FPC615

FIRE PUMP CONTROLLER

USER MANUAL

SMARTGEN (ZHENGZHOU) TECHNOLOGY CO.,LTD.

 Chinese trademark

English trademark
SmartGen — make your generator smart
SmartGen Technology Co., Ltd
No. 28 Jinsuo Road
Zhengzhou City
P. R. China
Tel: 0086-371-67988888
0086-371-67981888
0086-371-67991553
0086-371-67992951
0086-371-67981000 (overseas)
Fax: 0086-371-67992952
Web: www.smartgen.com.cn
www.smartgen.cn
Email: sales@smartgen.cn

All rights reserved. No part of this publication may be reproduced in any material form (including
photocopying or storing in any medium by electronic means or other) without the written permission of
the copyright holder.
Applications for the copyright holder’s written permission to reproduce any part of this publication
should be addressed to 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

Date Version Content

2017-12-07 1.0 Original release.
Added “Auto Mode”;
Added two transistor output ports;
2018-02-02 1.1
Modified schematic description and terminal drawing
illustration.
 FPC615 FIRE PUMP CONTROLLER USER MANUAL
This user manual only suits for FPC615 controller.

Table 2 - Notation Clarification

Symbol Instruction

NOTE Highlights an essential element of a procedure to ensure correctness.

Indicates a procedure or practice, which, if not strictly observed, could result in

CAUTION damage or destruction of equipment.
Indicates a procedure or practice, which could result in injury to personnel or loss of
WARNING life if not followed correctly.

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 3 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL

CONTENT
1 OVERVIEW......................................................................................................................................... 5

2 PERFORMANCE AND CHARACTERISTICS ..................................................................................... 5

3 SPECIFICATION ................................................................................................................................. 6

4 OPERATION ....................................................................................................................................... 7
4.1 INDICATOR LIGHT ................................................................................................................ 7
4.2 PUSH BUTTONS DESCRIPTION .......................................................................................... 8
4.3 MAINS SCREEN DISPLAY .................................................................................................... 9
4.4 PARAMETER SET SCREEN ............................................................................................... 10
4.5 MANUAL START/STOP OPERATION .................................................................................. 10
4.6 AUTO START/STOP OPERATION ....................................................................................... 11
4.7 START BATTERY SWITCHOVER IN AUTO MODE ............................................................. 11
5 PROTECTION .................................................................................................................................. 12
5.1 WARNINGS .......................................................................................................................... 12
5.2 SHUTDOWN ALARM ........................................................................................................... 13
6 CONNECTIONS ............................................................................................................................... 14

7 DEFINITION AND RANGE OF PARAMETERS ................................................................................ 16

7.1 PARAMETER CONTENTS AND RANGE............................................................................. 16
7.2 CONDITIONS OF CRANK DISCONNECT SELECTION...................................................... 20
7.3 DEFINITION CONTENT OF DIGITAL INPUT PORTS (Ground connected is active (B-)) .... 20
7.4 DEFINITION CONTENT OF RELAY OUTPUT PORTS........................................................ 22
7.5 SENSOR SELECTION ......................................................................................................... 23
7.6 SENSOR SELECT ............................................................................................................... 24
8 TYPICAL APPLICATION ................................................................................................................... 25

9 COMMISSIONING ............................................................................................................................ 25

10 INSTALLATION ................................................................................................................................. 26

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 4 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL
1 OVERVIEW

FPC615 Fire Pump Controller designed for controlling of fire pump unit. It fits with auto/manual mode
transfer function, which can start unit automatically via remote input signals in auto mode as well as
manual start unit via pressing start key on the front panel of the controller. It is able to monitor voltage
status of two battery packs and simultaneous collect sensor and digital signals of the unit to monitor
genset running status. Moreover, based on the user-defined data protection threshold, controller can
initiate warning or shutdown alarms and corresponding information will be displayed on LCD of the
controller to realize the intelligent protection for genset.

2 PERFORMANCE AND CHARACTERISTICS

Main characteristics are as follows,

132x64 pixel LCD with backlight, graphic screen with visualized display and easy operation;
Improved LCD wear-resistance and scratch resistance due to hard screen acrylic;
Silicon panel and pushbuttons for better operation in high/low temperature environment;
Detection function of engine speed;
3 analog sensors (water temperature sensor, oil pressure sensor and oil temperature sensor);
2 voltage sampling points of battery packs and 1 voltage sampling points of battery charger;
3 programmable digital input ports;
8 fixed relay output ports (start 1, start 2, stop, running, over speed, high engine temperature, low
engine temperature, and low oil pressure);
1 fixed transistor output port (high raw water temperature output) and 1 programmable transistor
output port;
2 battery packs can be switched to start the unit;
With engine high water temperature and engine low oil pressure protection functions;
Event log(max. 99 pieces), real-time clock;
3 groups of maintenance function, and actions can be set when maintenance time due;
Built-in multiple user-defined sensor curves;
Parameter setting function: parameters can be configured from front panel of controller and will
not lost in case of power dropout;
Widely power supply range DC (8-35) V, which is suitable for different voltage environment of
starting battery.
Waterproof security level IP55 due to rubber seal installed between the controller enclosure and
panel fascia;
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.

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 5 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL
3 SPECIFICATION

Table 3 – Technical Parameters

Items Content
Working Voltage DC8.0V to 35.0V, Continuous Power Supply.
Overall Consumption <3W(Standby mode: ≤2W)
Speed Sensor Voltage 1.0 to 24V(effective value)
Speed Sensor Frequency 10000Hz (max.)
Start 1 Relay Output 16Amp Connect to common port output
Start 2 Relay Output 16Amp Connect to common port output
Stop Relay Output 16Amp Connect to common port output
Genset Running Relay Output 7Amp Connect to common port output
Over Speed Relay Output 7Amp Connect to common port output
Engine High Temp. Relay Output 7Amp Connect to common port output
Engine Low Temp. Relay Output 7Amp Connect to common port output
Engine Low Oil Pressure Relay
7Amp Connect to common port output
Output
High Raw Water Temp.
B+ DC power supply output, 0.5A output current
Transistor Output
Programmable Transistor
B+ DC power supply output, 0.5A output current
Output
Analog Sensor 3 fixed sensors
Digital Input Port 3 digital input ports active when connect to B-
Overall Dimensions 197 mm x 152 mm x 47 mm
Panel Cutout 186mm x 141mm
Working Condition Temperature: (-25~+70)°C Humidity: (20~93)%RH
Storage Condition Temperature: (-25~+70)°C
Protection Level IP65 Gasket
Apply AC2.2kV voltage between high voltage terminal and low
Insulating Intensity voltage terminal;
The leakage current is not more than 3mA within 1min.
Weight 0.6kg

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 6 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL

4 OPERATION

4.1 INDICATOR LIGHT

Fig.1 – FPC615 Front Panel

Note: Selected indicators description:

Alarm indicator: flash slowly when warning alarms occur; flash quickly when shutdown alarms occur;
Running indicator: after genset start up, it is always light before energize to stop; for other periods, it is
extinguished.

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 7 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL
4.2 PUSH BUTTONS DESCRIPTION

Table 4 – Keys Function

Icons Function Description

Press and hold it for 1s to enter into menu configuration screen;
Menu
Return to the previous level of menu while configuring settings.

Reset Alarm Press it to reset shutdown alarms while unit is in standby mode.

Press it to mute controller alarms when alrms occur, meanwhile, alam

Mute
screen will be displayed.
Stop running pump unit in auto/manual mode;
Stop Press it again in stop process will stop pump unit quickly;
Press at least 3 seconds to test lights are normal or not.

Start 1 Use different battery pack to start the unit.

Press it, starter relay starts output;
Start 2 Release it, starter relay stops output.

Homepage Press it to return to the 1st screen quickly.

Event Log Press it to enter into event log screen quickly.

Up Screen scroll

Confirm Confirm setting information.

Down Screen scroll

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 8 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL
4.3 MAINS SCREEN DISPLAY

Table 5 – Display Description

Operation Display Content Remark

st
1 Screen： 35℃ 1 27.6V Engine temep. 1# Battery voltage
35℃ 2 27.6V Raw water temp. 2# Battery voltage
Press enters this
100kpa Oil pressure
screen Engine speed
1500r/min
Engine Status And Alarm Engine status and alarm display in turn.
nd
2 Screen： D+ Voltage 27.6V Voltage of chrger
Total Runing 00:00 Total running time
Press or to Total Starts 1000 Total start times
display this screen 2016-03-05(6) 10:00:00 Current time of controller
Engine Status And Alarm
rd
3 Screen： Maint. 1 Countdown 30:00 It is maintenance countdown time
Maint. 2 Countdown 30:00 display; if disabled maintenance function,
Press or to Maint. 3 Countdown 30:00 this screen is not display.
display this screen
Engine Status And Alarm
th
4 Screen： Genset Status Genset status display screen, controller
Auto Mode working mode and engine status.
Press or to Start Delay 1s
display this screen Engine Standby
5th Screen： Alarm 1/2 Alarms display, and scroll screen based
Warning on the pages. The maximum alarm
Press or to Low Oil Pressure Shutdown amount is 30 items.
display this screen

Event Log 1/3 Event logs display, and one screen

Press to display Shutdown Alarm displays one piece of event log. The
this screen, and press High Temp. Shutdown maximum event log amount is 99 pieces.
2016-03-05(6) 10:00:00
again (or ) to
Engine Status And Alarm
exit
User Manu： Exit 1. Check controller software version,
Parameter Set hardware version and input/output port
Long-pressed Controller Information status.
enters into this 2. Setting parameters
screen, and press

again to exit

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 9 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL

4.4 PARAMETER SET SCREEN

Hold and press enters into menu screen, and select “Set Parameter” item enters into
parameter setting screen after entering the correct password (default:00318).
Parameter settings include contents as below,
 Timers
 Engine
 Maintenance
 Sensors
 Digital Inputs
 Output
 Module
Taking the example of setting engine overspeed shutdown:

Table 6 – Parameter Setting

1st Step 2nd Step 3rd Step

>Exit >Return Over Speed Shutdown
>Timers >Flywheel Teeth Enable：Enabled
>Engine >Engine Rated Speed Set Value： 00114%
>Scheduler And Maintenance >Loss Speed Signal
> Sensors >Over Speed Shutdown Delay Value： 00005

Press or key select Press or key select Press to adjust cursor position

“Over Speed Shutdown” Setting

“Engine” Setting and press and press or key to adjust
and press enters into this
enters into parameter setting
delay value, and then press to
screen. setting screen.
confirm the parameter setting.

In all processes, press can cancel the current setting or return to the previous menu.

4.5 MANUAL START/STOP OPERATION

Manual start sequence:

a) Take start 1 as example, hold and press (start 1), start I indicator illuminate and start1 relay
starts output simultaneously.

b) Release after genset started successfully (through configure engine crank disconnect
conditions) and starter relay stops output. Then genset enters into safety on delay state, in which
time, alarms of high temperature, low oil pressure, and under speed are inactive. After safety on
delay expired, unit enters into high-speed warming up delay.
c) When warming up delay is expired, pump unit enters into normal running status.
Manual stop sequence:

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 10 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL

a) After pressing , pump unit starts stop and cooling and then enters into “ETS Solenoid Hold”
after cooling delay is expired;
b) During in period of “ETS Solenoid Hold”, ETS relay energized and automatic judging whether
pump unit is completely stop or not.
c) "Wait for Stop Delay" begins, and complete stop is detected automatically.
d) If pump unit stopped completely, “After stop” delay begins; otherwise, fail to stop alarm is initiated
and the corresponding alarm information is displayed on LCD (If pump unit stopped successfully
after “Failed to Stop” alarm, it will enter “After stop time” and remove alarm)
e) Pump unit enters into standby state after “After stop Delay” is expired.

4.6 AUTO START/STOP OPERATION

Auto start sequence:

a) If remote input is active, controller “Start Delay” begins countdown.
b) When start delay is over, start relay energized; if the pump unit fails to fire during this cranking
attempt then the start relay is disengaged for the pre-set rest period; “crank rest time” begins and
wait for the next crank attempt.
c) Should this start sequence continue beyond the set number of attempts, the fifth line of LCD
shadowed with black and “Fail to Start “ alarm will be displayed on the fifth line of LCD.
d) In case of successful crank attempt, the “Safety On” timer is activated, allowing low oil pressure,
high temperature, under speed, charge alternator failure and auxiliary inputs (if configured) to
stabilize without triggering the fault alarms. As soon as this delay is over, “warming up” delay
starts (if configured).
e) After the “warming up” delay, pump unit will enter into Normal Running status.
Auto stop sequence:
a) When remote start signal is deactivated, “Stop Delay” timer is initiated.
b) Once this “stop delay” has expired, the “Cooling Delay” starts..
c) When “ETS Solenoid Hold” begins, ETS relay is energized while fuel relay is de-energized.
d) "Wait for Stop Delay" begins, and complete stop is detected automatically.
e) Pump unit enters into its standby mode after the pump unit stopped completely; if pump unit stop
fail, controller will initiate alarm signals (LCD displays alarm information).
NOTE1: configure input ports as “Manual/Auto Switch” and “Remote Start”.
NOTE2: while unit is in remote start status, if stop key is pressed, engine also stops. If need remote
signals to start unit, remote start input must be invalid fist and then activate it again.
CAUTION: If shutdown alarms occur while unit is in remote start status, remote start input must be
disconnected first and then reset shutdown alarms, otherwise, unit will start again.

4.7 START BATTERY SWITCHOVER IN AUTO MODE

While unit is in start period, two battery packs are not under voltage, if 1# battery pack fails to start,
2# battery pack will be changed to start unit, if fails to start again, then change back to 1#...until reach
the maximum crank attempts. If unit is still fails to start, alarms will be initiated by the controller.
While unit is in start period, if there is one battery pack is under voltage, the other one battery pack
will responsible for starting the unit. If unit fails to start when reach the maximum start attempts, alarms
will be initiated by the controller.

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 11 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL
5 PROTECTION

5.1 WARNINGS
When the controller has detected warning alarm signals, it alarms only without shutdown. When
warning condition is no longer present, corresponding alarm will be cleared automatically. Warning
types are as follows:
No. Type Description
When the controller detects that the engine speed has exceeded the
1 Engine Over Speed
pre-set value, it will initiate a warning alarm.
When the controller detects that the engine speed has fallen below the
2 Engine Under Speed
pre-set value, it will initiate a warning alarm.
When the controller detects that the engine speed is 0 and the action
3 Loss of Speed Signal
select “Warning”, it will initiate a warning alarm.
After “After Stop” delay is expired, if unit does not stop completely, it
4 Fail To Stop
will initiate a warning alarm.
When the controller detects that charger voltage has fallen below the
5 Charge Alt Fail
pre-set value, it will initiate a warning alarm.
When the controller detects that battery1 voltage has exceeded the
6 Battery1 Over Voltage
pre-set value, it will initiate a warning alarm.
Battery1 Under When the controller detects that battery1 voltage has fallen below the
7
Voltage pre-set value, it will initiate a warning alarm.
When the controller detects that battery2 voltage has exceeded the
8 Battery2 Over Voltage
pre-set value, it will initiate a warning alarm.
Battery2 Under When the controller detects that battery2 voltage has fallen below the
9
Voltage pre-set value, it will initiate a warning alarm.
Engine Temperature When the controller detects that the temperature sensor is open circuit
10
Sensor Open Circuit and the action select “Warning”, it will initiate a warning alarm.
Engine High When the controller detects that engine temperature has exceeded
11
Temperature the pre-set value, it will initiate a warning alarm.
Engine Low When the controller detects that engine temperature has fallen below
12
Temperature the pre-set value, it will initiate a warning alarm.
Oil Pressure Sensor When the controller detects that the oil pressure sensor is open circuit
13
Open Circuit and the action select “Warning”, it will initiate a warning alarm.
Engine Low Oil When the controller detects that the oil pressure has fallen below the
14
Pressure pre-set value, it will initiate a warning alarm.
Oil Temperature When the controller detects that the oil temperature sensor is open
15
Sensor Open Circuit circuit and the action select “Warning”, it will initiate a warning alarm.
When the controller detects that oil temperature has exceeded the
16 High Oil Temperature
pre-set value, it will initiate a warning alarm.
When the controller detects that oil temperature has fallen below the
17 Low Oil Temperature
pre-set value, it will initiate a warning alarm.
Digital Input Port When digital input port configures as “Warning” and it is active,
18
A/B/C Warning controller will initiate a corresponding warning alarm.
Maintenance Time When maintenance countdown time is 0, and the action select
19
Due “Warning”, it will initiate a warning alarm.

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 12 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL
5.2 SHUTDOWN ALARM

When controller detects shutdown alarm, it will shutdown the unit immediately. Shutdown alarm must
be cleared manually and the fault removed to reset the module. Shutdown alarm types are as follows:
No. Type Description
When the controller detects that the generator speed has exceeded
1 Engine Over Speed
the pre-set value, it will initiate a shutdown alarm.
When the controller detects that the generator speed has fallen below
2 Engine Under Speed
the pre-set value, it will initiate a shutdown alarm.
When the controller detects that the engine speed is 0 and the action
3 Loss of Speed Signal
select “Shutdown”, it will initiate a shutdown alarm.
When the controller detects that the water temperature sensor is open
Water Temperature
4 circuit and the action select “Shutdown”, it will initiate a shutdown
Sensor Open Circuit
alarm.
Water High When the controller detects that water temperature has exceeded the
5
Temperature pre-set value, it will initiate a shutdown alarm.
Water Low When the controller detects that water temperature has fallen below
6
Temperature the pre-set value, it will initiate a shutdown alarm.
Engine Oil Pressure When the controller detects that the oil pressure sensor is open circuit
7
Open Circuit and the action select “Shutdown”, it will initiate a shutdown alarm.
Engine Low Oil When the controller detects that the oil pressure has fallen below the
8
Pressure pre-set value, it will initiate a shutdown alarm.
Oil Temperature When the controller detects that the sensor is open circuit and the
9
Sensor Open Circuit action select “Shutdown”, it will initiate a shutdown alarm.
When the controller detects that the sensor value is higher than the
10 High Oil Temperature
max. set value, it will initiate a shutdown alarm.
Digital Input Port When digital input port configures as “Shutdown” and it is active,
11
A/B/C Warning controller will initiate a corresponding shutdown alarm.
Maintenance Time When maintenance countdown time is 0, and the action select
12
Due “Shutdown”, it will initiate a shutdown alarm.

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 13 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL
6 CONNECTIONS

Fig.2 – FPC615 Back Panel

Description of terminal connections:

Table 9 – Terminal Connection

No. Function Cable Size Description
1 B- 2.5mm2 Connected with negative of starter battery.
Connected with positive of starter battery. If wire
2 B+ 2.5mm2 length is over 30m, better to double wires in parallel.
Max. 20A fuse is recommended.
3 COM1 Relay Common Port 2.5mm2 Relay output common port of No.4, No.5 and No.6.
2
4 Start 1 2.5mm Rated 16A. Connect to starter coil
2
5 Start 2 2.5mm Rated 16A. Connect to starter coil
6 Stop Relay Output 2.5mm2 Rated 16A. connect to stop electromagnet
2
7 COM2 Relay Common Port 1.5mm Relay output common port of No.8 and No.9.
It is output when genet meet with
8 Running Relay Output 1.5mm2 Rated 7A
the crank disconnect conditions.
It is output after genset sending over
9 Over Speed Relay Output 1.5mm2 Rated 7A
speed alarm signals.
10 High Water Temperature It is output after genset sending high
1.5mm2 Rated 7A
11 Relay Output water temperature alarm signals.
12 Low Water Temperature It is output after genset sending low
1.5mm2 Rated 7A
13 Relay Output water temperature alarm signals.
Low Lubricant Pressure
14 Relay Output (Normally 1.5mm2 Rated 7A
Close)
Low Lubricant Pressure
15 1.5mm2
Relay Common Output

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 14 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL
No. Function Cable Size Description
Low Lubricant Pressure
It is output after genset sending low
16 Relay Output (Normally 1.5mm2 Rated 7A
lubricant pressure alarm signals.
Open)
17-19 Not Connected (NC)
Connected with D+(W/L) terminal of charger. If
2
20 Charger D+ Input 1.0mm there is no D+(W/L) terminal in charger, it is
suspended.
21 Speed Sensor Input + Connected with engine speed sensor, and shielding
2
0.5mm wire is recommended to use. “Speed Sensor Input
22 Speed Sensor Input - –“has connected with B- in the controller.
23-25 Not Connected (NC)
Water Temperature Sensor Connected with analog quantity of temperature
26 1.0mm2
Input sensor.
Oil Temperature Sensor Connected with analog quantity of temperature
27 1.0mm2
Input sensor.
2
28 Oil Pressure Sensor Input 1.0mm Connected with analog quantity of pressure sensor.
2
29 Output DC 5V 1.0mm Voltage type sensor power supply terminal
Sensor common port, which internal of controller
30 COM(B-) 1.0mm2
has connected with B-.
31-38 Not Connected (NC)
39 Digital Input A 1.0mm2 Ground connected is active (B-)
2
40 Digital Input B 1.0mm Ground connected is active (B-)
2
41 Digital Input C 1.0mm Ground connected is active (B-)
Digital Input Common
42 1.0mm2 Ground connected is active (B-)
Ground
43 B1- Input 1.0mm2
Connected with battery 1
44 B1+Input 1.0mm2
45 B2- Input 1.0mm2
Connected with battery 2
46 B2+Input 1.0mm2
High Raw Water Tempe.
47 1.0mm2 B+ voltage output with rated current 0.5 A
Output
48 Relay Output A 1.0mm2 B+ voltage output with rated current 0.5 A
2
49 COM(B-) 1.0mm

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 15 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL

7 DEFINITION AND RANGE OF PARAMETERS

7.1 PARAMETER CONTENTS AND RANGE

Table 10 Parameter Definition & Scope
No. Items Parameter Default Description
Timers
When controller is in auto mode, it is time from
1 Start Delay (0-3600) s 1
remote start signal activated to genset start.
When controller is in auto mode, it is time from
2 Return Delay (0-3600) s 1
remote start signal deactivated to genset stop.
3 Cranking Time (3-60) s 8 It is time of starter powers up.
It is the waiting time before second power up
4 Crank Rest Time (3-60) s 10
when engine starts fail.
Alarms for low oil pressure, high temperature,
5 Safety On Delay (0-3600)s 10 under speed, charge fail are deactivated during
“Safety On Delay”..
Warming time between the pump unit takes
6 Warming Up Time (0-3600)s 10
load and high-speed running.
It is the radiating time before stop the pump
7 Cooling Time (0-3600)s 10
unit, after it unloads.
Stop electromagnet’s power on time when
8 ETS Hold Time (0-3600)s 20
pump unit is stopping.
Time between ending of pump unit cooling
delay and stopped completely when “ETS
Solenoid Hold” is set as 0;
9 Wait for Stop Time (0-3600)s 0
Time between ending of ETS delay and
stopped completely when “ETS Hold output
time” is not 0.
10 After Stop Time (0-3600)s 0 Time between pump unit stopped and standby.
Engine
Tooth number of the engine, for judging of
starter separation conditions and inspecting of
1 Flywheel Teeth (10-300) 118
engine speed. See the following Installation
Instruction.
2 Rated Speed (0-6000)r/min 1500 Offer standard to judge over/under speed.
Loss of Speed Signal Time from detecting speed is 0 to confirm the
4 (0-3600)s 5
Delay action.
Loss of Speed Signal
5 (0-1) 0 0: Warning; 1: Shutdown
Action
Over Speed
6 (0-1000)% 114%
Shutdown Setting value is percentage of rated speed, and
Under Speed delay value can be set.
7 (0-1000)% 80%
Shutdown
8 Over Speed Warning (0-1000)% 110% Setting value is percentage of rated speed, and
9 Under Speed (0-1000)% 86% return value and delay value can be set.
 FPC615 FIRE PUMP CONTROLLER USER MANUAL
No. Items Parameter Default Description
Warning
Battery 1 Rated Offer standard to judge battery over/under
10 (0-60.0)V 24.0
Voltage voltage.
Battery 1 High
11 (0-1000)% 120%
Voltage Warning Setting value is percentage of rated voltage,
Battery 1 Low and return value and delay value can be set.
12 (0-1000)% 85%
Voltage Warning
Battery 2 Rated Offer standard to judge battery over/under
13 (0-60.0)V 24.0
Voltage voltage.
Battery 2 High
14 (0-1000)% 120%
Voltage Warning Setting value is percentage of rated voltage,
Battery 2 Low and return value and delay value can be set.
15 (0-1000)% 85%
Voltage Warning
Charge Alt Fail In normal running, when charger D+(WL)
16 (0-60.0)V 8.0
Warning voltage under this value, charge failure alarms.
The maximum start attempts if engine failed to
start. When the pre-set number of start
17 Start Attempts (1-10) 3
attempts has been reached, controller initiates
failed to start alarms.
Crank Disconnect
18 (0-6) 1 Details please to see Table 11
Conditions
Speed of Crank
19 (0-100)% 24 It is percentage speed of crank disconnect.
Disconnect
Oil Pressure of
20 (0-1000)kPa 200
Crank Disconnect
Maintenance
1 Maintenance 1 (0-1) 0 0: Disable；1: Enable
2 Maintenance 2 (0-1) 0 Actions of maintenance time and maintenance
3 Maintenance 3 (0-1) 0 time due can be set at the same time.
Analog Sensors
Water Temperature Sensor
1 Curve Type (0-15) 7 SGX. See table14.
2 Open Circuit Action (0-2) 0 0: None; 1: Warning; 2: Shutdown
Shutdown when external sensor temperature is
High Water Temp. higher than this value. Detecting only after
3 (0~300)ºC 98
Shutdown safety delay is over. The delay value can be
set.
Shutdown when external sensor temperature is
Low Water Temp.
4 (0-300)ºC 20 lower than this value. The delay value can be
Shutdown
set.
Warning when external sensor temperature is
High Water Temp. higher than this value. Detecting only after
5 (0~300)ºC 95
Warning safety delay is over. The delay value and return
value can be set.

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 17 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL
No. Items Parameter Default Description
Warning when external sensor temperature is
Low Water Temp.
6 (0-300)ºC 70 lower than this value. The delay value and
Warning
return value can be set.
Users should set the corresponding curve
7 Custom Curve when select resistor curve type or current curve
type.
Raw Water Temperature Sensor
1 Curve Type (0-15) 7 SGX. See table 14.
2 Open Circuit Action (0-2) 0 0: None; 1: Warning; 2: Shutdown
Shutdown when external sensor temperature is
High Raw Water higher than this value. Detecting only after
3 (0~300)ºC 98
Temp. Shutdown safety delay is over. The delay value can be
set.
Warning when external sensor temperature is
High Raw Water higher than this value. Detecting only after
4 (0~300)ºC 95
Temp. Warning safety delay is over. The return value and delay
value can be set.
Users should set the corresponding curve
5 Custom Curve when select resistor curve type or current curve
type.
Engine Oil Pressure Sensor
1 Curve Type (0-15) 4 CURTIS. See table 14.
2 Open Action (0-2) 0 0: No action; 1: Warning; 2: Shutdown
Shutdown when oil pressure of external
Low Oil Pressure connected sensor is lower than this value.
3 (0-1000)kPa 103
Shutdown Detecting only after safety delay is over. The
delay value can be set.
Warning oil pressure of external connected
Low Oil Pressure sensor is lower than this value. Detecting only
4 (0-1000)kPa 124
Warning after safety delay is over. The delay value and
return value can be set.
Users should set the corresponding curve
5 Custom Curve when select resistor curve type or current curve
type.
Digital Input Ports
Digital Input Port A
1 Contents Setting (0-53) 8 Details please to see table 12.
2 Active Type (0-1) 0 0: Active: Close 1: Active: Open
Digital Input Port B
1 Contents Setting (0-53) 9 Details please to see table 12.
2 Active Type (0-1) 0 0: Active: Close 1: Active: Open
Digital Input Port C
1 Contents Setting (0-53) 27 Details please to see table 12.
2 Active Type (0-1) 0 0: Active: Close 1: Active: Open

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 18 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL
No. Items Parameter Default Description
Relay Output Port
1 Output A (0-33) 23 Details please to see table 13.
Module
1 Slave ID (1-254) 1 An address communicates with PC software.
0: Simplified Chinese
2 Language (0-2) 0 1: English
2: Other
3 Password (0-65535) 00318 Password enters into parameter setting screen.
Users can calibrate date and time by
4 Date and Time
themselves.
5 Temperature Unit (0-1) 0 0: ℃ 1: F
0:kPa
6 Pressure Unit (0-2) 0 1:Bar
2:PSI

CAUTION: please modify controller parameters (digital input configuration and all delays) in standby status,

otherwise, shutdown alarms or other abnormal situations may occur.

NOTE: while setting parameter threshold, please make sure that upper limit value must higher than the

lower limit value, otherwise, both over limit alarms and under limit alarms may occur.

NOTE: while setting warning alarms please set return value correctly, otherwise, alarms fault may occur

(return value must lower the over limit warning setting point and higher than the under limit warning setting
point).

NOTE: digital input ports cannot set as the same content, otherwise, errors will occur.

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 19 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL

7.2 CONDITIONS OF CRANK DISCONNECT SELECTION

Table 11 – Crank Disconnect Conditions Selection

No. Setting description
0 External Input
1 Engine Speed
2 External Input+ Engine Speed
3 Oil Pressure
4 Oil Pressure+ External Input
5 Engine Speed+ Oil Pressure
6 Engine Speed+ Oil Pressure+ External Input
NOTE:
a) Separation between starter and engine only controlling by the “Start” key, and crank disconnect conditions only use
to judge whether engine crank successfully or not.
b) Engine speed sensor is the magnetic equipment which be installed in starter for detecting flywheel teeth. After
selecting “Engine Speed”, please make sure that engine flywheel teeth number is the same as the preset value; if
there is no magnetic sensor, please don’t select conditions that including “Engine Speed”.
c) If select conditions that including “external Input”, users need to configure the input port as “7: Crank Success
Input”.

7.3 DEFINITION CONTENT OF DIGITAL INPUT PORTS (Ground connected is active (B-))

Table 12 – Digital Input Ports

No. Type Description
Including following functions,
Indication: indicate only, not warning or shutdown.
Warning: warning only, not shutdown.
Shutdown: alarm and shutdown immediately
0 Users Configured
Never: input inactive.
Always: input is active all the time.
From crank: detecting as soon as start.
From safety on: detecting after safety on run delay.
1 Reserved
2 Alarm Mute Can prohibit “Audible Alarm” output when input is active.
3 Alarm Reset Can reset shutdown alarm when input is active.
4 Reserved
5 Lamp Test All LED indicators are illuminating when input is active.
6 Reserved
If select conditions that including “external Input”, users need to
7 Crank Success Input configure the input port as “7: Crank Success Input”; when input is
active, which means generator starts successfully,
Manual/Auto Switch If input port is deactivated, controller is in manual mode; otherwise,
8
controller is in auto mode.
9 Remote Start In auto mode, when input is active, it can start genset automatically.
10 Reserved

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 20 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL
No. Type Description
11 Reserved
Over Speed Check When input is active, if engine speed exceeds 67% of rated speed, and
12 over speed shutdown delay is expired, shutdown action will be
executed.
13 Reserved
14 Reserved
15 Reserved
16 Reserved
17 Reserved
18 Reserved
19 Reserved
20 Reserved
21 Reserved
22 Reserved
23 Reserved
When this input is active, controller will reset maintenance time 1 as
24 Reset Maintenance 1
preset value.
High Raw Water Temp.
25 Connect to sensor digital input port.
Shutdown
High Water
26 Temperature Connect to sensor digital input port.
Shutdown
Low Oil Pressure
27 Connect to sensor digital input port.
Shutdown
28 Reserved
29 Reserved
30 Reserved
An external button can be connected (not self-lock), and simulated
31 Simulated Up Key
panel key is pressed.
An external button can be connected (not self-lock), and simulated
32 Simulated Down Key
panel key is pressed.
33-53 Reserved

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 21 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL

7.4 DEFINITION CONTENT OF RELAY OUTPUT PORTS

Table 13 – Functions of Output Ports

No. Type Function Description
0 Not Used Not output
1 Reserved
Action when engine starts up and disconnect after genset stopped
2 Louver Control
completely.
3 Fuel Pre-supply Actions in period of cranking to safety run.
4 Pre-lubricate Actions in period of pre-heating to safety run.
5 Common Alarm Action when common warning and common shutdown alarms occur.
6 Reserved
7 Common Shutdown Action when common shutdown alarms occur.
8 Reserved
9 Common Warning Action when common warning alarms occur.
10 Reserved
11 Battery 1 High Volt. Action when voltage of battery1 is over high.
12 Battery 1 Low Volt. Action when voltage of battery1 is over low.
13 Charge Alt Fail Action when charge failure warning alarms occur.
14 Battery 2 High Volt. Action when voltage of battery2 is over high.
15 Battery 2 Low Volt. Action when voltage of battery2 is over low.
16 Fail to Start Action when failed start alarms occur.
17 Fail to Stop Action when failed stop alarms occur.
Under Speed
18 Action when under speed warning alarms occur
Warning
Under Speed
19 Action when under speed shutdown alarms occur.
Shutdown
20 Over Speed Warning Action when engine over speed warning alarms occur.
Over Speed
21 Action when engine over speed shutdown alarms occur.
Shutdown
22 Reserved
23 Energize to Stop Output when unit shuts down.
24 Start Success Output after unit meeting with the crank disconnect conditions.
25 High Water Temp. Output when high water temp. alarms occur.
26 Low Water Temp. Output when low water temp. alarms occur.
27 Low Oil Pressure Output when low oil pressure alarms occur.
Raw Water High
28 Output when high raw water temperature alarms occur
Temp.
29 Reserved
30 System In Auto Mode Controller outputs in auto mode.
System In Manual
31 Controller outputs in manual mode.
Mode
32 Reserved
33 Reserved

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 22 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL
7.5 SENSOR SELECTION

Table 14 – Description of Sensors

No. Content Remark
0 Not used
1 Custom Res Curve
2 Custom 4-20mA curve
3 VDO
4 CURTIS
Water Temp. 5 VOLVO-EC
Defined resistance’s range is (0~6)KΩ,
1 Sensor & Raw 6 DATCON
default is SGX sensor.
Water Sensor 7 SGX
Temp. Sensor 8 SGD
9 SGH
10 Reserved
11 Cu50
12-15Reserved
0 Not used
1 Custom Res Curve
2 Custom 4-20mA curve
3 VDO 10Bar
4 CURTIS
Oil Pressure 5 VOLVO-EC Defined resistance’s range is (0~6)KΩ,
2
Sensor 6 DATCON 10Bar default is CURTIS sensor.
7 SGX
8 SGD
9 SGH
10-14 Reserved
15 Custom Voltage Curve

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 23 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL

7.6 SENSOR SELECT

1) When reselect sensors, the sensor curve will be transferred into the standard value. For example,
if select the SGX (120°C resistor type), the sensor curve is SGX (120°C resistor type)curve; if

temperature sensor is SGD (120°C resistor type), its sensor curve is SGD curve.

2) When there is difference between standard sensor curves and using sensor, user can adjust it in

“curve type”.

3) When input the sensor curve, X value (resistor) must be input from small to large, otherwise,
mistake occurs.

4) If select sensor type as “None”, sensor curve is not working.

5) If there is alarm switch only for the select sensor, user must set the sensor as “None”, otherwise,

maybe shutdown or warning occurs.

6) The headmost or backmost values in the vertical coordinates can be set as same as below,

Fig.3 – Pressure Setting Curve

Table 15 - Common unit conversion table

Items N/m2 (pa) kgf/cm2 bar (p/in2.psi)

－5 －5 －4
1Pa 1 1.02x10 1x10 1.45x10
1kgf/cm2 9.8x104 1 0.98 14.2
5
1bar 1x10 1.02 1 14.5
3 －2 －2
1psi 6.89x10 7.03x10 6.89x10 1

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 24 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL

8 TYPICAL APPLICATION

Fig.4 - FPC615 Typical Application Diagram

NOTE: relay output port A (terminal No.48) and high raw water temp. output port (terminal No. 47) are

output B+, and output current cannot exceed 500mA.

9 COMMISSIONING

Please make sure the following checks are made before commissioning,
Ensure all the connections are correct and wires diameter is suitable.
Ensure that the controller DC power has fuse, controller’s positive and negative connected to start
battery are correct.
Separately start genset with battery 1 and battery 2, observe whether starter disconnect immediately
and genset is normal running. If errors occur, stop the unit and check wire connection according to
the user manual.
If there is any other question, please contact SmartGen’s service.

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 25 of 26

 FPC615 FIRE PUMP CONTROLLER USER MANUAL
10 INSTALLATION

Controller is panel built-in design and it is fixed by clips when installed. Overall and cutout dimensions
are as follows,

Fig.5 – Overall & Cutout Dimensions

1) Battery Voltage Input

NOTE: FPC615 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 that connects from
power supply to battery must be over 2.5mm2. If floating charge configured, please firstly connect
output wires of charger to battery’s positive and negative directly, then, connect wires from battery’s
positive and negative to controller’s corresponding input ports in order to prevent charge disturbing the
controller’s normal working.

2) Speed Sensor Input

NOTE: Speed sensor is the magnetic equipment which be installed in starter and for detecting
flywheel teeth. Its connection wires to controller should apply for 2 cores shielding line. One side is
hanging in air and the else two signal wires are connecting to No. 21 and No. 22 terminals of controller
and No. 22 terminal internal connected with B-. The output voltage of speed sensor should be within
AC(1~24)V (effective value) during the full speed. AC12V is recommended (in rated speed). When
install the speed sensor, let the sensor spun to contacting flywheel first, then, port out 1/3 lap, and lock
the nuts of sensor at last.

3) Output And Expansion Relay

CAUTION: All outputs of controller are relay contact output type. If need to expand the relays,
please add freewheel diode to both ends of expand relay’s coils (when coils of relay has DC current) or
add resistance-capacitance return circuit (when coils of relay has AC current), in order to prevent
disturbance to controller or others equipment.

_________________________________

FPC615 Fire Pump Controller Version 1.1 2018-02-02 Page 26 of 26