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ALC404 LIGHTING TOWER CONTROLLER USER MANUAL

 

ALC404 Lighting Tower Controller                    2018-11-06                    Version 1.1                        Page 4 of 83 

CONTENTS

 

1 

OVERVIEW ............................................................................................................................................... 6 

2 

PERFORMANCE AND CHARACTERISTICS .......................................................................................... 6 

3 

SPECIFICATION....................................................................................................................................... 9 

4 

OPERATION ........................................................................................................................................... 10 

4.1 

PUSHBUTTONS ............................................................................................................................ 10 

4.2 

CONTROLLER

 

PANEL ................................................................................................................. 11 

4.3 

LCD

 

DISPLAY ................................................................................................................................ 11 

4.4 

SCHEDULED

 

START/STOP

 

OPERATION ................................................................................... 14 

4.4.1 

SCHEDULED START MODE SELECT OPERATION .............................................................. 14 

4.4.2 

SCHEDULED START OPERATION PROCESS ...................................................................... 15 

4.5 

SUNRISE/SUNSET

 

START

 

OPERATION .................................................................................... 16 

4.5.1 

SUNRISE/SUNSET START MODE SETTINGS ....................................................................... 16 

4.5.2 

SUNRISE/SUNSET START/STOP OPERATION PROCESS .................................................. 18 

4.6 

AUTO

 

REMOTE

 

START/STOP

 

OPERATION ............................................................................... 19 

4.6.1 

AUTO REMOTE START MODE SETTING .............................................................................. 19 

4.6.2 

AUTO REMOTE START/STOP PROCESS OPERATION ....................................................... 20 

4.7 

MANUAL

 

START/STOP

 

OPERATION .......................................................................................... 21 

4.8 

FORCE

 

START

 

OPERATION ....................................................................................................... 23 

5 

PROTECTIONS ...................................................................................................................................... 24 

5.1 

WARNING

 

ALARMS ...................................................................................................................... 24 

5.2 

SHUTDOWN

 

ALARMS .................................................................................................................. 27 

5.3 

TRIP

 

AND

 

STOP

 

ALARMS ............................................................................................................ 31 

6 

WIRING CONNECTION ......................................................................................................................... 32 

7 

SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS ................................................ 34 

7.1 

AUTO

 

START

 

PARAMETER

 

SETTINGS ...................................................................................... 34 

7.2 

GENERIC

 

PARAMETER

 

SETTINGS ............................................................................................ 35 

7.3 

FLEXIBLE

 

SENSOR

 

1

 

SETTINGS ................................................................................................ 50 

7.4 

FLEXIBLE

 

SENSOR

 

2

 

SETTINGS ................................................................................................ 51 

7.5 

FLEXIBLE

 

SENSOR

 

3

 

SETTINGS ................................................................................................ 53 

7.6 

SENSOR

 

CURVE

 

SELECTION ..................................................................................................... 54 

7.7 

SENSOR

 

SETTING ....................................................................................................................... 56 

7.8 

CONDITIONS

 

OF

 

CRANK

 

DISCONNECT

 

SELECTION .............................................................. 57 

7.9 

FUNCTION

 

DEFINITION

 

OF

 

INPUT

 

PORTS ................................................................................ 58 

7.10 

DEFINITION

 

OF

 

PROGRAMMABLE

 

INPUT

 

PORT

 

1-5 ................................................................ 60 

7.11 

ENABLE

 

DEFINITION

 

OF

 

PROGRAMMABLE

 

OUTPUT

 

PORT ................................................... 61 

7.12 

OVER

 

CURRENT

 

ACTION............................................................................................................ 65 

7.13 

LIGHT

 

INPUT

 

CONTROL

 

MODE .................................................................................................. 66 

7.14 

BATTERY

 

LOW

 

VOLT

 

AGE

 

START

 

MODE

 

(INVALID

 

WHILE

 

MAINS

 

SUPPLY

 

POWER) .......... 66 

7.15 

TIMER

 

MODE

 

SELECT ................................................................................................................. 67 

7.16 

SUNRISE/SUNSET

 

SETTING ...................................................................................................... 67 

7.17 

LOW

 

FUEL

 

LEVEL

 

REDUCE

 

LIGHT

 

NUMBER

 

(INVALID

 

WHILE

 

MAINS

 

SUPPLY

 

POWER) .... 67 

7.18 

REALIZE

 

MAINS

 

SUPPLY

 

POWER

 

VIA

 

EXTERNAL

 

DIGITAL

 

INPUT

 

PORT ............................. 67 

7.19 

DEEP

 

SLEEP

 

MODE ..................................................................................................................... 68 

Summary of Contents for ALC404

Page 1: ...ALC404 LIGHTING TOWER CONTROLLER USER MANUAL SMARTGEN ZHENGZHOU TECHNOLOGY CO LTD ...

Page 2: ...in any medium by electronic means or other without the written permission of the copyright holder Applications for the copyright holder s written permission to reproduce any part of this publication should be addressed to SmartGen Technology at the address above Any reference to trademarked product names used within this publication is owned by their respective companies SmartGen Technology reserv...

Page 3: ...e 2 Notation Clarification Symbol Instruction NOTE Highlights an essential element of a procedure to ensure correctness CAUTION Indicates a procedure or practice which if not strictly observed could result in damage or destruction of equipment WARNING Indicates a procedure or practice which could result in injury to personnel or loss of life if not followed correctly ...

Page 4: ...IONS 24 5 1 WARNING ALARMS 24 5 2 SHUTDOWN ALARMS 27 5 3 TRIP AND STOP ALARMS 31 6 WIRING CONNECTION 32 7 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS 34 7 1 AUTO START PARAMETER SETTINGS 34 7 2 GENERIC PARAMETER SETTINGS 35 7 3 FLEXIBLE SENSOR 1 SETTINGS 50 7 4 FLEXIBLE SENSOR 2 SETTINGS 51 7 5 FLEXIBLE SENSOR 3 SETTINGS 53 7 6 SENSOR CURVE SELECTION 54 7 7 SENSOR SETTING 56 7 8 CONDITIONS O...

Page 5: ...NS OF CONTROLLER WITH J1939 ENGINE 72 10 1 CUMMINS ISB ISBE 72 10 2 CUMMINS QSL9 72 10 3 CUMMINS QSM11 IMPORT 73 10 4 CUMMINS QSX15 CM570 73 10 5 CUMMINS QSM11 73 10 6 CUMMINS QSZ13 74 10 7 DETROIT DIESEL DDEC III IV 74 10 8 DEUTZ EMR2 74 10 9 JOHN DEERE 75 10 10 MTU MDEC 75 10 11 MTU ADEC SMART MODULE 75 10 12 MTU ADEC SAM MODULE 76 10 13 PERKINS 76 10 14 SCANIA 76 10 15 VOLVO EDC3 77 10 16 VOLVO...

Page 6: ... structure reliable operation and simple connections which is very easy to use and convenient to maintain 2 PERFORMANCE AND CHARACTERISTICS Based on microprocessor fitted with 132x64 LCD screen with graphic icons and backlit selectable Chinese English languages interface and pushbuttons Be compatible with both AC and DC light tower sets Deep sleep function Reducing the number of the lighting lamps...

Page 7: ...time and sunset time can be set by users as users wish Remote start stop function Manual start stop control of light tower set and manual on off control of lighting lamps Standard USB communication port makes it easier to communicate with PC and faster to configure parameters network monitoring can be achieved via USB port CANBUS interface can connect with J1939 EFI engine which can not only monit...

Page 8: ...t also can be print or be inquired via PC More kinds of curves of temperature oil pressure fuel level can be used directly and users can select User Configured sensor curves for unknown engine sensor Widely power supply range DC 8 35 V suitable to different starting battery voltage environment Modular design pluggable terminal built in mounting compact structure with easy installation ...

Page 9: ...B power supply output Configurable Relay Output 2 1A DC B power supply output Configurable Relay Output 3 1A DC B power supply output Configurable Relay Output 4 1A DC30V volt free output Configurable Relay Output 5 1A DC30V volt free output Configurable Relay Output 6 1A DC30V volt free output Configurable Relay Output 7 1A DC30V volt free output Case Dimensions 135 mm x 110 mm x 44 mm Panel Cuto...

Page 10: ...ff screen In light On Off screen in manual mode press to turn off the light and press to turn on the light Menu Confirm Press this key to enter into menu screen In parameter setting page press this key to right shift cursor and confirm the setting information Up Config Press this key to scroll screens in parameter display page menu page and records query page Up cursor and increase value in parame...

Page 11: ...ile genset is normal running 4 3 LCD DISPLAY Table 5 Main Screen Display Mains Screen Description First screen displays all lights status average voltage generator frequency generator speed water temperature oil pressure fuel level light tower set running status and alarm information Light On Light Off Battery Speed Generator Mains Coolant Temp Oil Pressure Fuel Level Note coolant temp oil pressur...

Page 12: ...wer values equal or above 100 no decimal will be displayed and users can check precise data via PC software The screen display DC voltage current and power when DC current is fitted Press button The screen displays lighting tower set input values of flexible sensors If one sensor is configured as Not Used no information about this sensor will be displayed if the sensor open circuit will be display...

Page 13: ...lays accumulated start times accumulated output active energy accumulated run time HH MM SS Press button The screen displays currently start time HH MM SS and output active energy of this time Press button The screen displays alarms information that detected by the controller Total Data Starts 1 Hours Run 1 03 40 Energy 14 0kWh 1 2 3 4 Current Boot Data Hours Run 0 32 45 Energy 7 0kWh Gens Normal ...

Page 14: ... Runing Action setting page and choose 01 Timer Mode Select through pressing and 3 Timer Mode Select Press key to enter into 01 Timer Mode Select setting screen and press again to select 00 Daily option via pressing or Then press to confirm and save the setting At this time through pressing or to return to auto timer mode detailed setting navigation screen 4 Auto Run Timer Set In auto timer mode d...

Page 15: ...ay 1 Configure the controller as scheduled start mode and choose Timer Mode 00 Daily and start time set as 18 30 continuous running time hours run set as 12 00 12hours 2 When there are 10s left from start time audible alarm relay is active if configured when start time is up audible alarm relay will stop output When start time is up and start remaining time is more than 0s light tower set begin cr...

Page 16: ... automatically when select other auto start mode if select Auto Timer Mode Daily lighting tower set will be auto started everyday at the pre set time 4 5 SUNRISE SUNSET START OPERATION 4 5 1 SUNRISE SUNSET START MODE SETTINGS Table 8 Sunrise Sunset Start Operation No Process Description Panel Display 1 Download city info via PC software Users should connect PC and ALC400 controller using USB commu...

Page 17: ... setting screen and configure the delay value through or key after pressing delay value can be confured as ahead of preset start time and after of preset start time And then press key to save the setting into the controller Meanwile press or to return to Sunrise set Action setting scrren 5 Sunset stop time delay setting In Sunrise set Action setting navigition screen press or to select 04 Sunrise ...

Page 18: ...ormation as Beijing via PC sofware sunset start time delay as 0min and sunrise stop time delay as 0min The actual start ime is 16 55 00 and stop time is 07 06 00 2 When there are 10s left from start time start time can be configured via PC software audible alarm relay is active if configured when start time is up audible alarm relay will stop output When start time is up light tower set begin cran...

Page 19: ...ights off Remark The Sunrise Sunset mode will be canceled automatically when select other auto start mode 4 6 AUTO REMOTE START STOP OPERATION 4 6 1 AUTO REMOTE START MODE SETTING Table 10 Auto Remote Start Mode Setting No Process Description Panel Display 1 Config input port Configure input port 1 as Remote Start Input 2 Enter into Auto Timer Mode detailed setting navigation screen Press its indi...

Page 20: ...quency has reached on load requirements speed on load speed voltage on load voltage and frequency on load frequency all the lights will illuminate in proper order and the illumination interval delay is 2s can be set as 1s 300s 4 When remote start input port is inactive remote stop delay begins when stop delay is over 1 4 lights will off in proper order and the extinguishing interval delay can be s...

Page 21: ...n off lights O stands for Open refers to and means is active C stands for Close refers to and means is active Table 13 Manually Start Stop Unit Operation No Operation Process Panel Display 1 Press its indicator lights on and controller enters Manual Mode Press light tower set begins cranking Manual Mode Manual Start Current Time 17 00 02 Cranking 5s 1 2 3 4 Manual Mode Wait Manual Start Current Ti...

Page 22: ...rder press once one light off 5 If users need to stop the light tower set press 1 4 lights will off in proper order when all lights are in illuminated status and the extinguishing interval delay can be set as 1s 300s can be configured The light tower set begin stopping when the lights are off Press again during this procedure will lead to all lights off at the same time and controller enters into ...

Page 23: ...CE START OPERATION Simultaneously pressing and in manual mode can force start light tower set at the moment starter disconnect controlled by the operator instead of judging from crank disconnect conditions When light tower set successfully start operator will release the keys and controller enters into safety running delay ...

Page 24: ...and the corresponding alarm information will be displayed on the LCD 6 Generator Over Frequency If it is enabled when controller detects the frequency of light tower set is higher than the set value it will send warning signal and the corresponding alarm information will be displayed on the LCD 7 Generator Under Frequency If it is enabled when controller detects the frequency of light tower set is...

Page 25: ...y users as xxx then xxx Warning will be displayed on the LCD 18 Input 2 Warning 19 Input 3 Warning 20 Input 4 Warning 21 Input 5 Warning 22 External Charge Fail When controller detects external charge fail input is active it will send warning signal and the corresponding alarm information will be displayed on the LCD 23 Light Fault Warning If it is enabled when controller detects the beacon lamp f...

Page 26: ... fuel level of light tower set is lower than the preset light off value it will send warning signal and the corresponding alarm information will be displayed on the LCD 37 Mains Over Frequency If it is enabled when controller detects the frequency of mains is higher than the maximum limit of preset value it will send warning signal and the corresponding alarm information will be displayed on the L...

Page 27: ...utdown signal and the corresponding alarm information will be displayed on the LCD 6 Under Speed If it is enabled when controller detects the generator speed is lower than the minimum limit of preset value it will send a shutdown signal and the corresponding alarm information will be displayed on the LCD 7 Loss of Speed Signal When controller detects the generator speed is 0 meanwhile action selec...

Page 28: ...red by users as xxx then xxx Shutdown will be displayed on the LCD 17 Input 3 Shutdown When input port 3 is selected as user defined and action type choose shutdown alarm if input port is active controller will send warning signal and the corresponding alarm information will be displayed on the LCD If input name is configured by users as xxx then xxx Shutdown will be displayed on the LCD 18 Input ...

Page 29: ...xxx then xxx High shutdown information will be displayed on the LCD 26 Sensor 3 High If it is enabled when controller detects the sensor 3 value is higher than the maximum limit of preset value it will send shutdown signal and the corresponding alarm information will be displayed on the LCD If the sensor name is configured by users as xxx then xxx High shutdown information will be displayed on the...

Page 30: ...d by EFI engine is higher than the maximum limit of preset value it will send shutdown signal and the corresponding alarm information will be displayed on the LCD 35 ECU Oil Pressure Low If it is enabled when controller detects the oil pressure transferred by EFI engine is lower than the minimum limit of preset value it will send shutdown signal and the corresponding alarm information will be disp...

Page 31: ...orresponding alarm information will be displayed on the LCD If the input port name is configured by users as xxx then xxx trip and stop will be displayed on the LCD 4 Digital Input 3 Trip and Stop User defined When the controller detects digital input port 3 trip alarms it will send a trip and stop alarm signal and the corresponding alarm information will be displayed on the LCD If the input port ...

Page 32: ...d external connected with positive of starter battery If the length is above 30m double wires need to be paralleled and 20A fuse is recommended 3 Aux Output 1 1 0 mm2 B output is supplied by terminal No 2 rated 5A If the fuel relay output needs to be connected users can configure Output 1 Settings in Relay Output Ports Setting page 4 Crank 1 0 mm2 B output is supplied by terminal No 2 rated 5A 5 C...

Page 33: ...hich connected B to activate 24 Aux Input 4 1 0 mm2 Digital input port which connected B to activate 25 Aux Input 5 1 0 mm2 Digital input port which connected B to activate 26 DC Current Input 1 0 mm2 Connect to the output port of Hall DC 4 20mA sensor DC generator current 27 DC Current Input 1 0 mm2 28 DC Voltage Input 1 0 mm2 Connect to output port of DC generator 29 DC Voltage Input 1 0 mm2 30 ...

Page 34: ... Duration hh mm Custom Sunday Start Time Run Duration 00 00 23 59 00 00 23 59 18 30 12 00 Start Time hh mm Run Duration hh mm Custom Monday Start Time Run Duration 00 00 23 59 00 00 23 59 18 30 12 00 Start Time hh mm Run Duration hh mm Custom Tuesday Start Time Run Duration 00 00 23 59 00 00 23 59 18 30 12 00 Start Time hh mm Run Duration hh mm Custom Wednesday Start Time Run Duration 00 00 23 59 ...

Page 35: ...er up when the engine starts fail Safety On Time 0 3600 s 10 During this time alarms including low oil pressure high temperature under speed gen under frequency gen under voltage and fail to charge are deactivated Start Idle Time 0 3600 s 10 It is genset idle running time while starting up Warming Up Time 0 3600 s 30 After generator entering into high speed running it is warming up time before ram...

Page 36: ...1 30 0 s 0 1 It is drop speed pulse output time output port configured as Drop Speed Pulse Engine Engine Type 00 39 00 Conventional Engine Default as conventional engine When connect to J1939 engine please select the corresponding engine model SPN Version 1 3 Version 1 Version 1 Version 2 Version 3 Flywheel Teeth 10 0 300 0 118 0 Flywheel teeth that installed on the engine which is used for judgin...

Page 37: ...en reached controller will send start fail signal Disconnect Condition 0 6 3 AC genset reference to Table 25 AC GENSET CRANK DISCONNECT CONDITION DC genset reference to Table 26 DC GENSET CRANK DISCONNECT CONDITION There are 3 conditions to make starter disconnected with engine and they all can be used separately or simultaneously aiming to disconnect starter motor with engine as soon as possible ...

Page 38: ... Voltage 0 60 0 V 24 0 Provide standard for judging battery over under voltage and charge fail Battery Charge Alternator Failure Warning Enable 0 1 1 0 Disabled 1 Enabled Set Value 0 200 75 The setting value is percentage of starting battery rated voltage While genset in normal running stage if D WL voltage of charger bellows setting limit and delay time is expired controller will send charge fail...

Page 39: ...uto and Manual Mode Active Max Run Time 0 1 100 0 h 4 0 If battery under voltage starts up when charging time exceeds the setting limit engine will automatically shut down and then charging will stop Full Charge Delay 0 1000 min 60 It is the time from battery voltage exceeds full charged voltage limit to under voltage start end Start Value 0 200 80 The setting value is percentage of starting batte...

Page 40: ...bled 1 Enabled Set Value 0 200 80 The setting value is percentage of rated speed Delay 0 3600 s 10 Over Speed Shutdown Enable 0 1 1 0 Disabled 1 Enabled Set Value 0 200 114 The setting value is percentage of rated speed Delay 0 3600 s 2 Under Speed Warning Enable 0 1 0 0 Disabled 1 Enabled Set Value 0 200 86 The setting value is percentage of rated speed Return Value 0 200 90 The setting value is ...

Page 41: ...utput time of fuel pump control aiming to prevent fuel pump continues working because of the sensor fault Fuel Tank Capacity Enable 0 1 0 0 Disabled 1 Enabled Capacity 0 10000 L 100 After it is enabled liquid unit displayed on the mains screen is changed from to L conversion formula Fuel capacity tank capacity fuel level Coolant Temperature Associated 0 3 1 0 Not Associated 1 ALC404 Sensor 1 2 ALC...

Page 42: ...ate engine speed if there is no speed sensor installed Generator Rated Voltage 10 1000 V 230 Provide standard for judging generator over under voltage and loading voltage If voltage transformer is used it is PT primary voltage If AC system set as 3P3W it is line voltage and if other AC system is selected it is phase voltage Generator Rated Frequency 10 0 600 0 Hz 50 0 Provide standard for judging ...

Page 43: ...rated voltage Delay 0 3600 s 5 Gen Under Frequency Shutdown Enable 0 1 1 0 Disabled 1 Enabled Set Value 0 200 80 The setting limit is percentage of generator rated frequency Delay 0 3600 s 10 Gen Over Frequency Shutdown Enable 0 1 1 0 Disabled 1 Enabled Set Value 0 200 114 The setting limit is percentage of generator rated frequency Delay 0 3600 s 3 Gen Under Voltage Warning Enable 0 1 1 0 Disable...

Page 44: ...3600 s 3 Mains Mains Supply Type 0 4 0 0 3Phase 4Wire 3P4W 1 3Phase 3Wire 3P3W 2 1Phase 2Wire 1P2W 3 2Phase 3Wire 2P3W 4 DC Power Mains Rated Voltage 10 1000 V 230 Provide standard for judging mains over under voltage If voltage transformer is used it is PT primary voltage If AC system set as 3P3W it is line voltage and if other AC system is selected it is phase voltage Mains Rated Frequency 10 0 ...

Page 45: ... The setting limit is percentage of mains rated frequency Return 0 200 94 The setting limit is percentage of mains rated frequency Delay 0 3600 s 5 Mains Over Frequency Warning Enable 0 1 1 0 Disabled 1 Enabled Set Value 0 200 114 The setting limit is percentage of mains rated frequency Return 0 200 110 The setting limit is percentage of mains rated frequency Delay 0 3600 s 5 Load CT Ratio Hall DC...

Page 46: ...The calculate formula of over current delay can reference to 7 12 OVER CURRENT ACTION Light Fault Check Configure Enable 0 1 0 0 Disabled 1 Enabled Single Light Fault 0 200 75 It is the percentage of rated current for each light Delay 0 3600 s 5 It is delay time used to confirm light fault Light Fault Action 0 3 1 0 No Action 1 Warning 2 Shutdown 3 Smart Action Note Smart action means controller w...

Page 47: ...the light warning Allowed Light on Amount 0 4 1 The number of turned on lights that allowed after controller sending fuel level drop turn off the light signal Note This function is invalid when mains power supply is active or fuel level does not associate with sensors Sensors Flexible Sensor 1 Details please to see7 3 FLEXIBLE SENSOR 1 SETTINGS Flexible Sensor 2 Details please to see7 4 FLEXIBLE S...

Page 48: ...please to see 7 9 FUNCTION DEFINITION OF INPUT PORTS Active 0 1 0 Close to activate 0 Close to activate 1 Open to activate Input 3 Set Function Config 0 59 09 2 Light Feedback Functions please to see 7 9 FUNCTION DEFINITION OF INPUT PORTS Active 0 1 0 Close to activate 0 Close to activate 1 Open to activate Input 4 Set Function Config 0 59 10 3 Light Feedback Functions please to see 7 9 FUNCTION D...

Page 49: ...lose Output 6 Set Function Config 0 119 108 3 Light Output 7 11 FUNCTION DEFINITION OF OUTPUT PORTS Output Type 0 1 0 Open 0 Open 1 Close Output 7 Set Function Config 0 119 109 4 Light Output 7 11 FUNCTION DEFINITION OF OUTPUT PORTS Output Type 0 1 0 Open 0 Open 1 Close Module Config Language Select 0 1 0 0 Simplified Chinese 1 English Power On Mode 0 4 0 0 Stop Mode 1 Manual Mode 2 Auto Timer Mod...

Page 50: ... SENSOR CURVE SELECTION 3 Open Circuit Action 0 2 0 0 Warning 1 Shutdown 2 No Action 4 Display Unit 0 1 0 0 1 5 Sensor High Shutdown 0 1 0 1 1 0 Disabled 1 Enabled 6 Set Value 0 1000 98 7 Delay 0 3600 s 3 8 Sensor Low Shutdown Enable 0 1 0 0 Disabled 1 Enabled 9 Set Value 0 1000 0 10 Delay 0 3600 s 3 11 Sensor High Warning Enable 0 1 1 0 Disabled 1 Enabled 12 Set Value 0 1000 95 13 Return Value 0 ...

Page 51: ... Value 0 4000 80 32 6th point Y Value 0 4000 60 33 7th point Y Value 0 4000 40 34 8th point Y Value 0 4000 20 35 User defined Strings User defined sensor name Chinese 发动机 温度 English Engine Temp PC software can write 10 Chinese characters and 20 English characters 7 4 FLEXIBLE SENSOR 2 SETTINGS Table 21 Flexible Sensor 2 Settings No Parameter Range Default Description 1 Sensor Type 0 3 2 0 Not Used...

Page 52: ...xis of user defined sensor curves are all with 8 points Unit of X axis is Ω Units of X axis are as follows Pressure kPa Fuel Level Temp 20 2nd point X Resistance 0 1000 30 21 3rd point X Resistance 0 1000 50 22 4th point X Resistance 0 1000 86 23 5th point X Resistance 0 1000 100 24 6th point X Resistance 0 1000 132 25 7th point X Resistance 0 1000 168 26 8th point X Resistance 0 1000 200 27 1st p...

Page 53: ...Sensor Low Shutdown Enable 0 1 0 0 Disabled 1 Enabled 9 Set Value 0 1000 0 10 Delay 0 3600 s 3 11 Sensor High Warning Enable 0 1 0 0 Disabled 1 Enabled 12 Set Value 0 1000 0 13 Return Value 0 1000 0 14 Delay 0 3600 s 5 15 Sensor Low Warning Enable 0 1 1 0 Disabled 1 Enabled 16 Set Value 0 1000 10 17 Return Value 0 1000 15 18 Delay 0 3600 s 10 19 User defined Sensor Curve 1st point X Resistance 0 1...

Page 54: ...r Curves No Items Content Remark 1 Temperature Sensor 0 Not Used 1 Digital closed for high temperature 2 Digital open for high temperature 3 User defined 4 VDO 120 degrees C 5 Datcon high 6 Datcon low 7 SGX 120 degrees C 8 Cummins 9 SGH 120 degrees C 10 Curtis 11 SGD 120 degrees C 12 Pt100 13 Reserved 14 Reserved 15 Reserved The range of user defined resistor type sensor is 0 999 9 Ω factory defau...

Page 55: ...1 Digital close for low fuel level 2 Digital open for low fuel level 3 User defined 4 VDO Ohm range 10 180 5 VDO Tube type 90 0 6 US Ohm range 240 33 7 GM Ohm range 0 90 8 GM Ohm range Ohm range 0 30 9 Ford 73 10 10 NKZR12 24 1 04 Ohm range 100 0 11 SGD 12 SGH 13 Reserved 14 Reserved 15 Reserved The range of user defined resistor type sensor is 0 999 9 Ω by default 11 SGD sensor curve is selected ...

Page 56: ...n there is difference between standard sensor curves and using sensor user can adjust it in curve type When user defined the sensor curve X value resistor must be input from small to large otherwise mistake occurs If select sensor type or sensor curve select as Not Used sensor curve is not working The headmost or backmost values in the vertical coordinates can be set as same as below Fig 3 User De...

Page 57: ...e oil pressure suggest be used together with speed and generator frequency The aim is to disconnect the starter motor as soon as possible b Speed is the real time speed collected by the speed sensor and speed sensor is the magnetic equipment which be installed in starter for detecting flywheel teeth c When set as speed must ensure that the number of flywheel teeth is as same as setting otherwise o...

Page 58: ...anel LCD 7 Reserved 8 1 Light Feedback Input When the input is active the corresponding light of the lighting tower set through the feedback input method to access the controller to participate in automatic control Details of control method please to see 7 13 LIGHT INPUT CONTROL MODE 9 2 Light Feedback Input 10 3 Light Feedback Input 11 4 Light Feedback Input 12 Reserved 13 1 Light Control Input W...

Page 59: ...te warning alarms 40 Low Oil Pressure Warning It is connect with digital input port of sensor when the input is active controller will initiate warning alarms 41 Low Fuel Level Warning It is connect with digital input port of sensor when the input is active controller will initiate warning alarms 42 Low Coolant Level Warning It is connect with digital input port of sensor when the input is active ...

Page 60: ...e Range Default Function Description 1 User defined Active Type 0 1 0 0 Close to Activate 1 Open to Activate 2 Working Range 0 3 2 0 Never input port is deactivated 1 Always input always been detected 2 From Crank detection of input port starts from crank 3 From Safety On detection of input port starts from safety on delay expired 3 Action 0 3 1 0 Indication only display status without warning and...

Page 61: ...Shutdown Action when the input port that configured as Low Oil Pressure Shutdown Input is active and controller detects low oil pressure shutdown alarms 7 Oil Pressure Sensor Open Circuit Shutdown Action when the input port that configured as Oil Pressure Open Circuit Shutdown Input is active and controller detects oil pressure sensor open circuit shutdown alarms 8 Start Relay Output Action when g...

Page 62: ...port 2 is active 30 Digital Input 3 Active Action when input port 3 is active 31 Digital Input 4 Active Action when input port 4 is active 32 Digital Input 5 Active Action when input port 5 is active 33 Reserved 34 Emergency Stop Action when emergency stop alarm occurs 35 Energize to Stop Action during ETS delay 36 Failed to Start Action when failed start alarm occurs 37 Fuel Pump Control It is cl...

Page 63: ...n Fail Shut It is indicate that ECU has failed to communicate with controller 55 ECU High Coolant Temp Warning It is output when the coolant temperature of ECU is high and arrived at the warning limit 56 ECU High Coolant Temp Shutdown It is output when the coolant temperature of ECU is high and arrived at the shutdown limit 57 ECU Low Oil Pressure Warning It is output when the oil pressure of ECU ...

Page 64: ... stop 83 Pre Lubrication Output Action in period of pre heat to safety on 84 Reserved 85 Strobe Light It is output between the periods from genset normal running to stop cooling or output when genset fail to stop 86 Audible Warning Action when there are 10s left from start time in auto start mode and stop output after starting the generator 87 Remote PC Output Control genset via PC software or rem...

Page 65: ...time while entering into stop idle period drop speed pulse output time of timer settings It is use to control partial ECU rise to idle speed Default action time is 0 1s and users can define it according to the requirement 106 1 Light Output It is 1 light output action 107 2 Light Output It is 2 light output action 108 3 Light Output It is 3 light output action 109 4 Light Output It is 4 light outp...

Page 66: ...he indicator on the panel shows the light on off based on the light output port status If the light configured as major control input at anytime irrelevant to genset running status the light output open close only judged by the light input port status and the indicator on the panel shows the light on off based on the light input port status Under this mode controller cannot automatic control the l...

Page 67: ...to reduce fuel consumption If this function is enabled and fuel level associated with the sensor lights number can be reduced automatically through adjusting parameters of Low Fuel Level Light off settings 7 18 REALIZE MAINS SUPPLY POWER VIA EXTERNAL DIGITAL INPUT PORT This function allows external connected mains to supply power for the unit If mains are active whatever working mode the unit stat...

Page 68: ...on 3 simultaneously in both timer start mode and sunrise set start mode 7 19 2 EXIT DEEP SLEEP MODE METHOD Methods of exiting deep sleep mode are as follows Method 1 Press or button of controller to exit low power consumption mode Method 2 Realizing remote start to wake controller from deep sleep mode must configure input port 1 as 04 Remote Start Input firstly activate input port 1 and then deact...

Page 69: ...ions 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 start...

Page 70: ... Chinese and English can be optional 8 5 EVENT LOG Maximum 99 pieces of event logs time of start stop and fault shutdown events can be circularly stored into ALC404 controller and fault shutdown events include fault shutdown type and occurs time and date If the alarm records are more than 99 pieces then the latest record will replace the oldest one Event log display please to see the following tab...

Page 71: ...ct 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 Set controller under manual mode press start button genset will start After the cranking times as setting controller will send signal of Start Fail then press stop to reset controller Recover the action of prevent engine start e g Connect wire o...

Page 72: ...le 33 9Pins Connector Terminals of controller 9 pins connector Remark SAE J1939 shield CAN communication shielding line connect with ECU terminal only CAN H SAE J1939 signal CAN L SAE J1939 return Engine type Cummins ISB 10 2 CUMMINS QSL9 Suitable for CM850 engine control mode Table 34 50Pins Connector Terminals of controller 50 pins connector Remark Aux output 1 39 Aux output 1 configured as Fuel...

Page 73: ...y CAN H A CAN L B Engine type Cummins ISB 10 4 CUMMINS QSX15 CM570 It is suitable for CM570 engine control module Engine type is QSX15 Table 38 50Pins Connector Terminals of controller 50 pins connector Remark Aux output 1 38 Oil spout switch Aux output 1 configured as Fuel Output Starter relay output Connect to starter coil directly Table 39 9Pins Connector Terminals of controller 9 pins connecto...

Page 74: ...igh speed warming of controller via external expansion relay CAN GND CAN communication shielding line CAN H 1 CAN L 21 Engine type Common J1939 10 7 DETROIT DIESEL DDEC III IV Table 42 Engine CAN Connector Terminals of controller CAN port of engine Remark Aux output 1 Expand 30A relay battery voltage of ECU is supplied by relay Aux output 1 configured as Fuel Output Start relay output Connect to s...

Page 75: ...er X1 connector Remark Aux output 1 BE1 Aux output 1 configured as Fuel Output Start relay output BE9 E CAN communication shielding line connect with one terminal only CAN H G CAN L F Engine type MTU MDEC 303 10 11 MTU ADEC SMART MODULE It is suitable for MTU engine with ADEC ECU8 and SMART module Table 46 ADEC X1 Connector Terminals of controller ADEC X1port Remark Aux output 1 X1 10 Aux output 1...

Page 76: ...ielding line CAN H X23 2 CAN L X23 1 Engine type Common J1939 10 13 PERKINS It is suitable for ADEM3 ADEM4 engine control module Engine type is 2306 2506 1106 and 2806 Table 50 Connector Terminals of controller Connector Remark Aux output 1 1 10 15 33 34 Aux output 1 configured as Fuel Output Starter relay output Connect to starter coil directly CAN communication shielding line CAN H 31 CAN L 32 E...

Page 77: ...ould be set to at least 3 seconds 10 16 VOLVO EDC4 Suitable engine types TD520 TAD520 optional TD720 TAD720 optional TAD721 TAD722 and TAD732 Table 54 Connector Terminals of controller Connector Remark Aux output 1 Expanded 30A relay and relay offers battery voltage for terminal14 Fuse is 16A Aux output 1 configured as Fuel Output Start relay output Connect to starter coil directly 1 Connected to ...

Page 78: ...tion shielding line CAN H 1 35 CAN L 1 34 Table 57 Engine 2 Pin Connector Battery Engine 2 pins Remark Battery negative 1 Wire diameter 2 5mm2 Battery positive 2 Wire diameter 2 5mm2 Engine type BOSCH 10 19 WEICHAI It is suitable for Weichai BOSCH common rail pump engine Table 58 Engine Connector Terminals of controller Engine port Remark Aux output 1 1 40 Aux output 1configured as Fuel Output Con...

Page 79: ...LLER USER MANUAL ALC404 Lighting Tower Controller 2018 11 06 Version 1 1 Page 79 of 83 11TYPICAL WIRING DIAGRAMS Fig 4 ALC404 Controls AC Non EFI Engine Set Application 3P4W Fig 5 ALC404 Controls AC EFI Engine Set Application 3P4W ...

Page 80: ...404 Lighting Tower Controller 2018 11 06 Version 1 1 Page 80 of 83 Fig 6 ALC404 Controls AC Unit Application 3P3W Fig 7 ALC404 Controls AC Unit Application 2P3W Fig 8 ALC404 Controls AC Unit Application 1P2W Fig 9 ALC404 Controls DC Unit Application ...

Page 81: ...igure the flexible sensor 1 3 separately as engine temperature oil pressure and fuel level to realize the routine controlling of the genset NOTE 3 EFI engine set can configure flexible sensor 1 as fuel level and the other two sensors are freely set to realize the routine controlling of the genset NOTE 4 While controlling of the DC genset users need to select the appropriate DC Hall sensors based o...

Page 82: ...nect 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 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 t...

Page 83: ...s service Symptoms Possible Solutions Controller no response with power Check starting batteries Check controller connection wirings Check DC fuse Light tower set shutdown Check whether the water cylinder temperature is too high or not Check the generator AC voltage Check DC fuse Controller emergency stop Check emergence stop button is correct or not Check whether the starting battery positive be ...

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