Smartgen HGM410E User manual

HGM400E Series Genset Controller

(HGM410E/HGM420E)

USER MANUAL

Smartgen Technology

Version

Date

Version

Note

2013-08-17

1.0

Original release.

2013-08-28

1.1

Change “Auxiliary Input”to “Emergency Shutdown”

This manual is suitable for HGM400E 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.

HGM400E Series Automatic Control Module

HGM400E Series Genset Controller ISSUE 2013-08-28 Version 1.1 Page 4 of 41

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 ....................................................................................15

6CONNECTIONS .............................................................................18

7DEFINITION AND RANGE OF PARAMETERS...............................21

7.1 PARAMETER CONTENTS AND RANGE (TABLE 1).....................................21

7.2 PROGRAMMABLE OUTPUT 1-5 (TABLE 2).................................................29

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

(TABLE 3)..............................................................................................................30

7.4 SENSOR SELECT (TABLE 4).......................................................................31

7.5 CONDITIONS OF CRANK DISCONNECT (TABLE 5)...................................32

8PARAMETERS SETTING...............................................................33

9SENSOR SELECT..........................................................................35

10 COMMISSIONING..........................................................................36

11 TYPICALAPPLICATION.................................................................37

12 INSTALLATION...............................................................................39

12.1FIXING CLIPS ...............................................................................................39

12.2OVERALL DIMENSION AND PANEL CUTOUT.............................................39

13 FAULT FINDING .............................................................................41

HGM400E Series Automatic Control Module

HGM400E Series Genset Controller ISSUE 2013-08-28 Version 1.1 Page 5 of 41

1 OVERVIEW

HGM400E 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 measure, 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 and Russian), and it is reliable and easy to use.

HGM400E 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, can use SG72 adaptor) 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.

HGM400E Series Automatic Control Module

HGM400E Series Genset Controller ISSUE 2013-08-28 Version 1.1 Page 6 of 41

2 PERFORMANCE AND CHARACTERISTICS

HGM400E series controller has two types:

HGM410E: ASM (Automatic Start Module)，it controls generator to start/stop by

remote signal;

HGM420E: AMF (Auto Mains Failure), updates based on HGM410E, 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 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 measure and display parameters about Engine,

Temp. (WT) °C/°F both be displayed

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

Fuel Level % (Unit)

Engine Speed (RP) RPM (Unit)

HGM400E Series Automatic Control Module

HGM400E Series Genset Controller ISSUE 2013-08-28 Version 1.1 Page 7 of 41

Battery Voltage (VB) V (unit)

Charger Voltage (VD) V (unit)

Hours counter (HC): Max. 999999 hours

Start times: Max.999999 times

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

with perfect fault indication and protection function;

With ETS, idle control, pre-heat control, speed raise control and speed drop control,

All output ports are relay-out;

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

power outage; all the 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

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

or flexible sensor.

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

and users can define the sensor curves by themselves;

Flexible 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 (speed sensor, 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, anti-flaming ABS plastic enclosure, pluggable connection terminals

and embedded installation way; compact structure with easy mounting.

HGM400E Series Automatic Control Module

HGM400E Series Genset Controller ISSUE 2013-08-28 Version 1.1 Page 8 of 41

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 (effective value)

Speed Sensor Frequency 10,000 Hz (max)

Start Relay Output 5A DC28V power supply

Programmable Relay Output 1 5A DC28V power supply

Programmable Relay Output 2 5A DC28V power supply

Programmable Relay Output 3 5A DC28V power supply

Programmable Relay Output 4 5A AC250V voltage-free output

Programmable 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

ApplyAC2.2kV voltage between high voltage

terminal and low voltage terminal;

The leakage current is not more than 3mA within

1min.

Weight 0.26kg

HGM400E Series Automatic Control Module

HGM400E Series Genset Controller ISSUE 2013-08-28 Version 1.1 Page 9 of 41

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.

Automatic 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.

HGM400E Series Automatic Control Module

HGM400E Series Genset Controller ISSUE 2013-08-28 Version 1.1 Page 10 of 41

4.2 INDICATOR LIGHT

HGM410E Panel Indicators

HGM420E Panel Indicators

HGM400E Series Automatic Control Module

HGM400E Series Genset Controller ISSUE 2013-08-28 Version 1.1 Page 11 of 41

4.3 AUTOMATIC START/STOP OPERATION

Auto mode is selected by pressing the button; a LED besides the button will

illuminate to confirm the operation.

Auto Start Sequence,

1) HGM420E: when mains is abnormal (over/under voltage, loss of phase), enter into

“Mains Abnormal Delay” and LCD displays count down time.When the delay is over,

“Start Delay” timer is initiated.

2) HGM410E: 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 energizes (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. The engine is cranked fora pre-set time. If the engine fails to

fire during this cranking attempt then the fuel relay and start relay are disengaged for

the pre-set rest period; “crank rest time” begins and wait for the next crank attempt.

6) Should this start sequence continue beyond the set number of attempts, the start

sequence will be terminated, the first 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, allowing Low

Oil Pressure, High Temperature, Under speed, Charge Alternator Failure and Aux.

inputs (configured) to stabilise without triggering the fault. 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).

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) HGM420E: during normal running process, if mains normal, enters into “Mains

Normal Delay”. When mains indicator illuminates, “Stop Delay”begins.

2) HGM410E: When the “Remote Start” signal is removed, the Stop Delay is initiated.

This manual suits for next models

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