1. Introduction
The SmartGen EP4300 and EP4301 are advanced engine controller modules designed for the control and data display of various engines, particularly electronic control engines (CAN instruments). These modules facilitate essential functions such as engine start/stop, precise speed control, comprehensive data measurement, and clear alarm display.
Equipped with a vibrant 4.3-inch color LCD, the controller supports both Chinese and English displays, making it versatile for a wide range of engine automation systems. Its robust design and intuitive interface ensure reliable performance and ease of use in demanding environments.
2. Safety Information
Please read all safety instructions carefully before installation and operation. Failure to follow these instructions may result in property damage, personal injury, or death.
- Ensure all power sources are disconnected before installation or maintenance.
- Only qualified personnel should perform installation and wiring.
- Verify all wiring connections are correct and secure to prevent short circuits or malfunctions.
- Protect the controller from moisture, extreme temperatures, and corrosive environments.
- Do not attempt to repair or modify the controller; refer to authorized service personnel.
3. Components and Overview
3.1 Front Panel
The front panel features a 4.3-inch color LCD and various control elements:
- Indicators: Alarm Indication, Running Status, Comm Indication, Power Indication.
- Controls: Four User-defined Buttons (1-4) and a central Knob.
Note on Panel Indicators:
- Alarm Indication: The icon flashes during the start process. After crank disconnect and before the ETS solenoid is held, the running status icon will rotate.
- Comm Indication: When communicating normally with a PC, the icon will show in turns and dynamically.
- Power Indication: Always illuminates when the unit is powered on.
3.2 Rear Panel Connections
The rear panel provides various connection ports for sensors, communication, and auxiliary functions:
- Sensors: SENSOR 1, SENSOR 2, SENSOR 3
- Magnetic Pick-up: MP1, MP2
- Power/Ground: D+, VDUT (+5V), GND, B+
- Communication: CAN H, CAN L, RS485, USB
- Auxiliary: AUX INPUT 1, AUX INPUT 2, AUX INPUT 3, AUX OUTPUT 1, AUX OUTPUT 2, AUX OUTPUT 3
4. Installation and Setup
4.1 Fixing Clips and Dimensions
The controller features a built-in design and is fixed using a pressure frame. Follow these steps for installation:
- Remove the pressure frame from the controller.
- Remove the four M4 bolts and place them in the corresponding slots of the front shell.
- Place the controller into the designated opening of the control cabinet.
- Align the pressure frame behind the controller using the four bolts.
- Install and tighten the flat washers, spring washers, and hexagonal nuts respectively.
4.2 Wiring Connections
Refer to the typical application diagram for correct wiring. The following table outlines specific wiring configurations:
| Mode | Wiring Description |
|---|---|
| Start/Stop Mode | The output ports need to be configured as fuel and start outputs. AUX. sensor 2 needs to be configured as an oil pressure sensor. |
| Others | No special configuration. |
4.3 Commissioning
Before commissioning, perform the following checks:
- Ensure all wiring connections are correct and the wire diameter is suitable.
- Verify that the controller DC power has a fuse, and the controller's positive and negative terminals, along with the starter battery, are correctly connected.
- To prevent the engine from cranking successfully during initial checks, take appropriate actions (e.g., temporarily remove the connection wire of the fuel valve). Once checks are complete, power on the start battery.
- Press the "start" button. The engine should attempt to start. If a "Start Failure" signal is sent after the set cranking times, press "stop" to reset the controller.
- Restore the action to allow the engine to crank successfully (e.g., connect the fuel valve wire).
- Press the start button again. The engine should start. If everything proceeds normally, the engine will run after idle running (if idle run is configured). During this phase, closely monitor the engine's running situation. If any abnormality occurs, stop the engine and re-check all wiring connections as per this manual.
- For any further questions, please contact SmartGen's service.
5. Operation
5.1 Menu Navigation
The controller's menu is navigated using the buttons and knob:
| Control | Description |
|---|---|
| Button 1 | Return/Cancel |
| Button 2 | Menu |
| Button 3 | Button 3 (User-defined) |
| Button 4 | Button 4 (User-defined) |
| Knob Button | Enter/Exit Menu |
| Knob | Select Menu Item |
5.2 Working Mode
The buttons also control various working modes:
| Control | Description |
|---|---|
| Button 1 | Return/Cancel |
| Button 2 | Button 2 (User-defined) |
| Button 3 | Button 3 (User-defined) |
| Button 4 | Button 4 (User-defined) |
| Knob Button | Enter/Exit Menu |
| Knob | Select Menu Item |
5.3 Instrument Display
When viewing instrument data, the buttons have the following functions:
| Control | Description |
|---|---|
| Button 1 | Button 1 (User-defined) |
| Button 2 | Button 2 (User-defined) |
| Button 3 | Button 3 (User-defined) |
| Button 4 | Button 4 (User-defined) |
| Knob Button | Enter Menu |
| Knob | Screen Scroll |
5.4 Idle/Rated Speed Control
For idle and rated speed adjustments:
| Control | Description |
|---|---|
| Button 1 | Idle Speed (Available to set) |
| Button 2 | Rated Speed (Available to set) |
| Button 3 | Button 3 (User-defined) |
| Button 4 | Button 4 (User-defined) |
| Knob Button | Enter Menu |
| Knob | Screen Scroll |
Function Description: One-touch sending the idle speed or rated speed. Press the button to send data, and the button will flash (Active for ECU engine).
5.5 Speed Controller Operation
To operate the speed controller:
| Control | Description |
|---|---|
| Button 1 | Idle Speed (Available to set) |
| Button 2 | Turn Left |
| Button 3 | Turn Right |
| Button 4 | Speed Controller Enable/Speed Controller Exhibit |
| Knob Button | Enter Menu |
| Knob | Speed Controller |
Function Description: One-touch sending the idle speed. Press the button to send the idle speed, and the button will flash (Active for ECU engine).
5.6 Start/Stop Operations
To control engine start and stop:
| Control | Description |
|---|---|
| Button 1 | Start |
| Button 2 | On Load |
| Button 3 | Off Load |
| Button 4 | Stop |
| Knob Button | Enter Menu |
| Knob | Screen Scroll |
6. Maintenance
Regular maintenance ensures the longevity and optimal performance of your SmartGen controller. While specific maintenance schedules may vary based on usage and environment, general guidelines include:
- Keep the controller clean and free from dust and debris. Use a soft, dry cloth for cleaning.
- Periodically inspect all wiring connections for tightness and signs of corrosion or damage.
- Ensure the operating environment remains within specified temperature and humidity ranges.
- Check for any visible damage to the casing or display.
- If the controller is exposed to harsh conditions, consider more frequent inspections.
For any complex issues or internal maintenance, please contact SmartGen technical support.
7. Troubleshooting
This section provides solutions to common issues you might encounter with your SmartGen EP4300/EP4301 controller.
7.1 Fault Finding
| Symptoms | Possible Solutions |
|---|---|
| Controller Inoperative | Check starting battery; Check connections of controller; Check the DC fuse. |
| Engine Stops | Check if water/cylinder temperature is too high; Check the DC fuse. Check switch and connections according to information on LCD; Check AUX. inputs. |
| Shutdown Alarm During Running | Check starting battery; Check speed sensor and its connections. |
| Crank Disconnect Failed | Refer to engine manual. Check connections. |
| RS485 Failure | Check if A and B of RS485 are connected reversely; Check if PC COM port is damaged. |
7.2 Warning Alarms
The controller detects various warning conditions. Refer to the table below for types and descriptions:
| No. | Type | Description |
|---|---|---|
| 1 | Loss of Speed Signal | When controller detects that the engine speed is 0, and the action type selects warning, it will send a warning. |
| 2 | Stop Failure | After the engine stop delay is over, if the unit is not stopped, the controller will send a warning. |
| 3 | Charging Failure | When the voltage difference between B+ and D+(WL) is greater than the charging failure voltage, it will send a warning. |
| 4 | Battery Overvoltage | When controller detects that the battery voltage of engine is over the preset limit, it will send a warning. |
| 5 | Battery Undervoltage | When controller detects that the battery voltage of engine is under the preset limit, it will send a warning. |
| 6 | ECU Warning | When controller receives a warning signal from engine via J1939, it will send a warning. |
| 7 | Flex. Sensor 1 Open Circuit | When controller detects the Flex. sensor 1 is open, and the action type selects warning, it will send a warning signal. |
| 8 | Flex. Sensor 1 High | When controller detects that the Flex. sensor 1 is higher than the upper limit value, it will send a warning signal. |
| 9 | Flex. Sensor 1 Low | When controller detects that the Flex. sensor 1 is lower than the lower limit value, it will send a warning signal. |
| 10 | Flex. Sensor 2 Open Circuit | When controller detects the Flex. sensor 2 is open circuit, and the action type selects warning, it will send a warning signal. |
| 11 | Flex. Sensor 2 High | When controller detects that the Flex. sensor 2 is higher than the upper limit value, it will send a warning signal. |
| 12 | Flex. Sensor 2 Low | When controller detects that the Flex. sensor 2 is lower than the lower limit value, it will send a warning signal. |
| 13 | Flex. Sensor 3 Open Circuit | When controller detects that the Flex. sensor 3 is open circuit, and the action type selects warning, it will send a warning signal. |
| 14 | Flex. Sensor 3 High | When controller detects that the Flex. sensor 3 is higher than the upper limit value, it will send a warning signal. |
| 15 | Flex. Sensor 3 Low | When controller detects that the Flex. sensor 3 is lower than the lower limit value, it will send a warning signal. |
| 16 | Input Port Warning | When the AUX. input port is set as warning and it is active, the controller will send a corresponding warning signal. |
| 17 | Low Fuel Level | When the AUX. input port is set as low fuel level warning and it is active, the controller will send a corresponding warning signal. |
7.3 Shutdown Alarms
The controller also issues shutdown alarms for critical conditions:
| No. | Type | Description |
|---|---|---|
| 1 | Over Speed | When controller detects that the engine speed is above the pre-set limit, it will send an alarm signal. |
| 2 | Under Speed | When controller detects that the engine speed is below the pre-set limit, it will send an alarm signal. |
| 3 | Loss of Speed Signal | When controller detects that the engine speed is 0 and the action type selects shutdown alarm, it will send an alarm signal. |
| 4 | Start Failure | Within the set start time, if the engine fails to start, it will send an alarm signal. |
| 5 | Flex. Sensor 1 Open Circuit | When controller detects that the Flex. sensor 1 is open and the action type selects shutdown alarm, it will send an alarm signal. |
| 6 | Flex. Sensor 1 High | When controller detects that the Flex. sensor 1 is higher than the upper limit value, it will send an alarm signal. |
| 7 | Flex. Sensor 1 Low | When controller detects that the Flex. sensor 1 is lower than the lower limit value, it will send an alarm signal. |
| 8 | Flex. Sensor 2 Open Circuit | When controller detects that the Flex. sensor 2 is open and the action type selects shutdown alarm, it will send an alarm signal. |
| 9 | Flex. Sensor 2 High | When controller detects that the Flex. sensor 2 is higher than the upper limit value, it will send an alarm signal. |
| 10 | Flex. Sensor 2 Low | When controller detects that the Flex. sensor 2 is lower than the lower limit value, it will send an alarm signal. |
| 11 | Flex. Sensor 3 Open Circuit | When controller detects that the Flex. sensor 3 is open and the action type selects shutdown alarm, it will send an alarm signal. |
| 12 | Flex. Sensor 3 High | When controller detects that the Flex. sensor 3 is higher than the upper limit value, it will send an alarm signal. |
| 13 | Flex. Sensor 3 Low | When controller detects that the Flex. sensor 3 is lower than the lower limit value, it will send an alarm signal. |
| 14 | Input Port | When AUX. input port is configured a shutdown alarm and it is active, the controller will send a corresponding alarm signal. |
| 15 | ECU | When controller receives the shutdown alarm signal of engine via J1939, it will send an alarm signal. |
8. Specifications
| Feature | Detail |
|---|---|
| Model Numbers | EP4300, EP4301 |
| Brand Name | SmartGen (SAIWEI) |
| Display | 4.3 Inch Colour LCD |
| Connectivity | RS485, USB, CANBUS |
| Origin | Mainland China |
| High-concerned chemical | None |
| Overall Width | 132 mm |
| Overall Height | 103 mm |
| Overall Depth (Front Panel) | 26.5 mm |
| Overall Depth (Rear Body) | 86.2 mm |
| Panel Cutout (Width) | 114 mm |
| Panel Cutout (Height) | 92 mm |
9. User Tips
- Always double-check wiring connections, especially power and sensor inputs, before applying power to prevent damage.
- Familiarize yourself with the user-defined buttons to customize the controller's functions for your specific application.
- When troubleshooting, systematically check each component mentioned in the 'Possible Solutions' column of the Fault Finding table.
- For optimal performance and to avoid false alarms, ensure all sensors are correctly calibrated and within their operational ranges.
10. Warranty and Support
For warranty information, technical support, or service inquiries, please contact your authorized SmartGen dealer or the manufacturer directly. Keep your purchase receipt and product model number handy for faster service.
