Smartgen HGM400N Series User manual

HGM400N SERIES

(HGM410N/HGM420N)

GENSET CONTROLLER

USER MANUAL

Chinese trademark

English trademark

SmartGen —make your generator

smart

SmartGen Technology Co., Ltd.

No.28 Jinsuo Road

Zhengzhou City

Henan Province

P. R. China

Tel: +86-371-67988888/67981888/67992951

+86-371-67981000(overseas)

Fax: +86-371-67992952

Web: www.smartgen.com.cn/

www.smartgen.cn/

Email: sales@smartgen.cn

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 Version History

Date

Version

Note

2016-08-01

1.0

Original release.

2017-03-29

1.1

Modify some details.

2017-04-21

1.2

Modify Storage Temperature and Operation Humidity.

2019-09-18

1.3

Fix a description.

2021-04-19

1.4

Modify the error in technical parameters and optimize other

problems.

2022-06-14

1.5

Update company logo, panel indication and rear panel diagrams.

 
HGM400N Series Genset Controller User Manual Page 3 of 38 
CONTENTS 
OVERVIEW................................................................................................................................................4 
PERFORMANCE AND CHARACTERISTICS ............................................................................................4 
SPECIFICATION .......................................................................................................................................6 
OPERATION..............................................................................................................................................7 
1 PUSHBUTTONS..................................................................................................................................7 
2 PANEL INDICATION...........................................................................................................................8 
3 AUTOMATIC START/STOP OPERATION..........................................................................................8 
4 MANUAL START/STOP OPERATION................................................................................................9 
5 EMERGENCY START....................................................................................................................... 10 
PROTECTION ........................................................................................................................................ 11 
1 WARNING ........................................................................................................................................ 11 
2 SHUTDOWN ALARM....................................................................................................................... 13 
CONNECTIONS ..................................................................................................................................... 16 
DEFINITION AND RANGE OF PARAMETERS ...................................................................................... 18 
1 PARAMETER CONTENTS AND RANGE ......................................................................................... 18 
2 DEFINED CONTENTS OF PROGRAMMABLE OUTPUT PORTS 1-5 .............................................. 26 
3 DEFINED CONTENTS OF PROGRAMMABLE INPUT PORTS 1-4.................................................. 27 
4 SENSOR SELECTION....................................................................................................................... 28 
5 CONDITIONS OF CRANK DISCONNECT ........................................................................................ 29 
PARAMETER SETTING......................................................................................................................... 30 
1 PARAMETER SETTING ................................................................................................................... 30 
2 CONTROLLER INFORMATION........................................................................................................ 30 
3 LANGUAGE ...................................................................................................................................... 31 
4 EVENT LOG...................................................................................................................................... 31 
5 MAINTENANCE SETTING............................................................................................................... 31 
SENSOR SETTING................................................................................................................................. 32 
COMMISSIONING ................................................................................................................................. 33 
TYPICAL APPLICATION ....................................................................................................................... 34 
INSTALLATION ..................................................................................................................................... 36 
1 FIXING CLIPS................................................................................................................................... 36 
2 OVERALL DIMENSION AND PANEL CUTOUT ............................................................................... 36 
FAULT FINDING .................................................................................................................................... 38 
 

HGM400N Series Genset Controller User Manual Page 4 of 38

1OVERVIEW

HGM400N series genset controller integrates digitization, intelligence and network technology together,

which is used for single unit automation and monitoring control system, to achieve functions of

automatic start/stop, data measurement, alarm protection, etc. It fits with LCD display, optional

language interface (Chinese, English, Spanish, Turkish, Russian and French). It is reliable and easy to

operate.

HGM400N series genset controller adopts micro-processor technology, realizing precise parameter

measuring, fixed value adjustment, time setting and set value adjusting etc. All parameters can be

configured from front panel, or they can be modified and monitored through USB interface by using PC.

It can be widely used in all types of automatic genset control system with compact structure, simple

wirings and high reliability.

2PERFORMANCE AND CHARACTERISTICS

HGM400N series controller has two types:

HGM410N: used for automation of single unit, which controls generator to start/stop by remote start

signal.

HGM420N: based on HGM410N, AMF (Auto Mains Failure) and Mains/Gens automatic transfer control

functions are added, which is especially suitable for single unit automation system composed by one

mains and one gens.

Main characteristics are as below:

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

Russian and French), push-button 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;

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, 3-phase 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)

Phase Sequence Phase Sequence

Load

Current (IA, IB, IC)

Split-phase and Total Active Power (kW)

Reactive Power (kvar)

Apparent Power (kVA)

Power Factor (PF)

Accumulated Gen Energy (kWh)

Output Percentage with Load (%)

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

HGM400N Series Genset Controller User Manual Page 5 of 38

generator, controller has over voltage, under voltage, over frequency, under frequency, over current

and over power detection functions;

Precisely collect and display all parameters of engine:

Temp. (WT) °C/°F

Oil pressure (OP) kPa/psi/bar

Fuel Level (FL) % Residual Fuel Level L

Engine Speed (RPM) r/min

Battery Voltage (VB) V

Charger Voltage (VD) V

Hours Counter (HC)

Start times

Control and protection function: automatic start/stop of the genset, ATS (Auto Transfer Switch)

control and perfect fault indication and protection function;

ETS (Energize to stop), idle control, pre-heat control, speed raise control and speed drop control

functions, and all output ports are relay outputs;

Parameter setting function: allows users to modify and set the parameters and meanwhile will be

stored in internal FLASH and won't be lost even in case of power outage; all controller parameters

can be adjusted on front panel of the controller or via USB interface on PC;

Multiplex input port 3 and 4 can be used in various occasions: 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;

Multiple temperature, oil pressure, and fuel level sensors can be used directly, and parameters can

be user-defined;

One configurable sensor: can be set to temperature sensor, oil pressure sensor or fuel level sensor,

which enables the detection of double temperatures, double oil-pressures and double fuel levels.

Multiple crank disconnect conditions (magnetic pickup, oil pressure, generator) are optional;

Emergency start function;

Flywheel teeth auto-recognition function;

Wide power supply range: DC(8~35)V, which suitable for different starting battery voltage

environments;

All parameters apply digital adjustment, instead of conventional analog modulation with normal

potentiometer, improving the wholesome reliability and stability;

Maintenance function: types can be set to date or running time. Actions (inactive, warning, alarm

shutdown) can also be set when maintenance time is out;

Event log function (max. 99 pieces of records), real-time clock, and schedule to start/stop generator

function (start once monthly/weekly/daily on/off load can be set);

IP55 waterproofness with rubber-ring gasket between enclosure and screen;

Metal fixing clips are used to fix the controller;

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

embedded installation way; compact structure with easy mounting.

HGM400N Series Genset Controller User Manual Page 6 of 38

3SPECIFICATION

Table 2 Technical Parameters

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

3 Phase 3 Wire

Single Phase 2 Wire

2 Phase 3 Wire

AC15V - AC360V (ph-N)

AC30V - AC620V (ph-ph)

AC15V - AC360V (ph-N)

Alternator Frequency

50Hz/60Hz

Speed Sensor Voltage

1.0V to 24V (RMS)

Speed Sensor Frequency

10,000Hz (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 DC28V voltage-free output

Auxiliary Relay Output 5

5A DC28V voltage-free output

Overall Dimensions

126mm x 109mm x 44mm

Panel Cutout

110mm x 90mm

CT Secondary Current

5A (rated)

Working Temperature

(-25~+70)°C

Working Humidity

(20~93)%RH

Storage Temperature

(-25~+70)°C

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

HGM400N Series Genset Controller User Manual Page 7 of 38

4OPERATION

4.1 PUSHBUTTONS

Table 3 Key Description

Icon

Key

Description

Stop/ Reset

Stop the running generator in Auto/Manual mode;

Reset alarms under genset alarm conditions;

In stop mode, keep holding down the button for over 3 seconds and

panel indicators can be tested (lamp test);

In stop process, press it again and generator stops immediately.

Start

Start genset in Manual mode. Press it again in starting process, genset

status will skip to next one and it can start genset quicker.

Manual

Pressing this key will set the module into manual mode.

Auto

Pressing this key will set the module into auto mode.

Close/Open

Close/Open transfer button; press and it can make controller display

between close/open page and home page;

In close/open page and in manual mode, press Up/Increase,

Down/Decrease and breaker close/open can be controlled.

Set/Confirm

Press and it will enter main menu page;

In parameter setting status, press this key and it can shift cursor or

confirm the set values.

Up/Increase

Scrolls the screen up; shift the cursor up or increase the set value in

parameter setting menu;

In close/open page and in manual mode:

It can control mains close/open (HGM420N);

It can control gen close (HGM410N).

Down/Decrease

Scrolls the screen down; shift the cursor down or decrease the set

value in parameter setting menu.

In close/open page and in manual mode:

It can control gen close/open (HGM420N);

It can control gen open (HGM410N).

HGM400N Series Genset Controller User Manual Page 8 of 38

4.2 PANEL INDICATION

Fig.1 Front Panel Indication

NOTE: Partial indicator illustration:

Alarm Indicator: slowly flash for warning alarms; fast flash for shutdown alarms; light off for none alarms.

Status Indicator: light off for genset stand by; flash 1 time per second in start or stop process and always light on for

normal running.

4.3 AUTOMATIC START/STOP OPERATION

Press and the indicator beside it is illuminated, which means genset is in auto start mode.

Auto Start Sequence:

1) HGM420N: when mains is abnormal (over/under voltage, loss of phase), genset enters into “Mains

Abnormal Delay” and LCD displays countdown time. “Start Delay” timer is initiated after the delay has

expired.

2) HGM410N: When “Remote Start” is active, “Start Delay” timer is initiated;

3) “Start Delay” countdown will be displayed on LCD;

4) When start delay is over, preheat relay is energized (if configured), “Preheat Delay XXs” information

will be displayed on LCD;

5) After the above delay, the Fuel Relay is energized, and then one second later, the Start Relay is

engaged. If the genset fails to fire during “Cranking Time”, then the fuel relay and start relay are

disengaged for the pre-set rest period; “Crank Rest Time” begins and genset will wait for the next

crank attempt.

6) This start sequence should continue beyond the set number of attempts, the start sequence will be

terminated, the fifth line of LCD display will be highlighted with black and Fail to Start fault will be

displayed.

7) In case of successful crank attempt, the “Safety On” timer is activated, low oil pressure, high

temperature, under speed, charge alternator failure and auxiliary input alarms (configured) are inactive.

As soon as this delay is over, “Start Idle” delay is initiated (if configured).

8) During “Start Idle” delay, under speed, under frequency, under voltage alarms are inhibited. When this

delay is over, “Warming up” delay is initiated (if configured).

HGM400N Series Genset Controller User Manual Page 9 of 38

9) After the “Warming up” delay, if generator status is normal, its indicator will be illuminated. If

generator voltage and frequency have reached on-load requirements, then the generator close relay

will be energized; genset will take load; generator power indicator will illuminate and generator will

enter into Normal Running status. If voltage or frequency is abnormal, the controller will initiate

shutdown alarm (alarm information will be displayed on LCD).

Auto Stop Sequence,

1) HGM420N: During normal running process, if mains becomes normal, controller enters into “Mains

Normal Delay”. When mains indicator illuminates, “Stop Delay” is initiated.

2) HGM410N: When the “Remote Start” signal is inactive, the Stop Delay is initiated.

3) Once this “Stop Delay” has expired, the Generator Breaker will open and the “Cooling Delay” is then

initiated. After “Transfer Delay”, the mains close relay will be energized; mains will take load; generator

power indicator will extinguish while mains power indicator will illuminate.

4) During “Stop Idle” Delay (if configured), idle relay is energized.

5) “ETS Solenoid Hold” begins, ETS relay is energized while fuel relay is de-energized.

6) “Fail to Stop Delay”begins, complete stop is detected automatically.

7) Generator is placed into its standby mode after its complete stop. Otherwise, fail to stop alarm is

initiated and the corresponding alarm information is displayed on LCD.

4.4 MANUAL START/STOP OPERATION

1) HGM420N: Manual mode is selected by pressing the button; a LED beside the button will

illuminate to confirm the operation. In this mode, press button to start the genset, it can

automatically judge crank success and accelerate to high speed running. If high temperature, low oil

pressure, over speed and abnormal voltage occur during genset running, controller can effectively

protect genset to stop (for detail procedures please refer to No.4~9 of auto start sequence). In Manual

Mode, load switch won’t auto-transfer. It needs to press to enter close/open interface, and it

controls mains switch to close/open by pressing and controls gen switch to close/open by

pressing .

2) HGM410N: Manual mode is selected by pressing the button; the LED beside the button will

illuminate to confirm the operation and start the genset. It can automatically judge crank success and

accelerate to high speed running. If high temperature, low oil pressure, over speed and abnormal

voltage occur during genset running, controller can effectively protect genset to stop (for detail

procedures please refer to No.4~9 of auto start sequence). After genset high speed normal running, It

needs to press to enter close/open interface, and it controls mains switch to close by pressing

and controls gen switch to open by pressing (gen is on load).

3) Manual stop: pressing key can stop the running genset. (For detail procedures please refer to

HGM400N Series Genset Controller User Manual Page 10 of 38

No.3~7 of auto stop sequence.)

4.5 EMERGENCY START

In manual mode, pressing and 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 is controlled by operators. When operators observe the genset has started

successfully, he/she will release the keys and the controller enters safety delay, and start is stopped to

output.

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