Smartgen APC715 User manual

APC715 Pump Unit Controller
USER MANUAL
Smartgen Technology

Chinese trademark
English trademark
Smartgen —make your generator smart
Smartgen Technology Co., Ltd.
No. 28 Jinsuo Road
Zhengzhou
Henan Province
P. R. China
Tel: [phone]
[phone]/67992951
[phone](overseas)
Fax: [phone]
Web: http://www.smartgen.com.cn
http://www.smartgen.cn
Email: [email protected]
All rights reserved. No part of this publication may be reproduced in any material form
(including photocopying or storing in any medium by electronic means or other) without
the written permission of the copyright holder.
Smartgen Technology reserves the right to change the contents of this document
without prior notice.

Version
Date
Version
Note
2013-08-28
1.0
Original release.
This manual is suitable for APC715 pump unit controller only.
Clarification of notation used within this publication.
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.

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CONTENTS
1OVERVIEW........................................................................................6
2PERFORMANCE AND CHARACTERISTICS ....................................7
3SPECIFICATION................................................................................9
4OPERATION....................................................................................10
4.1 INDICATOR LIGHT.........................................................................................10
4.2 PUSHBUTTONS.............................................................................................11
4.3 LCD DISPLAY.................................................................................................12
4.3.1 MAIN DISPLAY...................................................................................12
4.3.2 USER MENU AND PARAMETERS SETTING MENU ........................13
4.4 AUTO START/STOP OPERATION.................................................................16
4.5 MANUAL START/STOP OPERATION............................................................17
4.6 ON-LOAD CONTROL PROCESS...................................................................18
4.7 ADJUST SPEED CONTROL..........................................................................19
5PROTECTION .................................................................................20
5.1 WARNINGS....................................................................................................20
5.2 SHUTDOWNALARM .....................................................................................22
5.3 TRIP SHUTDOWN .........................................................................................24
5.4 FAULT IDLE....................................................................................................24
6CONNECTIONS ..............................................................................25
7DEFINITION AND RANGE OF PARAMETERS................................28
7.1 PARAMETER CONTENTS AND RANGE (TABLE 1)......................................28
7.2 PROGRAMMABLE OUTPUT 1-5 (TABLE 2)..................................................37
7.2.1 Custom Period Output........................................................................41
7.2.2 Custom Combined Output..................................................................42
7.3 DEFINED CONTENTS OF CONFIGURABLE INPUT PORTS (ALL ACTIVE
WHEN CONNECT TO GRAND (B-))......................................................................43
7.4 SELECTION OF SENSORS...........................................................................45
7.5 CONDITIONS OF CRANK DINSCONNECT SELECTION .............................46
8PARAMETERS SETTING................................................................47
9SENSOR SELECT...........................................................................48
10 TYPICALAPPLICATION..................................................................49
11 INSTALLATION................................................................................50
12 CONNECTIONS OF CONTROLLER WITH J1939 ENGINE............51
12.1CUMMINS ISB/ISBE.......................................................................................51
12.2CUMMINS QSL9 ............................................................................................51

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12.3CUMMINS QSM11(IMPORT) .........................................................................52
12.4CUMMINS QSX15-CM570 .............................................................................52
12.5CUMMINS GCS-MODBUS.............................................................................53
12.6CUMMINS QSM11..........................................................................................53
12.7CUMMINS QSZ13..........................................................................................54
12.8DETROIT DIESEL DDEC III / IV.....................................................................54
12.9DEUTZ EMR2.................................................................................................55
12.10 JOHN DEERE ..........................................................................................55
12.11 MTU MDEC ..............................................................................................55
12.12 MTU ADEC(SMART MODULE)................................................................56
12.13 MTU ADEC(SAM MODULE).....................................................................56
12.14 PERKINS..................................................................................................57
12.15 SCANIA....................................................................................................57
12.16 VOLVO EDC3...........................................................................................58
12.17 VOLVO EDC4...........................................................................................58
12.18 VOLVO-EMS2...........................................................................................59
12.19 YUCHAI....................................................................................................59
12.20 WEICHAI..................................................................................................60
13 USB.................................................................................................61
14 FAULT FINDING ..............................................................................62

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1 OVERVIEW
APC715 Pump Unit Controller is designed for pump systems which controlled by
engine. It allows automatic start/stop, data measurement, alarm protection as well as
remote control, remote measurement and remote communication function. It fit with
LCD display, optional languages interface, and it is reliable and easy to use.
Utilizing the GOV (Engine Speed Governor) control function, the controller is able to
stabilize the outlet pressure via GOV.
APC715 Pump Unit Controller also monitors the engine, indicating the operational
status and fault conditions accurately. When abnormal condition occurs, it can protect
the unit automatically; simultaneously the exact failure mode information is indicated
by the LCD display on the front panel. SAE J1939 interface enables the controller to
communicate with various ECU (ENGINE CONTROL UNIT) which fitted with J1939
interface.
APC715 Pump Unit Controller adopt powerful 32-bit microprocessor technology with
precision parameters measuring, fixed value adjustment, time setting and set value
adjusting and etc. The majority of parameters can be configured from front panel and
all the parameters can be set using PC (via USB port) and can be adjusted and
monitored with the help of RS485 ports. It can be widely used in a number of pump
control system with compact structure, simple connections and high reliability

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2 PERFORMANCE AND CHARACTERISTICS
With ARM-based 32-bit SCM, highly integrated hardware, new reliability level.
480x272 pixel, 4.3 inches LCD with backlight, multilingual interface (including
English, Chinese or other languages) which can be chosen at the site, making
commissioning convenient for factory personnel.
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 via ModBus protocol.
Equipped with CANBUS port and can communicate with J1939 genset. Not only
can you monitoring frequently-used data (such as water temperature, oil pressure,
engine speed, fuel consumption and so on) of ECU machine, but also control start,
stop, raising speed and speed droop via CANBUS port.
10 analog sensors; sensors can switch between resistor type and current type using
jumper.
More kinds of curves of temperature, oil pressure, fuel level can be used directly
and users can define the sensor curves by themselves.
Precision measure and display parameters about Engine and pump unit.
Protection: automatic start/stop of the pump unit, perfect fault indication and
protection function.
All output ports are relay-out;
Parameter setting: parameters can be modified and stored in internal FLASH
memory and cannot be lost even in case of power outage; most of them can be
adjusted using front panel of the controller and all of them can be modified using
PC via USB or RS485 ports.
Multiple crank disconnect conditions (speed sensor, oil pressure) are optional;
Widely power supply range DC(8~35)V, suitable to different starting battery voltage
environment;
Event log, real-time clock, scheduled start & stop pump unit (can be set as start
pump unit once a day/week/month whether with load or not);
Accumulative total run time and total electric energy of A and B. Users can reset it
as 0 and re-accumulative the value which make convenience to users to count the

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total value as their wish.
Can control engine heater, cooler and fuel pump.
With maintenance function. Actions (warning/shutdown) can be set when
maintenance time out;
All parameters used digital adjustment, instead of conventional analog modulation
with normal potentiometer, more reliability and stability;
Waterproof security level IP55 due to rubber seal installed between the controller
enclosure and panel fascia;
Metal fixing clips enable perfect performance in high temperature environment;
Modular design, anti-flaming ABS plastic enclosure, pluggable connection terminals
and embedded installation way; compact structure with easy mounting.

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3 SPECIFICATION
Items
Contents
Working Voltage
DC8. 0V to 35. 0V, Continuous Power Supply.
Overall Consumption
<4W(Standby mode: ≤2W)
Speed Sensor Voltage
1.0V to 24V (effective value)
Speed Sensor Frequency
10,000 Hz (max)
Start Relay Output
16Amp DC28V power supply
Fuel Relay Output
16Amp DC28V power supply
Programmable Relay Output 1-6
7Amp DC28V power supply
Programmable Relay Output 7-10
7Amp AC250V power supply
Analog Sensor
4 fixed sensor, 6 configurable sensor
Overall Dimensions
266 mm x 182 mm x 45 mm
Panel Cutout
214mm x 160mm
Working Condition
Temperature: (-25~70)ºC;
Humidity: (20~93)%RH
Storage Condition
Temperature: (-25~70)ºC
Protection Level
IP55 Gasket
Weight
0.95kg

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4 OPERATION
4.1INDICATOR LIGHT
Note: Selected indicators description:
Warning indicator and Alarm indicator:
Alarm Type
Warning Indicator
Alarm Indicator
Warning
Slow flashing
Slow flashing
Shutdown Alarm
Off
Fast flashing
Running indicator: illuminated from crank successful to ETS while off during other
periods.

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4.2PUSHBUTTONS
Stop
Stop running pump unit in Auto/Manual mode;
Reset alarm in stop mode; Lamp test (press at
least 3 seconds); During stopping process, press
this button again to stop pump unit immediately.
Start
Start pump unit in Manual/Test mode.
Manual Mode
Press this key and controller enters in Manual
mode.
Auto Mode
Press this key and controller enters in Auto mode.
Mute
Alarming sound off; If there is alarm, pressing the
button at least 3 seconds can reset this alarm.
Load
Can control the clutch to switch on or off in manual
mode.
Adjust Speed
Enter/Exit the speed adjust menu.
Up/Increase
1) Screen scroll; 2) Up cursor and increase
value in setting menu.
Down/Decrease
1) Screen scroll; 2) Down cursor and decrease
value in setting menu.
Left
1) Screen scroll; 2) Left move cursor in setting
menu.
Right
1) Screen scroll; 2) Right move cursor in setting
menu.
Set/Confirm
1. Enter into “help”interface;
2. Pressing and holding for more than 3 seconds
enters parameter configuration menu;
3. In settings menu confirms the set value.
Exit
1. Returns to the main menu;
2. In settings menu returns to the previous menu.
NOTE: In manual mode, pressing and simultaneously will force
generator to crank. Successful start will not be judged according to crank disconnect
conditions, operator will have to crank the starter motor manually; when operator
decides that the engine has fired, he/she should release the button and start relay will
be deactivated, safety on delay will start.
WARNING: Default password is 00318, user can change it in case of others
change the advanced parameters setting. Please clearly remember the password after
changing. If you forget it, please contact Smartgen services and send all information in
the controller page of “ABOUT”to us.

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4.3LCD DISPLAY
4.3.1 MAIN DISPLAY
Main screen is divided into left and right separate viewing areas, use to select a
viewing area; the selected area is marked with in its upper left corner. Both
viewing areas show pages; use to scroll the pages and to scroll the
screen.
★Engine, including as below,
Engine status, engine temperature, engine oil pressure, fuel level, Configurable Sensor1,
battery voltage, charger voltage, accumulated run time, accumulated start times.
NOTE: If connected with J1939 engine via CANBUS port, this page also includes:
coolant pressure, coolant level, fuel temperature, fuel pressure, inlet temperature,
exhaust temperature, turbo pressure, fuel consumption, total fuel consumption and so
on. (Different engine with different parameters)
★Pump Unit：
Outlet pressure, pump flow, pump head, config. sensor 2~6 (can be set as
temperature sensor, pressure sensor or level sensor)
Formula：Pump Head = ( Outlet pressure - Static Pressure)/0.0098.
★Alarm:
Display all warnings, shutdown alarms, trip shutdown alarms and the corresponding
information.
NOTE: For ECU alarms and shutdown alarms, if the alarm information is displayed,
check engine according to it, otherwise, please check the manual of generator according
to SPN alarm code.
◙Event log
Records all start/stop events (shutdown alarm, trip shutdown alarm, manual/auto start or
stop) and the real time when alarm occurs.
Others, including,
Time and Date, maintenance due time, input/output ports status.
◙About, including,
Issue time of software and hardware version, product PD number.

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★Status, including as below,
Engine speed, battery voltage 1, engine status
Indicator
Status
Green
Normal status; No alarm
Yellow
Warning or idle speed alarm occurs.
Red
Shutdown alarm occurs.
Example:
Engine
Pump
On load
Manual Mode
Normal Running
Outlet Pressure
1.0MPa 10Bar 145psi
Config Sensor 2
45℃113℉
Engine Temp.
85℃185℉
Config Sensor 3
465kPa 4.65Bar 67.4psi
Oil Pressure
465kPa 4.65Bar
67.4psi
Config Sensor 4
100%
1500rpm
27.6V
At Rest
Engine
Pump
Fuel Level
100%
Config Sensor 5
55℃131℉
Config Sensor 1
85℃185℉
Config Sensor 6
60℃140℉
Battery Voltage 1
27.6V
Pump Flow
200m³/h
Battery Voltage 2
27.6V
Pump Head
102m
1500rpm
27.6V
Emergency Stop
4.3.2 USER MENU AND PARAMETERS SETTING MENU
Press and hold for more than 3 seconds to enter into user menu;
★Parameter
After entering the correct password (factory default password is 00318), you can enter
into parameter settings interface.
★Language
Selectable Chinese, English and others (default: Espanol)

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★Commissioning
On load, off load or custom commissioning can be chosen. Custom commissioning
can configure on load or not during commissioning, when to commissioning and select
the mode after commissioning (manual mode, auto mode and stop mode).
★Clear users’accumulation
Can clear User Acc. Run A, User Acc. Run B and Engine Acc. Run time.
Parameter setting including as following,
★Timer settings
★Engine settings
★Analog sensor settings (Engine temperature, engine oil pressure, fuel level, config.
1~6, outlet pressure)
★Input port settings
★output port settings
★GOV settings
★Pump settings
★Module settings
★Scheduling and maintenance settings
Example,
Return
>Start Delay
>Stop Delay
>Preheat Delay
>Cranking Time
> Crank Rest Time
> Safety On Time
> Start Idle Time
> Warming Up Time
> Cooling Time
> Stop Idle Time
> ETS Hold Time
Form1: Use to scroll settings,
to enter settings (form2), to
exit settings menu.
Timers >
Engine
Temp. Sensor
OP Sensor
Level Sensor
Config Sensor 1
Config Sensor 2
Config Sensor 3
Config Sensor 4
Config Sensor 5

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Return
>Start Delay
Form 2: Use to scroll
settings, to enter settings (form3),
to return to previous menu. (form
1).
Timers >
>Stop Delay
>Preheat Delay
>Cranking Time
>Crank Rest Time
>Safety On Time
>Start Idle Time
>Warming Up Time
>Cooling Time
>Stop Idle Time
>ETS Hold Time
Engine
Temp. Sensor
OP Sensor
Level Sensor
Config Sensor 1
Config Sensor 2
Config Sensor 3
Config Sensor 4
Config Sensor 5
Return
>Start Delay
>Stop Delay
>Preheat Delay
Form 3: Use to scroll
settings, to enter settings (form4),
to return to previous menu. (form
1).
Timers >
Engine
Temp. Sensor
OP Sensor
Level Sensor
Config Sensor 1
Config Sensor 2
Config Sensor 3
Config Sensor 4
Config Sensor 5
>Cranking Time
>Crank Rest Time
>Safety On Time
>Start Idle Time
>Warming Up Time
>Cooling Time
>Stop Idle Time
>ETS Hold Time
>Start Delay
>Stop Delay
>Preheat Delay
Form 4：Press to enter settings
(form 5), to return to previous
menu. (form 6).
00008
>Cranking Time
>Crank Rest Time
>Safety On Time
>Start Idle Time
>Warming Up Time
>Cooling Time
>Stop Idle Time
>ETS Hold Time

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>Start Delay
>Stop Delay
>Preheat Delay
00008
Form5: Press to change cursor
position, are used for
changing cursor value, Confirm
setting (form 4), exit setting (form
4).
>Cranking Time
>Crank Rest Time
>Safety On Time
>Start Idle Time
> Warming Up Time
>Cooling Time
>Stop Idle Time
>ETS Hold Time
>Start Delay
>Stop Delay
>Preheat Delay
00008
Form 6: are used for
changing the setting contents.
Confirm setting (form 4), to return
to previous menu. (form 1).
>Cranking Time
>Crank Rest Time
>Safety On Time
>Start Idle Time
> Warming Up Time
>Cooling Time
>Stop Idle Time
>ETS Hold Time
>Wait Stop Time
NOTE: Pressing can exit setting directly during setting.
4.4 AUTO START/STOP OPERATION
Auto mode is selected by pressing the button; a LED besides the button will
illuminate to confirm the operation.
Automatic Start Sequence:
1. When “Remote Start” is active, “Start Delay” timer is initiated;
2. When start delay is over, preheat relay energizes (if configured), “preheat delay XX s”
information will be displayed on LCD;
3. After the above delay, the Fuel Relay is energized, and then one second later, the
Start Relay is engaged. The engine is cranked fora pre-set time. If the pump unit fails
to fire during this cranking attempt then the fuel relay and start relay are disengaged
for the pre-set rest period; “crank rest time” begins and wait for the next crank
attempt.
4. Should this start sequence continue beyond the set number of attempts, the start

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sequence will be terminated, the Fail to Start fault will be displayed on LCD.
5. In case of successful crank attempt, the “Safety On” timer is activated, allowing Low
Oil Pressure, High Temperature, Under speed and Charge Alternator Failure inputs
to stabilize without triggering the fault. As soon as this delay is over, “start idle” delay
is initiated (if configured).
6. During “start idle” delay, under speed alarm is inhibited. When this delay is over,
“warming up” delay is initiated (if configured).
7. After the “warming up” delay, If engine speed has reached on-load requirements,
then the pump close relay will be energized; pump uint will take load; pump unit will
enter into Normal Running status.
NOTE: In case of “Remote Start (off Load)”, the procedure is the same, except for
step NO. 7: the pump close relay will NOT be energised, generator will NOT accept load.
Automatic Stop Sequence,
1) When the “Remote Start” signal is deactivated while the “Remote Stop”signal is
active, the Stop Delay is initiated.
2) Once this “stop delay” has expired, the Pump Unit Breaker will open and the “Cooling
Delay” is then initiated. Should the Remote Start signal be re-activated during the
cooling down period, the unit will return running status. Once the “Cooling Delay”
expires, the “Stop Idle” delay is initiated.
3) During “Stop Idle” Delay (if configured), idle relay is energized.
4) “ETS Solenoid Hold” begins, ETS relay is energized while fuel relay is
de-energized and complete stop is detected automatically
5) "Fail to Stop Delay" begins, complete stop is detected automatically.
6) Pump unit is placed into its “After stop time”after its complete stop. Otherwise, fail
to stop alarm is initiated and the corresponding alarm information is displayed on
LCD (If pump unit stopped successfully after “Failed to Stop” alarm, it will enter
“After stop time” and remove alarm).
7) Pump unit is placed into its standby mode after its “After stop time”.
4.5 MANUAL START/STOP OPERATION
1 Manual Start: Manual mode is selected by pressing the button; a LED
besides the button will illuminate to confirm the operation; then press
button to start the unit; can automatically detect crank successful, and unit
accelerates to high-speed running automatically.

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When “After Unload Idle” is enabled, the unit is idle running when crank succeed;
unit accelerates to high-speed running automatically and take load after press
key by manual.
With high temperature, low oil pressure and over speed during pump unit running,
controller can protect it to stop quickly (please refer to No.2~7 of Auto start
operation for detail procedures).
2 MANUAL STOP: Press can stop the running pump unit. (please refer to
No.2~7 of Auto stop operation for detail procedures).
NOTE: In “manual mode”, users can control the pump unit on load or off load via
“Load”key.
4.6 ON-LOAD CONTROL PROCESS
When controller is in Manual mode, manual control will be executed.
Users can control the pump unit on load or off load by pressing key. The pump unit
will unload automatically when it is stopped.
If “After Unload Idle” is selected “Disable”
Start the pump unit in manual mode and press key during the normal running
process, then the generator will take load; press key again, the generator will
unload.
If “After Unload Idle” is selected “Enable”：
Start the pump unit in manual mode and it enters into idle running process. The pump
unit will not enter into normal running status until key is pressed and it will take
load as soon as the on-load requirements have reached.
When the pump unit is normal running with load, press key once again will lead to
the unit’s offload (i.e. load relay deactivated); then the “cooling delay”will be initiated.
Once this has expired, the unit will enter into idle running status.
When controller is in Auto mode, auto control will be executed.
The pump unit will take load automatically when it is normal running and the on-load
requirements have reached while unload automatically when it is stopped.

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4.7 ADJUST SPEED CONTROL
Users can set the outlet pressure as the rated value simply by adjusting the engine
speed. The “Adjust Speed Control”was divided into auto control and manual control.
Manual Adjust Speed: Adjust Speed mode is selected by pressing the button; In
this interface, users can adjust speed using navigational button: , manual adjust
speed; , auto adjust speed; , manual raise speed; , manual drop speed. “,
manual raise speed”and “, manual drop speed”buttons are active only when pump
unit is normal running under “Manual Adjust Speed”mode.
Auto Adjust Speed: Under this mode, during the unit is normal running, the
controller will adjust the outlet pressure to rated speed and maintain its steady
automatically according to the set value.
The “Auto Adjust Speed”was divided into relay adjust speed, GOV adjust speed and
CAN adjust speed.
Relay Adjust Speed: Control the engine servo motor simply by using speed raise relay
and speed drop relay.
GOV Adjust Speed: Control the electronic speed regulator simply by using GOV
analog signal. Users should set parameters according to the actual situation as
different regulators have different parameters.
CAN Adjust Speed: Control the ECU engine speed simply by using CAN interface.
Parameters setting and speed adjustment method are same as GOV. Some ECU
engine has CAN adjust speed function, e.g. EMS2. Other engine types need the
above two ways to adjust speed.

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5 PROTECTION
5.1WARNINGS
Warnings are not shutdown alarms and do not affect the operation of the genset.
Warning does not lead to shutdown, and when warning condition is no longer present,
warning alarm will be cleared automatically. Warning types are as follows:
No.
Type
Description
1
Over Speed
When the controller detects that the engine speed has
exceeded the pre-set value, it will initiate a warning
alarm.
2
Under Speed
When the controller detects that the engine speed has
fallen below the pre-set value, it will initiate a warning
alarm.
3
Loss of Speed
Signal
When the controller detects that the engine speed is 0
and the action select “Warn”, it will initiate a warning
alarm.
4
Fail To Stop
After “fail to stop” delay, if unit is not stop completely, it
will initiate a warning alarm.
5
Charge Alt Fail
When the controller detects that charger voltage has
fallen below the pre-set value, it will initiate a warning
alarm.
6
Battery 1 Over
Voltage
When the controller detects that battery 1 voltage has
exceeded the pre-set value, it will initiate a warning
alarm.
7
Battery 1 Under
Voltage
When the controller detects that battery 1 voltage has
fallen below the pre-set value, it will initiate a warning
alarm.
8
Maintenance Due
When maintenance countdown time is 0 and the action
select “Warn”, it will initiate a warning alarm.
9
ECU Warn
If an error message is received from ECU via J1939, it
will initiate a warning alarm.
10
Temperature
Sensor Open
Circuit
When the controller detects that the temperature
sensor is open circuit and the action select “Warn”, it
will initiate a warning alarm.
11
High Temperature
When the controller detects that engine temperature
has exceeded the pre-set value, it will initiate a warning
alarm.
12
Low Temperature
When the controller detects that engine temperature
has fallen below the pre-set value, it will initiate a
warning alarm.
13
Oil Pressure Open
Circuit
When the controller detects that the oil pressure sensor
is open circuit and the action select “Warn”, it will