Smartgen HGM501 User manual

HGM501 Gen-set Controller

USER MANUAL

Smartgen Technology

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

+86-371-67981888

+86-371-67991553

+86-371-67992951

+86-371-67981000(overseas)

Fax: 0086-371-67992952

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

http://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.

Smartgen Technology reserves the right to change the contents of this document without prior

notice.

Version History

Date

Version

Details

2012-07-10

V1.0

Original release

This manual is suitable for HGM501 series controllers only.

Clarification of signs used within this manual.

Sign

Explanation

Note

Concerns an operating procedure that needs highlighting.

Caution!

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

result in damage of the equipment.

Warning!

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

result in personal death, serious injury or significant property damage.

HGM501Genset Controller

HGM501 Genset Controller Version V1.0 2012-07-10 Page 3 of 15

Contents

1. OVERVIEW........................................................................................................4

2. PERFORMANCE AND CHARACTERISTICS....................................................4

3. TECHNICAL DATA.............................................................................................5

4. OPERATION......................................................................................................6

4.1. BUTTON DESCRIPTION ...........................................................................................6

4.2. START/STOP OPERATION........................................................................................7

4.2.1 STARTING PROCEDURE............................................................................7

4.2.2 STOPPING PROCEDURE...........................................................................7

5. AUTO PROTECTION.........................................................................................8

6. TERMINAL.........................................................................................................9

7. CONFIGURABLE PARAMETERS ...................................................................10

7.1. CONFIGURABLE PARAMETERS TABLE ...............................................................10

7.2. PARAMETER CONFIGURATION ............................................................................11

8. COMMISSIONING...........................................................................................13

9. TYPICAL WIRING DIAGRAM ..........................................................................14

10.INSTALLATION................................................................................................14

11.TROUBLESHOOTING.....................................................................................15

HGM501Genset Controller

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1. OVERVIEW

HGM501 gen-set controller is smart digital controller for control and protection

of single-engine gen-sets. It can carry out start/stop, data measurement, alarm

indication, shutdown protection and other functions. The controller is fitted with

LED indicators; it is reliable and easy to use.

HGM501 gen-set controller contains the microprocessor allows precise

measurement of multiple parameters, which can be configured using controller

front panel. With simple wiring, compact structure and high reliability, HGM501 can

be widely used for data display and fault protection of a large number of diesel and

petrol generator sets.

2. PERFORMANCE AND CHARACTERISTICS

1. Two specialized LED displays: single phase voltage display and total active

power voltage display (calculated using single phase power, taking load as

balanced);

2. Multifunction LED display that can be switched between single phase

frequency, single phase current, battery voltage, total running time (max 999

hours), engine and generator temperature;

3. Under voltage, over voltage, under frequency, over frequency, over load, over

temperature protection, starting with flashing lights alarm and followed by

shutdown protection after alarm delay;

4. Low oil pressure digital input that immediately shuts down the generator in

case of low oil pressure;

5. Displayed parameters can be selected using touch-buttons;

6. Wide selection of temperature sensor types in settings;

7. All the parameters can be set via front panel for easy and convenient

operation;

8. Modular design, anti-flaming ABS plastic enclosure, compact structure,

convenient embedded installation.

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3. TECHNICAL DATA

Parameter

Details

Operating voltage

DC9.0V to 18V uninterrupted power supply - DC12V

system used

Overall consumption

<2W (Standby mode ≤1W)

Alternator voltage inputs:

Single phase 2-wire (L

and N only)

2-phase 3-wire (L and N

only)

3-phase 4-wire (L and N

only)

AC 30V - 360V (ph-N)

Alternator frequency

50/60Hz

Start relay output

7A DC12V power supply output

Fuel relay output

7A DC12V power supply output

Case dimensions

118 mm x 128 mm x 36 mm

C. T. Secondary current

Rated 5mA

Operating conditions

Temperature: (-25~+70)°C Humidity:

(20~90)%

Storage conditions

Temperature: (-30~+80)°C

Protection level

IP42

Insulation strength

Object: input/output/power supply

Quoted standard: IEC688-1992

Test method: AC1.5kV/1min Leakage current 3mA

Weight

0.216kg

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4. OPERATION

4.1. BUTTON DESCRIPTION

FUNCTION

1. In configuration menu, pressing this button

enters setting or confirms;

2. During normal operation, press this button to

switch to frequency display;

3. In case of alarm shutdown, pressing and holding

the button for 1 second will reset the alarm.

UP/SCROLL

1. During parameter configuration, pressing this

button increases the set value;

2. During normal operation press this button to

switch to the upper LED.

DOWN/SCROLL

1. During parameter configuration pressing the

button decreases the set value;

2. During normal operation the button switches to

the lower LED.

LEFT

1. During parameter configuration pressing this

button will return to the previous menu;

2. During normal operation press this button to

switch to the next (upper) LED.

RIGHT

1. During parameter configuration press this button

to enter the next menu.

HGM501Genset Controller

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2. During normal operation the button switches to

the lower LED.

4.2. START/STOP OPERATION

4.2.1 STARTING PROCEDURE

In stop mode turn the starter key from OFF to ON position to power on the

controller, then change the starter key position to START to begin cranking; after

the engine fires, release the starter key, and voltage, power and frequency

windows will show the real measured values. Press or button to

switchover between indicators 1#-6# and multifunctional window will show

corresponding settings. Press button to return to the frequency window.

LED indicators state:

1# Frequency (Hz)

2# Current (A)

3# Battery voltage (V)

4# Run time (H)

5# Engine temp.(℃)

6# Generator temp.(℃)

7# Auto protection If on, auto protection is enabled; if not, it is

disabled.

8# Run on indicator Fuel relay output indicator

9# Crank indicator Start output indicator

10# Engine oil warning Low oil pressure indicator

NOTE: Before starting the engine please make sure that all the parameter

settings are correct.

NOTE“Engine oil warning”indicator operates according to the oil pressure

switch. Before the start of the gen-set, the light must be on; if it is not, it means that

oil pressure switch or its return circuit is faulty; in this case please do not proceed

before clearing up the problem.

4.2.2 STOPPING PROCEDURE

1 Auto stop

If auto protection condition occurs, the system will be stopped

automatically;

During normal running of the gen-set, if low oil pressure signal is detected,

the set will be stopped.

2 Manual stop

Under any circumstances, if starter key is turned from ON to OFF position,

it will lead to shutdown.

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5. AUTO PROTECTION

In auto protection mode, except for low oil pressure protection, all the other

protections (voltage, frequency, overload, temperature) are active.

1 Voltage protection

When the limits of rated voltage are exceeded by ±10%, Voltage LED starts

flashing; after 7 seconds delay in case of under voltage or 3 seconds delay in

case of over voltage, alarm shutdown is initiated. After that voltage LED

continues to flash and shows pre-alarm value.

2 Frequency protection

50Hz：(45~55)Hz

60Hz：(55~65)Hz

When the set value is exceeded, frequency LED starts flashing; after 7

seconds delay in case of under frequency and 3 seconds delay in case of over

frequency, alarm shutdown is initiated. After that frequency LED continues to

flash and shows pre-alarm value.

3 Overload protection

If the set value is exceeded by 5% or less, alarm will not be initiated;

If the set value is exceeded by more than 5%, power LED will start flashing;

If the set value is exceeded by 5-7.5% and continuous for more than 3 hours,

then alarm shutdown will be initiated;

If the set value is exceeded by 7.5-10% and continues for more than 1 hours,

alarm shutdown will be initiated;

If the set value is exceeded by more than 10%, the gen-set will be shut down

immediately (approximately 2 seconds);

After alarm shutdown is initiated power LED continues to flash and shows

pre-alarm value.

4 Low oil pressure protection

Irrespective of whether auto protection mode is enabled or not, low oil

pressure will lead to automatic disconnection of oil circuit;

5 High engine temperature protection

If engine temperature exceeds 108℃, LED window starts flashing; after 7

second delay, protection begins; LED window continues to flash and shows

pre-protection value (for air-cooled engine);

6 High generator temperature protection

When generator temperature exceeds 95℃, LED window starts flashing; after

7 second delay, protection begins; LED window continues to flash and shows

pre-protection value;

7 Battery voltage protection

Battery voltage protection is enabled irrespective of whether auto protection

mode is enabled or not and whether gen-set is running. If battery voltage value is

HGM501Genset Controller

HGM501 Genset Controller Version V1.0 2012-07-10 Page 9 of 15

lower than 8V or higher than 16.5V, LED display or indicator starts flashing, but

shutdown protection is not initiated.

NOTE: During Safety On delay, protection is disabled; after Safety On Delay,

when voltage, frequency, overload, high temperature protection is initiated, fuel

output deactivates.

6. TERMINAL

HGM501 controller back panel is shown below:

Terminal connections description

Terminal

Function

Wire size

Remarks

Generator voltage L

1.0mm2

Generator voltage N

1.0mm2

Load C. T. Secondary I

(out)

1.0mm2

C.T. Secondary max

current 5mA

Load C. T. Secondary I*

(in)

1.0mm2

Genset temperature

sensor input

Engine temperature

HGM501Genset Controller

HGM501 Genset Controller Version V1.0 2012-07-10 Page 10 of 15

sensor input

Low oil pressure input

Low oil pressure digital

or sensor signal input

port; must be

connected to B-

Battery negative input B-

1.5mm2

Controller power supply

input B-

Electric lock ON signal

input B+

1.5mm2

Controller power supply

input B+ and fuel relay

output (activates when

Electric key is turned to

ON position)

Electric lock START input

1.5mm2

Hand-turn start, start

relay output (Output

activates when electric

lock key is turned to

START position)

Start relay output

1.5mm2

Rated current 7A;

power supplied by

terminal 13

Fuel relay output

1.5mm2

Rated current 7A;

power supplied by

terminal 13

Fuel/start relay common

port

2.5mm2

Fused and connected

to start battery positive

7. CONFIGURABLE PARAMETERS

7.1. CONFIGURABLE PARAMETERS TABLE

Parameter

Range

Default

factory

value

Description

AC system

1P：1P2W

2P：2P3W

3P：3P4W

Rated

voltage

110 V

115 V

120 V

130 V

220 V

230 V

240V

220

Generator rated voltage

value selection

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