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Smartgen APC715 User Manual

Pump unit controller
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APC715
PUMP UNIT CONTROLLER
USER MANUAL
SMARTGEN (ZHENGZHOU) TECHNOLOGY CO., LTD.

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Summary of Contents for Smartgen APC715

  • Page 1 APC715 PUMP UNIT CONTROLLER USER MANUAL SMARTGEN (ZHENGZHOU) TECHNOLOGY CO., LTD.
  • Page 2 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 the contents of this document without prior notice. Table 1 Software Version...
  • Page 3 This manual is suitable for APC715 pump unit controller only. Clarification of notation used within this publication. Table 2 Notation Clarification Symbol Instruction Highlights an essential element of a procedure to ensure correctness. NOTE Indicates a procedure or practice, which, if not strictly observed, could result CAUTION! in damage or destruction of equipment.

  • Page 4: Table Of Contents

    7.3 DEFINED CONTENTS OF CONFIGURABLE INPUT PORTS ........... 42 7.4 SELECTION OF SENSORS ...................... 44 7.5 CONDITIONS OF CRANK DISCONNECT SELECTION ............45 7.6 MAINTENANCE SETTING ....................... 46 PARAMETERS SETTING......................... 47 SENSOR SETTING .......................... 48 APC715 Pump Unit Controller User Manual Page 4 of 62...
  • Page 5 12.16 VOLVO EDC3 .......................... 58 12.17 VOLVO EDC4 .......................... 59 12.18 VOLVO-EMS2 ......................... 59 12.19 YUCHAI ..........................60 12.20 WEICHAI ..........................60 13 USB ..............................61 14 FAULT FINDING ..........................62 APC715 Pump Unit Controller User Manual Page 5 of 62...

  • Page 6: Overview

    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. Utilizing the GOV (Engine Speed Governor) control function, the controller is able to stabilize the outlet/inlet pressure.

  • Page 7: Performance And Characteristics

     With maintenance function. Actions can be set when maintenance time out;  All parameters used digital adjustment, instead of conventional analog modulation with normal potentiometer, improving reliability and stability; APC715 Pump Unit Controller User Manual Page 7 of 62...
  • Page 8  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. APC715 Pump Unit Controller User Manual Page 8 of 62...

  • Page 9: Specification

    4 fixed sensors, 6 configurable sensors Overall Dimensions 266mm x 182mm x 45mm Panel Cutout 214mm x 160mm Working Conditions Temperature: (-25~+70)°C Humidity: (20~93)%RH Storage Condition Temperature: (-25~+70)°C Protection Level IP55 Gasket Weight 0.95kg APC715 Pump Unit Controller User Manual Page 9 of 62...

  • Page 10: Operation

    Table 4 Warning and Alarm Indicators Alarm Type Warning Indicator Alarm Indicator Warning Alarm Slow flashing Slow flashing Shutdown Alarm Fast flashing Running indicator: illuminated from crank success to ETS while off during other periods. APC715 Pump Unit Controller User Manual Page 10 of 62...

  • Page 11: Key Functions

    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. APC715 Pump Unit Controller User Manual Page 11 of 62...

  • Page 12: Lcd Display

    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 PD information in the controller page of “ABOUT” to us.
  • Page 13 55°C 131°F Config Sensor 1 Config Sensor 6 85°C 185°F 60°C 140°F Battery Voltage 1 Pump Flow 27.6V 200m³/h Battery Voltage 2 Pump Head 27.6V 102m 1500rpm 27.6V Emergency Stop Alarm APC715 Pump Unit Controller User Manual Page 13 of 62...

  • Page 14: User Menu And Parameters Setting Menu

    >Cooling Time Config Sensor 3 >Stop Idle Time Config Sensor 4 >ETS Hold Time Config Sensor 5 Return >Start Delay Table 2: Use to scroll settings Timers > >Stop Delay APC715 Pump Unit Controller User Manual Page 14 of 62...
  • Page 15 >Warming Up Time >Cooling Time >Stop Idle Time >ETS Hold Time >Start Delay Table 5: Press to change cursor >Stop Delay 00008 >Preheat Delay position, are used for changing >Cranking Time APC715 Pump Unit Controller User Manual Page 15 of 62...
  • Page 16 (table 1). >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. APC715 Pump Unit Controller User Manual Page 16 of 62...

  • Page 17: Auto Start/Stop Operation

    LCD (If pump unit stopped successfully after “Failed to Stop” alarm, it will enter “After stop time” and remove alarm). Pump unit is placed into its standby mode after its “After Stop Time”. APC715 Pump Unit Controller User Manual Page 17 of 62...

  • Page 18: Manual Start/Stop Operation

    When controller is in Auto mode, auto control will be executed. The pump unit will take load automatically when it is normally running and the on-load requirements have reached while unload automatically when it stops. APC715 Pump Unit Controller User Manual Page 18 of 62...

  • Page 19: Adjust Speed Control Procedure

    CAN Adjust Speed: Control the ECU engine speed simply by using CAN interface. Parameters setting and speed adjustment method are same as GOV. SW1 should set as 5.0 and SW2 as 2.0 while adjusting. APC715 Pump Unit Controller User Manual Page 19 of 62...

  • Page 20: Protection

    “Warn”, it will initiate a warning alarm. When the controller detects that the fuel level has fallen below Low Fuel Level the pre-set value, it will initiate a warning alarm. APC715 Pump Unit Controller User Manual Page 20 of 62...
  • Page 21 When the mandate time has expired and the action selects End of Mandate Time “Warn”, it will initiate a warning alarm. APC715 Pump Unit Controller User Manual Page 21 of 62...

  • Page 22: Shutdown Alarm

    Flexible Sensor 1~6 When the controller detects the sensor value is lower than the min. set value, it will initiate a shutdown alarm. APC715 Pump Unit Controller User Manual Page 22 of 62...
  • Page 23 When the mandate time has expired and the action selects End of Mandate Time “Shutdown”, it will initiate a shutdown alarm. APC715 Pump Unit Controller User Manual Page 23 of 62...

  • Page 24: Cooling Shutdown Alarm

    Maintenance Due selects “Indication”, it will initiate an indication alarm. When the action of digital input port selects “Indication” and Digital Input 1~9 active, it will initiate an indication alarm. APC715 Pump Unit Controller User Manual Page 24 of 62...

  • Page 25: Wiring Connection

    7A B+ power is supplied by terminal 2, Details Aux. Output 2 1.5mm rated 7A table 14 B+ power is supplied by terminal 2, Aux. Output 3 1.5mm rated 7A APC715 Pump Unit Controller User Manual Page 25 of 62...
  • Page 26 Normally open output, rated 7A Normally close output, rated 7A Aux. Output 9 1.5mm Public points of relay Normally open output, rated 7A Aux. Output 10 1.5mm Normally close output, rated 7A APC715 Pump Unit Controller User Manual Page 26 of 62...
  • Page 27 Impedance-120Ω shielding wire is recommended, its RS485+ 0.5mm single-end earthed. RS485- 0.5mm NOTE: USB ports in controller rear panel are programmable parameter ports, user can directly configure controller via PC in stop mode. APC715 Pump Unit Controller User Manual Page 27 of 62...

  • Page 28: Definition And Range Of Parameters

    Engine Setting Default: Conventional engine (not J1939) Engine Type (0-39) When connected to J1939 engine, choose the corresponding type. Flywheel Teeth (10-300) Tooth number of the engine, for judging APC715 Pump Unit Controller User Manual Page 28 of 62...
  • Page 29 Start Attempts (1-10) times number, controller will send start failure signal. See table 18. Crank Disconnect (0-2) There are 3 conditions of disconnecting starter with engine. Each condition can be APC715 Pump Unit Controller User Manual Page 29 of 62...
  • Page 30 B, timing method and reset Maintenance 4 (0-1) maintenance time. If maintenance due alarm occurs, users reset Maintenance 5 (0-1) maintenance alarm to remove it. Analog Sensors Setting Temperature Sensor APC715 Pump Unit Controller User Manual Page 30 of 62...
  • Page 31 It is detecting all the time. The delay value and return value can be set. Users should set the corresponding curve Custom Curve when select resistor curve type or current curve type. Flexible Sensor 1~6 APC715 Pump Unit Controller User Manual Page 31 of 62...
  • Page 32 Users should set the corresponding curve Custom Curve when select resistor curve type or current curve type. Rated Outlet (0-9000)kPa 1000 Set the outlet port’s rated working APC715 Pump Unit Controller User Manual Page 32 of 62...
  • Page 33 Flexible Input Port 5 Contents Setting (0-53) User defined. See table 15 Active Type (0-1) 0: Closed to active 1: Open to active Arming (0-3) 0: From safety on 1: From starting APC715 Pump Unit Controller User Manual Page 33 of 62...
  • Page 34 0: Normally open; 1: Normally close Flexible Output Port 4 Contents Setting (0-239) Reserved. See table 16. Active Type (0-1) 0: Normally open; 1: Normally close Flexible Output Port 5 APC715 Pump Unit Controller User Manual Page 34 of 62...
  • Page 35 Over Speed Warn (0-1000)% 110% Setting value is percentage of rated Under Speed speed. Delay value and return value can (0-1000)% Warn be set. APC715 Pump Unit Controller User Manual Page 35 of 62...

  • Page 36: Definition Of Programmable Output 1-5

    It is controlled by heating of temperature Heater Control sensor’s limited threshold. It is controlled by cooler of temperature Cooler Control sensor’s limited threshold. Oil Pre-supply Actions in period of cranking to safety run. Reserved APC715 Pump Unit Controller User Manual Page 36 of 62...
  • Page 37 ECU raising to normal speed (temporary reserved). Crank Success Close when detects a successful start signal. Reserved Reserved Reserved During cranking process, start battery will be Start Battery Cycle switched circularly if multiple crank is APC715 Pump Unit Controller User Manual Page 37 of 62...
  • Page 38 Action when battery 2 over voltage warning Battery 2 High Volts alarm. Action when battery 2 low voltage warning Battery 2 Low Volts alarm. Emergency Stop Action when emergency stop alarm. APC715 Pump Unit Controller User Manual Page 38 of 62...
  • Page 39 Config 4 High Shut Config 4 Low Shut Config 5 High Warn Config 5 Low Warn Config 5 High Shut Config 5 Low Shut Config 6 High Warn Config 6 Low Warn APC715 Pump Unit Controller User Manual Page 39 of 62...

  • Page 40: Custom Period Output

    Output port 1 inactive, defined output period is not outputting. 7.2.3 CUSTOM COMBINED OUTPUT Defined combination output is composed by 3 parts, OR condition output S1, OR condition output S2, AND condition output S3. APC715 Pump Unit Controller User Manual Page 40 of 62...
  • Page 41 If input port 3 inactive, defined combination output is not outputting; When input port 1 inactive and input port 2 inactive, whatever input port 3 is active or not, defined combination output is not outputting. APC715 Pump Unit Controller User Manual Page 41 of 62...

  • Page 42: Defined Contents Of Configurable Input Ports

    Load Inhibit Prohibit pump unit on-load when input is active. Reserved Reserved Reserved Reserved Reserved Reserved All shutdown alarms are prohibited except emergence Inhibit Alarm Stop stop. (Means battle mode) APC715 Pump Unit Controller User Manual Page 42 of 62...
  • Page 43 Simulate Start key pressed as simulate panel. Simulate Load key 39~51 Reserved Speed Raise Input An external button (not self-locking) can be connected and control GOV manually. Speed Drop Input APC715 Pump Unit Controller User Manual Page 43 of 62...

  • Page 44: Selection Of Sensors

    4 SGH 5~15 Reserved NOTE: User should take the controller apart to change the jumper hat from resistor side to current side if your pump unit fitted with 4~20mA sensor. APC715 Pump Unit Controller User Manual Page 44 of 62...

  • Page 45: Conditions Of Crank Disconnect Selection

    If pump unit without engine speed sensor, please don’t select corresponding items, otherwise, “start fail” or “loss speed signal” maybe caused. If pimp unit without oil pressure sensor, please don’t select corresponding items. APC715 Pump Unit Controller User Manual Page 45 of 62...

  • Page 46: Maintenance Setting

    Timer Mode The maintenance timer mode 1: Real Time Clock Reset Maintenance Reset maintenance alarm when the Alarm maintenance time is due. The maintenance name are user-set. E.g. Description Change oil APC715 Pump Unit Controller User Manual Page 46 of 62...

  • Page 47: Parameters Setting

    NOTE: Digital input could not be set as same items; otherwise, there are abnormal functions. However, the digital output can be set as same items. APC715 Pump Unit Controller User Manual Page 47 of 62...

  • Page 48: Sensor Setting

    Table 19 Common Unit Pressure Conversion Table (pa) kgf/cm (p/in .psi) 1.02x10 － 1x10 － 1.45x10 － 1kgf/cm 9.8x10 0.98 14.2 1bar 1x10 1.02 14.5 － － 1psi 6.89x10 7.03x10 6.89x10 APC715 Pump Unit Controller User Manual Page 48 of 62...

  • Page 49: Typical Application

    10 TYPICAL APPLICATION Fig.4 APC715 Typical Application APC715 Pump Unit Controller User Manual Page 49 of 62...

  • Page 50: Installation

    Fig.5 Overall Dimension and Panel Cutout Battery Voltage Input NOTE: APC715 controller can suit for widely range of battery voltage DC(8~35)V. Negative of battery must be connected with the engine shell soundly. The diameter of wire which from power supply to battery must be over 2.5mm...

  • Page 51: Connections Of Controller With J1939 Engine

    SAE J1939 shield-E (connect with ECU terminal only) Impedance 120Ω connecting line is CAN(H) SAE J1939 signal-C recommended. Impedance 120Ω connecting line is CAN(L) SAE J1939 return-D recommended. Engine type: Cummins-CM850. APC715 Pump Unit Controller User Manual Page 51 of 62...

  • Page 52: Cummins Qsm11 (Import)

    SAE J1939 shield-E (connect with ECU terminal only) Impedance 120Ω connecting line CAN(H) SAE J1939 signal-C is recommended. Impedance 120Ω connecting line CAN(L) SAE J1939 return-D is recommended. Engine type: Cummins QSX15-CM570. APC715 Pump Unit Controller User Manual Page 52 of 62...

  • Page 53: Cummins Gcs-Modbus

    CAN communication shielding line CAN GND (connect with controller’s this terminal only) Impedance 120Ω connecting line CAN(H) is recommended. Impedance 120Ω connecting line CAN(L) is recommended. Engine type: common J1939. APC715 Pump Unit Controller User Manual Page 53 of 62...

  • Page 54: Cummins Qsz13

    CAN communication shielding line CAN GND (connect with controller’s terminal only) Impedance 120Ω connecting line is CAN(H) CAN(H) recommended. Impedance 120Ω connecting line is CAN(L) CAN(L) recommended. Engine type: Common J1939. APC715 Pump Unit Controller User Manual Page 54 of 62...

  • Page 55: Deutz Emr2

    Starting relay output CAN communication shielding line CAN GND (connect with controller’s terminal only) Impedance 120Ω connecting line is CAN(H) recommended. Impedance 120Ω connecting line is CAN(L) recommended. Engine type: John Deere. APC715 Pump Unit Controller User Manual Page 55 of 62...

  • Page 56: Mtu Mdec

    CAN GND X4 3 (connect to controller’s this terminal only) CAN(H) X4 1 Impedance 120Ω connecting line is recommended. CAN(L) X4 2 Impedance 120Ω connecting line is recommended. Engine type: MTU-ADEC. APC715 Pump Unit Controller User Manual Page 56 of 62...

  • Page 57: Mtu Adec (Sam Module)

    Connect to starter coil directly CAN communication shielding line CAN GND (connect with controller’s terminal only) Impedance 120Ω connecting line is CAN(H) recommended. Impedance 120Ω connecting line is CAN(L) recommended. Engine type: Perkins. APC715 Pump Unit Controller User Manual Page 57 of 62...

  • Page 58: Scania

    Impedance 120Ω connecting line is CAN(H) recommended. Impedance 120Ω connecting line is CAN(L) recommended. Engine type: Volvo. NOTE: When this engine type is selected, preheating time should be set to at least 3 seconds. APC715 Pump Unit Controller User Manual Page 58 of 62...

  • Page 59: Volvo Edc4

    Impedance 120Ω connecting line is CAN(L) 2(Lo) recommended. Engine type: Volvo-EMS2, speed regulation can be implemented. NOTE: When this engine type is selected, preheating time should be set to at least 3 seconds. APC715 Pump Unit Controller User Manual Page 59 of 62...

  • Page 60: Yuchai

    Impedance 120Ω connecting line is recommended. Engine type: GTSC1, speed regulation can be implemented. NOTE: If there is any question about connection between controller and ECU communication, please feel free to contact Smartgen’s service. APC715 Pump Unit Controller User Manual Page 60 of 62...

  • Page 61: Usb

    Users can set the controller’s parameters and monitor the controller’s status via USB port using the test software which provided by SmartGen company. USB port is active in stop mode only while at other times it couldn’t be detected by PC.

  • Page 62: Fault Finding

    Get information from LCD of alarm page; If there is detailed alarm, check engine according to ECU Warning or Shutdown description. If not, please refer to engine manual according to SPN alarm code. __________________________________ APC715 Pump Unit Controller User Manual Page 62 of 62...

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