Smartgen HGM6000K Series User manual

HGM6000K Series

Automatic Generator Module

OPERATING MANUAL

Smartgen Electronic

HGM6000K Series Automatic Generator Module

HGM6000K Series Automatic Generator Module ISSUE 2011-06-20 Version 1.7 Page 3 of 34

CONTENT

1SUMMARY.....................................................................................4

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

3SPECIFICATION............................................................................6

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

4.1 KEY FUNCTION .....................................................................................6

4.2 DISPLAY DESCRIBE..............................................................................7

4.3 AUTOMATIC OPERATION......................................................................9

4.4 MANUAL OPERATION..........................................................................10

5PROTECTION..............................................................................11

5.1 WARN...................................................................................................11

5.2 SHUTDOWN ALARM............................................................................13

6CONNECTING TERMINAL .........................................................14

7PARAMETER RANGE AND DEFINE..........................................17

7.1 PARAMETERS TABLE (TABLE 1).........................................................17

7.2 OUTPUT 1-4 TABLE (TABLE 2)............................................................25

7.3 DIGIT INPUT 1-5 TABLE (TABLE 3)......................................................26

7.4 SENSOR (TABLE 4) .............................................................................26

7.5 CONDITION OF CRANK SUCCEED (TABLE 5)...................................27

8SETTING PARAMETER..............................................................28

9SENSOR SETTINGS...................................................................29

10 COMMISSIONING.......................................................................30

11 TYPICALWIRING DIAGRAM......................................................31

12 INSTALLATION............................................................................32

13 FAULT FINDING ..........................................................................33

HGM6000K Series Automatic Generator Module

HGM6000K Series Automatic Generator Module ISSUE 2011-06-20 Version 1.7 Page 4 of 34

1 SUMMARY

HGM6000K series Genset controller integrating digital, intelligent and network

techniques is used for automatic control system of diesel generator. It can carry

out functions including automatic start/stop, data measure and alarm protective.

The controller uses LCD display, with operation easy and reliable.

HGM6000K series Genset controller uses micro-processing technique which can

carry out precision measure, constant value adjustment, timing and threshold

setting and etc. functions. It can be widely used in all types of generator automatic

control system for compact structure, advanced circuits, simple connections and

high reliability, can be widely applied to various types of generating units

automation system.

2 PERFORMANCE AND CHARACTERISTICS

■HGM6000K controller has four types:

HGM6010K/6010KC: Automatic Start Module, it controls genset to start/stop by

remote start signal;

HGM6020K/6020KC: Based on HGM6010K/6010KC and add mains AC

monitoring, Mains/Genset automatic switching control functions (AMF), especially

suitable for the automation system composed by Mains and Genset.

Note1: HGM6010KC/6020KC with RS485 interface, HGM6010K/6020K without RS485 interface.

Note2: And then take HGM6010KC/6020KC with text as an example to describe.

■Using microprocessor as a core, graphics LCD with big screen and backlight,

display between character and icon display, key touch for operation;

■Have a RS485 port with Modus communication protocol;

■Adapt to 3phase-4wires, single phase-2wires or 2phase-3 wires (120/240V) ,

50/60Hz AC power system;

■Measure and display 3 phase voltage, 3 phase current, frequency, power etc.

parameter of Mains and Gens;

■Precision measure and display of

Mains Gens

Line voltage (Uab, Ubc, and Uca) Line voltage (Uab, Ubc, and Uca)

Phase voltage (Ua, Ub, and Uc) Phase voltage (Ua, Ub, and Uc)

Frequency HZ Frequency HZ

Load

Power Current IA, IB, IC

Active power KW

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Inactive power KVar

Apparent power KVA

Power factor Cos

Accumulate total gens power kWh

■Mains have over voltage, under voltage, loss phase function; Gens have over

voltage, under voltage, over frequency, under frequency, over current function;

■Precision measure and display parameters about Engine,

Temp. (WT), °C/ °F both are display

Oil pressure (OP), kPa/Psi/Bar all be display

Fuel oil level (FL), % (unit)

Speed (SPD), RPM (unit)

Voltage of Battery (VB) V (unit)

Voltage of Charger (VD) V (unit)

Hour count (HC) can accumulate Max. 999999 hours.

Starting up can accumulate Max.999999 times.

■Control protection: Automatic crank/stop of diesel engine, load transfer(ATS

control) and completely faults display protection;

■With ETS, idle control, pre-heat control, raises speed control functions, and all

types of them are belong to relay output;

■Parameters setting: Allow user to modify setting and store them by inside

internal FLASH memory, the parameters cannot be lost even with power off. All

of parameters can be set not only from the front panel, but by PC via SG72 (an

adaptor, USB-LINK-RS485) module; or, through RS485 port via PC;

■Most of temperature, pressure, oil level sensor can be directly used, and also

user can define sensor curve by themselves;

■Multiple crank disconnection conditions can be selected.(Speed sensor, oil

pressure, gens);

■Power supply range is wide(8~35)VDC, accommodating to different starting

battery voltage environments;

■All parameters use digital modulation, abandoning analog modulation using

conventional electronic potentiometer, more reliability and stability;

■Modular configuration design, Flame Retardant ABS plastic shell, inserted type

connection terminals, flush type installation, compact structure, easy

installation.

HGM6000K Series Automatic Generator Module

HGM6000K Series Automatic Generator Module ISSUE 2011-06-20 Version 1.7 Page 6 of 34

3 SPECIFICATION

Operating Voltage

DC8.0V to 35.0V, Continuous

Power Consumption

<3W(Standby mode: ≤2W)

Alternator Input Range

3-Phase 4 Wire

2-Phase 3 Wire

Single phase 2 Wire

15VAC - 360VAC (ph-N)

Frequency

50Hz - 60Hz

Magnetic AC voltage

1.0V to 24V (effective value)

Magnetic AC Frequency

10,000 Hz (max)

Start Relay Output

16 Amp DC28V at supply voltage.

Fuel Relay Output

16 Amp DC28V at supply voltage.

Auxiliary Relay Output (1-4)

(1) 7Amp DC28V at supply voltage,

(2)7Amp 250VAC free voltage contact,

(3, 4)16Amp 250VAC free voltage contact.

Overall Dimensions

209mm x 153mm x 55mm

Panel cutoff

186mm x 141mm

Operating Temp. Range

Temperature: (-25~+70)ºC Humidity: (20~90)%

Storage Condition

Temperature: (-30~80)ºC

Protective Level

IP55: when waterproof rubber ring added between

controller and its panel.

IP42: when waterproof rubber ring not have

between controller and its panel.

Insulation Intensity

Object: among in input/output/power

Quote standard: IEC688-1992

Test way: AC1.5 kV / 1min 3mA leakage current

C. T. Secondary

5A (rated )

Weight

0.69kg

4 OPERATION

4.1KEY FUNCTION

Stop/ Reset

Can stop genset under mode of Manual/Auto;

Can reset alarming under Stop;

To test panel indicators are OK or not, pressing this

HGM6000K Series Automatic Generator Module

HGM6000K Series Automatic Generator Module ISSUE 2011-06-20 Version 1.7 Page 7 of 34

key at least 3 seconds;

During stopping process, press this again can stop

genset immediately.

Start

To start genset under Manual or Auto mode.

Manual

Pressing this key will set the module into manual

mode.

Automatic

Pressing this key will set the module into automatic

mode.

Running with load

Pressing and controller is under manual testing

mode.

Under this mode, genset will run with load automatic

when gens are normal. (HGM6010KC without)

Set/ Confirm

Enters into Set menu after pressing this, and can shift

cursor to confirm.

Page up

/increase

Screen pages turning;

Shift cursor and increase its position no. in setting.

Page down

/decrease

Screen pages turning;

Shift cursor and decrease its position no. in setting.

4.2DISPLAY DESCRIBE

Mains: line voltage Uab, Ubc, Uca Mains: phase voltage Ua, Ub, Uc

Mains: frequency (Hz) F1 Genset: line voltage Uab, Ubc, Uca

Genset: phase voltage Ua, Ub, Uc Genset: speed, frequency (Hz) F2

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Load: current IA, IB, IC Load: active power (kW), inactive

power (kVar), apparent power (kVA)

Accumulate total gens power kWh Battery voltage BAT, Charger

Power factor voltage CHARG, Liquid level**%

Water temperature Gens oil pressure

Gens hours count Gens starts count

Gens status, Gens status delay countdown display

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HGM6000K Series Automatic Generator Module ISSUE 2011-06-20 Version 1.7 Page 9 of 34

4.3AUTOMATIC OPERATION

This mode is activated by pressing the . LED indicator is illuminating beside the

button confirms this action.

Sequence of Auto Start,

1. HGM6020KC, When Mains is abnormal (over and under voltage, or miss

phase), enters into mains “abnormal delay”and LCD display count down time.

When mains abnormal delay is over, enter into “start delay”.

2. HGM6010KC, entries into “start delay”as soon as “Remote Start”is input valid.

3. “Count down”of start delay is displayed in LCD.

4. When start delay is over, preheat relay is outputting (if be equipped), “preheat

start delay XX s”is displayed in LCD.

5. When preheat relay is over, oil relay is outputting 1s and then start relay-output;

if genset fails in starting during “cranking time”, the oil and start relays stop

outputting and enters into “crank rest time”and wait for next attempt.

6. If genset fails in starting within setting attempt times, LCD start-up failure

alarming icon flash.

7. Whatever times to start genset successfully, it will enter into “safety on time”.

During this period, alarms of low oil pressure, hi-temperature, under speed,

charge fail and Aux. input (been configured) are inactive. As soon as this delay

is over, genset will enter into “start idle delay”(if this be configured).

8. During “start idle delay”, alarms of under speed, under frequency, under voltage

are inactive. As soon as this delay is over, genset will enter into “warming up

time delay”(if this be configured).

9. When “warming up time delay”is over, gens status indicator is light if gens

normal. If alternator‟s voltage, frequency meets to requirement of load, gens will

close and relay is outputting, then genset will enter into normal running with load

and gens indicator is light; if genset voltage and frequency is abnormal,

controller will alarm and stop engine (gens alarming is displayed LCD).

Sequence of Auto Stop,

1. HGM6020KC, when Mains recovery during genset running, enters into mains

voltage “normal delay”and its indicator light after Mains normal be confirmed.

“Start delay”is beginning.

2. HGM6010KC, genset enters into “stop delay”as soon as “Remote Start” putting

is inactive.

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3. As soon as “stop delay”is over, genset enters into “High Speed cooling delay”.

Mains are close and breaker is disconnected. After switch “rest time delay”,

mains are close and relay is output as well as with loading. Gens‟indicator is

dark while mains‟light.

4. Idle relay has power and outputs as soon as entering “stop idle relay” (If this

been configured).

5. When enters “ETS relay”, ETS relay has power and outputs. Oil relay‟s output is

disconnected.

6. When genset enters “stop time”, automatic to decide whether genset is stopped

or not.

7. When genset will enter into “over stop time”as soon as genset is stopped. If

genset failed to stop and controller will alarm (“stop failed” will be displayed in

LCD).

Note: this page is nonce genset status, genset status delay countdown display,

for example:

At the first line, NO 4 is the Start interval state; 3s is the countdown to remain time

intervals of Start interval.

Gens Status List:

0: Genset Waiting 1: Start preheat 2: Fuel output 3: Start 4: Start Interval

5: Safety run 6: Start Idling 7: Start warm-up 8: Wait for the Load 9: Normal

Run 10: Stop for cooling 11: Stop idling 12: ETS stop 13: Wait for stop

steady 14: Shutdown failures

4.4MANUAL OPERATION

1. HGM6020KC, Auto starts mode is active when press and its indicator is

illuminating. Press , then controller under “Manual Test Mode”and its

indicator is illuminating. Under the both modes, press to start genset, and it

can automatic detect start successfully and accelerate to Hi-speed running. If

there is Hi-temperature, low oil level and voltage abnormal during diesel genset

HGM6000K Series Automatic Generator Module

HGM6000K Series Automatic Generator Module ISSUE 2011-06-20 Version 1.7 Page 11 of 34

running, controller can protect genset to stop quickly (detail procedures please

refer to No.4~9 of Auto start operation). Under “Manual Test Mode ”, genset

with load is decided by Mains is normal or not. If mains are normal, loading

switch is never transferred; while mains are abnormal, loading switch is

transferred into gens side. Under “Manual Test Mode ”, after genset runs well

in high speed, no matter mains is normal or not, loading switch must be

transferred into gens side.

2. HGM6010KC, Auto starts mode is active when press , and its indicator is

illuminating. Then press to start genset, it can automatic detect start

successfully and genset automatic accelerates to Hi-speed running. If there is

Hi-temperature, low oil level and voltage abnormal during diesel genset 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, controller

will send signal of gens close.

3. Manual stop, press can shutdown the running genset (detail procedures

please refer to No.3~7 of Auto stop operation).

5 PROTECTION

5.1WARN

Warns are non-critical alarm conditions and do not affect the operation of the

genset system; they serve to draw the operators attention to an undesirable

condition.

In the event of a warning, the module will display at the last screen of LCD.

Warn is shown as the below:

HIGH ENGINE TEMPERATURE WARN, if the module detects that the engine

coolant temperature has exceeded the high engine temperature setting level after

the Safety On timer has expired and the input of Inhibit WTH stop is activated, a

warn will occur. At the same time LCD screen icon lighten.

LOW OIL PRESSURE WARN, if the module detects that the engine oil pressure

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