User Manual: Genset Controller
User Manual: Genset Controller
User Manual: Genset Controller
(HGM611ON/6120N/6110NC/6120NC/6110CAN/6120CAN)
GENSET CONTROLLER
USER MANUAL
SMARTGEN{ZHENG2HOU)TECHNOLOGY CO.,LTD.
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smortGen xegisteredtrademark
No. 28 Xuemei Street, Zhengzhou, Henan,
China Tel: +86-371 -
6798B888/67981888/67992951
+8ó-371-67981000(overseas)
Fax:+86-37l-6799295Z
Web: www.smartgen.com.cn
www.smartgen.cn
Email: sales@smartgen.cn
AI 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.
SmartGen reserves the right to change the contents of this document without prior notice.
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1 OVERVIEW
HGM61 OON series genset controller, integrating digita/, intelligent and network techniques, is used
for automatic control and monitoring system of single genset. It can carry out functions of automatic
start/stop, data measurement, alarm protection and “three remote” (remote control, remote
measurement and remote communication). The controller uses LCD display, optional language
interface including Chinese, English, Spanish, Russian, Portuguese, Turkish, Pot ish and French
with easy and reliable operation.
HGM61 OON series genset contro ler uses micro-processing technique which can achieve precision
measurement, value adjustment, timing and threshold setting etc. All the parameters can be configured
from front panel or use USB interface (or RS485 interface) to adjust via PC. It can be widely used in all
types of automatic control system for its compact structure, simple connect:ions and high reliability.
Items Contents
Working Voltage DC8.0V to DC35.0V, continuous
Power Consumption <3w (Standby mode: 2W)
AC Syst:em
3P4W AC15V - AC360V (ph-
3P3W N) AC30V - AC6Z0V (ph-
1P2W ph) AC15V - AC36DV
2P3W (ph-N) ACI 5V -
AC36OV (ph-N)
AC Alternator Frequency S0Hz/60Hz
Speed Sensor Voltage 1.0V to 24V (RMS)
Speed Sensor Frequency 10,000 Hz (max.)
Start Relay Output 16A DC28V at supply voltage
Fuel Relay Output 16A DC28V at supply voltage
Auxiliary Relay Output 1 7A DC28V at supply voltage
Auxiliary Relay Output 2 7A AC250V volt-free output
Auxiliary Relay Output 3 16A AC2fi0V volt-free output
Auxiliary Relay Output 4 16A AC250V volt-free output
Overall Dimensions 209mm x 166mm x 45mm
Panel Cutout l86mmxl4lmm
C.T. Secondary Current SA (rated)
Working Temperature (-25 +70)°C
Working Humidity (ZO 93)%RH
Storage Temperature (-30-+80)°C
IP65: when water-proof gasket installed between control panel and
Protection Level
enclosure.
Apply AC2.2kV voltage between high voltage terminal and loyv voltage
Insulation Intensity
terminal. The leakage current is not more than 3mA within 1min.
Weight 0.56kg
Manual Pressing this key will set the module as Manual mode.
Auto Pressing this key will set the module as Auto mode.
Up,’ Increase
AIarm
Homepage.’ Return
Set/ Confirm
Status
Down/Decrease
Auto Mode
Auto
Close Start
Loa Stop Mode
d Stop.’ Reset
Open Manual Mode
Gen Normal Manual
Up/Increase
AIarm
Homepage,’ Return
Set ’’Confi rm
Down,‘ Decrease
Mains Normal Auto Mode
Mains Close/open Auto
Lo Start
ad Genset Stop Mode
Stop,' Reset
Close/Open
Manual Mode
Gen Normal
Manu al
Auto mode is activated by pressing the , LED indicator beside the key is illuminating which
confirms this action.
Starting Sequence
1) HGM6120: When mains is abnormal (over/under voltage, lass of phase), it enters into "Mains
Abnormal Delay” and LCD displays count-down time. When delay is over, "Start Delay" begins.
2) HGM6110: When "remote start” input is active, it enters 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 for 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 fifth line of LCD wit I turn black and Fail to Start
alarm will be displayed.
7) Any time to start genset successfully, it will enter into "Safety Running". During this period,
alarms of low oil pressure, high temperature, under speed, failed to charge and Aux. input (be
configured} are disabled. As soon as this delay is over, genset will enter into "Start Idle Delay"
(if configured).
8) Ouring start idle delay, a arms 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 genset reach the load requirement, close relay outputs, genset is taking load and
indicator illuminates; if voltage or frequency is abnormal, controller wit I alarm and shutdown
(LCD displays the alarm information).
Stopping Sequence
1) HGM6120: During normal running, if mains normal, genset will enter into °Mains Normal Delay”,
when mains indicator illuminates, "Stop Delay” begins.
2) HGM6110: Genset enters into ”Stop Delay" as soon as "Remote Start" is inactive.
3) When "Stop Delay" is over, genset enters into °CooIing Delay". Closing relay is disconnected.
After switch "Transfer Delay", closing relay is outputting, mains is taking load, generator
indicator extinguishes while mains indicator illuminates.
4) When entering "Stop Idle Delay" (if configured), idle relay is energized to output.
5) When entering "ETS Delay”, ETS relay is energized to output, fuel relay output is disconnected.
6) When entering “Genset After Stop Time", genset will automatically judge if it has stopped.
7) When genset has stopped, it enters into standby mode; if genset failed to stop, controller will send
alarms (“Fail to Stop” alarm will be displayed in LCD).
1) HGM6120: Manual Mode is active when press and its indicator illuminates. Under this mode,
press o start gensel, it can automatically detect crank disconnect and accelerate to high
HGM61OON Series Genset Canlraller User Manual 10 of 51
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speed running. If there is high 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 won't transfer automatically, it is
€iI•B
necessary to press@@Bto transfer load.
2) HGM6110: Manual Mode is active when pressing and its indicator is illuminating. Then
press o start genset, it can automatically detect crank disconnect and accelerate to high
speed running. If there is high 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, pres nd gens takes
load.
3) Manual Stop: Pressing an shut down the running genset (detail procedures please refer to
No.3-7 of Auto stop operation).
In manual mode, pressing and @.W simultaneously can compel genset to start. The controller
won't judge whether the controller has started successfully according to disconnect conditions and
the disconnection of starter needs to be controlled by operators. When operators observed the
genset has started successfully, loose 1he keys and the controller enters safety delay with start no
outputting.
5 PROTECTION
5.1 WARNINGS
When controller detects the warning signal, the genset only sends alarm and not stops. The
alarms are displayed in LCD.
When controller detects shutdown alarm, it will send signal to open and stop genset. The
alarms are displayed in LCD.
Compared with HGM6120, HGM6110 doesn't have 3-phase input terminal of mains voltage. The
back panel of HGM 6120 is as below.
NOTE2: If select high temperature inhibi1, or set programmable input as High Temperature Inhibit (this input is
active), when temperature is higher than pre setting threshold, controller sends warning signal only and not shutdown.
NOTE3: If select low oil pressure inhibit, or set programmable input as Low Oil Pressure Inhibit (this input is
active), when low oil pressure is lower than pre-setting threshold, controller sends warning signal only and not
shutdown.
NOTE4: If default password (0318) isn't changed, it doesn't need to input when configuring parameters via PC
software. if the password is changed for the first time via PC software, it needs to input password in password
window.
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HGM61OON Series Genset Canlraller User Manual 23 of 45
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No. Items Description
21 ECU Warning Indicate ECU sends a warning signal.
22 ECU Shutdown Indicate ECU sends a shutdown signal.
23 ECU Comm. Failure Indicate controller can't communicate with ECU.
Raising speed time is output while the unit entering into
24 Speed Raise Pulse
high-speed warming up.
Dropping speed time is output while the unit entering into stop
25 Speed Drop Pulse
idling.
This function only suits for HGMó1 OOCAN with engine type
Yuchai-LMB. When unit is standby, pump control output per 30
26 Oi1 Pump Control minutes. If oil pressure is above 100kPa or output delay is more
than 1minute, it will stop output; if unit is in re-heating state, oil
pump control will always output.
27 Fuel Pre-supply Output for 3s before fuel output.
Suitable for electrical injection engines. Ignition switch and ECU
power are not allowed to supply power simultaneously, is should
28 ECU Key Switch
be ECU power supply first, then ignition switch is supplied after a
delay of 3s.
Output when water temperature is higher than the open threshold
29 Cooling Fan of cooling fan, and disconnect when lower than the close
threshold of cooling fan.
Table 9 - Defined Contents of Programmable Input 1-5 (All Ground (B-) Connected Active)
ac1ive.
19 Alarm Mute Can prohibit "Audible Alarm” output when input is active.
In this mode, under voltage, under frequency and under speed
TO Idle Control Mode
are not protected.
No. Content
0 Speed
1 Frequency
2 Speed + Frequency
3 Speed + Oil pressure
4 Frequency + Oi1 pressure
5 Frequency + Speed + Oi1 pressure
6 Oil pressure
1) There are 3 kinds of crank disconnect conditions. Speed, Generator frequency and Oil pressure
can be used alone. Oil pressure used with speed and generator frequency together is
recommended, in order to make the starter and the engine disconnect as soon as possible.
2) Speed is the signal measured by magnetic sensor, which is installed in the engine for testing
flywheel teeth.
3) When choosing speed, 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 speed 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 generator frequency has not been selected, controller will not measure and display the
relative parameters (can be apps ied to the pump set); if speed has not been selected, the speed
wit I be calculated by the generating AC signal.
PARAMETER SETTING
After controller powered on, press to enter into the parameters setting menu:
1) Parameters Setting
2) Information
3) Language
4) Event Log
5) Maintenance Setting
— Parameters Setting
“0318" can set all items in table 7 during inputting password. When default password has been
changed, it needs to input the same password with controller for parameter setting via PC software.
If more parameter items need to be set or password is forgotten, such as voltage and current
calibration, please contact the factory.
NOTES:
1) HGM6110, there are no items 1-5 in table 7; programmable output 1-4 have no digital outputs
about mains.
2) Please modify the parameters in standby mode (crank conditions, auxi!iary input and output
— Information
1) LCD will display some informalion of controller, such as software version, issue date.
NOTE: Pressing will display the status of digital inputs and outputs.
2) Language
User may select display language as Chinese, English, Spanish, Russian, Portuguese, Turkey,
Polish and French.
Press and (or and ) and adjust LCD contrast ratio, which shall make the LCD
characters clearer. Adjustment range is 0-9.
— When choosing sensor, standard value of sensor curve will be needed. If temperature sensor is
set as SGH (1Z0°C resistor type), sensor curve should be SGH (120°C resistor type); If it is set
as SGD (120°C resistor type), sensor curve should be SGD curve.
— If there is difference between standard sensor curve and chosen sensor curve, select “defined
sensor”, and then input defined sensor curve.
— When sensor curve is inputted, X value (resistance) must be in accordance with the order of
higher to lower, otherwise errors will occur.
— When sensor is selected as “Not used°, temperature, pressure and fuel level will be display as "
-” in LCD.
— If there is no pressure sensor, but only has low pressure alarm switch, then you must set
pressure sensor as “Nat used”, otherwise oil pressure low alarm shutdown may appear.
— Can set several points of forehand or backmost as the same ordinate, as the following
picture: kPa
8OO
00
6OO
5 OO
400
300 — —'
200
1OO
0
32 6 4 96 1 28 1 60 192 224 '.› (o hm)
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1 O COMMISSIONING
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h . ..4 ING C O N T.. it 5' .A‹R 7E T.
11 TYPICAL APPLICATION
L1
LOAD
L2
L3
N
I
' AUX AUX E AUX
10
OUTPUT1 OUTPUT2 OUTPUTS
zs 23 24 25 26
2 QS 4 1 19 40 15 16 2O 21 22 38 39
FUEL
EM STOP
CHARGER D*
CRANłt
'“
MW lTG H2
GENS
V s :z
N N
e x mm 9—— AUX
I I I I 00 11OUTPUT1
(2
OUTPUT2
23 24 25 28 30 20 28 27 L‹ 6.I• I-‹4 31 32 33 34 *
2 4 17 1 e 15 16 2O 21 22 3B 3B 40
EM STOP
FUEL
CRANK
CHARGER D*’
MAGNETIC
PICKUP
SPEED SENSO
U L1
LOAD
V L2
ru
W L3
N N
AUX AUX E AUX
0 }11 OUTPUT1 OUTPUTS u OUTPUTS
23 24 25 28
2 5 4 4 1 9 40 15 18 20 21 22 38 39 35 36 37 41 42
43
MAGNETIC
PICI¢UP
SPEED sENSOR
SW ITCH1
GENS
N N
AUX
10 12
# 'I1OUTPUT 1 OUTPUTI
zs L+J 31 32 33 34 *
5 •i 1 18 9 15 16 20 21 22 38 39 40 3538 37 41 42
43
MAGNETIC
PICKUP
SPEED GENSO
27 30 J4 31
Single Phase 2
Wire
Fig. 9 - Single Phase 2 Wire
23 24 26 2/ 28 30 34 32 3
1
2 Phase 3 Wire
NOTE: Recommend that the output of crank and Fuel expand high capacity relay.
1 2 INSTALLATION
The module is held into the panel fascia using the supplied fixing clips.
— Withdraw the fixing clip screw (turn anticlockwise) until it reaches proper position.
— Pull the fixing clip backwards (towards the back of the module) ensuring four clips are inside their
allotted slots.
— Turn the fixing clip screws clockwise until they make contact with the panel.
— Care should be taken not to over tighten the screws of fixing clips.
Unit: mm
tt‹
18 6
i
O D -°
209
TabIe13 - Connector B
It is suitable for CM570 engine control module. Engine type is C,!SM11 G1, QSM11 GZ.
Table 17 - C1 Connector
lt is suitable for GCS engine control module. Use RS485-MODBUS to read information of engine.
Engine types are QSX15, QST30, QSK23 / 45/ó0/78 and so on
Table 26 - F Connector
It is suitable for MTU engine with ADEC (ECU8) and SMART module.
It is suitable for MTU engine with ADEC (ECU7) and SAM module.
lt is suitable for ADEM3/ ADEM4 engine control mode. Engine type is 2306, 250ó, 1106, and 2806.
Table 32 - Connector
13.14 SCANIA
lt is suitable for S6 engine control mode. Engine type is DC9, DC12, and DC16.
Table 33 - B1 Connector
NOTE: When this engine type is selected, preheating time should be set to at least 3 seconds.
Suitable engine types are TD520, TAD520 (optional), TD7Z0, TAD7Z0 (optional), TAD7Z1, TAD7Z2, and
TAD732.
Table 36 - Connector
13.17 VOLVO-EMS2
Volvo Engine types are TAD734, TAD940, TAD941, TAD1640, TAD1641, and TAD1642.
13.19 WEICHAI