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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
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!
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!
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
1. Machine room temperature detection, auto start in high temperature, control room air conditioner start-up;
2. Battery pack voltage monitoring, genset will start automatically to charge the battery pack if the voltage is low;
3. Dual power ATS transfer of mains/load, mains/air conditioner;
4. Mains has rules can be configured, 6 start conditions combination;
5. With mains, gen sampling display and protection functions;
6. With current sampling display and protection function;
7. With USB, RS485 communication port;
8. 6-way relay outputs, 5 digital inputs (max. 7-way can be defined), 2-way analog inputs (max. 4-way can be defined);
9. Event log, real-time clock, scheduled start/stop;
10. Access monitoring function.
Advantages
1. Small size, suitable for the unit demand of telecom base station;
2. Multifunctional, multiple built-in rules can be defined;
3. With RS485, USB port;
4. Define dual ATS transfer according to the unit power;
5. 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!
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
——2020-2021 Development Review of Electronic Control Workshop
Fast forward to 2021, when writing this article, it is the time for electronic control workshop to work orderly and make capacity improvement at full steam. Looking at the focused eyes of the staffs while working and the continuous products output on the newly added production line, I involuntarily think back to the previous time.
Once upon a time, the electronic control workshop in the production center was troubled by the few orders, poor efficiency, and production quality was controlled by manual inspection. The development of the whole department seems to have encountered a bottleneck, which is incompatible with the situation of the company’s frequent success reports. The director scratched his head and staffs were demoralized. What should we do to solve the difficulty?
At the beginning of 2020, department leaders and workshop staffs gathered together to list the current situation of the workshop one by one, making everyone deeply aware that “Unless change, otherwise a dead end!” Change started with the director. The director changed the concept, adjusted the leaders and clarified the rules and direction of production management in the workshop. What ignited was the passion of all leaders and staffs, what broke through was the barrier of inertial thinking. Soon, the efficiency was improved, the orders from big customers came in droves, the staff turnover rate was also dropped dramatically, and the workshop soul was created.
Be prepared for crisis is necessary for us. A moment of success is important, but if you want to be excellent all the time, you have to constantly summarize and improve, and firmly grasp the pulse of the workshop progress. Therefore, the main purpose of this article is to review past year and summarize the good experience.
Firstly, cultivate a strong team with people as the core. The company leaders often hire external elites and internal backbones for management knowledge, management methods and other trainings. In various trainings, the electronic control workshop gradually and systematically understands the core of workshop management and gradually practice it, which has also achieved good results.
The workshop constantly makes efforts to cultivate management backbone, technical backbone, and technical experts, to activate the working atmosphere of the staff, to enhance the enthusiasm of the staff, and to conduct technical competitions and production skills assessment regularly. We hold various recreational activities such as table tennis, badminton competitions, chess game, performance during break time.
Then, hold high the banner of “continuous improvement”, and continue to transform and optimize the production line with a focus on efficiency:
The daily delivery capacity of HT22M series small heaters can reach 50 sets at most. After many initial tests of one stream production mode, simulated operation, and the joint efforts of equipment and process department, electronic control workshop, and R&D center, the small heater has added an automatic belt production line. After several operations, line balance adjustment and other optimization and transformation, the daily delivery capacity has reached 150 sets. At the same time, the dry air tightness test transformation is being carried out on the line, and the daily delivery capacity of 200 sets will soon be realized! The operation action decomposition of each process, standardized operation methods, high-precision air tightness test equipment, strict insulation and voltage withstand test standard for testing, ensure the production of high-quality small heaters.
The orders of marine machine production line are mostly tailored for customers, “private customization” with high-quality lean production. But in order to improve the delivery capacity, equipment and process department and workshop also make a series of improvements. Specially designed L-shaped production line for marine machine, SOP, tools and materials are placed nearby. The production cycle of marine machine products is greatly shortened by designing the wiring line length in advance, processing wire early and working in different processes.
In order to meet the increasing order demand of customers, GCPB series backpack cabinet production line has been improved in one stream production mode operation for many times, one stream production mode operation of general assembly line; one stream production mode operation of bottom board wiring plus general assembly line; one stream production mode operation of controller wiring of heater control box, bottom board wiring plus general assembly production. The backpack cabinet production line not only has a daily delivery capacity of 100 sets, but can flexibly switch to produce more than 10 batch products of various types, such as heater control cabinet. Because the action decomposition and standardized operation, the operation difficulty is reduced and the product quality is effectively guaranteed.
HWP series large heater production line is being tested and simulated to run one stream production mode and can provide data and scheme feasibility for the transformation of automatic production line. Currently the control box is produced separately and the daily delivery capacity of large heaters has reached 50 sets.
Every production line transformation, all station improvements, pieces of SOP writing, each careful communication, groups of wire installation, steel pipe construction one by one, cooperation and operation over and over again, every bit of advice, clap and praise every time......
A workshop with the spirit of unity, technical leadership and continuous improvement is in full swing.
Looking back is to make great strides forward.
Let’s work together, let’s inspire each other, and strive forward with full energy. The history of electronic control workshop will leave the footprints of our youth!
Booth No.：1P13
Venue: Shanghai World Expo Exhibition & Convention Center
Date: 4.1~4.3, 2021
SmartGen marine control cabinet is applied to Changshu Gang—offshore wind power operation platform “Hengtong Yihang” work ship recently. Its perfect operation shows powerful strength again!
“Hengtong Yihang” offshore wind power operation platform, is a wind power foundation pile work ship. This ship is equipped with 3 Mitsubish S16R2-T2MPTK gensets, rated at 1750kW, with SmartGen MGCP100B-2 marine diesel control box, and HMC9000A controller as master control module.
Application Site
HMC9000A Diesel Engine Control Module
This platform also adopts 3 HRM3300 remote control modules for remote start/stop control of genset and data display.
Application Site
HRM3300 Remote Control Module
This platform also fits with 2 Cummins QSNT gensets with rated power of 250kW, which are used as harbor gensets to meet the power consumption of the operation platform in the downtime. It is also equipped with 2 SmartGen MGCP100B-2 marine control boxes.
Application Site
SmartGen marine control box and supporting products can suit for various application schemes of different manufacturers and units,worthy of your trust!
SmartGen Supporting Products of Marine and Ocean Engineering Series (Part)
On the afternoon of March 18, Hu Quan, Chairman of the Standing Committee of the People’s Congress of Zhengzhou and Secretary of the CPC Zhengzhou Committee; Wang Xinting, Secretary of the Party Working Committee of Zhengzhou High-tech Zone, visited SmartGen for research and guidance. Cui Wenfeng, general manager of SmartGen, received them.
Secretary Hu Quan and his party mainly visited the product manufacturing center and test center of SmartGen, had a deep understanding of company's manufacturing mode that combines informatization with automation, as well as various test and verification equipment such as EMC, environment, and genset. They affirmed the company's efforts and actions in lean, innovation and quality assurance system, and highly appreciated the company's achievements in the field of internal combustion power generation.
Secretary Hu Quan and his party pointed out that as the hidden champion of domestic industry, SmartGen should continue to advance along the overall direction of "lean and intelligent at the same time", and build the core competition of the enterprise with "lean management and intelligent manufacturing".
Cui Wenfeng, general manager of the company, introduced company's investment in scientific research and innovation in detail, and company's strategic development direction. Secretary Hu Quan expressed his appreciation for SmartGen’s deep cultivation in subdivided fields. He emphasized that SmartGen should increase its R&D innovation ability and market expansion ability in special period. He encouraged SmartGen to adhere to technological innovation, lean production, down to earth and continuous development, so as to contribute to national economic development.
Innovation, focus, lean-better. Under the care and guidance of government leaders, SmartGen will continue to adhere to the enterprise spirit of "continuous improvement, teamwork creates value", work hard in internal combustion power generation, continue to work hard for building a century-old SmartGen, and strive for intelligently made in China.
March 18th, a good day to celebrate, which is another wonderful day for SmartGen in the lively spring.
In order to thank you for your company and support over the years, the “SmartGen Cloud Plus” self-developed by SmartGen is officially launched today after many months of internal testing!
It is mainly applied to the intelligent monitoring of SmartGen series products in remote areas, with the following functions and features:
High concurrent equipment connection, low latency monitoring data, high customized and friendly interface;User can add, modify or delete equipment information independently;With subscribe and unsubscribe functions, can realize the monitoring and viewing of other user equipment;Websocket is used to actively push the data of cloud monitoring module, and the client can display in real time with less network traffic;Support three clients: mobile Android version, web version, PC version;Auto push alarm information;Available languages: Simplified Chinese, English, and Traditional Chinese.
1.“SmartGen Cloud Plus” Web Version: www.smartgencloudplus.com
1) "Homepage" intuitively display the unit numbers, running time, and accumulated power generation
2) Data measuring and display, equipment monitoring
3) History data viewing and download
4) Equipment information (location, status) viewing
5) "My Unit"displays the status of all units (running, at rest, offline, alarm)
6) Alarm push
7) Alarm analysis
8) Unit sharing
2."SmartGen Cloud Plus" Android Phone Terminal
“SmartGen Cloud Plus” APP: QR code Android phone downloading.
Scan the QR code with your browser to download
1) Monitoring, real-time data, history data
2) Add unit, subscribe equipment
3) Map and language
4) Permission setting
5) Alarm analysis
3.Simulation Unit Experience
Subscribe the unit and experience the “SmartGen Cloud Plus” through the “Subscription” function.Cloud modem ID: 36323536323751050056001FSubscription number: 123456
“SmartGen Cloud Plus” is mainly committed to providing intelligent cloud monitoring services to users in the industry. We strive for quick access to the cloud platform, simple operation, and constantly improve the intelligent monitoring level of various equipment. Because this is only the release of version 1.0, there will be some shortcomings at the beginning. Welcome to give us feedback and suggestions. We will continue to update and optimize it, and build a professional cloud service platform that best suits the industry demand. Let’s witness the vigorous development of “SmartGen Cloud Plus” together.We are grateful to have your company along the way.
www.smartgen.cn
