Smartgen HMC9000 User manual

1
HMC9000
DIESEL ENGINE CONTROLLER
(With J1939 Interface)
USER MANUAL
ZHENGZHOU SMARTGEN TECHNOLOGY CO.,LTD.

HMC9000 Diesel Engine Controller User Manual
HMC9000 Diesel Engine Controller 2015-12-25 Version 1.3 Page 8 of 52
4 TECHNICAL PARAMETERS
Parameter
Details
Working Voltage
DC18.0V to DC35.0V, uninterrupted power supply.
Power Consumption
<3W (Standby mode: ≤2W)
Speed Sensor Voltage
1.0V to 24V (RMS)
Speed Sensor Frequency
Max 10,000 Hz
GOV Output Voltage
DC (-10~10)V
Start Relay Output
16 A Connect to common output port.
Fuel Relay Output
16 A Connect to common output port.
Auxiliary Relay Output 1
7 AConnect to common output port.
Auxiliary Relay Output 2
7 A Connect to common output port.
Auxiliary Relay Output 3
7 A Connect to common output port.
Auxiliary Relay Output 4
7 A Connect to common output port.
Auxiliary Relay Output 5
7 A Connect to common output port.
Auxiliary Relay Output 6
7 A 250VAC voltage free output
Auxiliary Transistor Output 7~14
B+ DC supply output. Output current: 0.5A.
Case Dimension
240 mm x 172 mm x 57mm
Panel Cutout
214mm x 160mm
Working Conditions
Temperature: (-25~70)ºC; Humidity: (20~93)%RH
Storage Conditions
Temperature: (-25~70)ºC
Protection Level
IP55 Gasket
Insulation Intensity
Apply AC2.2kV voltage between high voltage terminal and low
voltage terminal;
The leakage current is not more than 3mAwithin 1min.
Weight
0.90kg

HMC9000 Diesel Engine Controller User Manual
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5 OPERATOR INTERFACE
5.1 PUSHBUTTONS DESCRIPTION
Stop
Stop running generator in local mode; During stopping process,
press this button again to stop generator immediately.
Start
Start genset in local mode.
Remote Mode
Places controller into its remote mode. In remote mode, engine
operation can be controlled via remote control module. In local mode,
except for stop button, all the other panel buttons will be locked.
Local Mode
Places controller into its local mode. In local mode, controller can be
started using panel button while remote control will have no effect.
Reset
If alarm occurs, pressing this button will reset it. All alarm only can
be removed after reset.
Lamp Test
Press this button will test panel LED indicators and display screen.
Mute
Alarm sound off;
Up/Increase
Screen scroll.
Up cursor and increase value in setting menu.
Down/Decrease
Screen scroll.
Down cursor and increase value in setting menu.
Left
Screen scroll.
Left move cursor in setting menu.
Right
Screen scroll.
Right move cursor in setting menu.
Set/Confirm
1. Pressing and holding for more than 3 seconds enters parameter
configuration menu;
2. In settings menu confirms the set value
Exit
1. Returns to the main screen.
2. In settings menu returns to the previous screen.
WARNING: Factory default password is 01234. Operator can change the password to prevent others
from free altering of the settings. Please clearly remember the password after changing. In case of
password loss, please contact Smartgen service department enclosing all the information from the
“ABOUT”page of the controller.

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5.2 LCD DISPLAY
5.2.1 Main Screen
The main screen displays revolution meter (0~3000r/min), thermograph (0~150 ºC; related sensor is
user-configurable, for example: HMC9000 sensor 1), oil manometer (0~1000kpa; related sensor is
user-configurable, for example: HMC9000 sensor 5) and two batteries voltage. The main screen
displays as follows:
5.2.2 Measured Data Display
The main screen is divided into two separate viewing areas: right and left. Left area display status and
cannot be scrolled; Right area can be scrolled using button.
★Status, including as below:
Status of genset , power supply status.
★Engine, including as below:
Engine speed, sensors 1-4 (resistance type), sensors 5-8 (current type), main battery voltage, standby
battery voltage, charger voltage, total running time, total start times and GOV output percentage.
(Note: sensor names are user-set)
★If J1939 is enabled，the following ECU data will also be displayed: coolant pressure, coolant level, oil
temperature, fuel temperature, fuel pressure, inlet temperature, exhaust temperature, turbo pressure,
fuel consumption, total fuel consumption and others. (Different engine with different parameters).
★Alarm, including as below:
It displays all kinds of warning alarms and shutdown alarms which detected by controller.
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.
HCM9000E has no J1939 port.
★Event log, including as below:
Records all shutdown events (shutdown alarm, trip and shutdown alarm) and the real time when alarm
occurs.
★Others, including as below:
Date and time, inputs/outputs status.

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9 INPUT/OUTPUT PORTS CONFIGURATION
9.1 AUXILIARY INPUTS 1~18 FUNCTIONAL CONFIGURATION
9.1.1 Digital Input Port Configuration
No.
Settings
Contents
Description
1
Feature Set
(0-50)
See 8.1.2 INPUT PORT FUNCTIONS
2
Active type
(0-1)
0: Close to activate
1: Open to activate
3
Arming
(0-3)
0: From Safety on
1: From Crank
2: Always
3: Never
4
Active action
(0-4)
0: Warn
1: Shutdown
2: Indication
5
Input Delay
(0-20.0)s
6
Open Check Enable
(0-1)
0:Disabled 1:Enable Only input ports
1~6 and speed input have this function.
7
Display string
User-defined input port
names
20 English symbols or 10 Chinese
characters
9.1.2 Input Ports Functions
No.
Function
Description
0
Not used
1
User-defined
Users configured input port settings
2
Alarm Mute
Can prohibit “Audible Alarm” output when input is active.
3
Reset alarm
Can reset all alarms when input is active.
4
Raise Speed
The generator will increase speed by GOV when the input is active.
5
Drop Speed
The generator will decrease speed by GOV when the input is active.
6
Reserved
7
Reserved
8
Lamp test
All LED indicators are illuminating when input is active.
9
Local mode in
Local mode is activated when input is active.
10
Remote mode in
Remote mode is activated when input is active.
11
Remote start
Automatically starts the generator in remote mode when the input is
active. Only the active shutdown input will be able to stop the
generator. (Inch or hold the button for more than 1s)
12
Remote stop
Stops the generator in remote mode when the input is active.
13
Remote start/stop
Automatically starts the generator in remote mode; the generator will
shut down when this input is deactivated.
14
Pre-lubricate
If output is set as pre-lubrication output, the relay disconnects after
the set pre-lubrication delay.

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15
Override mode in
Override mode is activated when the input is active; in override mode
only overspeed shutdown and emergency shutdown will stop the
engine.
16
Emergency stop
The controller shuts down the engine immediately and records
occurrence time.
17
Panel lock
All buttons in panel is inactive except and
there is in the left of first row in LCD when input is active.
18
Reserved
19
Power Change
Transfers from main battery to standby battery.
20
Raise Speed Aid
Raise speed relay will disconnect when the input is active.
21
Reserved
22
Drop Speed Aid
Drop speed relay will disconnect when the input is active.
23
Water Heating
feedback
The feedback signal of water heating output; The screen displays
Water Heating feedback when the input is active.
24
Pre-lube feedback
The feedback signal of Pre-lube output; The screen displays Pre-lube
feedback when the input is active.
25
Charging feedback
The feedback signal of Charging output; The screen displays
Charging feedback when the input is active.
26
Reserved
27
Reserved
28
Quick start
Cranking will start directly (without preheating) when the input is
active.
29
Reserved
30
60Hz Select
Frequency selection of ECU engine
31
Turning Chain
Start inhibition when the input is active.
32
Clean Cylinder
Start relay outputs when clean cylinder input is active.
33
Reserved
Reserved
34
Self-check
Alarms can test with no rotated speed when self-check input is active.
35-50
Reserved
Note: The name of the input ports 1~18 only can be configured via PC software.

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10 BACK PANEL
HMC9000 controller back panel layout:
Description of terminal connection:
Icon
No.
Function
Cable Size
Description
1
DC input B-
2.5mm2
DC power supply negative input. Connected
with negative of starter battery.
2
DC input B+
2.5mm2
DC power supply negative input. Connected
with positive of starter battery.
3
B1- input
2.5mm2
Battery 1 voltage input
4
B1+ input
2.5mm2
5
B2- input
2.5mm2
Battery 2 voltage input
6
B2+ input
2.5mm2
7
COM Relay
2.5mm2
Common relay power supply input
8
Fuel relay
2.5mm2
DC power is supplied by 7 terminal, rated
16A. Break wire protection function is fitted.
9
Start relay
2.5mm2
DC power is supplied by 7 terminal, rated 16A
10
Aux. output 1(A)
1.5mm2
DC power is supplied by 7 terminal, rated 7A.
Break wire protection function is fitted
(Configurable).
11
Aux. output 2(B)
1.5mm2
DC power is supplied by 7 terminal, rated 7A.
Break wire protection function is fitted
(Configurable).
12
Aux. output 3(C)
1.5mm2
DC power is supplied by 7 terminal, rated 7A.

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Icon
No.
Function
Cable Size
Description
Break wire protection function is fitted
(Configurable).
13
Aux. output 4(D)
1.5mm2
DC power is supplied by 7 terminal, rated 7A.
14
Aux. output 5(E)
1.5mm2
DC power is supplied by 7 terminal, rated 7A.
15
Aux. output 6(F)
1.5mm2
Volts Free; Rated current: 7A
16
17
18
MP1 (Magnetic
pickup+)
1.0mm2
Speed sensor input.
19
MP2 (Magnetic
pickup-)
1.0mm2
D+
20
D+ Charge input
1.0mm2
Charging generator D+ terminal input; Ground
connected is not allowed.
21
AUX. input 1(A)
1.0mm2
Digital input; Break wire protection function is
fitted (Configurable).
22
AUX. input 2(B)
1.0mm2
Digital input; Break wire protection function is
fitted (Configurable).
23
AUX. input 3(C)
1.0mm2
Digital input; Break wire protection function is
fitted (Configurable).
24
AUX. input 4(D)
1.0mm2
Digital input; Break wire protection function is
fitted (Configurable).
25
AUX. input 5(E)
1.0mm2
Digital input; Break wire protection function is
fitted (Configurable).
26
AUX. input 6(F)
1.0mm2
Digital input; Break wire protection function is
fitted (Configurable).
27
COM(B-)
1.0mm2
CANBUS
(EXPAN-
SION)
28
SCR (EXPANSION)
0.5mm2
For ECU module and expansion module
connection.
Impedance-120Ω shielding wire is
recommended, its single-end earthed.
There is 120Ω terminal resistance inside
already; if needed, make terminal 30, 31 short
circuits. (HCM9000E without)
29
CAN(H) (EXPANSION)
30
CAN(L) (EXPANSION)
31
120Ω
CANBUS
(REMOTE)
32
SCR
(REMOTE)
0.5mm2
For remote control module connection.
Impedance-120Ω shielding wire is
recommended, its single-end earthed.
There is 120Ω terminal resistance inside
already; if needed, make terminal 34, 35 short
circuits.
33
CAN(H)
(REMOTE)
34
CAN(L)
(REMOTE)
35
120Ω
36
Aux. output 7 (G)
0.5mm2
B+ voltage output, rated current is 0.5A.
37
Aux. output 8 (H)
0.5mm2
B+ voltage output, rated current is 0.5A.

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Icon
No.
Function
Cable Size
Description
38
Aux. output 9 (I)
0.5mm2
B+ voltage output, rated current is 0.5A.
39
Aux. output 10(J)
0.5mm2
B+ voltage output, rated current is 0.5A.
40
Aux. output 11(K)
0.5mm2
B+ voltage output, rated current is 0.5A.
41
Aux. output 12(L)
0.5mm2
B+ voltage output, rated current is 0.5A.
42
Aux. output 13(M)
0.5mm2
B+ voltage output, rated current is 0.5A.
43
Aux. output 14(N)
0.5mm2
B+ voltage output, rated current is 0.5A.
44
Aux. input 7(G)
1.0mm2
Digital input
45
Aux. input 8(H)
1.0mm2
Digital input
46
Aux. input 9(I)
1.0mm2
Digital input
47
Aux. input 10(J)
1.0mm2
Digital input
48
Aux. input 11(K)
1.0mm2
Digital input
49
Aux. input 12(L)
1.0mm2
Digital input
50
Aux. input 13(M)
1.0mm2
Digital input
51
Aux. input 14(N)
1.0mm2
Digital input
52
Aux. input 15(O)
1.0mm2
Digital input
53
Aux. input 16(P)
1.0mm2
Digital input
54
Aux. input 17(Q)
1.0mm2
Digital input
55
Aux. input 18(R)
1.0mm2
Digital input
56
COM(B-) input
1.0mm2
57
AIN1(A)
1.0mm2
Resistance sensor input
58
AIN2(B)
1.0mm2
Resistance sensor input
59
AIN3(C)
1.0mm2
Resistance sensor input
60
AIN4(D)
1.0mm2
Resistance sensor input
61
COM(B-) AIN1-4
1.0mm2
62
COM(B+) AIN5-8
1.0mm2
B+ Power supply output
63
AIN5(E)
1.0mm2
4-20mA sensor input
64
AIN6(F)
1.0mm2
4-20mA sensor input
65
AIN7(G)
1.0mm2
4-20mA sensor input
66
AIN8(H)
1.0mm2
4-20mA sensor input
GOV
67
GOV A(-)
1.0mm2
2 core shielding wire is recommended. Its
GOV terminal earthed. (HCM9000E without)
68
GOV B(+)
1.0mm2
RS485
69
RS485(B-)
0.5mm2
PC programming and monitoring port
(isolation type). Its single end earthed.
70
RS485(A+)
0.5mm2
71
RS485 SCR
0.5mm2
USB
USB
0.5mm2
Enables connection to PC monitoring software
Note: It is strictly prohibited to take out start battery when the engine is running. Failure to do so can
create excessive DC input voltage and result in damage of destruction of equipment!

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11 TYPICAL WIRING DIAGRAM
HMC9000 Typical Wiring Diagram
Note:
1．Power supply for fuel relay, start relay and auxiliary outputs 1~5 are supplied by terminal 7.
2．To activate battery transfer output you need to connect expansion relay with at least 50A current.
As following:

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1．Auxiliary outputs 7-14 use transistors (drive current is 0.5A); if you connect external device with
current lower than 0.5A, it can be connected directly.
2．Controller expansion modules can only be used together with the main controller; however, the
main controller can be used separately.
3．RS485 and USB ports can communicate with PC.
4．Remote modules that have CANBUS and RS485 ports can be connected to REMOTE or RS485
ports for remote control.

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12 RS485 COMMUNICATION AND CONNECTION
HMC9000 gen-set controller has RS485 port and USB port which allows the controller to connect to
open-type LAN. RS485 and USB applies ModBus communication protocol with the help of PC or DAS
(Data Acquisition Systems) operational software provides a simple and useful marine engine monitoring
system management scheme and enables remote control, remote measurement and remote
communication.
For more information about communication protocols see Smartgen document "HMC9000
communication protocols".
RS485 Communication parameters
Module address 1 (Range: 1~254, user-defined, default: 1)
Baud rate 9600 bps
Data bit 8 bit
Parity check bit None
Stop bit 2 bit
PC connects to the module’s USB as shown below.

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13.12 VOLVO-EMS2
Compatible with the following Volvo engines: TAD734, TAD940, TAD941, TAD1640, TAD1641,
TAD1642.
Terminals of controller
Engine CAN port
Remark
Auxiliary output 1
With the help of expansion
relay, when auxiliary output 1
is active, relay normally open
contact closes, which leads
to short circuit of engine 8 pin
terminal #4 wire and #6 wire.
Set auxiliary output 1 as “ECU shutdown”
Auxiliary output 2
With the help of expansion
relay, when auxiliary output 2
is active, relay normally open
contact closes, which leads
to short circuit of engine 8 pin
terminal #4 wire and #5 wire.
Set auxiliary output 2 as “Preheating until
cranking” and set preheating time as 5
seconds.
3
Power supply negative
4
Power supply positive
SCR (EXPANSION)
-
CAN communication shielding line (connect
to controller’sterminal only)
CAN(H) (EXPANSION)
1(Hi)
Impedance 120Ω connecting line is
recommended.
CAN(L) (EXPANSION)
2(Lo)
Impedance 120Ω connecting line is
recommended.
Engine type: Volvo-EMS2
13.13 BOSCH
Compatible with BOSCH common rail electronic engines.
Terminals of controller
42 pin engine port
Remark
Fuel relay output
1.40
Connect to engine ignition switch.
Start relay output
-
Connect to starter coil directly
SCR (EXPANSION)
-
CAN communication shielding line (connect to
controller’sterminal only)
CAN(H) (EXPANSION)
1.35
Impedance 120Ω connecting line is recommended.
CAN(L) (EXPANSION)
1.34
Impedance 120Ω connecting line is recommended.

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14 CONTROL PORT
This expansion port is a CANBUS port for connecting remote control module. Remote control module
enables start, stop, alarm mute and other functions to be performed on the distance. All engine
parameters and real-time events are displayed on the remote control module.
Note: Remote control module can only be used in remote mode of the engine; in local mode only
shutdown button will have effect.
15 INSTALLATION
The front panel of HMC9000 has embedded structure; the module is fixed with the help of fixing clips.
Overall dimensions and cutout dimensions can be seen below.
CUT OUT