Smartgen HGM6110U User manual

HGM6100U Series Automatic Control Controllers
(HGM6110U/6110UC/6120U/6120UC)
USER MANUAL
Smartgen Technology

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]
[phone]
[phone]/67992952
[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.
Software Version
Date Version Content
2011-09-15 1.0 Original release
2012-06-04 1.1 Some parameters are optimized.
2014-10-28 1.2 Modify the foil color.

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Contents
1SUMMARY.........................................................................................4
2PERFORMANCE AND CHARACTERISTICS.....................................5
3SPECIFICATION ................................................................................7
4OPERATION.......................................................................................8
4.1 KEYS DSCRIPTION......................................................................................... 8
4.2 CONTROLLER PANEL .................................................................................... 9
4.3 AUTOMATIC START/STOP OPERATION...................................................... 10
4.4 MANUAL START/STOP OPERATION............................................................ 12
5PROTECTION..................................................................................13
5.1 WARNINGS.................................................................................................... 13
5.2 SHUTDOWNALARMS................................................................................... 15
6CONNECTIONS...............................................................................17
7PARAMETER RANGE AND DEFINITION.........................................19
7.1 PARAMETER CONTENTAND RANGE TABLE (TABLE 1)............................ 20
7.2 PROGRAMMABLE OUTPUT 1-4 TABLE (TABLE 2) ..................................... 26
7.3 PROGRAMMABLE INPUT 1-5 TABLE (ALL IS ACTIVE WHEN CONNECT TO
GROUND (B-) (TABLE 3) ...................................................................................... 27
7.4 SENSOR SELECTION (TABLE 4) ................................................................. 28
7.5 CONDITIONS OF CRANK DISCONNECT (TABLE 5) ................................... 29
8PARAMETER SETTING...................................................................30
9SENSOR SETTING..........................................................................32
10 COMMISSIONING............................................................................33
11 TYPICAL APPLICATION................................................................34
12 INSTALLATION.................................................................................36
12.1FIXING CLIPS................................................................................................ 36
12.2OVERALL DIMENSION AND PANEL CUTOUT............................................. 37
13 FAULT FINDING...............................................................................39

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1 SUMMARY
HGM6100U series automatic controller, integrating digital, intelligent and network
techniques, is used for automatic control and monitoring system of genset. It can carry
out functions of automatic start/stop, data measurement, alarm protection and three
“remote” (remote control, remote measure and remote communication). The controller
uses LCD display, optional display interface including Chinese, English, Spanish and
Russian with easy and reliable operation.
HGM6100U series automatic controller uses micro-processing technique which can
achieve precision measurement, value adjustment, timing and threshold setting etc..
All the parameters can be configured from front panel or use programmable interface
(or RS485 interface) to adjust via PC. It can be widely used in all types of automatic
control system for its compact structure, simple connections and high reliability.

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2 PERFORMANCE AND CHARACTERISTICS
HGM6100U controller has four variants:
HGM6110U/6110UC: Automatic Start Module, it controls generator to start/stop by
remote start signal;
HGM6120U/6120UC: Based on HGM6110U/6110UC, it adds mains AC monitoring
and mains/generator automatic switching control (AMF), especially suitable for the
automation system composed by mains and genset.
Note1: HGM6110UC/6120UC has RS485 port, HGM6110U/6120U without.
Note2: HGM6110UC/6120UC is taken as an example to describe in this manual.
132*64 LCD display with backlight, optional language interface (Chinese, English,
Spanish and Russian), push-button operation;
Acrylic screen, improved wearable and scratch resistance property;
Silica-gel panel and keys can well adapt to higher and lower temperature;
With RS485 communication port, can achieve “three remote”functions via
MODBUS protocol;
Adapt to 3P4W, 3P3W, 1P2W and 2P3W (120V/240V), 50Hz/60Hz AC power
system;
Can measure and display 3 phase voltage, 3 phase current, frequency, power
parameter of mains/gens;
Mains Generator
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
Current IA, IB, IC
Active power KW
Reactive power KVar
Apparent power KVA
Power factor PF
Generator accumulated energy kWh
Mains have functions of over/under voltage and lack of phase; Gens have functions
of over/under voltage, over/under frequency and over current;
Precision measure and display of parameters about engine,

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Temp. (WT), °C/ °F both are displayed
Oil pressure (OP), kPa/Psi/Bar are all displayed
Fuel level (FL), %
Speed (SPD), RPM
Battery Voltage (VB), V
Charger Voltage (VD), V
Hours counter (HC) can accumulate Max. 999999 hours.
Start times can accumulate Max.999999 times.
Control protection: Automatic start/stop of genset, load transfer(ATS control) and
perfect failure display and protection;
With ETS, idle speed control, pre-heat control, speed droop/raising control, all of
them are relay output;
Parameter setting: Allow user to modify setting and store them in internal FLASH
memory. The parameters cannot be lost even when power off. All of parameters can
be set not only from the front panel, but also use programmable interface (or PS485
interface) to adjust them via PC.;
Multi sensors of temperature, pressure and fuel level can be used directly,
parameters can be defined by user;
Multi conditions of crank disconnect (speed sensor, oil pressure, generator) can be
selected;
Power supply range: (8~35)VDC, accommodating to different starting battery volts;
All parameters use digital modulation, instead of analog modulation using
conventional potentiometer, having improved reliability and stability;
Add rubber gasket between shell and controller screen, the waterproof can reach
IP55;
Controller is fixed by metal fixing clips;
Modular design, flame-retardant ABS shell, embedded mounting, compact structure
and easy installation.

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3 SPECIFICATION
Items Contents
Working Voltage DC8.0V to DC35.0V, continuous
Power Consumption <3W(Standby mode: ≤2W)
AC System
3P4W
3P3W
1P2W
2P3W
AC15V - AC360 V (ph-N)
AC30V - AC620 V (ph-ph)
AC15V - AC360 V (ph-N)
AC15V - AC360 V (ph-N)
AC Alternator Frequency 50Hz/60Hz
Rotate speed sensor Voltage 1.0V to 24V (RMS)
Rotate speed sensor Frequency 10,000 Hz (max.)
Start Relay Output 16 A DC28V at supply voltage
Fuel Relay Output 16 A DC28V at supply voltage
Programmable Relay Output 1 7 A DC28V at supply voltage
Programmable Relay Output 2 7A 250VAC volt-free output
Programmable Relay Output 3 16 Amp 250VAC volt-free output
Programmable Relay Output 4 16 A 250VAC volt-free output
Overall Dimensions 197 mm x 152 mm x 47mm
Panel Cutout 186mm x 141mm
C.T. Secondary Current 5A (rated)
Working Condition Temperature: (-25~70)ºC; Humidity: (20~93)%
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 0.56kg

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4 OPERATION
4.1KEYS DSCRIPTION
Stop/ Reset
Can stop generator under Manual/Auto mode; Can reset
shutdown alarm; Press this key at least 3 seconds to test
panel indicators are OK or not(lamp test);
During stopping process, press this key again can stop
generator immediately.
Start Start genset under Manual or Manual Test mode.
Manual Pressing this key will set the module as Manual mode.
Auto Pressing this key will set the module as Auto mode.
Running with load Controller is under manual testing mode.
Under this mode, gen-set will run automatically with load
when gens normal. (HGM6110UC without)
Gens Close/Open Can control gens to switch on or off in Manual mode.
Set/ Confirm Shift cursor to confirm In parameters setting menu.
Up/Increase Screen scroll;
Up cursor and increase value in setting menu.
Down/Decrease Scroll screen;
Down cursor and decrease value in setting menu.
Menu Pressing this key will set menu;
Again pressing this key can return main interface.

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4.2CONTROLLER PANEL
HGM6110UC Panel Indicators
HGM6120UC Panel Indicators

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4.3AUTOMATIC START/STOP OPERATION
Auto mode is activated by pressing the , LED indicator beside the button is
illuminating which confirms this action.
Starting Sequence,
1) HGM6120UC: When mains is abnormal (over/under voltage, lack of phase), enter
into “Mains Abnormal Delay” and LCD displays count-down time.When delay isover,
“Start Delay”begins.
2) HGM6110UC: when “remote start”input is active, enter into “Start Delay”.
3) “Count- down”of start delay is displayed in LCD.
4) When start delay is over, preheat relay is outputting (if configured), “Preheat Delay
XX s”is displayed in LCD.
5) When preheat delay is over, fuel relay is outputting for 1s and then start relay outputs;
if genset failed to start during “Crank Time”, the fuel and start relay stop outputting
and enter into “Crank Rest Time”and wait for next cranking.
6) If genset failed to start within set start times, the fourth line of LED will turn black and
Fail to Start alarm will be displayed.
7) Any time to start genset successfully, it will enter into “Safe Running”. During this
period, alarms of low oil pressure, high temperature, under speed, charge failure and
Aux. input (be configured) are disabled. As soon as this delay is over, genset will
enter into “Start Idle Delay”(if configured).
8) During start idle delay, alarms of under speed, under frequency, under voltage are
disabled. As soon as this delay is over, genset will enter into “Warming up Delay”(if
configured).
9) When “Warming up Delay”is over, the indicator is illuminating if gens normal. If
voltage and frequency of engine reach the load requirement, close relay outputs,
genset is taking load and indicator illuminates; if engine voltage or frequency is
abnormal, controller will alarm and shutdown (LCD displays the alarm information).
Stopping Sequence,
1) HGM6120UC: during normal running, if mains normal, genset will enter into “Mains
Normal Delay”, when mains indicator illuminates, “Stop Delay”begins.
2) HGM6110UC: genset enters into “Stop Delay”as soon as “Remote Start”is inactive.

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3) When “Stop Delay”is over, genset enters into “Cooling Delay”. Closing relay is
disconnected. After switch “Transfer Rest Delay”, closing relay is outputting, mains is
taking load, generator indicator eliminates while mains indicator illuminates.
4) When entering “Stop Idle Delay”, idle relay is energized to output. (If configured).
5) When entering “ETS Delay”, ETS relay is energized to output, fuel relay output is
disconnected.
6) When entering “Genset at Rest”, genset will automatically judge if it has stopped.
7) When genset has stopped, enter into standby mode; if genset failed to stop,
controller will alarm (“Fail to Stop”alarm will be displayed in LCD).

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4.4MANUAL START/STOP OPERATION
1) HGM6120UC, Auto Mode is active when press and its indicator illuminates.
Press , then controller enters into “Manual Test Mode”and its indicator is
illuminating. Under both of the modes, press to start genset, it can automatically
detect crank disconnect and accelerate to high speed running. If there is high
temperature, low oil pressure, over speed and abnormal voltage during genset
running, controller can protect genset to stop (detail procedures please refer to
No.4~9 of Auto start operation). Under Manual Mode, switch won’t transfer
automatically, it is necessary to press to transfer load. Under “Manual Test Mode”,
after genset runs well in high speed, no matter mains is normal or not, loading switch
will be transferred to gens.
2) HGM6110UC, Auto Mode is active when pressing , and its indicator is
illuminating. Then press to start genset, it can automatically detect crank
disconnect and accelerate to high speed running. If there is high temperature, low oil
pressure, over speed and abnormal voltage during 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, press and gens take load.
3) Manual stop, pressing can shut down the running genset (detail procedures
please refer to No.3~7 of Auto stop operation).

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5 PROTECTION
5.1WARNINGS
When controller detects the warning signal, the genset only alarm and not stop. The
alarms are displayed in LCD.
Warnings as following,
No. Items Description
1 Loss Of Speed
Signal
When the speed of genset is 0 and speed loss delay is 0,
controller will send warning alarm signal and it will be
displayed in LCD.
2 Genset Over
Current
When the current of genset is higher than threshold and
setting over current delay is 0, controller will send warning
alarm signal and it will be displayed in LCD.
3 Fail To Stop When genset cannot stop after the “stop delay”is over, controller will send warning alarm signal and it will be
displayed in LCD.
4 Low Fuel Level When the fuel level of genset is lower than threshold or low fuel level warning is active, controller will send warning
alarm signal and it will be displayed in LCD.
5 Charge Failure When the voltage of genset charger is lower than threshold, controller will send warning alarm signal and it will be
displayed in LCD.
6 Battery Under
Voltage
When the battery voltage of genset is lower than threshold,
controller will send warning alarm signal and it will be
displayed in LCD.
7 Battery Over
Voltage
When the battery voltage of genset is higher than threshold,
controller will send warning alarm signal and it will be
displayed in LCD.
8 Low Water Level When low water level input is active, controller will send
warning alarm signal and it will be displayed in LCD.
9 Temp. Sensor
Open Circuit
When sensor hasn’t connected to corresponding port,
controller will send warning alarm signal and it will be
displayed in LCD.
10 Oil Pressure Sensor Open
Circuit
When sensor hasn’t connected to corresponding port,
controller will send warning alarm signal and it will be
displayed in LCD.
11 Maintenance time
out warn
When genset running time is longer than maintenance time
of user setting, and the maintenance action is set as
warning, controller send warning alarm signal and it will be

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No. Items Description
displayed in LCD. When maintenance action type is set as
“Not used”, maintenance alarm reset.

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5.2SHUTDOWN ALARMS
When controller detects shutdown alarm, it will send signal to open switch and stop
genset. The alarms are displayed in LCD.
Shutdown alarms as following,
No. Items Description
1 Emergency Stop When controller detects emergency stop signal, it will send
a stop alarm signal and it will be displayed in LCD.
2 High Temp.
Shutdown
When the temperature of water/cylinder is higher than set
threshold, controller will send a stop alarm signal and it will
be displayed in LCD.
3 Low Oil Pressure
Shutdown When oil pressure is lower than threshold, controller will send a stop alarm signal and it will be displayed in LCD.
4 Over
Speed
Shutdown When genset speed is higher than set threshold, controller will send a stop alarm signal and it will be displayed in LCD.
5 Under Speed
Shutdown When genset speed is lower than set threshold, controller will send a stop alarm signal and it will be displayed in LCD.
6 Loss Of Speed
Signal Shutdown When rotate speed is 0 and delay is not 0, controller will
send a stop alarm signal and it will be displayed in LCD.
7 Genset Over Voltage
Shutdown
When genset voltage is higher than threshold, controller will
send a stop alarm signal and it will be displayed in LCD.
8 Genset Under Voltage
Shutdown
When genset voltage is under set threshold, controller will
send a stop alarm signal and it will be displayed in LCD.
9 Genset Over Current
Shutdown
When genset current is higher than set threshold and delay
is not 0, it will send a stop alarm signal and it will be
displayed in LCD.
10 Fail To Start Within set start times, if failed to start, controller will send a
stop alarm signal and it will be displayed in LCD.
11 Over Frequency
Shutdown
When genset frequency is higher than set threshold,
controller will send a stop alarm signal and it will be
displayed in LCD.
12 Under Frequency
Shutdown
When genset frequency is lower than set threshold,
controller will send a stop alarm signal and it will be
displayed in LCD.
13 Genset Failed When genset frequency is 0, controller will send a stop
alarm signal and it will be displayed in LCD.
14 Low Fuel Level When fuel level low input is active, controller will send a
stop alarm signal and it will be displayed in LCD.
15 Low Water Level When genset water level low input is active, controller will
send a stop alarm signal and it will be displayed in LCD.

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No. Items Description
16 Temp. Sensor
Open Circuit
When sensor hasn’t connected to corresponding port,
controller will send shutdown alarm signal and it will be
displayed in LCD.
17 Oil Pressure Sensor Open
Circuit
When sensor hasn’t connected to corresponding port,
controller will send shutdown alarm signal and it will be
displayed in LCD.
18 Maintenance time
out shutdown
When genset running is longer than maintenance time of
user setting, and maintenance action is set as shutdown,
controller send shutdown alarm signal and it will be
displayed in LCD. When maintenance action type is set as
“Not used”, maintenance alarm reset.

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6 CONNECTIONS
Compared with HGM6120UC, HGM6110UC doesn’t have 3-phase input terminal of
mains voltage. The back panel of HGM6110UC and HGM6120UC is as below.
Descriptions of terminal connection as following,
No. Function Cable Size Description
1 DC input B- 2.5mm2Connected to negative of starter battery
2 DC input B+ 2.5mm2
Connected to positive of starter battery.
If wire length is over 30m, better to
double wires in parallel. Max. 20A fuse
is recommended.
3 Emergency Stop 2.5mm2Connected to B+ via emergency stop
button.
4 Fuel Relay Output 1.5mm2B+ is supplied by 3 points, rated 16A
5 Start Relay Output 1.5mm2B+ is supplied by 3 points, rated 16A
Connect to starter coil
6 Aux. Relay Output 1 1.5mm2B+ is supplied by 2
points, rated 7A
Reference
table 2
7
Aux. Relay Output 2 1.5mm2
Normal close output, 7
A rated.
8 Relay common port
9 Normal open output, 7
A rated.
10 Aux. Relay Output 3 2.5mm2Relay normal open

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No. Function Cable Size Description
11 volt-free contact output
16 A rated
12 Aux. Relay Output 4 2.5mm2
13
14 Charging Generator D+
Input 1.0mm2Connect to D+ (WL) terminal. If without, the terminal is not connected.
15 Speed sensor input 0.5mm2Connected to Speed sensor, shielding
line is recommended.
16 Speed sensor input, B-
is connected.
17 Temp. Sensor Input 1.0mm2Connect to water /cylinder temp.
resistance type sensor Reference
table 4
18 Oil Pressure Sensor
Input 1.0mm2Connect to oil pressure resistance type sensor
19 Liquid Level Sensor
Input 1.0mm2Connect to liquid level resistance type sensor
20 Configurable Input 1 1.0mm2Ground connected is
active (B-) Reference
table 3
21 Configurable Input 2 1.0mm2Ground connected is
active (B-)
22 Configurable Input 3 1.0mm2Ground connected is
active (B-)
23 CT A Phase Sensing
Input 1.5mm2Connect secondary coil, rated 5A
24 CT B Phase Sensing
Input 1.5mm2Connect secondary coil, rated 5A
25 CT C Phase Sensing
Input 1.5mm2Connect secondary coil, rated 5A
26 CT Common Port 1.5mm2Refer to INSTALLATION description.
27 Generator U phase Voltage
Sensing Input 1.0mm2Connect to U phase output(2A fuse is
recommended)
28 Generator V phase
Voltage sensing Input 1.0mm2Connect to V phase output(2A fuse is
recommended)
29 Generator W phase
Voltage Sensing Input 1.0mm2Connect to W phase output(2A fuse is
recommended)
30 Generator N2 Input 1.0mm2Connect to generator N-wire
31 Mains R phase Voltage
Sensing Input 1.0mm2Connect to mains R phase(2A fuse is
recommended) HGM6110UC without
32 Mains S phase Voltage
Sensing Input 1.0mm2Connect to mains S phase (2A fuse is
recommended) HGM6110UC without.
33 Mains T phase Voltage
Sensing Input 1.0mm2Connect to mains T phase, (2A fuse is
recommended) HGM6110UC without.

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No. Function Cable Size Description
34 Mains N1 Input 1.0mm2Connect to mains N-wire, HGM6110UC
without.
35 RS485 Common
Ground / Impedance-120Ω shielding wire is
recommended, its single-end connect
with ground.
36 RS485 - 0.5mm2
37 RS485+ 0.5mm2
38 Configurable Input 4 1.0mm2Ground connected is
active (B-) Reference
table 3
39 Configurable Input 5 1.0mm2Ground connected is
active (B-)
40 Sensor Common 1.0mm2Sensor common port
Note: LINK ports in controller rear panel are programmable parameter ports, user
can directly program SG72 via PC.

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7 PARAMETER RANGE AND DEFINITION
7.1 PARAMETER CONTENT AND RANGE TABLE (TABLE 1)
No. Items Range Default Description
1 Mains Normal
Delay (0-3600)s 10 The delay from abnormal to normal or from normal to
abnormal. It used for ATS
(automatic transfer switch)
control.
2 Mains Abnormal
Delay (0-3600)s 5
3 Mains Under
Voltage (30-620)V 184
When mains voltage is under
the point, mains under voltage
active. When the value is 30,
mains under voltage disabled.
4 Mains Over
Voltage (30-620)V 276
When mains voltage is
greater than the point, mains
over voltage active. When the
point is 620V, mains over
voltage disabled.
5 Transfer Rest
Time (0-99.9)s 1.0
It’s the delay from mains open
to generator closed or from
generator open to mains
closed.
6 Start Delay (0-3600)s 1 Time from mains abnormal or remote start signal is active to
start genset.
7 Stop Delay (0-3600)s 1 Time from mains normal or remote start signal is inactive
to genset stop.
8 Start Times (1-10) times 3
When engine start failure, it’s
the maximum cranking times.
When setting crank times out,
controller send start fail
signal.
9 Preheat Time (0-300)s 0 Time of pre-powering heat plug before starter is powered
up.
10 Crank Time (3-60)s 8 Time of starter power up each
time.
11 Crank Rest Time (3-60)s 10 The second waiting time before power up when engine
start fail.
12 Safe Running
Time (1-60)s 10
Alarm for low oil pressure,
high temp, under speed,
under frequency /voltage,
charge fail are all inactive.