SmartGen | Troubleshooting Methods of Remote Start Paradox
It seems that there is no connection between remote start signal and paradox, so why put them together? Read on, the answer will come out.
Let’s introduce “Fault Symptom” first: customer gives feedback that all three units in three different locations fail to start remotely.
NO.1
Fault symptom: Customer said that after the first remote auto start failure, and manual alarm was reset, the second time whether manual or auto start, genset could operate normally.
Fault reason analysis: This is an 900kW ECU unit, and due to the large engine, it is equipped with an electric pre-supply pump to supply fuel to the system before starting the engine, so as to ensure the necessary lubrication of each friction interface during the crank process. The required pre-supply time is 30s, and the oil pressure should reach 150kPa when engine ECU detects crank. But the (pre-heat time) pre-supply time set by controller is only 2s. Therefore, oil pressure is difficult to reach 150kPa when engine is cold starting. ECU issues oil pressure low shutdown alarm and unit failed to crank.
Solution: Set (pre-heat time) pre-supply time as 30s by controller and change controller crank disconnect condition from “frequency + oil pressure” to “frequency + speed”. The positive pole of ECU main power and ignition switch signal line are connected in parallel to controller’s FUEL output, and fuel output time is set to 5s. After the above parameter setting is finished and remote start signal is active, unit cranks success.
NO.2
Fault symptom: Customer said that genset couldn’t start automatically when mains power off.
Fault reason analysis: Under normal operation, the unit will start automatically after the remote start input port of the controller is linked to close by external closed contacts. Reasons for not start automatically: 1. Problem of remote start signal; 2. Problem of Controller.
Fault finding:
1.Set controller in auto mode, and make remote start input port and common ground short connected with wire, controller start automatically. Controller problem is excluded.
2.In this case, the normally closed contacts of external AC220V relay is used as remote start signal to output. When mains signal is disconnected, relay normally closed contacts do not close and relay function is abnormal.
Solution: After replacing AC220V relay, remote start signal recovers normal and problem is solved.
NO.3
Fault symptom: Customer said that genset always failed to crank whether manual or auto start, controller issued low oil pressure shutdown.
Fault reason analysis: If low oil pressure shutdown occurs frequently during cranking, It is speculated that the engine may not really start successfully, and the oil pressure may be selected under the successful starting conditions. Oil pressure is often low and unstable during cranking, especially in winter.
Fault finding: Open controller parameter setting and view selection of crank disconnect conditions. You can see that customer chooses “frequency + oil pressure”, and controller’s speed signal sampling does not connect to speed sensor.
Solution: Change the crank disconnect conditions to “speed + frequency”, make speed signal paralleled to speed sampling of GOV board (speed sampling of GOV board is connected to speed sensor). When remote start signal is active, auto start is normal; start the unit manually, unit cranks normally.
The solutions of above 3 cases are involved the root cause. Seeing the symptom through the essence perfectly explains the “paradox” of the title.
Summary: For situation similar to remote start, unit crank failure, it appears to be unit crank failure, but in fact this fault is caused by various reasons, which are summarized in the following table. We hope these cases can help you to deal with similar problems accurately and quickly.
Troubleshooting Table of Remote Start Failure
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SmartGen | Triple Protection, Free Transfer—2-line 1-bus-tie
HAT821, SmartGen two-line one-bus-tie controller released in 2018, has perfect and mature functions after two years of technical accumulation and market integration.
At the same time, we have developed two bus-tie controller adapters and supporting wiring harnesses, and added synchronous parallel transfer function (HAT821S), to meet the demand of different customers. This has been well received by customers and has delivered a satisfactory answer for customers who are using it.
Logic interlock and electrical interlock are very important part in two-line one-bus-tie system. To ensure the reliable operation of transfer switch, we use the adapter with controller logic lock to achieve triple interlock.
Primary Interlock: Controller Logic Lock
Logic interlock is realized by controller’s powerful software function. In the non-parallel transfer mode, if two breakers have closed, ensure that the third breaker will not close.
HAT821
Double Interlock: Electrical Interlock via ATA821 Adapter
Through the coordination of ATA821 adapter and switch auxiliary contacts, two sets of normally closed contacts of each breaker switch are used to interlock the closing output signal of controller, avoiding the malfunction caused by the contact adhesion of closing relay due to the damage of controller.
ATA821
Triple Interlock: Electrical Interlock via ATA821MN Adapter
Through the coordination of ATA821MN adapter and switch auxiliary contacts, four sets of normally closed contacts of each breaker switch are used to interlock controller’s closing signal and undervoltage tripper of each switch, avoiding the misoperation when the user use the switch body button to close breaker. If two breakers have been closed, the undervoltage trip coil of the third breaker will be powered off, and cannot be closed even with the switch body button.
ATA821MN
Controller logic lock + electrical interlock of closing signal + electrical interlock of undervoltage tripper, triple interlock, triple protection. Make transfer more reliable, make power utilization safer!
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SmartGen | 2021 SmartGen ATS Control Technology Exchange Meeting Opened
3-day ATS control technology exchange meeting was held in Zhengzhou from April 13 to 15, 2021. This meeting coincided with the third day of the third lunar month, the Xinchou ancestor worship ceremony of Yellow Emperor’s hometown was grandly held at his birthplace in Xinzheng, Henan. The Chinese people from home and abroad gathered in Henan to visit the human ancestor Yellow Emperor, promote the Yellow River culture, and pray for the prosperity of the Chinese nation. They praised same origin and ancestor, prayed peace and harmony. ATS industry leaders and experts from all over the country came to Zhengzhou to discuss the industry technology application and the current problems, and look forward to the development trend of the future products.
The leaders and enterprises participating in this meeting mainly include: Mr. Qu Degang, senior expert in ATSE industry, Schneider Electric, Beijing Bevone, Shanghai Nader, XJ Group Corporation, Shenyang SIWO, Suzhou Feiteng, Wuxi Hankwang, DAQO KFINE, Foretech, Irongxk, Jiangsu U·PRO, AISIKAI, SUYANG, OPOUTIL, Lovato Electric, Wuxi SOTOC, Cangzhou Xingyu, Fujian Yihua, Guangzhou Wanon and other related company.
Firstly, Cui Wenfeng, general manager of SmartGen, welcomed everyone and introduced the company’s development history, current situation and future development plan.
Yao Guanbao, marketing director of SmartGen, introduced the company’s current situation, product series and product solutions.
Zhouwei, director of ATS division, introduced product series and main application filed of ATS controller.
Mr. Qu, senior expert in ATSE industry, shared ATSE technology analysis report and elaborated from five aspects: ATSE technology, structure, main research topic, BTSE and MV-TSE. He also put forward guidance for the function, performance, specification and development of industry products. The representatives attended the meeting listened carefully to his wonderful sharing.
Shui Qinghua, SmartGen R&D center, introduced three powers, bustie and intelligent control technology of fast-transfer in detail.
Zhangwei, SmartGen R&D center, introduced bypass, MV control technology and future development products in detail.
Leaders and experts visited SmartGen dust-free automatic production workshop, product testing center and R & D center together, and had a deeper understanding of SmartGen's R & D, production and quality management system.
Everyone expressed their affirmation and support for the ATS control technology exchange meeting, which was an in-depth exchange of ATSE control technology. We gathered in Zhengzhou to look forward to the future of ATS industry, make suggestions and contribute to high-quality power supply, reliable operation of equipment and safe transfer. I believe that with the joint efforts of a group of doers, made in China will be better tomorrow!
Time together is always too short, looking forward to next time to meet again. Welcome to the open Henan! Welcome to your hometown Henan!
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SmartGen | “SmartGen” Involved in Malawi Base Station Project
Recently, Malawi base station project, located in the southeastern Africa, has applied multi-genset with SmartGen control module HGM4020T, and cloud monitoring module CMM366A-4G, can realize unit intelligent control via SmartGen cloud platform. Thus, all data is under control without going out.
On-site Pictures
HGM4020T genset controller is especially designed for communication base station and its functions are completely followed by the actual situation of the base station.
Main features
- Machine room temperature detection, auto start in high temperature, control room air conditioner start-up;
- Battery pack voltage monitoring, genset will start automatically to charge the battery pack if the voltage is low;
- Dual power ATS transfer of mains/load, mains/air conditioner;
- Mains has rules can be configured, 6 start conditions combination;
- With mains, gen sampling display and protection functions;
- With current sampling display and protection function;
- With USB, RS485 communication port;
- 6-way relay outputs, 5 digital inputs (max. 7-way can be defined), 2-way analog inputs (max. 4-way can be defined);
- Event log, real-time clock, scheduled start/stop;
- Access monitoring function.
Advantages
- Small size, suitable for the unit demand of telecom base station;
- Multifunctional, multiple built-in rules can be defined;
- With RS485, USB port;
- Define dual ATS transfer according to the unit power;
- Integrated genset auto control and ATS control.
Cloud monitoring module in the case: CMM366A-4G
SmartGen cloud platform
Moreover, the all-in-one machine developed and produced by SmartGen has been released.
The all-in-one controller has a built-in network communication module, which enables the genset to access to the Internet. After the controller is registered to the cloud platform, the data information of the genset (including GPS location, altitude, etc.) will be uploaded to the corresponding cloud server in real time, and users can monitor the genset and query the operation status and event log in real time through phone APP (IOS or Android system), computer and other terminal devices. At the same time, the controller parameters can be configured via the cloud server and the network communication module also has SMS function.
SmartGen All-in-one Controller—HGM7220N/S
SmartGen, making control easier!
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Smartgen | CIBS2021 & SmartGen Products Passed BV Certification
In the sunny March, SmartGen all series of marine products have passed the type certification of BV. SmartGen marine engine controller and its supporting distributed IO module, MGCP100B series diesel engine control box, automatic power station power management system and power protection module have both BV and CCS certification so far.
On April 1, 2021, the 25th China (Shanghai) International Boat Show opened in hall H1 of Shanghai World Expo Exhibition & Convention Center. SmartGen has participated in this exhibition for many years, welcome to 1P13 booth for communication.
Exhibition Site：
Following the design concept of “Making Control Easier”, the performance and reliability of SmartGen marine products have been fully verified after more than ten years of real ship application. The products not only can be flexibly adjusted and combined according to the control requirements of different ship types, but also have an increasing market share in the field of diesel engine control and automatic power station power management for mid-to-high end ships year by year.
Application cases of Yacht and Passenger Ship:
MGCP100B-2 control box with Cummins QSM11 host for yacht project
HMC9800RM simultaneously monitors two hosts to achieve remote control of driving console
Automatic power station management system consisting of MGCP100B-2 diesel engine control box +HMC6 power management controller for water bus
HMC6 power management controller for main switchboard of 45m cruise “Hanjiang Shenyun”
Power management system built by HMC6 power management controller for motorboat
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SmartGen | Tomb Sweeping Day
Tomb Sweeping Day is from April 3 to April 5 ,total of 3 days.
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