Smartgen HGM6100K Series User manual

HGM6100K Series

Automatic Generator Module

OPERATING MANUAL

Smartgen Electronics

Smartgen Electronic Equipment Co., Ltd

No.28 Jinsuo Road

Zhengzhou

Henan Province

P. R. China

Tel: 0086-371-67988888/67981888

0086-371-67991553/67992951/67992952

0086-371-67981000(overseas)

Fax: (0086)-371-67992952/67981000

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

http://www.smartgen.cn

Email: sales@smartgen.com.cn

form (including 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 Electronics at the address

above.

Any reference to trademarked product names used within this publication is owned

by their respective companies.

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

without prior notice.

Software Version

Version

Date

Note

1.0

2009-10-10

Original release.

1.1

2010-04-07

Add a typical wiring diagram and an AUX.INPUT4 (38 Pin) and

an AUX.INPUT5 (39 Pin) and an Earth wire (40 Pin).

1.2

2010-04-20

Add a language of Spanish. Modify the panel cutout size, and

the operation temperature range.

1.4

2010-08-17

Add a configurable output item of fuel pump control and a

configurable input item of automatic inhibit start and an option

(active connecting with B+ or B-) for all input port.

1.5

2010-12-09

Add High speed control option in output ports; Add prohibit stop

when High temperature, low oil pressure in programmable

parameters; Revise range of sensor curve input.

1.6

2011-04-12

Add Russian and five programmable output port options.

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HGM6100K Series Automatic Generator Module ISSUE 2011-04-12 Version 1.6 Page 3 of 31

CONTENT

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

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

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

4OPERATION ..................................................................................7

4.1 KEY FUNCTION......................................................................................7

4.2 AUTOMATIC OPERATION......................................................................7

4.3 MANUAL OPERATION............................................................................9

5PROTECTION................................................................................9

5.1 WARNING...............................................................................................9

5.2 SHUTDOWN ALARM ............................................................................10

6CONNECTING TERMINAL..........................................................11

7PARAMETER RANGE AND DEFINE..........................................14

7.1 PARAMETERS TABLE (TABLE 1).........................................................14

7.2 PROGRAMMABLE OUTPUT 1-4 TABLE (TABLE 2).............................19

7.3 PROGRAMMABLE DIGIT INPUT 1-5 TABLE (ALL IS VALID WHEN

CONNECT GRAND (B-) (TABLE 3)..............................................................21

7.4 SENSOR SELECTION (TABLE 4).........................................................22

7.5 CONDITIONS OF CRANK SUCCEED (TABLE 5).................................23

8PARAMETER SETTING..............................................................24

9SENSOR SELECTION ................................................................25

10 COMMISSIONING.......................................................................26

11 TYPICALAPPLICATION..............................................................27

12 INSTALLATION............................................................................29

13 FAULT FINDING...........................................................................30

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1 SUMMARY

HGM6100K 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, optional Chinese, English, Spanish and Russian

display interface with operation easy and reliable.

HGM6100K 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

■HGM6100K controller has four types:

HGM6110K/6110KC: Automatic Start Module, it controls generator to start/stop

by remote start signal;

HGM6120K/6120KC: Based on HGM6110K/6110KC and add mains AC

monitoring, Mains/Generator automatic switching control functions (AMF),

especially suitable for the automation system composed by Mains and Generator.

Note1: HGM6110KC/6120KC with RS485 interface, HGM6110K/6120K without RS485 interface.

Note2: And then take HGM6110KC/6120KC with text as an example to describe.

■Using microprocessor as a core, symbol LCD with backlight display, the three

languages display Chinese, English and Spanish, key touch 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;

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

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Load

Power Current IA, IB, IC

Active power KW

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 can not 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

HGM6100K Series Automatic Generator Module

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connection terminals, flush type installation, compact structure, easy

installation.

3 SPECIFICATION

Operating Voltage

DC8.0V to 35.0V, Continuous

Power Consumption

<3W(Standby mode: ≤2W)

AC voltage Input Range

3-Phase 4 Wire

2-Phase 3 Wire

Single phase 2 Wire

15V AC - 360 V AC (ph-N)

Frequency

50Hz - 60 Hz

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

7 Amp DC28V

Auxiliary Relay Output 2

7A 250VAC passive

Auxiliary Relay Output 3

16A 250VAC passive

Auxiliary Relay Output 4

16A 250VAC passive

Overall Dimensions

209mm x 153mm x 55mm

Panel cutoff

186mm x 141mm

C.T. Secondary

5A (rated )

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

Weight

0.71kg

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4 OPERATION

4.1 KEY FUNCTION

Stop/ Reset

Can stop generator under mode of Manual/Auto;

Can reset alarming under Stop;

To test panel indicators are OK or not, pressing this

key at least 3 seconds;

During stopping process, press this again can stop

generator 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. (HGM6110KC 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.

4.2 AUTOMATIC OPERATION

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

button confirms this action.

Sequence of Auto Start,

a) HGM6120KC, 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”.

b) HGM6110KC, entries into “start delay”as soon as “Remote Start”is input valid.

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

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

start delay XX s”is displayed in LCD.

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e) 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.

f) If genset fails in starting within setting attempt times, thefourth line of LED willin

black and start failed alarm will be displayed on it.

g) 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).

h) 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).

i) 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,

a) HGM6120KC, 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.

b) HGM6110KC, genset enters into “stop delay”as soon as “Remote Start”putting

is inactive.

c) 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.

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

been configured).

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

disconnected.

f) When genset enters “stop time”, automatic to decide whether generator is

stopped or not.

g) 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).

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4.3 MANUAL OPERATION

1) HGM6120KC, 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

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) HGM6110KC, Auto starts mode is active when press , and its indicator is

illuminating. Then press to start generator, 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 shut down the running genset (detail procedures

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

5 PROTECTION

5.1 WARNING

When controller detects the warning signal, only alarm and not stop genset. The

alarms are displayed in LCD.

Warnings as following,

No.

Type

Description

Lost of speed

When controller detected the speed of genset is 0 and

speed lost delay set as 0, controller will send warning

alarm signal and it will be displayed in LCD

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HGM6100K Series Automatic Generator Module ISSUE 2011-04-12 Version 1.6 Page 10 of 31

No.

Type

Description

Gens Over

Current

When controller detected the current of genset is over

than threshold and over current delay set as 0,

controller will send warning alarm signal and it will be

displayed in LCD

Failed To Stop

When generator not stops after the “stop relay”is over,

controller will send warning alarm signal and it will be

displayed in LCD

Low oil level

When controller detected the oil level of genset is lower

than threshold or low oil level warn input is active,

controller will send warning alarm signal and it will be

displayed in LCD

Charge Alt Fail

When controller detected the voltage of genset charger

is lower than threshold, controller will send warning

alarm signal and it will be displayed in LCD

Battery Low

Voltage

When controller detected the voltage of genset battery

is lower than threshold, controller will send warning

alarm signal and it will be displayed in LCD

Battery High

Voltage

When controller detected the voltage of genset battery

is higher than threshold, controller will send warning

alarm signal and it will be displayed in LCD

Low water level

When controller detected the warning of low water level

input is active, controller will send warning alarm signal

and it will be displayed in LCD

5.2 SHUTDOWN ALARM

When controller detected shutdown alarm, it will send signal to break off and to stop.

The alarms are displayed in LCD.

Stop alarms as following,

No.

Type

Description

Emergency Stop

When controller detected emergency stop signal, it will

send a stop alarm signal and it will be displayed in LCD

High Temp

alarm

When controller detected the temperature of

water/cylinder is higher than set, it will send a stop

alarm signal and it will be displayed in LCD

Lower OP

alarm

When controller detected oil pressure is lower than set

for alarming, it will send a stop alarm signal and it will

be displayed in LCD

Over speed

alarm

When controller detected genset speed is over than set

for alarming, it will send a stop alarm signal and it will

be displayed in LCD

Under speed

When controller detected genset speed is under than

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