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: [phone]
[phone]
[phone]
[phone]
[phone](overseas)
Fax: [phone]
Web: http://www.smartgen.com.cn
http://www.smartgen.cn
Email: [e-mail]
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 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.

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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

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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)
AC 30V - 360V (ph-N)
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.

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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

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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
1
Generator voltage L
1.0mm2
2
Generator voltage N
1.0mm2
3
Load C. T. Secondary I
(out)
1.0mm2
C.T. Secondary max
current 5mA
4
Load C. T. Secondary I*
(in)
1.0mm2
5
Genset temperature
sensor input
6
Engine temperature

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sensor input
7
Low oil pressure input
Low oil pressure digital
or sensor signal input
port; must be
connected to B-
8
Battery negative input B-
1.5mm2
Controller power supply
input B-
9
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)
10
Electric lock START input
1.5mm2
Hand-turn start, start
relay output (Output
activates when electric
lock key is turned to
START position)
11
Start relay output
1.5mm2
Rated current 7A;
power supplied by
terminal 13
12
Fuel relay output
1.5mm2
Rated current 7A;
power supplied by
terminal 13
13
Fuel/start relay common
port
2.5mm2
Fused and connected
to start battery positive
7. CONFIGURABLE PARAMETERS
7.1. CONFIGURABLE PARAMETERS TABLE
No
Parameter
Range
Default
factory
value
Description
1
AC system
1P
2P
3P
1P
1P：1P2W
2P：2P3W
3P：3P4W
2
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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No
Parameter
Range
Default
factory
value
Description
3
Rated
frequency
50Hz
60Hz
50
Generator rated frequency
selection
4
Rated power
(0.0-99.9)kw
5.0
Generator rated Active
power
5
Enable Auto
protection
Enable
Disable
Enable
Irrespective of whether
gen-set auto protection is
enabled
6
C. T. Ratio
(0-999)/5
20/5
Unit: A/5mA
(Must correspond to the
used current transformer)
7
Engine
temperature
sensor type
L-0
L-1
L-2
L-3
L-4
L-0
L-0：Not used
L-1：TE1
L-2：TE2
L-3：TE3
L-4：TE4
Select this according to the
used sensor.
8
Generator
temperature
sensor type
L-0
L-1
L-2
L-3
L-4
L-0
L-0：Not used
L-1：TG1
L-2：TG2
L-3：TG3
L-4：TG4
Select this according to the
used sensor.
7.2. PARAMETER CONFIGURATION
Before using controller for the first time, parameters must be configured: rated
voltage, rated frequency, rated power set values must comply with the used
generator, set C.T. ratio value should comply to the used current transformer.
1 When the controller is disconnected, press button, then change start key
position from OFF to ON; after the controller is powered on release
button and all the three windows (voltage window, frequency window and
multifunctional window will show set parameters; at the same time voltage
window will start flashing showing three choices (1P/2P/3P) which mean
1P2W,2P3W, and 3P4W respectively. Use and to choose AC wire
type and to confirm and automatically enter the next menu item;
2 Rated voltage value settings: there are 7 possible variants of voltage
(110/115/120/130/220/230/240V), use and to switchover between

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them (each pressing will increase/decrease the value for one step). When the
screen shows the needed value, press to confirm and enter the next
menu item;
3 Rated power settings: power LED window first digit will start flashing; use
and to choose a value from 0 to 9, then press to confirm and enter
next settings; power window second digit will start flashing, use and
to choose a value from 0 to 9 and to confirm; power window third digit will
start flashing, use and to choose a value from 0 to 9 and to
confirm and enter the next menu item;
4 Rated frequency setting: frequency LED indicator illuminates, multifunctional
window starts flashing; press and to choose frequency value (there
are 2 choices: 50 and 60Hz), every time you press the button the value will
change; when the needed value is displayed, press to confirm and
automatically enter the next setting;
5 Auto protection setting: when auto protection light indicator is on, press to
confirm and auto protection will continue to be enabled; use or to
make indicator off and press to disable auto protection. When the light
indicator is off, it means that auto protection is disabled. Enabling this function
is recommended;
6 C.T setting: multifunctional window first digit will start flashing; use and
to choose a value from 0 to 9, then press to confirm and enter next
settings; power window second digit will start flashing, use and to
choose a value from 0 to 9 and to confirm; power window third digit will
start flashing, use and to choose a value from 0 to 9 and to
confirm and enter the next menu item;
7 Engine temperature sensor type setting: when engine temperature indicator is
on, multifunctional window will start flashing: use and to select
temperature sensor type (there are five choices: L-0，L-1，L-2，L-3，L-4. L-0
stands for 'no temperature sensor used'). Every time you press the button, the
temperature sensor type will change; when the needed type is displayed,
press button to confirm and automatically enter the next setting;
8 Generator temperature sensor type setting: the same as 7.
9 Turn the start key from ON to OFF position to finish configuration.
NOTE: during configuration use button to enter the next menu item and

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to return to the previous.
CAUTION: Please change inner controller parameters (rated generator voltage,
generator frequency etc.) only in standby mode, otherwise in can lead to shutdown
or other abnormal condition.
8. COMMISSIONING
It is recommended that the following checks are made before starting the system:
1. Check that all the connections are correct and wire sizes are suitable.
2. Ensure all parameters are configured correctly and oil pressure light is on.
3. Ensure the controller DC power supply is fused and correctly connected to the
positive and negative of starter battery.
4. Take propermeasures to prevent the engine from starting (e. g. unplug fuel valve
wire). After checking that there are no faults, connect the starter battery, change
start key position from OFF to ON, and the controller will carry out the procedure.
5. Then change start key position to START to start cranking. After the engine is
fired, remove start key; voltage, frequency and power windows will show true
collected values.
6. For further information please contact Smartgen services.

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9. TYPICAL WIRING DIAGRAM
Typical wiring diagram is shown below:
10. INSTALLATION
The controller is designed for panel mounting, it is held with the help of fixing clips.
Overall and cutout dimensions can be seen below (unit: mm)
1) Battery Voltage Input
NOTE: HGM501 controller is suitable for 9-18 VDC battery voltage. Battery
negative must be reliably connected to the enclosure of the engine. The
controller power supply B+ and B- must be connected to battery positive and

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negative, and the wire size must not be less then 1.5mm2. In case of floating
charger connect charger output to battery positive and negative directly, then,
connect battery positive and negative poles to controller positive and negative
power supply input port using single lines to prevent charger interference into
normal operation of the controller.
WARNING: When the engine is running, start battery must not be removed.
1) AC input
Current transformer with rated secondary current 5mA must be externally
connected to the controller current input.
WARNING! When generator is on-load, C. T. secondary must not be open
circuit.
2) Withstanding voltage test
CAUTION: If withstanding voltage test is conducted after the controller has
already been installed onto the control panel, please unplug all controller
terminal connections in order to prevent high voltage from damaging it.
11. TROUBLESHOOTING
Problem
Possible solution
Controller does not respond
on power on
Check start battery.
Check wiring to the controller
Check DC fuse
Low oil pressure alarm after
crank disconnect
Check oil pressure sensor and its wiring.
Alarm shutdown during
running
Check corresponding switch and wiring in
accordance with the information on the display
Fail to start
Check fuel return circuit and wiring
Check start battery
Consult engine manual
Starter motor does not
respond
Check the wiring to the starter
Check start battery