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.

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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

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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.

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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)

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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.

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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 (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

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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.
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.

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4.2 INDICATOR LIGHT
HGM410E Panel Indicators
HGM420E 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) 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.