Smartgen HGM6000K Series User manual

HGM6000K Series
Automatic Generator Module
OPERATING MANUAL
Smartgen Electronic

HGM6000K Series Automatic Generator Module
HGM6000K Series Automatic Generator Module ISSUE 2011-06-20 Version 1.7 Page 3 of 34
CONTENT
1SUMMARY.....................................................................................4
2PERFORMANCE AND CHARACTERISTICS...............................4
3SPECIFICATION............................................................................6
4OPERATION ..................................................................................6
4.1 KEY FUNCTION .....................................................................................6
4.2 DISPLAY DESCRIBE..............................................................................7
4.3 AUTOMATIC OPERATION......................................................................9
4.4 MANUAL OPERATION..........................................................................10
5PROTECTION..............................................................................11
5.1 WARN...................................................................................................11
5.2 SHUTDOWN ALARM............................................................................13
6CONNECTING TERMINAL .........................................................14
7PARAMETER RANGE AND DEFINE..........................................17
7.1 PARAMETERS TABLE (TABLE 1).........................................................17
7.2 OUTPUT 1-4 TABLE (TABLE 2)............................................................25
7.3 DIGIT INPUT 1-5 TABLE (TABLE 3)......................................................26
7.4 SENSOR (TABLE 4) .............................................................................26
7.5 CONDITION OF CRANK SUCCEED (TABLE 5)...................................27
8SETTING PARAMETER..............................................................28
9SENSOR SETTINGS...................................................................29
10 COMMISSIONING.......................................................................30
11 TYPICALWIRING DIAGRAM......................................................31
12 INSTALLATION............................................................................32
13 FAULT FINDING ..........................................................................33

HGM6000K Series Automatic Generator Module
HGM6000K Series Automatic Generator Module ISSUE 2011-06-20 Version 1.7 Page 4 of 34
1 SUMMARY
HGM6000K 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, with operation easy and reliable.
HGM6000K 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
■HGM6000K controller has four types:
HGM6010K/6010KC: Automatic Start Module, it controls genset to start/stop by
remote start signal;
HGM6020K/6020KC: Based on HGM6010K/6010KC and add mains AC
monitoring, Mains/Genset automatic switching control functions (AMF), especially
suitable for the automation system composed by Mains and Genset.
Note1: HGM6010KC/6020KC with RS485 interface, HGM6010K/6020K without RS485 interface.
Note2: And then take HGM6010KC/6020KC with text as an example to describe.
■Using microprocessor as a core, graphics LCD with big screen and backlight,
display between character and icon display, key touch for 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;
■Precision measure and display of
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
Load
Power Current IA, IB, IC
Active power KW

HGM6000K Series Automatic Generator Module
HGM6000K Series Automatic Generator Module ISSUE 2011-06-20 Version 1.7 Page 5 of 34
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 cannot 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
connection terminals, flush type installation, compact structure, easy
installation.

HGM6000K Series Automatic Generator Module
HGM6000K Series Automatic Generator Module ISSUE 2011-06-20 Version 1.7 Page 6 of 34
3 SPECIFICATION
Operating Voltage
DC8.0V to 35.0V, Continuous
Power Consumption
<3W(Standby mode: ≤2W)
Alternator Input Range
3-Phase 4 Wire
2-Phase 3 Wire
Single phase 2 Wire
15VAC - 360VAC (ph-N)
15VAC - 360VAC (ph-N)
15VAC - 360VAC (ph-N)
Frequency
50Hz - 60Hz
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 (1-4)
(1) 7Amp DC28V at supply voltage,
(2)7Amp 250VAC free voltage contact,
(3, 4)16Amp 250VAC free voltage contact.
Overall Dimensions
209mm x 153mm x 55mm
Panel cutoff
186mm x 141mm
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
C. T. Secondary
5A (rated )
Weight
0.69kg
4 OPERATION
4.1KEY FUNCTION
Stop/ Reset
Can stop genset under mode of Manual/Auto;
Can reset alarming under Stop;
To test panel indicators are OK or not, pressing this

HGM6000K Series Automatic Generator Module
HGM6000K Series Automatic Generator Module ISSUE 2011-06-20 Version 1.7 Page 7 of 34
key at least 3 seconds;
During stopping process, press this again can stop
genset 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. (HGM6010KC 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.
4.2DISPLAY DESCRIBE
Mains: line voltage Uab, Ubc, Uca Mains: phase voltage Ua, Ub, Uc
Mains: frequency (Hz) F1 Genset: line voltage Uab, Ubc, Uca
Genset: phase voltage Ua, Ub, Uc Genset: speed, frequency (Hz) F2

HGM6000K Series Automatic Generator Module
HGM6000K Series Automatic Generator Module ISSUE 2011-06-20 Version 1.7 Page 8 of 34
Load: current IA, IB, IC Load: active power (kW), inactive
power (kVar), apparent power (kVA)
Accumulate total gens power kWh Battery voltage BAT, Charger
Power factor voltage CHARG, Liquid level**%
Water temperature Gens oil pressure
Gens hours count Gens starts count
Gens status, Gens status delay countdown display

HGM6000K Series Automatic Generator Module
HGM6000K Series Automatic Generator Module ISSUE 2011-06-20 Version 1.7 Page 9 of 34
4.3AUTOMATIC OPERATION
This mode is activated by pressing the . LED indicator is illuminating beside the
button confirms this action.
Sequence of Auto Start,
1. HGM6020KC, 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”.
2. HGM6010KC, entries into “start delay”as soon as “Remote Start”is input valid.
3. “Count down”of start delay is displayed in LCD.
4. When start delay is over, preheat relay is outputting (if be equipped), “preheat
start delay XX s”is displayed in LCD.
5. 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.
6. If genset fails in starting within setting attempt times, LCD start-up failure
alarming icon flash.
7. 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).
8. 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).
9. 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,
1. HGM6020KC, 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.
2. HGM6010KC, genset enters into “stop delay”as soon as “Remote Start” putting
is inactive.

HGM6000K Series Automatic Generator Module
HGM6000K Series Automatic Generator Module ISSUE 2011-06-20 Version 1.7 Page 10 of 34
3. 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.
4. Idle relay has power and outputs as soon as entering “stop idle relay” (If this
been configured).
5. When enters “ETS relay”, ETS relay has power and outputs. Oil relay‟s output is
disconnected.
6. When genset enters “stop time”, automatic to decide whether genset is stopped
or not.
7. 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).
Note: this page is nonce genset status, genset status delay countdown display,
for example:
At the first line, NO 4 is the Start interval state; 3s is the countdown to remain time
intervals of Start interval.
Gens Status List:
0: Genset Waiting 1: Start preheat 2: Fuel output 3: Start 4: Start Interval
5: Safety run 6: Start Idling 7: Start warm-up 8: Wait for the Load 9: Normal
Run 10: Stop for cooling 11: Stop idling 12: ETS stop 13: Wait for stop
steady 14: Shutdown failures
4.4MANUAL OPERATION
1. HGM6020KC, 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

HGM6000K Series Automatic Generator Module
HGM6000K Series Automatic Generator Module ISSUE 2011-06-20 Version 1.7 Page 11 of 34
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. HGM6010KC, Auto starts mode is active when press , and its indicator is
illuminating. Then press to start genset, 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 shutdown the running genset (detail procedures
please refer to No.3~7 of Auto stop operation).
5 PROTECTION
5.1WARN
Warns are non-critical alarm conditions and do not affect the operation of the
genset system; they serve to draw the operators attention to an undesirable
condition.
In the event of a warning, the module will display at the last screen of LCD.
Warn is shown as the below:
HIGH ENGINE TEMPERATURE WARN, if the module detects that the engine
coolant temperature has exceeded the high engine temperature setting level after
the Safety On timer has expired and the input of Inhibit WTH stop is activated, a
warn will occur. At the same time LCD screen icon lighten.
LOW OIL PRESSURE WARN, if the module detects that the engine oil pressure