Smartgen HGM400 Series User manual

HGM400 Series Genset Controller
(HGM410/HGM420)
USER MANUAL
ZHENGZHOU SMARTGEN TECHNOLOGY CO.,LTD

Chinese trademark
English trademark
SmartGen —make your generator smart
Smartgen Technology Co., Ltd.
No. 28 Jinsuo Road
Zhengzhou
Henan Province
P. R. China
Tel: [phone]
[phone]/67992951
[phone](overseas)
Fax: [phone]
Web: http://www.smartgen.com.cn
http://www.smartgen.cn
Email: [email protected]
All rights reserved. No part of this publication may be reproduced in any material form
(including 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
Date
Version
Note
2011-07-06
1.0
Original release.
2012-03-15
1.1
Modify typical application.
2012-10-30
1.2
Modify some details.
2013-08-08
1.3
Change input port 3 and 4 to multiplex input port, that is
to say, the input port 3 and input port 4 can be used as
auxiliary input port or analog input port.
2013-08-28
1.4
Change “External Shutdown”input to “Emergency
Shutdown”input.
2014-08-28
1.5
Some functions are added.
2015-05-27
1.6
Modify the description of output raise/drop speed.
This manual is suitable for HGM400 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.

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 .....................................................................................16
6CONNECTIONS ..............................................................................19
7DEFINITION AND RANGE OF PARAMETERS................................22
7.1 PARAMETER CONTENTS AND RANGE (TABLE 1)......................................23
7.2 PROGRAMMABLE OUTPUT 1-5 (TABLE 2)..................................................31
7.3 PROGRAMMABLE INPUT 1-4 TABLE (ACTIVE WHEN CONNECT GND (B-)
(TABLE 3)...............................................................................................................32
7.4 SENSOR SELECT (TABLE 4)........................................................................34
7.5 CONDITIONS OF CRANK DISCONNECT (TABLE 5)....................................35
8PARAMETERS SETTING................................................................36
9SENSOR SETTING .........................................................................37
10 COMMISSIONING...........................................................................38
11 TYPICALAPPLICATION..................................................................39
12 INSTALLATION................................................................................41
12.1FIXING CLIPS ................................................................................................41
12.2OVERALL DIMENSION AND PANEL CUTOUT..............................................42
13 FAULT FINDING ..............................................................................44

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1 OVERVIEW
HGM400 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 measurement, 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, Turkish and Russian), and it is reliable and easy to use.
HGM400 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, SG72 adaptor produced by Smartgen is recommended) 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.

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2 PERFORMANCE AND CHARACTERISTICS
HGM400 series controller has two types:
HGM410: ASM (Automatic Start Module)，it controls generator to start/stop by
remote signal;
HGM420: AMF (Auto Mains Failure), updates based on HGM410, 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, Turkish 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 collect and display parameters about Engine,
Temp. (WT) °C/°F both be displayed
Oil pressure (OP) kPa/Psi/Bar all be displayed

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Fuel Level (FL) % (Unit)
Engine Speed (RP) RPM (Unit)
Battery Voltage (VB) V (unit)
Charger Voltage (VD) V (unit)
Hours Counter (HC): Max. 999999 hours
Start times: Max.999999 times
Control & Protection: automatic start/stop of the genset, ATS(Auto Transfer Switch)
control with perfect fault indication and protection function;
With ETS(Energize To Stop), idle control, pre-heat control, speed raise control and
speed drop control function, All output ports are relay-out;
Parameter setting: parameters can be modified and cannot be lost even in case of
power outage; all the controller 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
auxiliary input port or fuel level sensor while input 4 can be used as auxiliary input
port or configurable sensor.
More kinds of curves of temperature, oil pressure, fuel level can be used directly
and users can define the sensor curves by themselves;
Configurable 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 (magnetic pickup, 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, self-extinguished ABS plastic enclosure, pluggable connection
terminals and embedded installation way; compact structure with easy mounting.

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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)
AC15V - AC360V (ph-N)
AC15V - AC360V (ph-N)
AC30V - AC620V (ph-ph)
Alternator Frequency
50Hz/60 Hz
Speed Sensor Voltage
1.0V to 24V (RMS)
Speed Sensor Frequency
10,000 Hz (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 AC250V voltage-free output
Auxiliary 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
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

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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.
Auto
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.

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4.2 INDICATOR LIGHT
HGM410 Panel Indicators
HGM420 Panel Indicators

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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) HGM420: when mains is abnormal (over/under voltage, loss of phase), enter into
“Mains Abnormal Delay” and LCD displays count down time. “Start Delay” timer is
initiated after the delay has expired.
2) HGM410: 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 for a 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 fourth line of LCD display will be highlighted with

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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
Auxiliary 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) HGM420: During normal running process, if mains normal, enters into “Mains
Normal Delay”. When mains indicator illuminates, “Stop Delay”is initiated.
2) HGM410: When the “Remote Start” signal is removed, 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) HGM420: Manual mode is selected by pressing the button; a LED besides the
button will illuminate to confirm the operation; Press key, select “Mode Select”,
then choose “Test Mode”. Under the two modes, 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

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running, controller can effectively protect genset to stop (detail procedures please
refer to No.4~9 of Auto start sequence). Under Manual Mode , if mains normal,
load breaker won’t transfer; if mains abnormal, load breaker will transfer to generator.
Under Test Mode, after genset high speed normal running, no matter mains normal
or not, load will be transferred to generator.
2) HGM410: Manual mode is selected by pressing the button; a LED besides the
button will illuminate to confirm the operation; Then press button to start the
generator, 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 (detail
procedures please refer to No.4~9 of Auto start sequence). After genset high speed
normal running, controller will send Gen Closed signal.
3) Manual stop: pressing key can stop the running genset. (detail procedures please
refer to No.3~7 of Auto stop sequence)
5 PROTECTION
5.1 WARNINGS
Warnings are not shutdown alarms and do not affect the operation of the gen-set.
Warning alarms does not lead to shutdown. The alarm information will be displayed on
LCD.
Warning alarms types are as follows:
No.
Items
Description
1
High
Temperature
When the controller detects that engine temperature has
exceeded the pre-set value while shutdown is prohibited, or
detects that the Aux. input high temperature while shutdown
is prohibited, it will initiate a warning alarm and the
corresponding alarm information will be displayed on LCD.
2
Low Oil
Pressure
When the controller detects that the oil pressure has fallen
below the pre-set value while shutdown is prohibited, or
detects that the Aux. input low oil pressure while shutdown is
prohibited, it will initiate a warning alarm and the
corresponding alarm information will be displayed on LCD.

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3
Gen Over
Current
When the controller detects that the genset current has
exceeded the pre-set value and the over current delay has
expired, it will initiate a warning alarm and the corresponding
alarm information will be displayed on LCD.
4
Fail To Stop
After “fail to stop” delay/ ETS delay has expired, if gen-set
does not stop completely, it will initiate a warning alarm and
the corresponding alarm information will be displayed on
LCD.
5
Low Fuel Level
When the controller detects that the fuel level has fallen
below the pre-set value while shutdown is prohibited, or
detects that the Aux. input low fuel level while shutdown is
prohibited, it will initiate a warning alarm and the
corresponding alarm information will be displayed on LCD.
6
Charge Alt
Failure
When the controller detects that charger voltage has fallen
below the pre-set value, it will initiate a warning alarm and
the corresponding alarm information will be displayed on
LCD.
7
Battery Under
Volt
When the controller detects that battery voltage has fallen
below the pre-set value, it will initiate a warning alarm and
the corresponding alarm information will be displayed on
LCD.
8
Battery Over
Volt
When the controller detects that battery voltage has
exceeded the pre-set value, it will initiate a warning alarm
and the corresponding alarm information will be displayed on
LCD.
9
Auxiliary Input
When the controller detects that the auxiliary input warning
signals, it will initiate a warning alarm and the corresponding
alarm information will be displayed on LCD.
10
Loss Of Speed
Signal
When the controller detects that the engine speed is 0 and
the delay is 0, it will initiate a warning alarm and the
corresponding alarm information will be displayed on LCD.
11
Low Coolant
Level
When the controller detects the low coolant level input is
active, it will initiate a warning alarm and the corresponding
alarm information will be displayed on LCD.
12
Temp. Sensor
Open
When the controller detects that the temperature sensor is
open circuit and the action select “Warn”, it will initiate a
warning alarm and the corresponding alarm information will
be displayed on LCD.
13
Oil Pressure
Sensor Open
When the controller detects that the oil pressure sensor is
open circuit and the action select “Warn”, it will initiate a
warning alarm and the corresponding alarm information will
be displayed on LCD.

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14
Level Sensor
Open
When the controller detects that the level sensor is open
circuit and the action select “Warn”, it will initiate a warning
alarm and the corresponding alarm information will be
displayed on LCD.
15
Temp. Sensor
2 Open
If the config. sensor set as temperature sensor, When the
controller detects that the temperature sensor is open circuit
and the action select “Warn”, it will initiate a warning alarm
and the corresponding alarm information will be displayed on
LCD.
16
Oil Pressure
Sensor 2
Open
If the config. sensor set as oil pressure sensor, When the
controller detects that the oil pressure sensor is open circuit
and the action select “Warn”, it will initiate a warning alarm
and the corresponding alarm information will be displayed on
LCD.
17
Level Sensor 2
Open
If the config. sensor set as level sensor, When the controller
detects that the level sensor is open circuit and the action
select “Warn”, it will initiate a warning alarm and the
corresponding alarm information will be displayed on LCD.
18
High
Temperature 2
When the controller detects that config. sensor temperature
(sensor type: temperature sensor) has exceeded the pre-set
value while shutdown is prohibited, it will initiate a warning
alarm and the corresponding alarm information will be
displayed on LCD.
19
Low Oil
Pressure 2
When the controller detects that config. sensor oil pressure
(sensor type: oil pressure sensor) has fallen below the
pre-set value while shutdown is prohibited, it will initiate a
warning alarm and the corresponding alarm information will
be displayed on LCD.
20
Low Fuel Level
2
When the controller detects that config. sensor fuel level
(sensor type: level sensor) has fallen below the pre-set value
while shutdown is prohibited, it will initiate a warning alarm
and the corresponding alarm information will be displayed on
LCD.
21
Maintenance
Due
When genset running time has exceeded the user setting
maintenance time and the action select “Warn”, it will initiate
a warning alarm and the corresponding alarm information will
be displayed on LCD. The maintenance alarm will reset if the
action select “Inactive”.

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5.2 SHUTDOWN ALARM
When controller detects shutdown alarm, it will send signal to open breaker and shuts
down generator. The alarm information will be displayed on LCD.
Shutdown alarms as following:
No
Items
Description
1
Emergency
Shutdown
When the controller detects that the emergency shutdown
signal, it will initiate a shutdown alarm and the corresponding
alarm information will be displayed on LCD.
2
High
Temperature
When controller detects that the water/cylinder temperature
has exceeded the pre-set value, it will initiate a shutdown
alarm and the corresponding alarm information will be
displayed on LCD.
3
Low Oil
Pressure
When the controller detects that the oil pressure has fallen
below the pre-set value, it will initiate a shutdown alarm and
the corresponding alarm information will be displayed on
LCD.
4
Over Speed
When the controller detects that the generator speed has
exceeded the pre-set value, it will initiate a shutdown alarm
and the corresponding alarm information will be displayed on

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No
Items
Description
LCD.
5
Under Speed
When the controller detects that the generator speed has
fallen below the pre-set value, it will initiate a shutdown alarm
and the corresponding alarm information will be displayed on
LCD.
6
Loss Of Speed
Signal
When the controller detects that the engine speed is 0 and
the delay is NOT 0, it will initiate a shutdown alarm and the
corresponding alarm information will be displayed on LCD.
7
Gen Over
Voltage
When the controller detects that the genset voltage has
exceeded the pre-set value, it will initiate a shutdown alarm
and the corresponding alarm information will be displayed on
LCD.
8
Gen Under
Voltage
When the controller detects that the genset voltage has
fallen below the pre-set value, it will initiate a shutdown alarm
and the corresponding alarm information will be displayed on
LCD.
9
Gen Over
Current
When the controller detects that the genset current has
exceeded the pre-set value and delay is not 0, it will initiate a
shutdown alarm and the corresponding alarm information will
be displayed on LCD.
10
Fail To Start
If the engine does not fire after the pre-set number of
attempts, it will initiate a shutdown alarm and the
corresponding alarm information will be displayed on LCD.
11
Gen Over
Frequency
When the controller detects that the genset frequency has
exceeded the pre-set value, it will initiate a shutdown alarm
and the corresponding alarm information will be displayed on
LCD.
12
Gen Under
Frequency
When the controller detects that the genset frequency has
fallen below the pre-set value, it will initiate a shutdown alarm
and the corresponding alarm information will be displayed on
LCD.
13
No Gens
Frequency
When the controller detects that the genset frequency is 0, it
will initiate a shutdown alarm and the corresponding alarm
information will be displayed on LCD.
14
Low Fuel Level
When the controller detects that the fuel level has fallen
below the pre-set value or detects that the low fuel level input
is active, it will initiate a shutdown alarm and the
corresponding alarm information will be displayed on LCD.
15
Low Coolant
Level
When the controller detects the low coolant level input is
active, it will initiate a shutdown alarm and the corresponding
alarm information will be displayed on LCD.
16
Temp. Sensor
When the controller detects that the temperature sensor is

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No
Items
Description
Open
open circuit and the action select “Shutdown”, it will initiate a
shutdown alarm and the corresponding alarm information will
be displayed on LCD.
17
Oil Pressure
Sensor Open
When the controller detects that the oil pressure sensor is
open circuit and the action select “Shutdown”, it will initiate a
shutdown alarm and the corresponding alarm information will
be displayed on LCD.
18
Level Sensor
Open
When the controller detects that the level sensor is open
circuit and the action select “Shutdown”, it will initiate a
shutdown alarm and the corresponding alarm information will
be displayed on LCD.
19
Temp. Sensor
2 Open
If the config. sensor set as temperature sensor, When the
controller detects that the temperature sensor is open circuit
and the action select “Shutdown”, it will initiate a shutdown
alarm and the corresponding alarm information will be
displayed on LCD.
20
Oil Pressure
Sensor 2 Open
If the config. sensor set as oil pressure sensor, When the
controller detects that the oil pressure sensor is open circuit
and the action select “Shutdown”, it will initiate a shutdown
alarm and the corresponding alarm information will be
displayed on LCD.
21
Level Sensor 2
Open
If the config. sensor set as level sensor, When the controller
detects that the level sensor is open circuit and the action
select “Shutdown”, it will initiate a shutdown alarm and the
corresponding alarm information will be displayed on LCD.
22
High
Temperature 2
When the controller detects that config. sensor temperature
(sensor type: temperature sensor) has exceeded the pre-set
value, it will initiate a shutdown alarm and the corresponding
alarm information will be displayed on LCD.
23
Low Oil
Pressure 2
When the controller detects that config. sensor oil pressure
(sensor type: oil pressure sensor) has fallen below the
pre-set value, it will initiate a shutdown alarm and the
corresponding alarm information will be displayed on LCD.
24
Low Fuel Level
2
When the controller detects that config. sensor fuel level
(sensor type: level sensor) has fallen below the pre-set
value, it will initiate a shutdown alarm and the corresponding
alarm information will be displayed on LCD.
25
Maintenance
Due
When genset running time has exceeded the user setting
maintenance time and the action select “Shutdown”, it will
initiate a shutdown alarm and the corresponding alarm
information will be displayed on LCD. The maintenance
alarm will reset if the action select “Inactive”.

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6 CONNECTIONS
Compared with HGM420, HGM410 has no Mains AC Voltage input terminals. The rear
panel of HGM410 and HGM420 is as below.

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Description of terminal connections:
Pin
Function
Cable
Size
Description
1
B-
1.5mm2
Connected with negative of starter
battery.
2
B+
1.5mm2
DC power supply. Connected with
positive of starter battery. If wire length is
over 30m, better to double wires in
parallel. Max. 20A fuse is recommended.
3
Aux. Output 1
1.0mm2
B+ is supplied by 2 point, rated 5A.
4
Crank
1.0mm2
Crank Relay Output; B+ is supplied by 2
point, rated 5A. Connect to starter coil.
5
Aux. Output 2
1.0mm2
B+ is supplied by 2 point, rated 5A.
6
Aux. Output 3
1.0mm2
B+ is supplied by 2 point, rated 5A.
7
Aux. Input 1
1.0mm2
Ground connected is
active (B-)
See Table 3
8
Aux. Input 2
1.0mm2
Ground connected is
active (B-)
9
Aux. Input 3
1.0mm2
Ground connected is
active (B-); Can be used
as Level Sensor.
10
Aux. Input 4
1.0mm2
Ground connected is