User Manual: HGM6200K Series Automatic Control Module

HGM6200K Series
Automatic Control Module

(HGM6210K/6210KC/6220K/6220KC)

USER MANUAL

Smartgen Technology

Smartgen Technology Co., Ltd
No.28 Jinsuo Road
Zhengzhou
Henan Province
P. R. China
Tel: 0086-371-67988888/67981888
0086-371-67991553/67992951/67992952
0086-371-67981000(overseas)
National Free Tel: 400318139
Fax: 0086-371-67992952/67981000
Web: http://www.smartgen.com.cn
http://www.smartgen.cn
Email: sales@smartgen.com.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 holders 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.
Software Version
Date Version Contents
2009-7-17 1.0 Original release.
2009-12-31 1.1 Modify Typical Application.
2010-04-21 1.2
Add functions: event log, real-time clock, scheduled
start/stop, Spanish.
Add output: (15) over current.
Add input: (25) low water level warning; (26) low water
level shutdown.
2010-06-21 1.3
Modify Panel Cutout: length and width are both increased
2mm. Change working temperature of the controller.
2010-07-07 1.4 Optimize some details in this manual.
2011-06-20 1.5 Modify single/3-phase input range.
2011-12-26 1.6
Add Fuel Moisture Content Warn.
Modify parts of parameter items.

HGM6200K Series Automatic Control Module
HGM6200K Series Generator Controller ISSUE 2011-12-26 Version 1.6 Page 3 of 31
CONTENTS
1 SUMMARY ....................................................................................... 4
2 PERFORMANCE AND CHARACTERISTICS ................................. 4
3 SPECIFICATION .............................................................................. 6
4 OPERATION .................................................................................... 7
4.1 KEY FUNCTION ......................................................................................... 7
4.2 AUTOMATIC OPERATION ......................................................................... 8
4.3 MANUAL OPERATION ............................................................................... 9
5 PROTECTION ............................................................................... 10
5.1 WARNINGS .............................................................................................. 10
5.2 SHUTDOWN ALARM ............................................................................... 11
6 CONNECTIONS ............................................................................ 12
7 PARAMETER RANGE AND DEFINITION ..................................... 15
7.1 PARAMETER CONTENT AND RANGE TABLE (TABLE 1) ..................... 15
7.2 PROGRAMMABLE OUTPUT 1-6 TABLE (TABLE 2) ............................... 21
7.3 PROGRAMMABLE INPUT 1-7 TABLE (ALL IS ACTIVE WHEN CONNECT
TO GRAND (B-) (TABLE 3) ............................................................................ 22
7.4 SENSOR SELECTION (TABLE 4) ........................................................... 24
7.5 CONDITIONS OF CRANK DISCONNECT (TABLE 5) ............................. 25
8 PARAMETER SETTING ................................................................ 25
9 SENSOR SETTING ....................................................................... 26
10 COMMISSIONING ....................................................................... 27
11 TYPICAL APPLICATION .............................................................. 28
12 INSTALLATION ............................................................................ 29
13 FAULT FINDING .......................................................................... 31
1 SUMMARY
HGM6200K series automatic controller, integrating digital, intelligent and network
techniques, is used for automatic control and monitoring system of genset. It can
carry out functions of automatic start/stop, data measurement, alarm protection and
three remote (remote control, remote measure and remote communication). The
controller uses LCD display, optional display interface including Chinese, English,
Spanish and Russian with easy and reliable operation.
HGM6200K series automatic controller uses micro-processing technique which can
achieve precision measurement, value adjustment, timing and threshold setting and
etc.. All the parameters can be configured from front panel or use programmable
interface (or PS485 interface) to adjust via PC. It can be widely used in all types of
automatic control system for its compact structure, simple connections and high
reliability.
2 PERFORMANCE AND CHARACTERISTICS
HGM6200K controller has four variants:
HGM6210K/6210KC: Automatic Start Module, it controls generator to start/stop by
remote start signal;
HGM6220K/6220KC: Based on HGM6210K/6210KC, it adds mains AC monitoring
and mains/gens automatic switching control (AMF), especially suitable for the
automation system composed by mains and genset.
Note1: HGM6210KC/6220KC has RS485 interface, HGM6210K/6220K without.
Note2: HGM6210KC/6220KC is taken as an example to describe in this manual.
128x64 LCD display with backlight, optional language interface (Chinese, English,
Spanish), push-button operation;
With RS485 communication interface, can achieve three remote functions via
MODBUS protocol;
Adapt to 3P4W, 1P2W and 2P3W (120V/240V), 50Hz/60Hz AC power system;
Can measure and display 3 phase voltage, 3 phase current, frequency, power
parameter of mains and gens;
Mains Gens
Line voltage (Uab, Ubc, and Uca) Line voltage (Uab, Ubc, and Uca)
Phase voltage (Ua, Ub, and Uc) Phase voltage (Ua, Ub, and Uc)
Frequency HZ Frequency HZ
Load
Current IA, IB, IC
Active power KW
Reactive power KVar
Apparent power KVA
Power factor Cos
Gens accumulated energy kWh
Mains have functions of over/under voltage and lack of phase; Gens have
functions of over/under voltage, over/under frequency and over current;
Stop mode, manual mode and auto mode can be selected;
Dual temperature sensor and oil pressure sensor input;
Precision measure and display of parameters about engine,
Temp. (WT), C/ F both are displayed
Oil pressure (OP), kPa/Psi/Bar all are displayed
Fuel level (FL), %
Speed (SPD), RPM
Battery Voltage (VB), V
Charger Voltage (VD), V
Hours count (HC) can accumulate Max. 999999 hours.
Start times can accumulate Max.999999 times.
Control protection: Automatic start/stop of genset, load transfer(ATS control) and
complete failure display and protection;
With ETS, idle speed control, pre-heat control, speed droop control, all of them
are relay output;
Event log, real-time clock and scheduled start/stop;
Parameter setting: Allow user to modify setting and store them in internal FLASH
memory. The parameters cannot be lost even when loss of power. All of
parameters can be set not only from the front panel, but use programmable
interface (or PS485 interface) to adjust via PC;
Multi sensors of temperature, pressure and fuel level can be used directly, sensor
curve can be defined by user;
Multi conditions of crank disconnect (speed sensor, oil pressure, gens) can be
selected;
Power supply range: (8~35)VDC, accommodating to different starting battery
volts;
All parameters use digital modulation, instead of analog modulation using
conventional potentiometer, having improved reliability and stability;
Modular design, flame-retardant ABS shell, embedded mounting, compact
structure and easy installation;
3 SPECIFICATION
Operating Voltage DC8.0V to 35.0V, continuous power supply
Power Consumption <3W(Standby mode: 2W)
AC Voltage Input Range
3P4W
1P2W
2P3W

15V AC - 360V AC (ph-N)
15V AC - 360V AC (ph-ph)
15V AC - 360V AC (ph-N)
AC Alternator Frequency 50Hz/60 Hz
Magnetic AC Voltage 1.0V to 24V (RMS)
Magnetic AC Frequency 10,000 Hz (max.)
Start Relay Output 16 Amp DC28V at supply voltage
Fuel Relay Output 16 Amp DC28V at supply voltage
Aux. Relay Output 1 7 Amp DC28V at supply voltage
Aux. Relay Output 2 7A 250VAC passive output
Aux. Relay Output 5 16 Amp 250VAC passive output
Aux. Relay Output 6 16 Amp 250VAC passive output
Case Dimensions 209mm x 153mm x 55mm
Panel Cutout 186mm x 141mm
C.T. Secondary 5A (rated)
Working Condition Temperature: (-25~70)C; Humidity: (20~90)%
Storage Condition Temperature: (-30~+80)C
Protection Level
IP55: when waterproof rubber gasket added
between controller and its panel.
IP42: when waterproof rubber gasket not added
between controller and its panel.
Insulation Intensity
Object: among in input/output/power
Quote standard: IEC688-1992
Test way: AC1.5 kV / 1min 3mA leakage current
Weight 0.73kg
4 OPERATION
4.1 KEY FUNCTION

Stop/ Reset
Can stop generator under Manual/Auto mode;
Can reset alarms when a shutdown alarm occurs;
Pressing this key at least 3 seconds can test panel
indicators (lamp test);
During stopping process, pressing this again can stop
genset immediately.

Start
To start genset under Manual or Manual Test mode.

Manual
Press this key to set the module as Manual mode.

Auto
Press this key to set the module as Auto mode.

Run with load
Press to set controller into Manual Test mode.
Under this mode, if gens normal genset will run with
load automatically. (HGM6210KC without)

Set/ Confirm
In parameter setting, can shift cursor and confirm setting.

Up/Increase
Scroll screen;
In parameter setting, can shift cursor or increase value.

Down/Decrease
Scroll screen;
In parameter setting, can shift cursor or decrease value.
4.2 AUTOMATIC OPERATION
Auto mode is activated by pressing the . LED indicator beside the button is
illuminating which confirms this action.
Starting Sequence,
1) HGM6220KC: When mains is abnormal (over/voltage, lack of phase), enter into
Mains Abnormal Delay and LCD displays count-down time. When delay is over,
Start Delay begins.
2) HGM6210KC: when remote start input is enabled, enter into Start Delay.
3) Count- down of start delay is displayed in LCD.
4) When start delay is over, preheat relay is outputting (if configured), Preheat Delay
XX s is displayed in LCD.
5) When preheat delay is over, fuel relay is outputting 1s and then start relay outputs;
if genset failed to start during Crank Time, the fuel and start relay stop outputting
and enter into Crank Rest Time and wait for next cranking.
6) If genset failed to start within set start times, the fourth line of LED will turn black
and Fail to Start alarm will be displayed.
7) Any time to start genset successfully, it will enter into Safety on Run. During this
period, alarms of low oil pressure, hi-temperature, under speed, charge failure and
Aux. input (be configured) are disabled. As soon as this delay is over, genset will
enter into Start Idle Delay (if configured).
8) During start idle delay, alarms of under speed, under frequency, under voltage are
disabled. As soon as this delay is over, genset will enter into Warming up Delay
(if configured).
9) When Warming up Delay is over, the indicator is illuminating if gens normal. If
voltage and frequency of engine meets to the load requirement, close relay
outputs, genset is taking load and indicator illuminates; if voltage or frequency of
engine is abnormal, controller will alarm to shutdown (LCD displays the alarm).
Stopping Sequence,
1) HGM6220KC: during normal running, if mains normal, genset will enter into
Mains Normal Delay of voltage, mains indicator illuminates, Start Delay begins.
2) HGM6210KC: genset enters into Stop Delay as soon as Remote Start is
enabled.
3) When Stop Delay is over, genset enters into Cooling Delay. Close relay is
disconnected. After switch Transfer Rest Delay, close relay is outputting, mains
is taking load, power supply indicator of gens eliminates while indicator of gens
illuminates.
4) When entering Stop Idle Delay, idle relay is energized to output. (If configured).
5) When entering ETS Delay, ETS relay is energized to output, fuel relay output is
disconnected.
6) When entering Genset at Rest, genset will automatically judge if it has stopped.
7) When genset has stopped, enter into standby mode; if genset failed to stop,
controller will alarm (Failed to Stop alarm will be displayed in LCD).
4.3 MANUAL OPERATION
1) HGM6220KC: Auto Mode is enabled when press and its indicator illuminates.
Press , then controller enters into Manual Test Mode and its indicator is
illuminating. Under both of the modes, press to start genset, it can automatically
detect crank disconnect and accelerate to hi-speed running. If there is
hi-temperature, low oil pressure, over speed and abnormal voltage during genset
running, controller can protect genset to stop (detail procedures please refer to
No.4~9 of Auto start operation). Under Manual Mode , switch wont transfer
automatically. Under Manual Test Mode , after genset runs well in high speed,
no matter mains is normal or not, loading switch will be transferred to gens.
2) HGM6210KC: Auto Mode is enabled when pressing , and its indicator is
illuminating. Then press to start genset, it can automatically detect crank
disconnect and accelerate to hi-speed running. If there is hi-temperature, low oil
pressure, over speed and abnormal voltage during running, controller can protect
genset to stop quickly (detail procedures please refer to No.4~9 of Auto start
operation). After genset runs well in high speed, if remote start signal is active,
controller will close gens, if remote start signal is inactive, controller will not close
gens.
3) Manual stop, pressing can shut down the running genset (detail procedures
please refer to No.3~7 of Auto stop operation).
5 PROTECTION
5.1 WARNINGS
When controller detects the warning signal, only alarm and not stop genset. The
alarms are displayed in LCD.
Warnings as following,
No. Type Description
1
Loss Of Speed
Signal
When the speed of genset is 0 and set the delay as 0,
controller will send warning alarm signal and t will be
displayed in LCD.
2 Gens Over Current
When the current of genset is higher than threshold and
set over current delay as 0, controller will send warning
alarm signal and t will be displayed in LCD.
3 Fail To Stop
When genset cannot stop after the stop delay is over,
controller will send warning alarm signal and it will be
displayed in LCD.
4 Low Fuel Level
When the fuel level of genset is lower than threshold or
low fuel level warning is enabled, controller will send
warning alarm signal and it will be displayed in LCD.
5 Charge Failure
When the voltage of genset charger is lower than
threshold, controller will send warning alarm signal and it
will be displayed in LCD.
6
Battery Under
Voltage
When the battery voltage of genset is lower than
7
Battery Over
Voltage
When the battery voltage of genset is higher than
8 Over Speed
When genset speed is higher than set threshold,
displayed in LCD.
9 Under Speed
When genset speed is lower than set threshold,
displayed in LCD.
10 Gens Over Voltage
When genset voltage is higher than threshold, controller
will send warning alarm signal and it will be displayed in
LCD.
11
Gens Under
Voltage
When genset voltage is under set threshold, controller
will send a warning alarm signal and it will be displayed
in LCD.
12 Over Frequency
When genset frequency is higher than set threshold,
displayed in LCD.
13 Under Frequency
When genset frequency is lower than set threshold,
displayed in LCD.
14 High Temp 1
When the temperature 1 of water/cylinder is higher than
set threshold, controller will send warning alarm signal
and it will be displayed in LCD.
15 Low OP 1
When oil pressure 1 is lower than threshold, controller
LCD.
16 High Temp 1
set threshold, controller will send warning alarm signal
and it will be displayed in LCD.
17 Low OP 2
When oil pressure 2 is lower than threshold, controller
LCD.
5.2 SHUTDOWN ALARM
When controller detects shutdown alarm, it will send signal to open switch and to stop
genset. The alarms are displayed in LCD.
Shutdown alarms as following,
1 Emergency Stop
When controller detects emergency stop signal, it will
send a stop alarm signal and it will be displayed in LCD.
2
High
Temperature 1
set threshold, controller will send a stop alarm signal and it
3 Low OP 1
When oil pressure 1 is lower than threshold, controller will
4
High
Temperature 2
set threshold, controller will send a stop alarm signal and it
5 Low OP 2
When oil pressure 2 is lower than threshold, controller will
6 Over Speed
When genset speed is higher than set threshold, controller
will send a stop alarm signal and it will be displayed in
LCD.
7 Under Speed
When genset speed is lower than set threshold, controller
LCD.
8
Loss Of Speed
Signal
When rotate speed is 0 and delay is not 0, controller will
9
Gens Over
Voltage
When genset voltage is higher than threshold, controller
LCD.
10
Gens Under
Voltage
When genset voltage is under set threshold, controller will
11 Gens Over
Current
When genset current is higher than set threshold and
delay is not 0, it will send a stop alarm signal and it will be
displayed in LCD.
12 Fail To Start
Within set start times, if failed to start, controller will send a
stop alarm signal and it will be displayed in LCD.
13 Over Frequency
When genset frequency is higher than set threshold,
controller will send a stop alarm signal and it will be
displayed in LCD.
14 Under Frequency
When genset frequency is lower than set threshold,
displayed in LCD.
15 Gens Failed
When genset frequency is 0, controller will send a stop
alarm signal and it will be displayed in LCD.
16
Temp. Sensor 1
Open Circuit
When controller detects temperature sensor 1 open
circuit, controller will send a stop alarm signal and it will be
displayed in LCD.
17
OP Sensor 1
Open Circuit
When controller detects oil pressure sensor 1 open circuit,
displayed in LCD.
18
Temp. Sensor 2
Open Circuit
When controller detects temperature sensor 2 open
circuit, controller will send a stop alarm signal and it will be
displayed in LCD.
19
OP Sensor 2
Open Circuit
When controller detects oil pressure sensor 2 open circuit,
displayed in LCD.
6 CONNECTIONS
Compared with HGM6220KC, HGM6210KC doesnt have 3-phase input terminal of
mains voltage. The back panel of HGM6210KC and HGM6220KC is as below.

Descriptions of terminal connection as following,
No. Function
Cable
Size
Description
1 DC Plant Supply B- 2.5mm
2
Connect to starting battery negative
2 DC Plant Supply B+ 2.5mm
2

Connect to starting battery positive. If
more than 30m, use 2 cables to
parallel ; Recommended 20A fuse
3 Emergency Stop 2.5mm
2

Plant Supply B+
4 Fuel Relay Output 1.5mm
2

Plant Supply B+ from pin 3.
16 Amp rated.
5 Start Relay Output 1.5mm
2

Plant supply B+ from pin 3.
16 Amp rated. Connect to start coil.
Connect to starting coil
6 Aux. Relay Output 1 1.5mm
2

Plant Supply B+ from
pin 2. 7 Amp rated.
Reference
table 2
2

Normally close output,
7 Amp rated.
2
Relay common port
9
Aux. Relay Output 4 1.5mm
2

Normally open output,
7 Amp rated.
10
Normally open contact
of relay,16 Amp rated,
Passive contact output.
11
No. Function
Cable
Size
Description
12
2

13
14
2

15
16
Charge Alternator D+
Input
1.0mm
2

Connect to D+ (WL) terminal. If without,
the terminal vacant.
17 Aux. Input 1 1.0mm
2
Connect to GND (B-)
2
Connect to GND (B-)
2
Connect to GND (B-)
2
Connect to GND (B-)
2
Connect to GND (B-)
2
Connect to GND (B-)
2
Connect to GND (B-)
24 Aux. Input Common GND (B-)
25 Magnetic Pickup Shield
Connect to Magnetic Pickup device. Recommend
using screen.
26 Magnetic Pickup B+
27 Magnetic Pickup B-
28
Temp. Sensor 1Input
Connect to temperature resistor
sensor.
Reference
table 4
29
OP Sensor 1Input
Connect to oil pressure resistor
sensor.
30
Liquid Level Sensor
Input
Connect to liquid level resistor
sensor.
31 Temp. Sensor 2 Input
Connect to temperature resistor
sensor.
32 OP Sensor 2 Input
Connect to oil pressure resistor
sensor.
33 Resistor Sensor Input Connect to resistor-type sensor.
34 CT A Phase Sensing 1.5mm
2
Connect to secondary coil, rated 5A
35 CT B Phase Sensing 1.5mm
2
36 CT C Phase Sensing 1.5mm
2
37 CT Common Port 1.5mm
2
Refer to INSTALLATION description.
38
Generator A Voltage
Sensing
1.0mm
2

Connect to A phase
(Recommend 2A fuse)
39
Generator B Voltage
Sensing
1.0mm
2

Connect to B phase
(Recommend 2A fuse)
40 Generator C Voltage 1.0mm
2
Connect to C phase
No. Function
Cable
Size
Description
Sensing (Recommend 2A fuse)
41 Generator N Input 1.0mm
2
Connect to generator neutral
42
Mains A Voltage
Sensing
1.0mm
2

Connect to mains A phase
(Recommend 2A fuse);
HGM6210KC without
43
Mains B Voltage
Sensing
1.0mm
2

Connect to mains B phase,
(Recommend 2A fuse)
HGM6210KC without.
44
Mains C Voltage
Sensing
1.0mm
2

Connect to mains C phase,
(Recommend 2A fuse)
HGM6210KC without.
45 Mains N Input 1.0mm
2

Connect to mains neutral,
HGM6210KC without
46 RS485 Common GND 0.5mm
2

Use 120 RS485 screen and screen
must be grounded at one end.
47 RS485 - 0.5mm
2

48 RS485+ 0.5mm
2

Note: LINK interface in back is programmable interface. Controller can be
programmable by PC via an SG72 adapter.
7 PARAMETER RANGE AND DEFINITION
7.1 PARAMETER CONTENT AND RANGE TABLE (TABLE 1)
No. Item Range Default Description
1
Mains Normal
Delay
(0-3600)s 10
Its the delay for confirming
whether mains normal or not,
used for ATS control. 2
Mains
Abnormal
Delay
(0-3600)s 5
3
Mains Under
Voltage
(30-360)V 184
When mains voltage is under
the point, mains under voltage
enabled. When the value is 30,
mains under voltage disabled.
4
Mains Over
Voltage
(30-360)V 276
When mains voltage is over the
point, mains over voltage
enabled. When the point is
360V, mains over voltage
disabled.
5
Transfer Rest
Time
(0-99.9)s 1.0
Its the delay from mains open to
generator closed or from
generator open to mains closed.
6 Start Delay (0-3600)s 1
Its the delay from mains failure
or remote start signal enabled,
to start generator.
7 Stop Delay (0-3600)s 1
Its the delay from mains normal,
or remote start signal disabled
to stop genset.
8 Start Times (1-10)times 3
When engine start not success,
maximum cranking times. When
setting crank times up, controller
send out fail to start signal.
9 Preheat Time (0-300)s 0
Power the preheat plug before
engine starts with power.
10 Crank Time (3-60)s 8
The time used to pre-power the
starter.
11
Crank Rest
Time
(3-60)s 10
Time for waiting the second
powering if failed to start at the
first time.
12
Safety Run
Time
(1-60)s 10
Alarms of Low OP, high temp,
under speed/freq/volt, charge
failure, are disabled
13 Start Idle Time (0-3600)s 0 Idle running time when started
14
Warming Up
Time
(3-3600)s 10
Time for warming up before
close breaker
15 Cooling Time (3-3600)s 10
Time for cooling before
stopping.
16 Stop Idle Time (0-3600)s 0
Genset idle running time during
stopping.
17
ETS Solenoid
Hold
(0-120)s 20
Its the delay for energizing to
stop.
18
Over Stop
Delay
(0-120)s 0
If ETS solenoid hold set as 0, it
is the time from end of idle delay
to gen-set at rest; if not 0, it is
from end of ETS solenoid delay
to gen-set at rest
19
ATS Close
Delay
(0-10)s 5.0
Mains or generator switch
closing pulse width, when it is 0,
output is continuous.
20 Flywheel Teeth (10-300) 118
Number of flywheel teeth, can
detect disconnection conditions
and engine speed.
21
Gens Abnormal
Delay
(0-20.0)s 10.0 Over or under volt alarm delay
22
Gens Over Volt
Shutdown
(30-360)V 264
When gens voltage is over the
point, generator over voltage is
360V, generator over voltage is
disabled.
23
Gens Under
Volt Shutdown
(30-360)V 196
When generator voltage is
under the point, generator under
voltage is enabled. When the
point is 30V, generator under
voltage is disabled.
24
Under Speed
Shutdown
(0-6000)RPM 1200
When the engine speed is under
the point for 10s, shutdown
alarm signal is sent out.
25
Over Speed
Shutdown
(0-6000)RPM 1710
When the engine speed is over
the point for 2s, shutdown alarm
signal is sent.
26
Under Freq
Shutdown
(0-75.0)Hz 45.0
When generator frequency is
lower than the point for 10s,
shutdown alarm signal is sent.
27
Over Freq
Shutdown
(0-75.0)Hz 57.0
over the point and holds for 2s,
generator over frequency is
enabled.
28
High Temp 1
Shutdown
(80-300)C 98
When engine temperature
sensor 1 is over this point, send
out shutdown alarm. Active from
safety run timer over (only
suited for temperature sensor)
29
Low OP 1
Shutdown
(0-400)kPa 103
When engine oil pressure
sensor 1 is under this point,
send out shutdown alarm. Active
from safety run timer over
30
High Temp 2
Shutdown
(80-300)C 98
out shutdown alarm. Active from
safety run timer over (only
suited for temperature sensor)
31
Low OP 2
Shutdown
(0-400)kPa 103
send out shutdown alarm. Active
from safety run timer over
32 Low Fuel Level (0-100)% 10
When fuel level sensor value
under this point and remains for
10s, send out warning alarm.
33
Loss Of Speed
Signal Delay
(0-20.0)s 5.0
When the delay is 0, send out
warning alarm.
34
Gens Over Volt
Warn
(30-360)V 256
When gens voltage is over the
point, generator over voltage is
360V, generator over voltage is
disabled.
35
Gens Under
Volt Warn
(30-360)V 205
When generator voltage is
under the point, generator under
voltage is enabled. When the
point is 30V, generator under
voltage is disabled.
36
Under Speed
Warn
(0-6000)RPM 1350
When the engine speed is under
the point, a warning alarm signal
is sent.
37
Over Speed
Warn
(0-6000)RPM 1650
When the engine speed is over
the point, a warning alarm signal
is sent.
38
Under Freq
Warn
(0-75.0)Hz 47.0
lower than the point, a warning
alarm signal is sent.
39
Over Freq
Warn
(0-75.0)Hz 55.0
over the point, a warning alarm
signal is sent.
40 Charge Failure (0-30)V 6.0
During generator is running,
when charge alternator WL/D+
voltage is under this point and
remain for 5s, generator will
warning alarm.
41
Battery Over
Volt Warn
(12-40)V 33.0
When generator battery voltage
is over the point and holds for
20s, battery over voltage signal
is enabled. Its a warning alarm.
42
Battery Under
Volt Warn
(0-30)V 8.0
When generator battery voltage
is under the point and holds for
20s, battery under voltage
signal is enabled. Its a warning
alarm.
43
High Temp 1
Warn
(80-300)C 95
warning alarm. Active from
safety run timer over.
44 Low OP 1 Warn (0-400)kPa 124
send out warning alarm. Active
from safety run timer over.
45
High Temp 2
Warn
(80-300)C 95
warning alarm. Active from
safety run timer over.
46 Low OP 2 Warn (0-400)kPa 124
send out warning alarm. Active
from safety run timer over.
47 CT Rate (5-6000)/5 500 Current transformer rate
48
Full Load
Current
(5-6000)A 500 Rated current of generator
49
Over Current
Shutdown
(50-130)% 120
When load current is over the
point, the over current delay is
initiated.
50
Over Current
Delay
(0-3600)s 1296
point, over current signal is sent.
When the delay is 0, warn only
not shutdown.
51
Over Current
Warn
(50-130)% 110
point, a warning signal is sent.
52 Aux. Output 1 (0-35) 16 Default: From preheat to crank
53 Aux. Output 2 (0-35) 1 Default: Common alarm
54 Aux. Output 3 (0-35) 10 Default: Energized to stop
55 Aux. Output 4 (0-35) 7 Default: Idle control
56 Aux. Output 5 (0-35) 21 Default: Gens closed
57 Aux. Output 6 (0-35) 22 Default: Mains closed
58 Aux. Input 1 (0-26) 8
Default: Remote start (only for
6210KC)
59
Aux. Input 1
Delay
(0-20.0)s 2.0
60 Aux. Input 2 (0-26) 1 Default: High temperature alarm
61
Aux. Input 2
Delay
(0-20.0)s 2.0
62 Aux. Input 3 (0-26) 2 Default: Low oil pressure alarm
63
Aux. Input 3
Delay
(0-20.0)s 2.0
64 Aux. Input 4 (0-26) 3 Default: External alarm input
65
Aux. Input 4
Delay
(0-20.0)s 2.0
66 Aux. Input 5 (0-26) 4
Default: External shutdown
alarm input
67
Aux. Input 5
Delay
(0-20.0)s 2.0
68 Aux. Input 6 (0-26) 19 Default: Low fuel level warn
69
Aux. Input 6
Delay
(0-20.0)s 2.0
70 Aux. Input 7 (0-26) 21 Default: Default: Lamp test
71
Aux. Input 7
Delay
(0-20.0)s 2.0
72
Power Mode
Select
(0-2) 0 Default: Stop Mode;
73
Module
Address
(1-254) 1 The address of controller.
74 Password (0-9999) 1234
75
Crank
Disconnect
Condition
(0-5) 2
Conditions of disconnecting
starter (gens, magnetic pickup
sensor, oil pressure)
76 Engine Speed (0-6000)RPM 360
When engine speed is over this
point, starter will disconnect.
77
Engine
Frequency
(0-30)Hz 14
over this point, starter will
disconnect.
78
Engine Oil
Pressure
(0-400)kPa 200
When engine oil pressure is
over this point, starter will
disconnect.
79
Single/3-phase
Input
(0-2) 0
0: 3P4W; 1: 2P3W;
2: 1P2W
80 Temp. Sensor 1 (0-10) 08 SGX (120C resistor)
81 OP Sensor 1 (0-10) 08 SGX (10Bar resistor)
82
Liquid Level
Sensor
(0-5) 03 SGD
83 Temp. Sensor 2 (0-10) 00 Not Used
84 OP Sensor 2 (0-10) 00 Not Used
85 Poles Number (2-32) 04
Number of magnetic poles, used
for calculating rotating speed of
generator without speed sensor.
7.2 PROGRAMMABLE OUTPUT 1-6 TABLE (TABLE 2)
No. Items Description
0 Not Used Output is disabled when this item is selected.
1 Common Alarm
Including all shutdown alarm and warning
alarm. When a warning alarm occurs, the alarm
wont self-lock; When a shutdown alarm occurs,
the alarm will self-lock until alarm is reset.
2
Common Shutdown
Alarm
Action when a common shutdown alarm
occurs.
3 Common Warn Alarm Action when a common warning alarm occurs.
4 Reserved
5 Start Relay Output
This output will disconnect when unit has
started.
6 Fuel Relay Output This output will disconnect when unit at rest.
7 Idle Control
Used for the genset with idle speed. Pick-up
when crank while disconnect when enter into
warming up. Pick-up during stop idle while
disconnect when genset at rest.
8 Speed Raise Control
Pick-up when enter into warming up time.
Disconnect if raise speed auxiliary input
enabled.
9 Speed Droop Control
Pick-up when enter into stop idle or ETS
solenoid stop (shutdown alarm). Disconnect if
droop speed auxiliary input enabled.
10 ETS Control
Used for the genset with stop solenoid. Pick-up
when idle speed is over while disconnect when
ETS delay is over.
11 Magnetizing Control
12V or 24V DC supply.
Pick-up when engine cranks and disconnect
when voltage is normal.
12 Fuel Pump Control
Pick-up when the fuel level lower than the
threshold and disconnect when the fuel level
higher than 85% of the threshold.
13 Air Flap Control
The output controls the closing of the air-flaps in
an Emergency Stop or Over Speed situation.
14 Louver Control
The output controls the opening of the louvers
on engine starting and closure when engine has
stopped.
No. Items Description
15
Over Current Output Action when load current is over the threshold.
16
Pre-Heat (During
Preheat Timer)
Pre-heat output is available from preheat delay
to cranking begins.
17
Pre-Heat (Until End Of
Cranking)
to cranking ends.
18
Pre-Heat (Until End Of
Warming Up)
to warming up ends.
19
Pre-Heat (Until Safety
On)
to safety run ends.
20
Reserved
21 Close Gens
When set close time as 0, it is continuous
closing.
22 Close Mains 6210KC without
23 Open Breaker
When set close time as 0, Open Breaker is
disabled.
24 Reserved
25 Crank Disconnect Action when the engine has fired successfully.
26 Genset Normal Run
Pick-up during warming up and disconnect
during cooling time.
27
Gens Normal This output indicates that the voltage is normal.
28 Reserved
29
System In Manual Test
Mode
This output indicates that the module is in the
Manual Test mode.
30 System In Auto Mode
The output indicates that the module is in the
Auto mode.
31
System In Manual
Mode
This output indicates that the module is in the
Manual mode.
32 System In Stop Mode
The output indicates that the module is in the
Stop mode.
33
Reserved
34
Mains Abnormal Over/under voltage and lack of phase of mains.
6210KC without.
35
Reserved
7.3 PROGRAMMABLE INPUT 1-7 TABLE (ALL IS ACTIVE WHEN
CONNECT TO GRAND (B-) (TABLE 3)
No. Item Description
0 Not Used
1 High Temp. Alarm
After safety run on, if the signal is enabled,
genset will immediately alarm to shutdown. 2 Low OP Alarm
3 Auxiliary Alarm Only warn, not shutdown.
4 Aux. Shutdown Alarm
If the signal is enabled, genset will immediately
alarm to shutdown.
5 Coolant To Stop
During engine running and the input is enabled, if
high temperature shutdown occurs, controller will
stop after high speed cooling; when the input is
disabled, controller will stop immediately.
6 Gens Closed Input
7 Mains Closed Input
8 Remote Start Input Access to remote start signal.
9 High Temp. Inhibit
When it is enabled, high oil temperature stop is
inhibited.
10 Low OP Inhibit
When it is enabled, low oil pressure stop is
inhibited.
11 Analogy Manual Key
12 Analogy Auto Key
13 Analogy Start Key

14 Analogy Stop Key

15
Analogy Manual Test
Key

16 Panel Lock
When the input is activated, all the panel keys are
inactive. The right corner of the forth line will
show .
17 Auto Stop Inhibit
In auto mode, when the input is active, auto stop
is not allowed.
18 Auto Start Inhibit
In Auto Mode, when the input is enabled, no
matter mains normal or not, genset wont start. If
genset is in normal running, stop process wont
be executed. When input is disabled, genset will
automatically start or stop.
19 Low Fuel Level Warn
Only warn, not shutdown.
20 Alarm Reset
When the input is activated, shutdown alarm, trip
alarm can be removed.
21 Lamp Test When the input is activated, all LED indicators
will illuminate.
22
Fuel Moisture Content
Warn
When the input is activated, controller will send
and display a warning alarm.
23 Speed Raise Input
When the input is activated, speed raise output is
inhibited.
24 Speed Droop Input
When the input is activated, speed droop output
is inhibited.
25 Low Water Level Warn
and display a warning alarm.
26
Low Water Level
Shutdown
and display a shutdown alarm.
7.4 SENSOR SELECTION (TABLE 4)
No. Items Content Description
1
Temperature
Sensor
0 Not used
1 Defined Res. Type
2 VDO
3 SGH(Huanghe sensor)
4SGD(DongKang sensor)
5 CURTIS
6 DATCON
7 VOLVO-EC
8 SGX
9 Reserved
10 Reserved
Defined input resistance
range is 0~999.9,
factory default is SGX
sensor.
2
Pressure
Sensor
0 Not used
1 Defined Res. Type
2 VDO 10Bar
3 SGH(Huanghe sensor)
4 SGD(DongKang sensor)
5 CURTIS
6 DATCON 10Bar
7 VOLVO-EC
8 SGX
9 Reserved
10 Reserved
Defined input resistance
range is 0~999.9,
factory default is SGX
sensor.
3
Fuel Level
Sensor
0 Not used
1 Defined Res. Type
2 SGH
3 SGD
4 Reserved
5 Reserved
Defined curve input
resistance range is
0-999.9, factory default
is SGD sensor.
7.5 CONDITIONS OF CRANK DISCONNECT (TABLE 5)
No. Content
0 Magnetic pickup sensor
1 Gens
2 Magnetic pickup sensor + Gens
3 Magnetic pickup sensor + Oil pressure
4 Gens + Oil pressure
5 Gens + Magnetic pickup sensor + Oil pressure
1) There are 3 kinds of crank disconnect conditions. Magnetic pickup sensor and
gens can be used alone. Oil pressure must be used with magnetic pickup sensor
and the gens, in order to make the starter and the engine disconnect as soon as
possible.
2) Magnetic pickup sensor is installed in the engine for testing flywheel teeth.
3) When choosing magnetic pickup sensor, ensure the number of flywheel teeth is
same as the pre-set, otherwise over or under speed shutdown may appear.
4) If generator has no magnetic pickup sensor, don't choose corresponding item;
otherwise Fail to Start or Loss of Speed Signal shutdown will occur.
5) If the generator has no oil pressure sensor, don't choose corresponding item.
6) If gens has not been selected, controller will not measure and display the relative
parameters (can be applied to the pump set); if magnetic pickup sensor has not
been selected, the rotating speed will calculated by the generating AC signal.
8 PARAMETER SETTING
After controller powered on, press to enter into the parameters setting menu:
1. Parameters Setting
2. Information
3. Language
Parameters Editing
When inputting password, "1234" can set the items of 1-47; "0318" can set all
items. If more parameter items are needed to set, such as voltage and current
calibration, please contact the factory.
NOTE:
HGM6210KC, there are not items 1-5 in table1; programmable output 1-6 have no
digital outputs about mains.
1. Please modify the parameters in standby mode (crank conditions, auxiliary input
and output configuration, multi delays, etc.) otherwise shutdown alarm or other
abnormal conditions may appear.
2. The over-voltage threshold must be greater than the under-voltage threshold;
otherwise over-voltage and under-voltage will occur at the same time.
3. The over-speed threshold must be greater than under-speed threshold,
otherwise over speed and under speed will occur at the same time.
4. Set frequency value (after crank disconnect) as low as possible, in order to
disconnect starter quickly.
5. Programmable input 1-5 cannot be set as the same items, otherwise cannot
realize correct function; programmable output 1-4 can be set as the same item.
6. If need to shut down after cooling, please set any input as " stop after cooling ",
then connect this input to GND.
Information
LCD will display some information of controller, such as software version, issue
date.
Note: Pressing will display the status of digital inputs and outputs.
Language
User may select display language as Chinese, English and Spanish.
Note: Pressing key at any time will exit the editor and back to main interface.
9 SENSOR SETTING
1 When choosing sensor, standard of sensor curve will be needed. If set
temperature sensor as SGD (120C resistor type), sensor curve should be SGD
(120
o
C resistor type); If set as SGH (120C resistor type), sensor curve should
be SGH curve.

2 If there is difference between standard sensor curve and chosen sensor, select
"defined sensor", and then input defined sensor curve.
3 When inputting sensor curve, X value (resistance) must be in accordance with
the order of higher to lower, otherwise errors will occur.
4 When select sensor "Not used", sensor curve does not work, LCD screen will
display " - - -".
5 If there is no pressure sensor, but only has low pressure alarm switch, then you
must set pressure sensor as "Not used", otherwise oil pressure low alarm
shutdown may appear.
6 Can set several points of forehand or backmost as the same ordinate, like the
following picture:

Conventional pressure unit conversion table
1N/m
2
(pa) 1kgf/cm
2
1bar (1b/in
2
) psi
1Pa 1 1.02x10
5
1x10
5
1.45x10
4

1kgf/cm
2
9.8x10
4
1 0.98 14.2
1bar 1x10
5
1.02 1 14.5
1psi 6.89x10
3
7.03x10
2
6.89x10
2
1
10 COMMISSIONING
Before operation, the following checking should be carried out:
1. Check and ensure all the connections are correct and wires diameter is suitable.
2. Ensure that the controller DC power has insurance; battery positive and negative
have correctly connected.
3. Emergence stop input must be connected to positive of starting battery via
normally close contact of emergency stop.
4. Take proper actions to prevent engine to disconnect crank (e. g. Remove the
connections of fuel value). If checking is OK, connect start battery, select Manual
Mode, controller will execute the program.
5. Set controller as Manual Mode, press start button to start genset. If failed within
the setting crank times, controller will send Failed to Start signal; then press
Reset to reset controller.
6. Recover actions of preventing engine to disconnect crank (e. g. Connect wire of
fuel value), press start button again, genset will start. If everything goes well,
genset will normal run after idle running (if configured). During this period, watch
for engines running situations and voltage and frequency of alternator. If abnormal,
stop genset and check all connections according to this manual.
7. Select the Auto Mode from front panel, connect to mains signal. After the mains
normal delay, controller will transfer ATS (if configured) and into mains load. After
cooling, controller will stop genset and into standby state until mains abnormal
again.
8. When mains abnormal again, genset will start automatically and into normal
running, send signal to make gens close, transfer ATS and make genset take load.
If not like this, please check connections of ATS according to this manual.
9. If there are any other questions, please contact Smartgens technical personnel.
11 TYPICAL APPLICATION
HGM6210KC Typical Wiring Diagram

HGM6220KC Typical wiring diagram

Single Phase 2 Wire (HGM6220KC)

2 Phase 3 Wire (HGM6220KC)

Note: Recommend that the output of crank and Fuel expand high capacity relay.
12 INSTALLATION
The module is held into the panel fascia using the supplied fixing clips. Case
dimensions and panel cutout are shown as below.

1) Battery Voltage Input
HGM6200K series controller can be applicable to (8-35) VDC battery voltage.
Battery negative must be reliably connected to engine shell. The connection
between controller power and battery should not be less than 2.5mm
2
, if a float
charger is fitted, please connect output line of the charger with battery positive
directly, then from battery positive separately connect to power input terminal of
controller, in case that charger will interfere with the normal running of controller.
2) Speed Sensor Input
Speed sensor is installed in the engine for testing flywheel teeth. The connection
with controller uses 2-core screen, shield layer should be connected to
terminal25 of controller with the other end vacant. The other two signal lines are
respectively connected to terminal26 and terminal27. At full speed, output
voltage range is 1-24VAC (RMS), recommended 12VAC (rated speed). During
installing, make the speed sensor contact the flywheel firstly, then pour out 1/3
laps, finally lock nut on the sensor.
3) Output And Expansion Relay
All the outputs of controller are relay output. If need to expand relay, please add
freewheeling diode in both ends of relay coil (when expansion relay coil links
DC), or add RC loop (when expansion relay coil links AC), in case controller or
other equipments are interfered.
4) AC Input
HGM6200K series controller must externally connect current transformer, CT
current must be 5A. Besides, the phase position of CT and input voltage must
be correct, otherwise the sampling current and active power may be incorrect.
Note: A. ICOM must connect battery anode power controllers.
B. When the load current, open circuit is inhibited in the transformer
secondary.
5) Withdraw Voltage Test
When the controller has been installed in the control panel, during the test
please disconnect all the terminals, lest high voltage damages the controller.
13 FAULT FINDING
Fault Possible Remedy
Generator Inoperative
Check starting battery;
Check connections of controller.
Check the DC fuse.
Genset Stops
Check if water/cylinder temperature too high.
Check alternator voltage.
Check the DC fuse.
Emergency Stop
Check if an emergency stop button is fitted; Ensure
battery positive is connected to the emergency stop
input.
Check if connection is open circuit.
Low Oil Pressure Alarm
(After Crank Disconnect)
Check oil pressure sensor and connections.
High Temp. Alarm (After
Crank Disconnect)
Check temperature sensor and connections.
Shutdown Alarm During
Running
Check switch and connections according to
information on LCD.
Check configuration inputs.
Crank Not Disconnect
Check connections of fuel solenoid.
Check starting battery.
Check speed sensor and its connections. Refer to
engine manual.
Starter Inoperative
Check connections of starter;
Check starting battery.
Genset Running While ATS
Not Transfer
Check ATS;
Check connections between ATS and controller.
RS485 COM Failure
Check connections;
Check if COM port is correct;
Check if A and B of RS485 is connected reversely;
Check if PC COM port is damaged;
Recommended using 120ohm resistance between
PR485 and AB.

User Manual: HGM6200K Series Automatic Control Module

Uploaded by

Copyright:

Available Formats

User Manual: HGM6200K Series Automatic Control Module

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

User Manual: HGM6200K Series Automatic Control Module

Uploaded by

Copyright:

Available Formats

HGM6200K Series

Automatic Control Module

You might also like