/45/60/78 and so on.

Table 30 D-SUB Connector 06

Terminals of controller

D-SUB connector 06

Auxiliary output 1

5&8

Start relay output

–

Remark Set Aux. output 1 as “Fuel Output”. Outside expand relay, when fuel output, connect port 5 and 8 of the 06 connector. Connect to starter coil directly.

Table 31 D-SUB Connector 06

Terminals of controller RS485 GND
RS485+ RS485-

D-SUB connector 06 20
21 18

Remark CAN communication shielding line (connect to ECU terminal only). Using impedance 120 connecting line. Using impedance 120 connecting line.

Engine type: Cummins QSK-MODBUS, Cummins QST-MODBUS, Cummins QSX-MODBUS.

16.6 CUMMINS QSM11

Table 32 Engine OEM Connector

Terminals of controller Auxiliary output 1 Start relay output CAN_SCR CAN(H) CAN(L)

OEM connector of engine 38 46 37

Engine type: Common J1939.

Remark Set Aux. output 1 as “Fuel Output”. Connect with starter coil directly. CAN communication shielding line. Using impedance 120 connecting line. Using impedance 120 connecting line.

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16.7 CUMMINS QSZ13

Table 33 Engine OEM Connector

Terminals of controller Auxiliary output 1 Start relay output

OEM connector of engine 45 –

Auxiliary output 2

16&41

Auxiliary output 3

19&41

CAN_SCR

–

CAN(H)

1

CAN(L)

21

Engine type: Common J1939.

Remark
Connect to starter coil directly. Setting to idle speed control, normally open output. Making 16 connect to 41 during high-speed running of controller via external expansion relay. Setting to pulse raise speed control, normally open output. Making 19 connect with 41 for 0.1s during high-speed warming of controller via external expansion relay. CAN communication shielding line. Using impedance 120 connecting line. Using impedance 120 connecting line.

16.8 DETROIT DIESEL DDEC III/IV

Table 34 Engine CAN Port

Terminals of controller
Auxiliary output 1
Start relay output CAN_SCR CAN(H) CAN(L)

CAN port of engine Expand 30A relay, battery voltage of ECU supplied by relay. CAN(H) CAN(L)

Remark
Set Aux. output 1 as “Fuel Output”.
Connect to starter coil directly. CAN communication shielding line. Using impedance 120 connecting line. Using impedance 120 connecting line.

Engine type: Common J1939.

16.9 DEUTZ EMR2

Table 35 F Connector

Terminals of controller
Auxiliary output 1
Start relay output CAN GND CAN(H) CAN(L)

F connector Expand 30A relay, battery voltage of terminal 14 is supplied by relay. Fuse is 16A. 1 12 13

Remark
Set Aux. output 1 as “Fuel Output”.
Connect to starter coil directly. Connect to battery negative pole. CAN communication shielding line. Using impedance 120 connecting line. Using impedance 120 connecting line.

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Engine type: VolvoEDC4.

16.10 JOHN DEERE

Table 36 21-pin Connector

Terminals of controller Auxiliary output 1 Start relay output CAN_SCR CAN(H) CAN(L)

21 pins connector G, J D V U

Remark Set Aux. output 1 as “Fuel Output”.
CAN communication shielding line. Using impedance 120 connecting line. Using impedance 120 connecting line.

Engine type: John Deere.

16.11 MTU ADEC (SAM MODULE)

It is suitable for DEC (ECU7) and MTU engine of SAM module.

Table 37 ADEC (X1 Port)

Terminals of controller Auxiliary output 1

ADEC (X1 port) X1 43

Start relay output

X1 37

Remark Set Aux. output 1 as “Fuel Output”. X1 Terminal 28 Connected to negative of battery. X1 Terminal 22 Connected to negative of battery.

Table 38 SAM (X23 Port)

Terminals of controller CAN_SCR CAN(H) CAN(L)

SAM (X23 port) X23 3 X23 2 X23 1

Engine type: Common J1939.

Remark CAN communication shielding line. Using impedance 120 connecting line. Using impedance 120 connecting line.

16.12 PERKINS

It is suitable for ADEM3/ADEM4 engine control module. Engine type is 2306, 2506, 1106, and 2806.

Table 39 Connector

Terminals of controller Auxiliary output 1 Start relay output CAN_SCR CAN(H) CAN(L)
Engine type: Perkins.

Connector 1,10,15,33,34 31 32

Remark Set Aux. output 1 as “Fuel Output”. Connect to starter coil directly CAN communication shielding line Using impedance 120 connecting line Using impedance 120 connecting line

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16.13 SCANIA

It is suitable for S6 engine control mode. Engine type is DC9, DC12, and DC16.

Table 40 B1 Connector

Terminals of controller Auxiliary output port 1 Start relay output CAN GND CAN(H) CAN(L)
Engine type: Scania.

B1 connector 3 9 10

Remark Set configurable output 1 as “Fuel Output”. Connect to starter coil directly CAN communication shielding line Using impedance 120 connecting line Using impedance 120 connecting line

16.14 VOLVO EDC3

Suitable engine control mode is TAD1240, TAD1241, and TAD1242.

Table 41 “Stand alone” Connector

Terminals of controller Auxiliary output 1 Start relay output
Auxiliary output port 2

“Stand alone” connector H E
P

Remark Set Aux. output 1 as “Fuel Output”.
ECU power; Configurable output 2, “ECU power”.

Table 42 “Data bus” Connector

Terminals of controller CAN_SCR CAN(H) CAN(L)
Engine type: Volvo.

“Data bus” connector 1 2

Remark CAN communication shielding line Using impedance 120 connecting line Using impedance 120 connecting line

NOTE: When this engine type is selected, preheating time should be set to at least 3 seconds.

16.15 VOLVO EDC4

Suitable engine types are TD520, TAD520 (optional), TD720, TAD720 (optional), TAD721, TAD722, and TAD732.

Table 43 Connector

Terminals of controller
Auxiliary output 1
Start relay output
CAN_SCR CAN(H) CAN(L)

Connector Expanded 30A relay, and relay offers battery voltage to terminal 14. Fuse is 16A 1 12 13

Remark
Set Aux. output 1 as “Fuel Output”.
Connect to starter coil directly. Connected to negative of battery. CAN communication shielding line. Using impedance 120 connecting line. Using impedance 120 connecting line.

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Engine type: VolvoEDC4.

16.16 VOLVO-EMS2

Volvo Engine types are TAD734, TAD940, TAD941, TAD1640, TAD1641, and TAD1642.

Table 44 Engine CAN Port

Terminals of controller

Engine’s CAN port

Remark

Auxiliary output 1

6

ECU stop; Set Aux. output 1 as “ECU stop”.

Auxiliary output 2

5

ECU power; Set Aux. output 2 as “ECU power”.

3

Negative power.

4

Positive power.

CAN_SCR

–

CAN communication shielding line.

CAN(H)

1(Hi)

Using impedance 120 connecting line.

CAN(L)

2(Lo)

Using impedance 120 connecting line.

Engine type: Volvo-EMS2.

NOTE: When this engine type is selected, preheating time should be set to at least 3 seconds.

16.17 YUCHAI

It is suitable for BOSCH common rail electronic-controlled engine.

Table 45 Engine 42-pin Port

Terminals of controller
Auxiliary output 1
Start relay output CAN_SCR CAN(H) CAN(L)

Engine 42 pins port
1.40
1.35 1.34

Remark Set Aux. output 1 as “Fuel Output”. Connect to engine ignition lock. Connect to starter coil directly. CAN communication shielding line. Using impedance 120 connecting line. Using impedance 120 connecting line.

Table 46 Engine 2-pin Port

Battery Battery negative Battery positive Engine type: BOSCH.

Engine 2 pins port 1 2

Remark Wire diameter 2.5mm2. Wire diameter 2.5mm2.

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16.18 WEICHAI

It is suitable for Weichai BOSCH common rail electronic-controlled engine.

Table 47 Engine Port

Terminals of controller

Engine port

Remark

Auxiliary output 1

1.40

Set Aux. output 1 as “Fuel Output”. Connect to engine ignition lock.

Start relay output

1.61

CAN_SCR

–

CAN communication shielding line.

CAN(H)

1.35

Using impedance 120 connecting line.

CAN(L)

1.34

Using impedance 120 connecting line.

Engine type: GTSC1.

NOTE: If there is any question of connection between controller and ECU communication, please feel free to contact

SmartGen service.

17 FAULT FINDING

Table 48 Fault Finding

Symptoms Controller no response with power.
Genset shutdown Low oil pressure alarm after crank disconnect High water temp. alarm after crank disconnect Shutdown alarm in running
Start failure
Starter no response
RS485 Communication Failure
CAN Communication Failure

Possible Solutions Check starting batteries; Check controller connection wirings; Check DC fuse. Check the water/cylinder temperature is too high or not; Check the genset AC voltage; Check DC fuse.
Check the oil pressure sensor and its connections.
Check the temperature sensor and its connections.
Check related switch and its connections according to the information on LCD; Check programmable inputs. Check fuel oil circuit and its connections; Check starting batteries; Check speed sensor and its connections; Refer to engine manual. Check starter connections; Check starting batteries. Check whether wirings are correct or disconnected; Check whether COM ports settings are correct; Check whether communication baud rate and stop bit are consistent; Check whether PC port is damaged or not. Check whether wirings are correct or disconnected; Check whether communication baud rate is consistent; Check whether PC port is damaged or not.

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HMC4000 Marine Genset Controller User Manual

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References

• smartgen.cn/
• smartgen.com.cn/

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