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