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ACC4100 Diesel Air Compressor Controller User Manual Page 4 of 52

CONTENT

1 OVERVIEW............................................................................................................................................ 6

2 PERFORMANCE AND CHARACTERISTICS ........................................................................................ 7

3 SPECIFICATION ................................................................................................................................... 8

4 OPERATION ......................................................................................................................................... 9

4.1 KEY FUNCTION DESCRIPTION .................................................................................................... 9

4.2 CONTROLLER PANEL ................................................................................................................. 10

4.3 START/STOP OPERATION ......................................................................................................... 10

4.3.1 START SEQUENCE ............................................................................................................ 10

4.3.2 STOP SEQUENCE .............................................................................................................. 10

4.4 START OPERATION FOR FUEL PRE-SUPPLY OUTPUT SETTING ............................................ 11

4.5 EMERGENCY START .................................................................................................................. 11

4.6 LOAD/UNLOAD SPEED REGULATION PROCESS OF AIR COMPRESSOR ............................... 11

5 MANUAL DPF REGENERATION ........................................................................................................ 12

5.1 ILLUSTRATION............................................................................................................................ 12

5.2 PANEL ICON DESCRIPTION OF DPF REGENERATION ............................................................. 13

5.3 DPF MANUAL REGENERATION OPERATION............................................................................ 13

6 PROTECTION ..................................................................................................................................... 15

6.1 WARNINGS .................................................................................................................................. 15

6.2 SHUTDOWNS .............................................................................................................................. 16

7 WIRE CONNECTION .......................................................................................................................... 18

8 CONFIGURATION PARAMETER RANGE AND DEFINITION ............................................................. 20

8.1 PARAMETER RANGE AND DEFINITION .................................................................................... 20

8.2 DEFINABLE CONTENTS OF AUXILIARY OUTPUT PORTS 1~6 ................................................ 29

8.2.1 DEFINABLE CONTENTS OF AUXILIARY OUTPUT PORTS 1~6 ...................................... 29

8.2.2 CUSTOM PERIOD OUTPUT ............................................................................................... 33

8.2.3 DEFINED COMBINATION OUTPUT .................................................................................. 33

8.3 DEFINED CONTENTS OF DIGITAL INPUT PORTS .................................................................... 34

8.4 SELECTION OF SENSORS .......................................................................................................... 36

8.5 CONDITIONS OF CRANK DISCONNECT SELECTION ............................................................... 37

8.6 MAINTENANCE SETTING .......................................................................................................... 37

9 PARAMETERS SETTING .................................................................................................................... 38

10 SENSOR SETTING ........................................................................................................................... 40

11 COMMISSIONING ............................................................................................................................ 41

12 TYPICAL APPLICATION .................................................................................................................. 41

Содержание ACC4100

Страница 1: ...ACC4100 DIESEL AIR COMPRESSOR CONTROLLER USER MANUAL SMARTGEN ZHENGZHOU TECHNOLOGY CO LTD ...

Страница 2: ...ing 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 their respective companies SmartGen Te...

Страница 3: ... 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 ...

Страница 4: ...N 12 5 2 PANEL ICON DESCRIPTION OF DPF REGENERATION 13 5 3 DPF MANUAL REGENERATION OPERATION 13 6 PROTECTION 15 6 1 WARNINGS 15 6 2 SHUTDOWNS 16 7 WIRE CONNECTION 18 8 CONFIGURATION PARAMETER RANGE AND DEFINITION 20 8 1 PARAMETER RANGE AND DEFINITION 20 8 2 DEFINABLE CONTENTS OF AUXILIARY OUTPUT PORTS 1 6 29 8 2 1 DEFINABLE CONTENTS OF AUXILIARY OUTPUT PORTS 1 6 29 8 2 2 CUSTOM PERIOD OUTPUT 33 8 ...

Страница 5: ...MINS QSM11 IMPORT 44 14 4 CUMMINS QSX15 CM570 44 14 5 CUMMINS GCS MODBUS 45 14 6 CUMMINS QSM11 45 14 7 CUMMINS QSZ13 46 14 8 DETROIT DIESEL DDEC III IV 46 14 9 DEUTZ EMR2 47 14 10 JOHN DEERE 47 14 11 MTU MDEC 47 14 12 MTU ADEC SMART MODULE 48 14 13 MTU ADEC SAM MODULE 48 14 14 PERKINS 48 14 15 SCANIA 49 14 16 VOLVO EDC3 49 14 17 VOLVO EDC4 49 14 18 VOLVO EMS2 50 14 19 YUCHAI 50 14 20 WEICHAI 50 15...

Страница 6: ... which can control various ECU or non ECU diesel air compressors ACC4100 Diesel Air Compressor Controller applies 32 bit ARM micro processor technology which can realize functions of precise measurement for many parameters set point adjustment timing and threshold setting etc A majority of parameters can be adjusted from the control panel All parameters can be adjusted and monitored on PC by RS485...

Страница 7: ...tection functions which provides high water temperature low oil pressure over speed and under speed protection and discharge pressure high discharge temperature high protection etc Speed regulator function can automatically adjust speed according to discharge pressure of the air compressor All outputs are relay outputs Parameter setting function allows users to change and set the parameters and at...

Страница 8: ...Frequency 50 1 000 Hz Starting Relay Output 5A DC28V Programmable Output 1 5A DC28V Programmable Output 2 6 1A DC28V Analog Sensor 3 ways of fixed resistance type fuel level programmable sensor 1 programmable sensor 2 3 ways of flexible resistance current voltage types discharge pressure programmable sensor 3 programmable sensor 4 Case Dimensions 135mm x 110mm x 44mm Panel Cutout 116mm x 90mm Work...

Страница 9: ...again and exit from alarm page Maintenance Press it and it enters maintenance page press it again and exit from the page press it longer at this page it enters password interface input password and maintenance setting is entered Stop 1 Stop the running air compressor at start mode 2 Press it for 3s or longer test whether panel indicators are normal lamp test 3 Press it again in stop process and co...

Страница 10: ...the pre set start attempts if air compressor doesn t succeed to start then controller issues failed to start alarm and meanwhile LCD alarm page displays Failed to Start alarm e During any one of the start attempts if crank disconnect is fulfilled then it enters Safety On Delay during which oil pressure low water temperature high under speed and charging failure alarms are all inactive after safety...

Страница 11: ...pre supply time enters pre supply phase and LCD displays Fuel Pre supply Time XX and pre supply relay outputs after pre supply delay is over fuel relay outputs the pre set fuel time default 1s before start then starting relay outputs the following start process is the same as the START PROCEDURE for start process please see 4 3 1 d g If output port is configured to Fuel Pre supply Output air compr...

Страница 12: ...ve DPF regeneration function Usually engine can clear the particulates in DPF by automatic regeneration function However engine usually is at short time state no load running or low speed low load running state automatic regeneration cannot completely clear out the DPF particulates and there may appear particulate block and beyond the limitation Under this circumstance manual DPF regeneration oper...

Страница 13: ... to DPF Manual Regeneration Request and connect a button not self lock externally Press on controller panel and enter parameter setting menu Press and select DPF Regeneration and press again to enter DPF regeneration Controller display is as Fig 3 Fig 3 DPF Regeneration When manual regeneration is needed press DPF Manual Regeneration Request button On DPF panel DPF response indicator is light on a...

Страница 14: ...arts DPF regeneration request indicator is light off DPF response indicator is always light on and DPF discharge temperature indicator is always light on Controller screen is as Fig 5 Fig 5 DPF Regeneration Start When manual regeneration is completed DPF response indicator is light off and DPF discharge temperature indicator is light off Controller screen display is as Fig 3 shows ...

Страница 15: ...eceives warning signal of engine by J1939 it issues warning signal 9 Temp Sensor Open Warn When controller detects sensor is open and action type is selected Warning it issues warning signal 10 High Temp Warn When controller detects temperature is higher than pre set high temp warning value it issues warning signal 11 Low Temp Warn When controller detects temperature is lower than pre set low temp...

Страница 16: ... Over 28 Engine Oil Filter Over 29 Engine Fuel Filter Over 30 Engine Lubrication Over 31 Maintenance 8 Over 32 Maintenance 9 Over 33 Maintenance 10 Over 6 2 SHUTDOWNS When controller detects shutdown alarm signal it immediately stops When engine stops completely it needs to press manually Alarm Reset button to remove alarms Table 7 Shutdown Alarms No Type Description 1 Emergency Stop When controll...

Страница 17: ...issues shutdown alarm signal 18 Low Discharge Press When controller detects sensor is below pre set pressure shutdown value it issues shutdown alarm signal 19 Flexible Sensor 1 4 Open When controller detects sensor is open and action type is selected Shutdown it issues shutdown alarm signal 20 Flexible Sensor 1 4 High When controller detects sensor value is above pre set upper shutdown limit value...

Страница 18: ...wer Input B 1 5mm2 Connects starter battery negative 2 DC Power Input B 1 5mm2 Connects starter battery positive 3 COM1 Relay 1 5mm2 Connects COM1 output Rated 5A DC28V 4 Crank Relay Output 1 0mm2 5 AUX Output 1 1 0mm2 6 COM2 Relay 1 0mm2 Connects COM2 output Rated 1A DC28V Please see Table 10 for setting items 7 AUX Output 2 1 0mm2 8 AUX Output 3 1 5mm2 9 AUX Output 4 1 5mm2 10 AUX Output 5 1 0mm...

Страница 19: ... D W L terminal hung up it if the terminal doesn t exist 26 Aux Input COM 0 5mm2 Connected already with B internally 27 W L 0 5mm2 Connects charger W 28 MP2 Speed Sensor Input Connected with battery negative already internally 0 5mm2 Connects engine speed sensor shielding wire is recommended 29 MP1 Speed Sensor Input 0 5mm2 30 Fuel Level Sensor 1 0mm2 Connects engine fuel level sensor resistance P...

Страница 20: ...t password is 1234 It can be changed by operator for purpose of preventing others changing controller advanced configuration If password is changed please remember clearly If it is forgotten please contact company service person 4 Date and Time Users can calibrate date and time 5 Maintain Password 0 9999 1234 Independent password for maintenance Timer Setting 1 Preheat Delay 0 3600 s 0 Time for pr...

Страница 21: ... supply Time 3 30 s 5 Time for pre supply output when output is configured to fuel pre supply Engine Setting 1 Engine Type 0 39 34 Default 34 GTSC1 2 Enable ECU Alarm Shut 0 1 1 0 Disable 1 Enable NOTE When engine detects red light alarm it will stop when it is enabled 3 Source of Speed Signal 0 1 0 0 Speed Sensor 1 W L 4 W L Ratio 0 99 99 9 04 5 Flywheel Teeth 1 0 300 0 118 0 Flywheel teeth of en...

Страница 22: ...down 17 Battery Rated Voltage 0 60 0 V 24 0 Provide standard for battery over under voltage detection 18 Battery Overvolt Warn Set 0 200 120 Set value is the percentage of battery rated voltage Return value and delay value can also be set Return 0 200 115 Delay 0 3600 s 60 19 Battery Undervolt Warn Set 0 200 85 Return 0 200 90 Delay 0 3600 s 60 20 Charge Alt Fail Set 0 60 0 V 8 0 During engine nor...

Страница 23: ...perature ECU Setting 1 Display Unit 0 1 0 0 C 1 F 2 Over Shutdown 50 300 C 98 When external temp sensor value is larger than this value controller issues temp high shutdown alarm This value is detected only after safety on delay Delay value can be set 3 Over Warn 50 300 C 95 When external temp sensor value is over this value controller issues temp high shutdown alarm This value is detected only af...

Страница 24: ...alue controller issues shutdown alarm Alarm enable and delay value can be set 5 Under Warn 0 300 20 When external sensor value is less than this value controller issues warning alarm Alarm enable return and delay value can be set 6 Fuel Pump Control 0 300 10 When external fuel level sensor value is less than this value fuel pump control outputs return value and delay value can also be set 7 Fuel T...

Страница 25: ...nsor types 3 Open Action 0 2 0 0 Warning 1 Shutdown 2 None 4 Display Unit 0 1 0 0 C 1 F NOTE Unit is different for different sensor 5 Over Shutdown 0 9000 100 When external sensor value is larger than this value controller issues shutdown alarm Alarm enable and delay value can be set 6 Under Shutdown 0 9000 10 When external sensor value is less than this value controller issues shutdown alarm alar...

Страница 26: ...orrelate Set 0 4 0 0 Not Used 1 Flexible Sensor 1 2 Flexible Sensor 2 3 Flexible Sensor 3 4 Flexible Sensor 4 Digital Input Ports Digital Input 1 1 Contents Setting 0 53 3 Alarm Reset Please refer to Table 11 for details 2 Active Type 0 1 0 0 Close 1 Open Digital Input 2 1 Contents Setting 0 53 26 High Temp Shutdown Input Please refer to Table 11 for details 2 Active Type 0 1 0 0 Close 1 Open Digi...

Страница 27: ...details 2 Output Type 0 1 0 0 Normally Open 1 Normally Close Auxiliary Output 2 1 Contents Setting 0 129 28 Starting relay output Please refer to Table 10 for details 2 Output Type 0 1 0 0 Normally Open 1 Normally Close Auxiliary Output 3 1 Contents Setting 0 129 30 Idle speed control Please refer to Table 10 for details 2 Output Type 0 1 0 0 Normally Open 1 Normally Close Auxiliary Output 4 1 Con...

Страница 28: ...l be adjusted according to alternate configuration settings after load 3 Engine Unload Speed 0 100 0 70 0 4 Air Com Rated Pressure 0 30000 kPa 700 5 Air Com Unload Act Press 0 30000 kPa 600 Maintenance Setting 1 Oil Filter Set 0 1 0 0 Disable 1 Enable Maintenance time maintenance time due action maintenance timing method maintenance time reset can also be set at the same time After maintenance mai...

Страница 29: ...et corresponding curve Then set discharge temperature display related setting Choose corresponding sensor and at this time first page shall have discharge temperature If alarm output function will be set corresponding flexible sensor output shall be set 8 2 DEFINABLE CONTENTS OF AUXILIARY OUTPUT PORTS 1 6 8 2 1 DEFINABLE CONTENTS OF AUXILIARY OUTPUT PORTS 1 6 Table 10 Definable Contents of Auxilia...

Страница 30: ...engine with idle speed Pull in before start and disconnect at entering warming up time Pull in at the process of stop idle speed and disconnect when engine stops completely 31 Speed Raise Output Act in warming up period and controlled by speed regulator in normal running period 32 Speed Drop Output Act from stop idle to waiting for stop period and controlled by speed regulator in normal running pe...

Страница 31: ...gency stop alarm occurs 68 Failed to Start Act when failed to start alarm occurs 69 Failed to Stop Act when failed to stop alarm occurs 70 Under Speed Warn Act when engine under speed warning occurs 71 Under Speed Shutdown Act when engine under speed shutdown occurs 72 Over Speed Warn Act when engine over speed warning occurs 73 Over Speed Shutdown Act when engine over speed shutdown occurs 74 Res...

Страница 32: ...lexible Sensor 1 Low Shut Act when sensor 1 low shutdown occurs 101 Flexible Sensor 2 High Warn Act when sensor 2 high warning occurs 102 Flexible Sensor 2 Low Warn Act when sensor 2 low warning occurs 103 Flexible Sensor 2 High Shut Act when sensor 2 high shutdown occurs 104 Flexible Sensor 2 Low Shut Act when sensor 2 low shutdown occurs 105 Flexible Sensor 3 High Warn Act when sensor 3 high war...

Страница 33: ...d combination output is composed by 3 parts OR condition output S1 OR condition output S2 AND condition output S3 S1 or S2 is true and S3 is true then combination output works S1 and S2 both are false or S3 is false then combination output doesn t work NOTE S1 S2 and S3 can be any contents except itself defined combination output of the output settings NOTE S1 S2 and S3 cannot include or recursive...

Страница 34: ...t is active 6 Panel Lock All buttons in panel is inactive except UP DOWN CONFIRM keys Parameters cannot be configured But users can set language check event log and controller information There is in the bottom right corner on LCD when input is active 7 Crank Success Input When this function is active it means the engine is started successfully If this function is configured the speed and oil pres...

Страница 35: ...ine can be started automatically when input is inactive engine can be stopped automatically 33 Reserved 34 Simulate Stop key An external button unlatched can be connected and pressed as simulate panel 35 Simulate Load Unload key An external button unlatched can be connected and pressed as simulate panel 36 Reserved 37 Simulate Start key An external button unlatched can be connected and pressed as ...

Страница 36: ...rved 2 Oil Pressure Sensor 0 Not used 1 Custom Res Curve 2 Custom 4 20 mA Curve 3 Custom Volt Curve 4 VDO 10bar 5 CURTIS 6 VOLVO EC 7 DATCON 10bar 8 SGX 9 SGD 10 SGH 11 15 Reserved Defined resistance s range is 0 1 kΩ default is Not Used Users can select the corresponding curve by themselves If pre set sensor channel doesn t support current and voltage type then curve type item 2 and 3 display Res...

Страница 37: ...ed shutdown may be caused If engine doesn t have speed sensor please don t select corresponding items otherwise start failure or loss speed signal may be caused If engine doesn t have oil pressure sensor please don t select corresponding items 8 6 MAINTENANCE SETTING Table 14 Maintenance Setting Item Content Description Enable Choose 0 Disabled 1 Enabled Set maintenance function active or not Main...

Страница 38: ...ings press to enter setting Screen 3 press to return Screen 1 Or select Return by pressing and and press to go back to the previous screen 1 Return Preheat Delay Prestart Fuel Time Cranking Time Preheat Delay Screen 3 Press and move cursor select the value and press to modify Press to save your modification Then press to return Screen 2 00000s Timers Set Screen 4 Press select and modify the value ...

Страница 39: ...owns or faults may occur Over high threshold must be greater than lower threshold otherwise over high and over low circumstances may occur simultaneously Please set return value correctly when warning alarm is set otherwise the controller can t alarm normally When over warning is set the return value should be set lower than set value when low warning is set return value should be set greater than...

Страница 40: ...t the time of inputting the sensor curve X value must be inputted from small to large otherwise some mistake may occur If sensor is selected to Not Used then sensor curve doesn t work If corresponding sensor only has alarm switch then it is a must that set the sensor Not Used otherwise shutdown alarm or warning may occur It is applicable to set the headmost and backmost values in the vertical coor...

Страница 41: ...ve If everything is OK make the starting battery power on and controller will execute routine d Press start button engine will start After pre set start times controller will send failed to start signal then press stop button to reset controller e Recover the action of stop engine start e g Connect wire of fuel valve and press start button again then engine will start If everything goes well engin...

Страница 42: ...onnect wires from battery s positive and negative to controller s positive and negative input ports in order to prevent charger disturbing the controller s normal working SPEED SENSOR INPUT Speed sensor is the magnetic equipment installed in the starter for detecting flywheel teeth The connection wires with controller should apply 2 core shielding line The shielding layer should be connected to No...

Страница 43: ...939 shield CAN communication shielding line connect with ECU terminal only CAN H SAE J1939 signal Impedance 120Ω connecting line is recommended CAN L SAE J1939 return Impedance 120Ω connecting line is recommended 14 2 CUMMINS QSL9 Suitable for CM850 engine control module Engine type Cummins CM850 Table 18 50 pin Connector Terminals of controller 50 pins connector Remark Fuel relay output 39 Starti...

Страница 44: ...unication shielding line connect with ECU terminal only CAN H A Using impedance 120Ω connecting line CAN L B Using impedance 120Ω connecting line 14 4 CUMMINS QSX15 CM570 Suitable for CM570 engine control module Engine type is QSX15 etc Engine type Cummins QSX15 CM570 Table 22 50 pin Connector Terminals of controller 50 pins connector Remark Fuel relay output 38 Oil spout switch Starting relay out...

Страница 45: ...nd 8 of connector 06 connected at fuel output Starting relay output Connect to starter coil directly Table 25 D SUB Connector 06 Terminals of controller D SUB connector 06 Remark 20 Communication shielding line connect with ECU this terminal only RS485 21 Using impedance 120Ω connecting line RS485 18 Using impedance 120Ω connecting line 14 6 CUMMINS QSM11 Engine type Common J1939 Table 26 Engine O...

Страница 46: ... external extended relay Auxiliary output 2 19 41 Pulse speed raising control normally open output Make 19 connected with 41 for 0 1s during warming up via external extended relay CAN H 1 Using impedance 120Ω connecting line CAN L 21 Using impedance 120Ω connecting line 14 8 DETROIT DIESEL DDEC III IV Engine type Common J1939 Table 28 Engine CAN Port Terminals of controller CAN port of engine Rema...

Страница 47: ... line is recommended 14 10 JOHN DEERE Engine type John Deere Table 30 21 pin Connector Terminals of controller 21 pins connector Remark Fuel relay output G J Starting relay output D CAN H V Using impedance 120Ω connecting line CAN L U Using impedance 120Ω connecting line 14 11 MTU MDEC Suitable for MTU engines 2000 series 4000series Engine type mtu MDEC 303 Table 31 X1 Pin Connector Terminals of c...

Страница 48: ...ine with ADEC ECU7 and SAM module Engine type Common J1939 Table 34 ADEC X1 Port Terminals of controller ADEC X1port Remark Fuel relay output X1 43 X1 Terminal 28 connected to negative of battery Starting relay output X1 37 X1 Terminal 22 connected to negative of battery Table 35 SAM X23 Port Terminals of controller SAM X23 port Remark CAN H X23 2 Using impedance 120Ω connecting line CAN L X23 1 U...

Страница 49: ...relay output E Programmable output 1 P ECU power Set configurable output 1 ECU power Table 39 Data Bus Connector Terminals of controller Data bus connector Remark CAN H 1 Using impedance 120Ω connecting line CAN L 2 Using impedance 120Ω connecting line NOTE When this engine type is selected preheating time should be set to at least 3 seconds 14 17 VOLVO EDC4 Suitable engine models are TD520 TAD520...

Страница 50: ...ting can be realized Table 42 Engine 42 pin Port Terminals of controller Engine 42 pins port Remark Fuel relay output 1 40 Connect to engine ignition lock Starting relay output Connect to starter coil directly CAN H 1 35 Using impedance 120Ω connecting line CAN L 1 34 Using impedance 120Ω connecting line Table 43 Engine 2 pin Port Battery Engine 2 pins Remark Battery negative 1 Wire diameter 2 5mm...

Страница 51: ...e Check fuel circuit and related wirings Check starting battery Check speed sensor and its wire connections Refer to engine manual None response for starter Check starter wire connections Check starting battery RS485 communication is abnormal Check RS485 wire connections Check RS485 COM port settings are correct or not Check RS485 A and B are connected reversely or not Check RS485 conversion modul...

Страница 52: ...sel Air Compressor Controller User Manual Page 52 of 52 16 PACKING LIST Table 46 Packing List No Name Number Remark 1 Controller 1 2 Fixing Clips 2 3 Certificate 1 4 User Manual 1 _________________________________ ...

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