Smartgen HGM400 Series User manual

HGM400 Series Genset Controller

(HGM410/HGM420)

USER MANUAL

ZHENGZHOU SMARTGEN TECHNOLOGY CO.,LTD

Chinese trademark

English trademark

SmartGen —make your generator smart

Smartgen Technology Co., Ltd.

No. 28 Jinsuo Road

Zhengzhou

Henan Province

P. R. China

Tel: +86-371-67988888/67981888

+86-371-67991553/67992951

+86-371-67981000(overseas)

Fax: 0086-371-67992952

Web: http://www.smartgen.com.cn

http://www.smartgen.cn

Email: [email protected]

(including photocopying or storing in any medium by electronic means or other) without

the written permission of the copyright holder.

Smartgen Technology reserves the right to change the contents of this document

without prior notice.

Version

Date

Version

Note

2011-07-06

1.0

Original release.

2012-03-15

1.1

Modify typical application.

2012-10-30

1.2

Modify some details.

2013-08-08

1.3

Change input port 3 and 4 to multiplex input port, that is

to say, the input port 3 and input port 4 can be used as

auxiliary input port or analog input port.

2013-08-28

1.4

Change “External Shutdown”input to “Emergency

Shutdown”input.

2014-08-28

1.5

Some functions are added.

2015-05-27

1.6

Modify the description of output raise/drop speed.

This manual is suitable for HGM400 series controller only.

Clarification of notation used within this publication.

SYMBOL

INSTRUCTION

NOTE

Highlights an essential element of a procedure to ensure

correctness.

CAUTION!

Indicates a procedure or practice, which, if not strictly observed,

could result in damage or destruction of equipment.

WARNING!

Indicates a procedure or practice, which could result in injury to

personnel or loss of life if not followed correctly.

CONTENTS

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

2PERFORMANCE AND CHARACTERISTICS ....................................6

3SPECIFICATION................................................................................8

4OPERATION......................................................................................9

4.1 PUSHBUTTONS...............................................................................................9

4.2 INDICATOR LIGHT.........................................................................................10

4.3 AUTOMATIC START/STOP OPERATION......................................................11

4.4 MANUAL START/STOP OPERATION............................................................12

5PROTECTION .................................................................................13

5.1 WARNINGS....................................................................................................13

5.2 SHUTDOWNALARM .....................................................................................16

6CONNECTIONS ..............................................................................19

7DEFINITION AND RANGE OF PARAMETERS................................22

7.1 PARAMETER CONTENTS AND RANGE (TABLE 1)......................................23

7.2 PROGRAMMABLE OUTPUT 1-5 (TABLE 2)..................................................31

7.3 PROGRAMMABLE INPUT 1-4 TABLE (ACTIVE WHEN CONNECT GND (B-)

(TABLE 3)...............................................................................................................32

7.4 SENSOR SELECT (TABLE 4)........................................................................34

7.5 CONDITIONS OF CRANK DISCONNECT (TABLE 5)....................................35

8PARAMETERS SETTING................................................................36

9SENSOR SETTING .........................................................................37

10 COMMISSIONING...........................................................................38

11 TYPICALAPPLICATION..................................................................39

12 INSTALLATION................................................................................41

12.1FIXING CLIPS ................................................................................................41

12.2OVERALL DIMENSION AND PANEL CUTOUT..............................................42

13 FAULT FINDING ..............................................................................44

HGM400 Series Genset Controller User Manual

HGM400 Series Genset Controller ISSUE 2015-05-27 Version 1.6 Page 5 of 44

1 OVERVIEW

HGM400 series genset controllers integrate digitization, intelligentization and network

technology which are used for genset automation and monitor control system of single

unit to achieve automatic start/stop, data measurement, alarm protection and “three

remote” (remote control, remote measuring and remote communication; SG485

module must be fitted). It fit with LCD display, optional languages interface (Chinese,

English, Spanish, Turkish and Russian), and it is reliable and easy to use.

HGM400 series genset controllers adopt micro-processor technology with precision

parameters measuring, fixed value adjustment, time setting and set value adjusting

and etc. All parameters can be configured from front panel or through programmable

interface (USB to LINK, SG72 adaptor produced by Smartgen is recommended) via

PC. It can be widely used in all types of automatic genset control system with compact

structure, advanced circuits, simple connections and high reliability.

HGM400 Series Genset Controller User Manual

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2 PERFORMANCE AND CHARACTERISTICS

HGM400 series controller has two types:

HGM410: ASM (Automatic Start Module)，it controls generator to start/stop by

remote signal;

HGM420: AMF (Auto Mains Failure), updates based on HGM410, moreover, has

mains electric quantity monitoring and mains/generator automatic transfer control

function, especially for automatic system composed by generator and mains.

132x64 LCD with backlight, selectable language interface (Chinese, English,

Spanish, Turkish and Russian), push-button operation;

Suitable for 3-phase 4-wire, 3-phase 3-wire, single phase 2-wire, and 2-phase

3-wire systems with voltage 120/240V and frequency 50/60Hz;

Collects and shows 3-phase voltage, current, power parameter and frequency of

generator or mains.

Mains Generator

Line Voltage (Uab, Ubc, Uca) Line Voltage (Uab, Ubc, Uca)

Phase Voltage (Ua, Ub, Uc) Phase Voltage (Ua, Ub, Uc)

Frequency (HZ) Frequency (HZ)

Load

Current (IA, IB, IC)

Active Power (KW)

Reactive Power (KVar)

Apparent Power (KVA)

Power Factor (PF)

Accumulated Energy (kWh)

For Mains, controller has over voltage, under voltage and loss of phase detection

functions; For generator, controller has over voltage, under voltage, over frequency,

under frequency and over current detection functions;

Precision collect and display parameters about Engine,

Temp. (WT) °C/°F both be displayed

Oil pressure (OP) kPa/Psi/Bar all be displayed

HGM400 Series Genset Controller User Manual

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Fuel Level (FL) % (Unit)

Engine Speed (RP) RPM (Unit)

Battery Voltage (VB) V (unit)

Charger Voltage (VD) V (unit)

Hours Counter (HC): Max. 999999 hours

Start times: Max.999999 times

Control & Protection: automatic start/stop of the genset, ATS(Auto Transfer Switch)

control with perfect fault indication and protection function;

With ETS(Energize To Stop), idle control, pre-heat control, speed raise control and

speed drop control function, All output ports are relay-out;

Parameter setting: parameters can be modified and cannot be lost even in case of

power outage; all the controller parameters can be adjusted using front panel of the

controller or via PC using an SG72 adaptor.

Multiplex input port 3 and 4 can be used in various fields: input 3 can be used as

auxiliary input port or fuel level sensor while input 4 can be used as auxiliary input

port or configurable sensor.

More kinds of curves of temperature, oil pressure, fuel level can be used directly

and users can define the sensor curves by themselves;

Configurable sensor: can be set as temperature sensor, oil pressure sensor or fuel

level sensor, enable the detection of double temperature, double oil-pressure and

double fuel level.

Multiple crank disconnect conditions (magnetic pickup, oil pressure, generator

frequency) are optional;

Widely Power supply range: DC(8~35)V, suitable to different start battery voltage

environment.

All parameters used digital adjustment, instead of conventional analog modulation

with normal potentiometer, more reliability and stability;

Modular design, self-extinguished ABS plastic enclosure, pluggable connection

terminals and embedded installation way; compact structure with easy mounting.

HGM400 Series Genset Controller User Manual

HGM400 Series Genset Controller ISSUE 2015-05-27 Version 1.6 Page 8 of 44

3 SPECIFICATION

Items

Contents

Working Voltage

DC8. 0V to 35. 0V, Continuous Power Supply.

Overall Consumption

<3W(Standby mode: ≤2W)

AC voltage Input:

3 Phase 4 Wire

2 Phase 3 Wire

Single phase 2 Wire

3 Phase 3 Wire

AC15V - AC360V (ph-N)

AC30V - AC620V (ph-ph)

Alternator Frequency

50Hz/60 Hz

Speed Sensor Voltage

1.0V to 24V (RMS)

Speed Sensor Frequency

10,000 Hz (max)

Start Relay Output

5A DC28V power supply

Auxiliary Relay Output 1

5A DC28V power supply

Auxiliary Relay Output 2

5A DC28V power supply

Auxiliary Relay Output 3

5A DC28V power supply

Auxiliary Relay Output 4

5A AC250V voltage-free output

Auxiliary Relay Output 5

5A AC250V voltage-free output

Overall Dimensions

130mm x 112mm x 39mm

Panel Cutout

110mm x 90mm

CT Secondary Current

5A (rated)

Working Condition

Temperature: (-25~70)ºC;

Humidity: (20~93)%RH

Storage Condition

Temperature: (-25~70)ºC

Protection Level

IP55 Gasket

Insulation Intensity

Apply AC2.2kV voltage between high voltage

terminal and low voltage terminal;

The leakage current is not more than 3mA within

1min.

Weight

0.26kg

HGM400 Series Genset Controller User Manual

HGM400 Series Genset Controller ISSUE 2015-05-27 Version 1.6 Page 9 of 44

4 OPERATION

4.1 PUSHBUTTONS

Stop/ Reset

Stop running generator in Auto/Manual mode;

In case of alarm condition, pressing the button will reset

alarm;

In stop mode, pressing and holding the button for 3

seconds will test indicator lights (lamp test);

During stopping process, press this button again to stop

generator immediately.

Start

Start genset in Manual/Test mode.

Manual

Pressing this key will set the module into manual mode.

Pressing and (or ) simultaneously can

adjust LCD contrast.

Auto

Pressing this key will set the module into auto mode.

Set/Confirm

Pressing this key will enter into Main Menu;

In setting parameter status, press this key will shift cursor

or confirm setting value.

Up/Increase

Scrolls the screen up;

Shift the cursor up or increase the set value in

parameter setting menu.

Down/Decrease

Scrolls the screen down;

Shift the cursor down or decrease the set value in

parameter setting menu.

HGM400 Series Genset Controller User Manual

HGM400 Series Genset Controller ISSUE 2015-05-27 Version 1.6 Page 10 of 44

4.2 INDICATOR LIGHT

HGM410 Panel Indicators

HGM420 Panel Indicators

This manual suits for next models

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