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Smartgen APC615, User Manual

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                                                                APC615 Pump Unit Controller User Manual 

APC615 Pump Unit Controller                      Version 1.0                    2017-10-20                      Page 17 of 54

 

NOTE

：

  ECU warning and ECU shutdown illustration: if detailed alarm content displayed on the LCD of 

controller, please check engien condition according to the displayed content; otherwise, please look up engine 

user manual based on the SPN code to receive information.   

6 

CONNECTIONS 

 

Fig. 2 

– APC615 Back Panel

 

Description of terminal connections:

 

No. 

Function 

Cable Size 

Description 

1 

B- 

2.5mm

2

 

Connected with negative of starter battery. 

2 

B+ 

2.5mm

2

 

Connected  with  positive  of  starter  battery.  If  wire  length  is 

over 30m, better to double wires in parallel. Max. 20A fuse is 

recommended. 

3 

COM1 

Relay 

Common Port 

1.5mm

2

 

Connect to COM1 output with rated 16A. 

4 

Crank 

1.5mm

2

 

5 

Fuel   

1.5mm

2

 

6 

Aux. Output 1 

1.5mm

2

 

7 

COM2 

1.5mm

2

 

Connect to COM2 output with rated 7A. 

Detailed 

setting 

items  please  to 

8 

Aux. Output 2 

1.5mm

2

 

Summary of Contents for APC615

Page 1: ...APC615 PUMP UNIT CONTROLLER USER MANUAL SMARTGEN ZHENGZHOU TECHNOLOGY CO LTD ...

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

Page 3: ...otation 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: ... STOP OPERATION 11 4 7 ELECTRIC DRIVEN PUMP START STOP OPERATION 12 4 8 EMERGENCY START 12 4 9 PUMP UNIT CONTROLELR ADJUST SPEED OPERATION 12 5 PROTECTION 14 5 1 WARNINGS 14 5 2 SHUTDOWN ALARM 15 6 CONNECTIONS 17 7 DEFINITION AND RANGE OF PARAMETERS 20 7 1 PARAMETER CONTENTS AND RANGE 20 7 2 DEFINITION CONTENT OF RELAY OUTPUT PORTS 28 7 2 1 CUSTOM PERIOD OUTPUT 32 7 2 2 CUSTOM COMBINED OUTPUT 32 7...

Page 5: ...47 13 4 CUMMINS QSX15 CM570 48 13 5 CUMMINS GCS MODBUS 48 13 6 CUMMINS QSM11 48 13 7 CUMMINS QSZ13 49 13 8 DETROIT DIESEL DDEC III IV 49 13 9 DEUTZ EMR2 49 13 10 JOHN DEERE 49 13 11 MTU MDEC 50 13 12 MTU ADEC SMART MODULE 50 13 13 MTU ADEC SAM MODULE 50 13 14 PERKINS 51 13 15 SCANIA 51 13 16 VOLVO EDC3 51 13 17 VOLVO EDC4 51 13 18 VOLVO EMS2 52 13 19 YUCHAI 52 13 20 WEICHAI 52 14 TROUBLESHOOTING 5...

Page 6: ...ristics are as follows 132x64 pixel LCD with backlight multilingual interface including English and Chinese languages and easy operation interface Improved LCD wear resistance and scratch resistance due to hard screen acrylic Silicon panel and pushbuttons for better operation in high low temperature environment RS485 communication port enabling remote control remote measuring remote communication ...

Page 7: ...nvironment Modular design anti flaming ABS plastic enclosure pluggable connection terminals and embedded installation way compact structure with easy mounting 3 SPECIFICATION Table 3 Technical Parameters Items Content Working Voltage DC8 0V to 35 0V Continuous Power Supply Overall Consumption 3W Standby mode 2W Speed Sensor Voltage 1 0 to 24V effective value Speed Sensor Frequency 10000Hz max Star...

Page 8: ... to set controller enters into Auto mode Manual Press it to set controller enters into Manual mode Mute Press it to mute controller alarms Idle Press it to set controller enters into Idle mode Start Press it to start generator in auto mode Raise Speed Press it to raise engine speed in manual speed control status Drop Speed Press it to drop engine speed in manual speed control status Up Increase 1 ...

Page 9: ...e 9 of 54 4 2 INDICATOR LIGHT Fig 1 APC615 Front Panel Note Selected indicators description Common warning indicator flash slowly when warning alarms occur flash quickly when shutdown alarms occur light is off when there are no alarms Running indicator always light when engine is normal running ...

Page 10: ...dle delay is initiated if configured g During start idle delay under speed alarm is deactivated When this delay is over warming up delay is initiated if configured h After the warming up delay pump unit will enter into Normal Running status If engine speed is abnormal controller will shutdown with alarms alarm information will be displayed on alarm page of LCD 4 3 2 AUTOMATIC STOP SEQUENCE a When ...

Page 11: ...unning status When generator is idle running in Idle Mode press to stop the generator and generator from Idle Running enters into Stop Idle Delay if configured The remaining stop process is the same as auto stop procedure details please to see 4 3 2 No c g of AUTO STOP OPERATION 4 6 DIESEL DRIVEN PUMP START STOP OPERATION Water suction pump type set as diesel driven suction pump Diesel driven pump...

Page 12: ...p output When generator is in ETS Solenoid Hold starter relay of electric driven suction pump will stop output 4 8 EMERGENCY START NOTE In manual mode press and at the same time can force start genset At this moment whether gesnset starts successfully or not is not based on the crank disconnect conditions The starter disconnection is controlled by the operator operator releases the buttons when he...

Page 13: ...djust speed mode manual or auto via pressing and keys In manual mode through pressing or key to connect or disconnect rise drop speed relay in auto mode speed control doesn t work NOTE If adjust speed object is inlet pressure flexible sensor 1 need to be set as inlet pressure and curve type must be effective Manual Adjust Speed Select Adjust Speed Type in Adjust Speed item and configure it as 3 Ma...

Page 14: ...ed the pre set value it will initiate a warning alarm 7 Battery Under Voltage When the controller detects that battery voltage has fallen below the pre set value it will initiate a warning alarm 8 ECU Warning When the controller receives engine warning signals from ECU via J1939 it will initiate a warning alarm 9 Engine Temperature Sensor Open Circuit When the controller detects that the temperatu...

Page 15: ...andate time and action select Warning it will initiate a warning alarm 5 2 SHUTDOWN ALARM When controller detects shutdown alarm it will shutdown the unit immediately Shutdown alarm must be cleared manually and the fault removed to reset the module Shutdown alarm types are as follows No Type Description 1 Emergency Stop When the controller detects an emergency stop alarm signal it will initiate a ...

Page 16: ...ler detects that the sensor value is higher than the max set value it will initiate a shutdown alarm 18 Outlet Pressure Low When the controller detects that the sensor value is lower than the min set value it will initiate a shutdown alarm 19 Flexible Sensor 1 2 Open Circuit When the controller detects that the sensor is open circuit and the action select Shutdown it will initiate a shutdown alarm...

Page 17: ...ceive information 6 CONNECTIONS Fig 2 APC615 Back Panel Description of terminal connections No Function Cable Size Description 1 B 2 5mm2 Connected with negative of starter battery 2 B 2 5mm2 Connected with positive of starter battery If wire length is over 30m better to double wires in parallel Max 20A fuse is recommended 3 COM1 Relay Common Port 1 5mm2 Connect to COM1 output with rated 16A 4 Cra...

Page 18: ...nsor Input 0 5mm2 Connect to speed sensor of engine shield line is recommended to use 32 Speed sensor input internal of controller has connected with B 0 5mm2 33 Temperature sensor 1 0mm2 Connected to temp sensor Resistor current type Detailed setting items please to see Table 12 34 Fuel level sensor 1 0mm2 Connected to fuel level sensor Resistor current type 35 Oil pressure sensor 1 0mm2 Connecte...

Page 19: ... 49 Aux Input 3 C 0 5 mm2 Ground connected is active B 50 Aux Input 4 D 0 5 mm2 Ground connected is active B 51 Aux Input 5 E 0 5 mm2 Ground connected is active B 52 Aux Input COM 0 5 mm2 Internal of controller has connected with B 53 56 NC 57 RS485 B 0 5mm2 120Ω impedance shielded wire is recommended to use and single end earthed 58 RS485 A 0 5mm2 59 RS485 Shield Link Can realize communicate with...

Page 20: ...en pump unit 7 Safety On Delay 0 3600 s 10 Alarms for low oil pressure high temperature under speed under frequency voltage charge fail are deactivated during Safety On Delay 8 Start Idle Time 0 3600 s 0 Idle running time of the pump unit when starting 9 Warming Up Time 0 3600 s 10 Warming time between the pump unit take load and high speed running 10 Cooling Time 0 3600 s 10 Radiating time before...

Page 21: ...ver under loading speed 4 Start Attempts 1 10 times 3 The maximum start attempts if engine failed to start When the pre set number of start attempts has been reached controller initiates failed to start alarms If diesel driven pump unit is enabled it also can be start attempts of diesel driven pump unit 5 Crank Disconnect Condition 0 2 2 Details please to see Table 14 There are three conditions th...

Page 22: ...e Warning Set Value 0 1000 85 Return Value 0 1000 90 Delay 0 3600 s 60 17 Charge Alt Fail Set Value 0 60 0 V 8 0 In normal running when charger D WL voltage under this value charge failure alarms Return Value 0 60 0 V 10 0 Delay 0 3600 s 10 18 Engine Idle 0 100 60 Setting value is percentage of rated speed and speed need to be stabilized at the setting point while in idle running 19 Suction Pump C...

Page 23: ...perature Sensor 1 Curve Type 0 15 9 SGD See table12 2 Open Circuit Action 0 2 0 0 Warning 1 Shutdown 2 No action 3 Display Unit 0 1 0 0 1 4 High Temp Shutdown 0 300 ºC 98 Shutdown when external sensor temperature is higher than this value Detecting only after safety delay is over The delay value can be set 5 High Temp Warning 0 300 ºC 95 Warning when external sensor temperature is higher than this...

Page 24: ...able 12 2 Open Action 0 2 0 0 Warning 1 Shutdown 2 No action 3 Display Unit 0 2 0 0 kPa 1 bar 2 psi 4 Low Oil Pressure Shutdown 0 1000 kPa 103 Shutdown when oil pressure of external connected sensor is lower than this value Detecting only after safety delay is over The delay value can be set 5 Low Oil Pressure Warning 0 1000 kPa 124 Warn oil pressure of external connected sensor is lower than this...

Page 25: ...n be set 15 Over Flow Shutdown 0 1000 120 While unit is running if flow exceeds the setting point shutdown alarms will be initiated Alarm enabled or not return value and delay value can be set 16 Flow Curve Different discharge pressures correspond to different flow values Flexible Sensor 1 2 1 Flexible Sensor Setting 0 7 0 0 Not used 1 Temperature sensor 2 Pressure Sensor 3 Fuel level Sensor 4 Flo...

Page 26: ...e table 11 2 Active Type 0 1 0 0 Active Close 1 Active Open 3 Arming 0 3 2 0 From safety on 1 From crank 2 Always 3 Never 4 Active Actions 0 2 0 0 Warning 1 Shutdown 2 Indication 5 Active Delay 0 20 0 s 2 0 It is time from detecting input port is active to action confirmation 6 Input Port Description User defined Digital Input Port 5 1 Contents Setting 0 53 0 User defined See table 11 2 Active Typ...

Page 27: ...ust speed 2 CAN adjust speed 2 Output Center SW1 0 10 0 5 0 Factory default center voltage is 5 0V 3 Output Range SW2 0 10 0 2 0 Factory default voltage range is 2 5 2 5 V 4 Speed Gain 0 1000 20 Automatic speed gain control 5 Speed Control Stability 0 1000 20 Automatic speed control stability 6 Relay Adjust Speed Dead 0 10 0 1 0 Relay auto adjust speed control 7 Speed Adjusting Relay Gain 0 100 10...

Page 28: ...rts up and disconnect after genset stopped completely 20 Fuel Pump Control It is controlled by fuel pump of level sensor controls upper and lower limits to control its action 21 Heater Control It is controlled by heating of temperature sensor controls upper and lower limits to control its action 22 Cooler Control It is controlled by cooler of temperature sensor controls upper and lower limits to c...

Page 29: ...ble for engines which fitted with ECU used for control ECU stop 41 ECU Power Supply Suitable for engines which fitted with ECU used for control ECU power supply 42 Reserved 43 Crank Success Close when detects a successful start signal 44 Normal Running Close when detects unit is normal running 45 Reserved 46 Reserved 47 Reserved 48 Common Alarm Action when pump unit common warning and common shutd...

Page 30: ...alarms occur 101 Fail To Stop Action when failed stop alarms occur 102 Engine Under Speed Warning Action when under speed alarms occur 103 Engine Under Speed Shutdown Action when under speed shutdown alarms occur 104 Engine Over Speed Warning Action when over speed warning alarms occur 105 Engine Over Speed Shutdown Action when over speed shutdown alarms occur 106 135 Reserved 136 Bypass Valve Con...

Page 31: ...rms occur 158 Flexible Sensor 1 Low Warning Action when flexible sensor 1 low warning alarms occur 159 Flexible Sensor 1 High Shutdown Action when flexible sensor 1 high shutdown alarms occur 160 Flexible Sensor 1 Low Shutdown Action when flexible sensor 1 low shutdown alarms occur 161 Flexible Sensor 2 High Warning Action when flexible sensor 2 high warning alarms occur 162 Flexible Sensor 2 Low ...

Page 32: ...output is composed by 3 parts condition output S1 S2 and condition output S3 S1 or S2 is TRUE while S3 is TRUE Defined combination output is outputting S1 and S2 are FALSE or S3 is FALSE Defined combination output is not outputting NOTE S1 S2 S3 can be set as any contents except for defined combination output in the output setting NOTE 3 parts of defined combination output S1 S2 and S3 couldn t in...

Page 33: ... input is active which means generator starts successfully crank disconnect conditions engine speed oil pressure are inactive 8 Idle Speed Active Unit enters into idle speed mode if input is active 9 Auto Stop Inhibit In Auto mode when input is active after engine is normal running pump unit automatic stop is inhibiting 10 Auto Start Inhibit In Auto mode when input is active pump unit automatic st...

Page 34: ...of Water Tank When this input is active in auto mode pump unit can be started automatically drain flooded fields 31 Low Level of Water Tank When this input is active in auto mode High Level of Water Tank input is deactivated pump unit can be stopped automatically drain flooded fields 32 Manual Start Input In manual mode when this input is active pump unit can be started automatically When this inp...

Page 35: ...e s range is 0 1 KΩ default is SGD sensor 2 Fuel Level Sensor 0 Not used 1 Custom Res Curve 2 Custom 4 20mA curve 3 Custom Volt Curve 4 SGD 5 SGH 6 Voltage Type 0 5V 4 5V 7 15 Reserved Defined resistance s range is 0 1 KΩ default is SGD sensor 3 Pressure Sensor 0 Not used 1 Custom Res Curve 2 Custom 4 20mA curve 3 Custom Volt Curve 4 VDO 10bar 5 CURTIS 6 VOLVO EC 7 DATCON 10bar 8 SGX 9 SGD 10 SGH ...

Page 36: ...sor Corresponding to J2 Jumper plug to J2 s No 1 and No 2 terminals Jumper plug to J2 s No 2 and No 3 terminals Oil Pressure Sensor Corresponding to J3 and J7 Jumper plug to J3 s No 1 and No 2 terminals Jumper plug to J7 Jumper plug to J3 s No 2 and No 3 terminals Outlet Pressure Sensor Corresponding to J4 and J8 Jumper plug to J4 s No 1 and No 2 terminals Jumper plug to J8 Jumper plug to J4 s No ...

Page 37: ...e should be using with engine speed sensor together in order to make the starter motor is separated with engine immediately and can check crank disconnect exactly Engine speed sensor is the magnetic equipment which be installed in starter for detecting flywheel teeth When set as engine speed must ensure that the number of flywheel teeth is as same as setting otherwise over speed shutdown or under ...

Page 38: ... the maintenance time is due Pre alarm A Time 0 30000 h Maintenance remaining time Pre alarm A Action Similar to Maintenance Due Action They are the alarm action types when the maintenance remaining time is reaching pre alarm A time Pre alarm B 0 30000 h Maintenance remaining time Pre alarm B Action Similar to Maintenance Due Action They are the alarm action types when the maintenance remaining ti...

Page 39: ... return to the previous level Screen 1 Return Start Delay Return Delay Preheat Delay Start Delay Screen 3 Pressing to shift cursor to select the digit that to be configured and change the digit through pressing or After the parameter is setting completed press to save it and then press Down key to return to the previous level Screen 2 00001s Timers Screen 4 Pressing to select target item and the s...

Page 40: ...o digit of fuel tank capacity setting Users can change parameters via pressing or and press to save it 1 L Fuel Tank Capacity 01000 NOTE Please change the controller parameters when generator is in standby mode only e g Crank disconnect conditions selection digital input digital output various delays otherwise shutdown and other abnormal conditions may occur Maximum set value must over minimum set...

Page 41: ...s and using sensor user can adjust it in curve type When input the sensor curve X value resistor must be input from small to large otherwise mistake occurs If select sensor type as None sensor curve is not working If there is alarm switch only for the select sensor user must set the sensor as None otherwise maybe shutdown or warning occurs The headmost or backmost values in the vertical coordinate...

Page 42: ...n wire of fuel valve If checking is OK make the start battery power on choose manual mode and controller will executive routine d Set controller under manual 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 e Recover the action to prevent engine to crank success e g Connect wire of fuel va...

Page 43: ...Unit Controller User Manual APC615 Pump Unit Controller Version 1 0 2017 10 20 Page 43 of 54 11 TYPICAL APPLICATION Fig 5 APC615 Typical Application Diagram Fig 6 Typical Application with Diesel Driven Suction Pump ...

Page 44: ...APC615 Pump Unit Controller User Manual APC615 Pump Unit Controller Version 1 0 2017 10 20 Page 44 of 54 Fig 7 Typical Application with Electric Driven Suction Pump ...

Page 45: ...pply 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 corresponding input ports in order to prevent charge disturbing the controller s normal working Speed Sensor Input Speed sensor is the magnetic equipment which be installe...

Page 46: ... 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 has DC current or add resistance capacitance return circuit when coils of relay has AC current in order to prevent disturbance to controller or others equipment ...

Page 47: ...9 Suitable for CM850 engine control mode Table 19 50 Pins Connector Terminals of controller 50 pins connector Remark Fuel relay output 39 Starter relay output Connect to starter coil directly Table 20 9 Pins Connector Terminals of controller 9 pins connector Remark SAE J1939 shield E CAN communication shielding wire connect to ECU terminal only CAN H SAE J1939 signal C Using 120Ω impedance connect...

Page 48: ...INS 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 25 D SUB Connector 06 Terminals of controller D SUB connector 06 Remark Fuel relay output 5 8 Outside expand relay when fuel output making port 5 and 8 of the connector 06 be connected Start relay output Connect to starter coil direc...

Page 49: ... be implemented 13 8DETROIT DIESEL DDEC III IV Table 29 Engine CAN Port Terminals of controller CAN port of engine Remark Fuel relay output Expand 30A relay battery voltage of ECU is supplied by relay Starter relay output Connect to starter coil directly CAN H CAN H Using 120Ω impedance connecting wire CAN L CAN L Using 120Ω impedance connecting wire Engine type Common J1939 13 9DEUTZ EMR2 Table 3...

Page 50: ...t Remark Fuel relay output X1 10 X1 Terminal 9 Connected to negative of battery Starter relay output X1 34 X1 Terminal 33 Connected to negative of battery Table 34 SMART X4 Port Terminals of controller SMART X4 port Remark CAN H X4 1 Using 120Ω impedance connecting wire CAN L X4 2 Using 120Ω impedance connecting wire Engine type MTU ADEC 13 13 MTU ADEC SAM MODULE It is suitable for MTU engine with...

Page 51: ...e Engine type Scania 13 16 VOLVO EDC3 Suitable engine control mode is TAD1240 TAD1241 and TAD1242 Table 39 Stand alone Connector Terminals of controller Stand alone connector Remark Fuel relay output H Starter relay output E Programmable output 1 P ECU power supply Programmable output 1 configured as ECU power Table 40 Data bus Connector Terminals of controller Stand alone connector Remark CAN H 1...

Page 52: ... Engine 42 Pins Port Terminals of controller Engine 42 pins port Remark Fuel relay output 1 40 Connect to engine ignition lock Starter relay output Connect to starter coil directly CAN H 1 35 Using 120Ω impedance connecting wire CAN L 1 34 Using 120Ω impedance connecting wire Table 44 Engine 2 Pins Port Battery Engine 2 pins port Remark Battery Negative Electrode 1 Wire diameter is 2 5mm2 Battery ...

Page 53: ...ng to the information on LCD Check programmable inputs Crank not disconnect Check fuel oil circuit and its connections Check starting batteries Check speed sensor and its connections Refer to engine manual Starter no response Check starter connections Check starting batteries RS485 Communication Fail Check connections Check setting of COM port is correct or not Check RS485 s connections of A and B...

Page 54: ...ump Unit Controller Version 1 0 2017 10 20 Page 54 of 54 15 PACKING LIST Table 47 Packing List No Name Quantity Remark 1 Controller 1 2 Fixing Clips 4 3 120Ω Resistor 2 4 Certification 1 5 Installation Instruction 1 _________________________________ ...

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