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HEM4000 Engine Controller User Manual Page 44 of 46

13

INSTALLATION

13.1

FIXING CLIPS

HEM4000 controller is designed as panel mounting. Panels are fixed by the clips.

─

Screw out the metal clips to proper position anticlockwise.

─

Pull the fixed clips towards the controller back direction, and ensure four fixed metal clips are all
fixed inside the allotted slots.

─

Screw up the metal clips clockwise, and make sure they are fixed on the panels.

NOTE:

The screw of the clips shall not be tightened up too much.

13.2

OVERALL DIMENSION AND CUTOUT

Fig.8

–

Overall Dimensions and Cutout (Unit: mm)

—

BATTERY VOLTAGE INPUT

HEM4000 controller is applicable to battery voltage DC (8~35)V environment. Negative anode of the

battery must be connected with the engine shell. Sectional area of the wire that connects with the
controller power B+ and B- must be equal to or over 1.5mm

2

. If floating charger is configured, please

connect output wires directly to the battery’s positive and negative anodes, and then connect wires from
battery’s positive and negative to the controller’s positive and negative input ends in order to prevent
charger disturbing the controller’s normal working.

—

SPEED SENSOR INPUT

Speed sensor is the magnetic equipment installed in the engine body to detect flywheel teeth number.

The wires used to connect with the controller shall be 2-core shielding wires. The shielding layer shall be
connected to No. 28 terminal on the controller, and meanwhile the other terminal shall be hanging in the air.
Another two signal wires shall be connected to No.28 and No.29 terminals on the controller. The output
voltage of the speed sensor shall be within AC (1~24)V (RMS) in the range of full speed and AC12V is
recommended (at rated speed). As to speed sensor installation, the sensor can firstly be spun to the
connection flywheel, then invert 1/3 lap, and finally tighten up the screw on the sensor.

—

OUTPUT AND EXPAND RELAYS

All controller outputs are relay contact outputs. If the expansion relay is needed, freewheel diode (relay

coil is DC) and resistor and capacitor circuit (relay coil is AC) shall be added to the two ends of the relay
coils in order to prevent disturbing the controller or others equipment.

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Summary of Contents for HEM4000

Page 1: ...HEM4000 ENGINE CONTROLLER USER MANUAL ...

Page 2: ...nic 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 reserves the right to change t...

Page 3: ...on 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 error operation may cause death serious injury and significant property damage ...

Page 4: ...TION OPERATIONS 14 5 1 D DRIVEN PUMP START STOP OPERATION 14 5 2 E DRIVEN PUMP START STOP OPERATION 15 6 PROTECTION 16 6 1 WARNINGS 16 6 2 SHUTDOWN ALARMS 17 7 WIRING CONNECTION 19 8 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS 21 8 1 SCOPES AND DEFINITIONS OF PARAMETERS 21 8 2 DEFINED CONTENTS OF AUXILIARY OUTPUT PORTS 1 6 29 8 2 1 DEFINED CONTENTS TABLE OF AUXILIARY OUTPUT PORTS 1 6 29 8 2 ...

Page 5: ...HEM4000 Engine Controller User Manual Page 5 of 46 14 FAULT FINDING 45 15 PACKING LIST 46 ...

Page 6: ...rol systems which include water pump system beacon system air compressor engineering machinery system and so on 2 PERFORMANCE AND CHARACTERISTICS Key characteristics are as below 132x64 LCD with backlight multilingual interface including English and Chinese languages and easy operating interface Hard acrylic screen protection with improved wear resistance and scratch resistance Silicon panel and p...

Page 7: ...op functions start one time once a day week month Heater cooler and fuel pump control functions Maintenance function Actions warning or shutdown can be set when maintenance time due All parameters adopt digital adjustment instead of conventional analog modulation with a potentiometer which improves the reliability and stability Waterproof security level IP65 of the front panel due to the rubber se...

Page 8: ...0 24 V RMS Frequency 50 1000 Hz Starting Relay Output 5A DC28V Auxiliary Relay Output 1 5A DC28V Auxiliary Relay Output 2 6 1A DC28V Analog Sensor 3 way fixed resistor sensors temperature flexible sensor 1 flexible sensor 2 3 way sensors can be configured as resistor current voltage type sensors oil pressure flexible sensor 3 flexible sensor 4 Case Dimension 135mm x 110mm x 44mm Panel Cutout 116mm...

Page 9: ...mediately Auto Press this key and controller goes to Auto mode Manual Press this key and controller goes to Manual mode Speed If speed adjusting enabled press this key to enter adjusting speed page to raise drop engine speed Start Start engine in Manual mode Up Increase 1 Screen scroll 2 Moving cursor up and increase value in setting menu Down Decrease 1 Screen scroll 2 Moving cursor down and decr...

Page 10: ...input is active start delay is initiated and auto mode indicator flashes at the same time c After start delay auto mode indicator changed from flashing to illuminating and preheating relay outputs if configured preheating delay XX will be displayed on the LCD d After the preheating delay the fuel relay outputs pre start fuel time 1 second default and then the starting relay outputs If it fails to ...

Page 11: ...ed c During the stop idle delay if configured idle relay outputs with power d The ETS delay goes on next ETS relay is energized and fuel relay is de energized e Stop delay begins and complete stop is detected automatically f When the engine stops completely after stop delay will be initiated Otherwise the controller fails to stop and meanwhile the alarm of stop failure is initiated If the engine s...

Page 12: ...utput port is set fuel pre supply output and the engine is in the standby status the set fuel pre supply rest time and fuel pre supply time output circularly If the fuel pre supply rest time is 0 the fuel pre supply does not work 4 6 IDLE MODE Input setting 8 Idle Mode If engine is in good running status and the idle mode input is active the idle mode starts and the engine enters idle running At t...

Page 13: ...o to high speed warming up phase at this time speed increasing relay outputs When the high speed warming up delay ends the speed increasing stops outputting the engine goes to normal running After speed adjustment type collocation speed can be adjusted in normal running status In the process of the idle running press and make the engine stop The engine goes from idle running to stop idle delay if ...

Page 14: ... input input is to be configured is invalid during the D driven suction pump s starting time the pump starting relay stops outputting and enters pump starting interval waiting for next starting during the set starting times if the pump fails to start the controller will output starting failure alarm and stop and the alarm screen displays pump starting failure alarm shutdown At any one time of star...

Page 15: ...ay is over the starting relay outputs output is to be configured E driven pump stop When the engine is between start idle time and high speed cooling time if the input is pump pressure coming input is to be configured or the outlet pressure is larger than the value of stop pressure of E driven suction pump the starting relay stops to output If the engine is in ETS delay the starting relay stops to...

Page 16: ...attery voltage has fallen below the pre set value it will initiate a warning alarm 8 Engine Temp Sensor Open Circuit When the controller detects that the temperature sensor is open circuit and the selected action is Warning it will initiate a warning alarm 9 Engine High Temperature When the controller detects that engine temperature has exceeded the pre set value it will initiate a warning alarm 1...

Page 17: ...pe Description 1 Emergency Stop When the controller detects emergency stop alarm signals it will initiate a shutdown alarm 2 Over Speed When the controller detects that the engine speed has exceeded the pre set value it will initiate a shutdown alarm 3 Under Speed When the controller detects that the engine speed has fallen below the pre set value it will initiate a shutdown alarm 4 Loss of Speed ...

Page 18: ...set lower limit value it will initiate a shutdown alarm 15 Suction Pump Crank Failure If diesel driven pump fails to start within preset attempts controller will initiate a shutdown alarm 16 Suction Pump Fault When the controller is in the phase of breakdown stop delay and the input pressure coming signal is invalid controller will initiate a shutdown alarm 17 Input Port 1 5 Shutdown When digital ...

Page 19: ...output rated 5A DC28V 4 Crank Relay Output 1 5mm2 5 Aux Relay Output 1 1 5mm2 6 COM2 Relay Common Port 1 0mm2 Connected with COM2 output rated 1A DC28V For settings refer to Table 9 7 Aux Relay Output 2 1 0mm2 8 Aux Relay Output 3 1 0mm2 9 Aux Relay Output 4 1 0mm2 10 Aux Relay Output 5 1 0mm2 Relay s normally open passive contact rated 1A DC28V 11 1 0mm2 12 Aux Relay Output 6 1 0mm2 Normally open...

Page 20: ...y 27 W L 0 5mm2 Connected with W terminal of charging generator 28 MP2 Speed Sensor Input controller internally has connected to B 0 5mm2 Connected with engine speed sensor Shielding wire is recommended 29 MP1 Speed Sensor Input 0 5mm2 30 Temperature Sensor 1 0mm2 Connected with temperature sensor resistor type For settings refer to Table 11 31 Oil Pressure Sensor 1 0mm2 Connected with pressure se...

Page 21: ...default password is 0318 and operator can change it to prevent others from changing controller s advanced configuration at will Please memorize the new password after changing If forget it please contact with supplier service personnel 5 LCD Backlight Contrast Ratio 0 10 5 Brightness 0 5 5 Backlight Delay 0 3600 min 5 If delay time is set as 0 min backlight is always light 6 Date and Time Users ca...

Page 22: ...dle running time when engine stop 12 ETS Output Time 0 3600 s 20 The time of powering up the ETS before stopping If diesel driven suction pump enabled it is also can be stop output time of diesel driven suction pump 13 Waiting Stop Time 0 3600 s 0 Time between ending of idle delay and stopping completely when ETS Output Time is 0 Time between ending of ETS delay and stopping completely when ETS Ou...

Page 23: ...is higher than the set value starter will be disconnected See the installation instruction 8 Disconnect Oil Pressure 0 1000 kPa 200 When oil pressure is higher than the set value starter will be disconnected See the installation instruction 9 Overspeed Warn Set Value 0 200 0 110 0 Set value is the percentage of rated speed Return value and delay value can also be set Return 0 200 0 108 0 Delay 0 3...

Page 24: ...s valid 23 Outlet Pressure for E driven Suction Pump Shutdown 0 1000 kPa 100 Pressure value when E driven suction pump start output stops outputting Analog Sensor Setting Temperature Sensor 1 Curve Type 0 15 9 SGD Details see Table 11 2 Open Circuit Action 0 2 0 0 Warning 1 Shutdown 2 No Action 3 Display Unit 0 1 0 0 ºC 1 ºF 4 High Temp Shutdown 0 300 ºC 98 Shutdown alarm when external sensor temp...

Page 25: ...ated curve needs to be set Auxiliary Sensor 1 4 1 Sensor Selection 0 8 0 0 Not Used 1 Temperature Sensor 2 Pressure Sensor 3 Level Sensor 4 Flow Sensor 5 Pipe Pressure Sensor 6 Inlet Pressure Sensor 7 Water Level Sensor 8 Outlet Pressure Sensor 2 Curve Type Changing based on the sensor type 3 Open Circuit Action 0 2 0 0 Warning 1 Shutdown 2 No Action 4 Display Unit 0 1 0 0 ºC 1 ºF NOTE Different s...

Page 26: ...ow Enable Set 0 1 0 0 Disable 1 Enable 4 Static Water Pressure 9000 9000 kPa 0 Setting static pressure of pump outlet 5 Flow Unit 0 1 0 0 m h 1 L s 6 Rated Flow 0 10000 m h 1000 Rated working flow of engine 7 Over Flow Warn 0 1000 110 Warning if flow value is higher than this value during running Alarms enable delay value and return value can be set 8 Over Flow Shutdown 0 1000 120 Shutdown if flow...

Page 27: ... 0 4 1 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 confirmed 6 Description User defined Auxiliary Output Ports Auxiliary Output Port 1 1 Content Set 0 119 29 Fuel relay outputs Details see Table 9 2 Active Type 0 1 0 0 Normally Open 1 Normally Close Auxiliary Output Port 2 1 Content Set 0 119 28 Crank relay outputs Details ...

Page 28: ... action maintenance timing way and reset maintenance time can be set simultaneously After unit maintenance the maintenance time due alarm can be recovered by maintenance time reset Details see Table 13 4 Maintenance 2 0 1 0 5 Maintenance 3 0 1 0 6 Maintenance 4 0 1 0 7 Maintenance 5 0 1 0 NOTE When parameter configuration is going on via PC software there is no need to input password if default pa...

Page 29: ...6 Custom Period Output 6 7 Custom Combined Output 1 8 Custom Combined Output 2 9 Custom Combined Output 3 10 Custom Combined Output 4 11 Custom Combined Output 5 12 Custom Combined Output 6 13 Reserved 14 Reserved 15 Air Flap Control Act when over speed shutdown and emergence stop and it can close the air inflow to stop the engine sooner 16 Audible Alarm Act when warning and shutdown alarms occur ...

Page 30: ... idle key is pressed relay will close and starts outputting 31 Speed Raise Output Act in the course of high speed warming up It is controlled by speed adjustment during regular working period 32 Speed Drop Output Act during the period from stop idle speed time to waiting stop time It is controlled by speed adjustment during regular working period 33 ETS Control Applicable to oil engines with ETS e...

Page 31: ...en 68 Crank Failure Alarm Act when crank failure alarms happen 69 Stop Failure Alarm Act when stop failure alarms happen 70 Under Speed Warning Act when under speed warnings happen 71 Under Speed Shutdown Act when under speed shutdown alarms happen 72 Over Speed Warning Act when over speed warnings happen 73 Over Speed Shutdown Act when over speed shutdown alarms happen 74 Reserved 75 Reserved 76 ...

Page 32: ...sor 3 Low Shutdown Act when auxiliary sensor 3 low shutdowns happen 101 Sensor 4 High Warning Act when auxiliary sensor 4 high warnings happen 102 Sensor 4 Low Warning Act when auxiliary sensor 4 low warnings happen 103 Sensor 4 High Shutdown Act when auxiliary sensor 4 high shutdowns happen 104 Sensor 4 Low Shutdown Act when auxiliary sensor 4 low shutdowns happen 105 Reserved 106 Reserved 107 Re...

Page 33: ...are FALSE or S3 is FALSE users defined combined output does not work NOTE S1 S2 and S3 can be any other contents except original users defined combined output in the output setting NOTE The 3 parts of users defined combined output S1 S2 and S3 cannot include or recursively include original outputs OR condition output S1 contents input port 1 is active OR condition output S1 close status active ina...

Page 34: ... parameter setting but can do language setting check event log and controller information when input is active except Page Up Confirm and Page Down ones Home screen displays icon at the bottom right corner 7 Cranking Success Input Crank is successful when input is active If it is configured speed and oil pressure cranking conditions shall be invalid 8 Idle Mode Enter idle mode when input is active...

Page 35: ...nput 27 Low OP Shutdown Connect to sensor digital input 28 Remote Start In Auto mode when input is active engine can be started automatically 29 Remote Stop In Auto mode when input is active and remote start input is inactive engine can be stopped automatically 30 High Level Input In Auto mode when input is active engine can be started automatically drain flood 31 Low Level Input In Auto mode when...

Page 36: ...D sensor Default 2 Pressure Sensor 0 Not used 1 Custom Resistance Curve 2 Custom 4 20 mA Curve 3 Custom Voltage Curve 4 VDO 10bar 5 CURTIS 6 VOLVO EC 7 DATCON 10bar 8 SGX 9 SGD 10 SGH 11 15 Reserved Defined resistance range is 0 1 kΩ SGD sensor Default 3 Fuel Level Sensor 0 Not used 1 Custom Resistance Curve 2 Custom 4 20 mA Curve 3 Custom Voltage Curve 4 SGD 5 SGH 6 15 Reserved Defined resistance...

Page 37: ... loss of speed signal alarm and shutdown may happen If there is not oil pressure sensor in the unit please do not select corresponding items 8 6 MAINTENANCE SETTING Table 13 Maintenance Setting Item Content Description Enable Choice 0 Disabled 1 Enabled Applicable to set whether maintenance function is active or not Maintenance Time 0 30000 h Hours from maintenance enable to maintenance start Main...

Page 38: ...s Return Module Set Timer Set Engine Set Timer Set Screen 2 Press to change the settings press to enter parameter setting Screen 3 press to return to the last screen Screen 1 Select Return and press Confirm key the previous screen Screen 1 appears Return Start Delay Stop Delay Preheating Delay Start Delay Screen 3 Press and move the cursor then pick on the value that needs to be changed and press ...

Page 39: ...ump Fault Shutdown Delay 00090s Pump Cranking Set 1 D driven Suction Pump Fault Shutdown Delay 00090s Screen 9 Press and move cursor select the value and press to modify Press to save your modification Then press to return NOTE Please modify inner parameters under the standby status e g cranking disconnection condition selection auxiliary input output configuration all kinds of delays etc otherwis...

Page 40: ...s defined sensor can be selected and it naturally is defined sensor curve If Not Used is selected the sensor curve does not work Not used must be selected if the sensor only has an alarm switch otherwise shutdown or warning may happen The Y axis values of the several points at the headmost and backmost can be set the same Please see Fig 4 Fig 4 Curve Setting Table 14 Normal Pressure Unit Conversio...

Page 41: ...correct and power on the starter battery then the controller shall conduct program d Press Start button and the engine shall start After the starting times set the controller shall give out starting failure signal Press Stop button and the controller shall recover e Recover the actions that stop the engine to start successfully recover the connection wire of the fuel valve and press the Start butt...

Page 42: ...HEM4000 Engine Controller User Manual Page 42 of 46 12 TYPICAL APPLICATION Fig 5 HEM4000 Typical Application Diagram Fig 6 D driven Suction Pump Typical Application Diagram ...

Page 43: ...HEM4000 Engine Controller User Manual Page 43 of 46 Fig 7 E driven Suction Pump Typical Application Diagram ...

Page 44: ...es from battery s positive and negative to the controller s positive and negative input ends in order to prevent charger disturbing the controller s normal working SPEED SENSOR INPUT Speed sensor is the magnetic equipment installed in the engine body to detect flywheel teeth number The wires used to connect with the controller shall be 2 core shielding wires The shielding layer shall be connected ...

Page 45: ...nection wires High water temp alarm after successful start Check the temperature sensor and its connection wires Shutdown alarm in running Check relating switches and connection wires according to the information on the LCD Check auxiliary input ports Crank failure Check fuel circuit and its connections Check starting battery Check speed sensor and its connections Refer to engine manual Starter no...

Page 46: ...HEM4000 Engine Controller User Manual Page 46 of 46 15 PACKING LIST Table 45 Packing List No Name Quantity Remark 1 Controller 1 2 Fixed Clip 2 3 User Manual 1 _________________________________ ...

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