Smartgen HGM6510 User manual

HGM6510 Genset Parallel Unit
USER MANUAL
Smartgen Technology

HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit
ISSUE 2013-07-15
Version 1.7
Page 4 of 52
CONTENTS
1 OVERVIEW ...........................................................................................6
2 PERFORMANCE AND CHARACTERISTICS ........................................7
3 SPECIFICATION.................................................................................... 10
4 FRONT PANEL..........................................................................................11
4.1 INDICATORLIGHT.............................................................................................11
4.2 PUSHBUTTONS ............................................................................................... 12
5 OPERATION........................................................................................... 13
5.1 AUTOMATIC OPERATION(MULTIPLE SETS).................................................. 13
5.2 MANUAL OPERATION(MULTIPLE SETS)........................................................ 14
6 PROTECTIONS................................................................................... 16
6.1 WARNINGALARMS.......................................................................................... 16
6.2 SHUTDOWNALARMS...................................................................................... 19
6.3 TRIP ANDSTOPALARMS................................................................................. 23
7 PANEL CONFIGURATION..................................................................... 26
7.1 LCD DISPLAY........................................................................................................26
7.1.1 STATUS DISPLAY..............................................................................................26
7.1.2 ENGINE DISPLAY .............................................................................................27
7.1.3 GENERATOR DISPLAY........................................................................................27
7.1.4 BUS DISPLAY....................................................................................................28
7.1.5 SYNCHRONIZATION DISPLAY........................................................................28
7.1.6 ALARM DISPLAY...............................................................................................28
7.1.7 EVENT LOG................................................................................................... 29
7.1.8 “ABOUT” DISPLAY ............................................................................................29
7.2 PARAMETERCONFIGURATION...................................................................... 29
7.3 DATE/TIMESETTING....................................................................................... 34
7.4 DATADISPLAY......................................................................................................34
7.4.1 BASIC DISPLAY.................................................................................................34
7.4.2 ECU DISPLAY....................................................................................................35
8 INPUT AND OUTPUTPORTS CONFIGURATION................................ 36
8.1 CONFIGURABLE INPUTPORTS 1~9............................................................... 36
8.2 CONFIGURABLE OUTPUTPORTS 1-5............................................................ 38
9 EVENT LOG........................................................................................ 42
10 BACK PANEL.............................................................................................42
11 ECU INTERFACE................................................................................... 45
12 DEBUGGING PROCEDURE ............................................................... 45
12.1 STEP 1. SINGLEUNITDEBUGGING................................................................ 45

HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit
ISSUE 2013-07-15
Version 1.7
Page 5 of 52
12.2 STEP2: MANUALPARALLELOPERATIONOFF-LOAD................................... 46
12.3 STEP3: MANUALPARALLELOPERATIONON-LOAD..................................... 46
12.4 STEP4: FULLYAUTOMATICPARALLELOPERATION.......................................46
13 POWER MANAGEMENT MODE ......................................................... 48
14 TROUBLESHOOTING......................................................................... 49
15 TYPICAL WIRING DIAGRAMS............................................................ 50
15.1 HGM6510 TYPICALWIRING DIAGRAM ........................................................... 50
15.2 HGM6510 MAINSPARALLELAPPLICATION......................................................50
15.3 HGM6510 MULTI-SET PARALLELAPPLICATION...............................................51
16 COMMUNICATION INTERFACE ........................................................... 52
17 CASE DIMENSIONS AND PANEL CUTOUT......................................... 52

HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit
ISSUE 2013-07-15
Version 1.7
Page 6 of 52
1 OVERVIEW
HGM6510 controller is designed for manual/auto parallel systems of up to 20 generators
with similar or different capacity. Additionally, it is suitable for single unit constant power
output and mains paralleling. It allows automatic start/stop, data measurement, alarm
protection as well as remote control, remote measurement and remote communication
function. It fit with LCD display, optional languages interface, and it is reliable and easy to
use.
Utilizing the GOV (Engine Speed Governor) and AVR (Automatic Voltage Regulator)
control function, the controller is able to synchronize and share load automatically; it can
be used to parallel with other HGM6510 controller.
HGM6510 controller also monitors the engine, indicating the operational status and fault
conditions accurately. When abnormal condition occurs, it splits bus and shuts down the
genset, simultaneously the exact failure mode information is indicated by the LCD display
on the front panel.
The powerful 32-bit Microprocessor contained within the module allows for many features
to be incorporated as standard. SAE J1939 interface enables the controller to
communicate with various ECU (ENGINE CONTROL UNIT) which fitted with J1939
interface. Multiple parameters such as engine speed, water temperature, oil temperature,
and oil pressure can be transmitted via J1939 interface and displayed on LCD, so there is
no need to install additional sensors and complicated wiring is avoided while electric
parameters accuracy is ensured.

HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit
ISSUE 2013-07-15
Version 1.7
Page 7 of 52
2 PERFORMANCE AND CHARACTERISTICS
 2 application modes:
1) Multi-set parallel operation;
2) Single unit (constant power output) parallel with mains.
 32-bitARM microprocessor, LCD display with backlight, optional languages interface,
push-button operation;
 Complete monitoring functions: almost all generator electric/non-electric parameters
are monitored, as follows:
Generator electric parameters:
3-phase phase voltage Ua, Ub, Uc Unit: V
3-phase line voltage Uab, Ubc, Uca Unit: V
3-phase current Ia, Ib, Ic Unit: A
Frequency F1 Unit: Hz
Split phase active power PA, PB, PC Unit: kW
Total phase active power P Unit: kW
Split phase reactive power RA, RB, RC Unit: kVar
Total phase reactive power P Unit: kVar
Split phase apparent power SA, SB, SC Unit: kVA
Total phase apparent power S Unit: KVA
Split phase power factor PF1, PF2, PF3
Average power factor APF
Total active energy Unit: kWh
Total reactive energy Unit: kVarh
Total apparent energy Unit: kVAh
3-phase voltage phase sequence and phase angle
Bus/mains electricity parameters:
3-phase phase Voltage Ua, Ub, Uc Unit: V
3-phase line Voltage Uab, Ubc, Uca Unit: V
Frequency F1 Unit: Hz
3-phase voltage phase sequence and phase angle
Synchronization parameters:
Voltage difference between generator and bus/mains
Phase angle difference between generator and bus/mains
Frequency difference between generator and bus/mains

HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit
ISSUE 2013-07-15
Version 1.7
Page 8 of 52
Generator abnormal conditions:
Over Voltage
Under Voltage
Over Frequency
Under Frequency
Loss of Phase
Phase Sequence Wrong
No power
Fault display and alarm:
High temperature warn
High temperature shutdown
Low oil pressure warn
Low oil pressure shutdown
Over speed shutdown
Low fuel level warn
Start battery over voltage warn
Start battery under voltage warn
Over current shutdown
Fail to start alarm
Fail to stop alarm
Emergency shutdown
Close fault
Open fault
Oil pressure sensor open circuit alarm
Reverse power
Phase sequence wrong
ECU Com fail
……
 A number of options exist for the Auto Mode: off-load running, on-load running ,
demand parallel running;
 Ramp on and ramp offfunction;
 Weekly and monthly start/stop; on-load (parallel operation)/off loadcommissioning;
 SAE J1939 interface for ECU engine monitoring;
 True R.M.S. voltage monitoring function makes it suitable for multiple abnormal
electric quantity situations;

HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit
ISSUE 2013-07-15
Version 1.7
Page 9 of 52
 Accurately measure and display the electric parameters as well as water temperature,
oil pressure, fuel level and others;
 Control and protection: Genset automatic start/stop/parallel operation,
synchronization detection, load sharing and alarm protection;
 Maintenance function, maintenance due warning/shutdown alarm;
 For the engines without J1939: temperature, pressure and fuel level sensors can be
connected externally; multiple ready to use and user-defined sensorcurves;
 Free adjustment of input port information that is displayed on LCD when the input
port is active: Chinese/English support, 20 English letters or 10 Chinese characters
maximum;
 Close to activate/open to activate configurable input port types; normally
open/normally closed configurable output port types;
 Custom logic output;
 Real-time calendar, real-time clock and total run counter;
 99 event logs can be saved circularly and can be inquired on thespot.
 Multi-level password protection to avoid misuse by non-qualifiedpersonnel;
 Genset parameters can be adjusted from front panel or viaPC;
 Wide power supply range DC(8-35)V enables compatibility with different start battery
voltage environment;
 RS485/232C communication interface utilizing MODBUS protocol enables remote
control, remote measurement, remote communication and remote adjustment of the
genset;
 Modular design, anti-flaming ABS plastic enclosure, pluggable connection terminals
and embedded installation way; compact structure with easy mounting.

HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit
ISSUE 2013-07-15
Version 1.7
Page 10 of 52
3 SPECIFICATION
Parameter
Details
Working Voltage
DC8. 0V to 35. 0V, Continuous Power Supply.
Overall Consumption
<3W (Standby mode: ≤2W)
Alternator Voltage Input:
3 Phase 4 Wire
3 Phase 3 Wire
Single Phase 2 Wire
2 Phase 3 Wire
AC15V - AC360V (ph-N)
AC30V - AC600V (ph-ph)
AC15V - AC360V (ph-N)
AC15V - AC360V (ph-N)
True RMS Accuracy
1%
Alternator Frequency
50Hz/60Hz
Speed Sensor Voltage
1. 0 V to 24 V (RMS)
Speed Sensor Frequency
Maximum 10,000 Hz
Start Relay Output
16A DC28V power supply output
Fuel Relay Output
16A DC28V power supply output
Configurable Relay Output 1
16A DC28V power supply output
Configurable Relay Output 2
16A DC28V power supply output
Configurable Relay Output 3
16A DC28V power supply output
Configurable Relay Output 4
16A AC250V passive output
Configurable Relay Output 5
16A AC250V passive output
RS485 Interface
1500V Isolation;
Maximum transmission distance: 1.2 kilometers;
Baud rate:9600;
Stop bits: 1 bit;
Parity: No.
Terminal matched resistance:120 Ω
RS232 Interface
Non-isolated
Maximum transmission distance: 15 meters;
Baud rate:9600;
Stop bits: 1 bit;
Parity: No.
MSC CAN Interface
1500V Isolation;
Maximum transmission distance:
190 meters: Baud rate:330K;
250 meters: Baud rate:250K;
500 meters: Baud rate:125K;
Terminal matched resistance:120 Ω
Case Dimensions
260mm x 182mm x 57mm
Panel Cutout
214mm x 160mm
CT Secondary Current
Rated 5A
Working Conditions
Temperature: (-25~+70)°C
Humidity: (20~93)% without condensation

HGM6510 GENSET PARALLEL UNIT
HGM6510 Genset Parallel Unit
ISSUE 2013-07-15
Version 1.7
Page 11 of 52
4.1 INDICATOR LIGHT
4 Configurable LED
Stop Mode
Manual Mode
Gen Closed
Auto Mode
Gen Normal
Parameter
Details
Storage Conditions
Temperature:(-40~+85)°C
Protection Level
IP55 Gasket
Insulation Intensity
Apply AC2.2kV voltage between high voltage terminal
and low voltage terminal;
The leakage current is not more than 3mA within 1min.
Weight
0.90kg
4 FRONT PANEL

HGM6510 Genset Parallel Unit
ISSUE 2013-07-15
Version 1.7
Page 12 of 52
HGM6510 GENSET PARALLEL UNIT
4.2PUSHBUTTONS
Stop/Reset
When the genset is running, pressing this button will ramp off
and stop running the generator;
In case of alarm condition, pressing the button will resetalarm;
In stop mode, pressing and holding the button for 3 seconds
will test indicator lights (lamptest);
During stopping process, press this button again to stop
generator immediately.
Start
In manual mode, pressing this button will start the gen-set
(The button has effect in manual mode only)
Manual
Press this key and controller enters in Manual mode.
Reserved
Auto
Press this key and controller enters in Auto mode.
Gen Closed
In manual mode, when busbar has voltage, pressing the
button will synchronize generator with bus and, after that,
parallel generator with bus; when busbar has no voltage,
pressing the key will close generator breaker immediately.
Gen Open
In manual mode, when parallel mode is active, pressing the
button will transfer load to other generators and then open
breaker; when parallel mode is deactivated, pressing the
button will open the breaker immediately.
Up
Scrolls the screen up;
Increase the set value in parameter setting menu.
Down
Scrolls the screen down;
Decrease the set value in parameter setting menu.
Left
Scrolls the screen left;
Move cursor left in parameter setting menu.
Right
Scrolls the screen right;
Move cursor right in parameter setting menu.
Confirm
Confirm the set value in parameter setting menu.