Smartgen HGM7110DC User manual

HGM7110DC DC Genset Controller
USER MANUAL
ZHENGZHOU SMARTGEN TECHNOLOGY CO.,LTD

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]/67992951
[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.
Version history
Date
Version
Contents
2014-09-27
1.0
Original release

This manual is suitable for HGM7110DC controller only.
Clarification of notation used within this publication.
SIGN
INSTRUCTION
Note
Highlights an essential element of a procedure to ensure correctness.
Caution!
Indicates a procedure or practice, which, if not strictly observed, could
result in damage or destruction of equipment.
Warning!
Indicates error operation may cause death, serious injury and
significant property damage.

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Contents
1 OVERVIEW...................................................................................................................... 6
2 PERFORMANCE AND CHARACTERISTICS .................................................................. 7
3 SPECIFICATION............................................................................................................ 10
4 OPERATION ...................................................................................................................11
4.1. PUSHBUTTONS.................................................................................................11
4.2. LCD DISPLAY.................................................................................................... 12
4.2.1. MAIN DISPLAY............................................................................................ 12
4.2.2. PARAMETERS SETTING MENU................................................................ 12
4.3. AUTO START/STOP OPERATION.................................................................... 15
4.4. MANUAL START/STOP OPERATION............................................................... 17
5 SWITCH CONTROL PROCEDURES ............................................................................ 18
5.1 ACCUMULATOR/GENSET PRIORITY SYSTEM: ............................................. 18
5.2 TWO ACCUMULATOR PRIORITY SYSTEM..................................................... 20
6 PROTECTIONS ............................................................................................................. 22
6.1 WARNING ALARMS.......................................................................................... 22
6.2 SHUTDOWNALARM ........................................................................................ 24
6.3 TRIPAND STOP ALARM .................................................................................. 26
6.4 TRIP ALARM ..................................................................................................... 27
7 WIRING CONNECTION................................................................................................. 28
8 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS ......................... 31
8.1 CONTENTS AND SCOPES OF PARAMETERS ............................................... 31
8.2 PROGRAMMABLE OUTPUT PORTS............................................................... 42
8.2.1 DEFINED COMBINATION OUTPUT........................................................... 45
8.3 PROGRAMMABLE INPUT PORTS (ALL ACTIVE WHEN CONNECT TO GRAND
(B-)) 47
8.4 SELECTION OF SENSORS.............................................................................. 50
8.5 CONDITIONS OF CRANK DINSCONNECT SELECTION ................................ 51
9 SENSORS SETTING..................................................................................................... 52
10 COMMISSIONING................................................................................................... 53
11 TYPICALAPPLICATION.......................................................................................... 54
12 INSTALLATION........................................................................................................ 55
13 GSM SHORT MESSAGE ALARM AND REMOTE CONTROL................................. 57
13.1 GSM SHORT MESSAGE ALARM ..................................................................... 57
13.2 GSM SHORT MESSAGE REMOTE CONTROL................................................ 58
14 CONNECTIONS OF CONTROLLER WITH J1939 ENGINE.................................... 60
14.1 CUMMINS ISB/ISBE.......................................................................................... 60
14.2 CUMMINS QSL9 ............................................................................................... 60
14.3 CUMMINS QSM11 (import) ............................................................................... 61

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14.4 CUMMINS QSX15-CM570 ................................................................................ 61
14.5 CUMMINS GCS-MODBUS................................................................................ 62
14.6 DETROIT DIESEL DDEC III / IV........................................................................ 62
14.7 DEUTZ EMR2.................................................................................................... 63
14.8 JOHN DEERE.................................................................................................... 63
14.9 MTU MDEC ....................................................................................................... 64
14.10 PERKINS........................................................................................................... 64
14.11 SCANIA ............................................................................................................. 65
14.12 VOLVO EDC3.................................................................................................... 65
14.13 VOLVO EDC4.................................................................................................... 66
14.14 VOLVO-EMS2.................................................................................................... 66
14.15 BOSCH.............................................................................................................. 67
15 FAULT FINDING ...................................................................................................... 68

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1 OVERVIEW
HGM7110DC genset controller is used for genset automation and monitor control system of
single unit to achieve automatic start/stop, data measurement, alarm protection and “three
remote” (remote control, remote measuring and remote communication). The controller
adopts large liquid crystal display (LCD) and selectable Chinese, English or other languages
interface with easy and reliable operation.
HGM7110DC controller adopts 32 bits micro-processor technology with precision parameters
measuring, fixed value adjustment, time setting and threshold adjusting and etc. The majority
of parameters can be set using front panel and all the parameters can be set using PC (via
USB port) and can be adjusted and monitored with the help of RS485 ports. It can be widely
used in all types of automatic genset control system with compact structure, advanced circuits,
simple connections and high reliability.

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2 PERFORMANCE AND CHARACTERISTICS
HGM7110DC：Control the genset to start/stop by detecting the accumulator voltage or
charger current.
With ARM-based 32-bit SCM, highly integrated hardware, new reliability level;
132x64 LCD with backlight, multilingual interface (including English, Chinese or other
languages) which can be chosen at the site, making commissioning convenient for
factory personnel;
Improved LCD wear-resistance and scratch resistance due to hard screen acrylic;
Silicon rubber panel and pushbuttons for better operation in high/low temperature
environment;
RS485 communication port enables remote control, remote measuring, remote
communication via ModBus protocol.
Equipped with SMS (Short Message Service) function. When genset is alarming,
controller can send short messages via SMS automatically to max. 5 telephone numbers.
Besides, generator status can be controlled and checked using SMS.
Equipped with CANBUS port and can communicate with J1939 genset. Not only can you
monitoring frequently-used data (such as water temperature, oil pressure, speed, fuel
consumption and so on) of ECU machine, but also control starting up, shutdown , raising
speed and speed droop via CANBUS port.
Suitable for Accumulator Priority System, Generator Priority System, Or Double
Accumulator System;
Accumulator Priority System：The accumulator supplies the power for load continuously.
In Auto mode, the genset will start automatically to charger the accumulator if the
accumulator voltage has fallen below the “Charge Start Voltage”.
Generator Priority System: The generator supplies the power for load continuously. If
there is shutdown alarm occurs by either engine or generator, the accumulator will supply
the power for load. In Auto mode, the genset will charge the accumulator if the
accumulator voltage has fallen below the “Charge Start Voltage”; When the accumulator
voltage has fallen below the “Nominal Voltage”, in addition, the generator abnormal
condition occurs, Shutdown alarm will be initiated
Double Accumulator System: Firstly, the accumulator 1# supplies the power for load; if
the accumulator 1# satisfies the charger requirement, then it will charged by the genset
and the accumulator 2# supplies the power for load.

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Collects and shows parameters:
Accumulator
Accumulator Voltage (after the compensation)
Accumulator Temperature
Accumulator Charge Current
Accumulator Discharge Current
Load
Current
Generator Current
Accumulator over voltage, under voltage protection functions;
3 fixed analog sensors (temperature, oil pressure and liquid level);
2 configurable sensors can be set as sensor of temperature, oil pressure or fuel level;
Precision measure and display parameters about Engine,
Temp. (WT) °C/°F both be displayed
Oil pressure (OP) kPa/Psi/Bar all be displayed
Fuel level (FL) %(unit)
Speed (SPD) r/min (unit)
Voltage of Battery (VB) V (unit)
Voltage of Charger (VD) V (unit)
Hour count (HC) can accumulate to max. 65535 hours.
Start times can accumulate to max. 65535 times.
Protection: automatic start/stop of the genset, perfect fault indication and protection
function;
All output ports are relay-out;
Parameter setting: parameters can be modified and stored in internal FLASH memory
and cannot be lost even in case of power outage; most of them can be adjusted using
front panel of the controller and all of them can be modified using PC via USB or RS485
ports.
More kinds of curves of temperature, oil pressure, fuel level can be used directly and
users can define the sensor curves by themselves;
Multiple crank disconnect conditions (speed sensor, oil pressure) are optional;
Widely power supply range DC(8~35)V, suitable to different starting battery voltage
environment;
Event log, real-time clock and Scheduled start & stop function (can be set as start genset

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once a day/week/month);
Can be used as an indicating instrument (indicate and alarm are enable only, relay is
inhibited );
With maintenance function. Actions (warning, shutdown) can be set when maintenance
time out;
All parameters used digital adjustment, instead of conventional analog modulation with
normal potentiometer, more reliability and stability;
Waterproof security level IP55 due to rubber seal installed between the controller
enclosure and panel fascia;
Metal fixing clips enable perfect in high temperature environment;
Modular design, self-extinguishingABS plastic enclosure, pluggable connection terminals
and embedded installation way; compact structure with easy mounting.

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3 SPECIFICATION
Parameter
Details
Working Voltage
DC8. 0V to 35. 0V, continuous power supply
Overall Consumption
<3W (Standby mode: ≤2W)
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
7A DC28V power supply output
Configurable Relay Output 2
7A AC250V passive output
Configurable Relay Output 3
16A AC250V passive output
Configurable Relay Output 4
16A AC250V passive output
Configurable Relay Output 5
7A DC28V power supply output
Configurable Relay Output 6
7A DC28V power supply output
Case Dimensions
197mm x 152mm x 47mm
Panel Cutout
186mm x 141mm
Working Conditions
Temperature: (-25~+70)°C
Humidity: (20~93)%RH
Storage Conditions
Temperature:(-25~+70)°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
0.75kg

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4 OPERATION
4.1. PUSHBUTTONS
Stop
Stop running generator in Auto/Manual mode; Lamp test (press at
least 3 seconds); Reset alarm in stop mode; During stopping
process, press this button again to stop generator immediately.
Start
Start genset in Manual mode.
Manual Mode
Press this key and controller enters in Manual mode.
Auto Mode
Press this key and controller enters in Auto mode.
Close/Open
Can control generator to switch on or off in Manual mode.
Mute/Reset
Alarm
Alarming sound off; If there is trip alarm, pressing the button at
least 3 seconds can reset this alarm.
Raise Speed
Control the genset accelerate in Manual mode.
Drop Speed
Control the genset decelerate in Manual mode.
Menu/Confirm
1) Enter into Menu interface;
2) Shift cursor and confirm the set information.
Up/Increase
1) Screen scroll;
2) Up cursor and increase value in setting menu.
Down/Decrea
se
1) Screen scroll;
2) Down cursor and decrease value in setting menu.
NOTE: Pressing to enter into Menu interface; select “Parameters” and input correct
passwords allows the users to set parameters.
NOTE: Pressing and simultaneously will increase LCD contrast; Pressing
and simultaneously will decrease LCD contrast; When controller is powered on after
outage, LCD contrast will return factory default.
WARNING: Default password is 00318, user can change it in case of others change the
advanced parameters setting. Please clearly remember the password after changing. If you
forget it, please contact Smartgen services and send all information in the controller page of
“ABOUT” to us.

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4.2. LCD DISPLAY
4.2.1. MAIN DISPLAY
Main screen show pages; use to scroll the screen.
★Main Screen, including as below,
Genset status, ATS status, Accumulator voltage, Accumulator temperature, Generator
Current, Accumulator Charge Current, Accumulator Discharge Current, ，Load current，
Engine speed
★Accumulator Charging Curve Screen, including as below,
Charge Start Voltage，Const Charge Voltage，Charge Stop Voltage，Accumulator Voltage,
Accumulator Current，Charging Status
★Engine 1#, including as below,
Engine Speed, GOV/AVR, Engine Temperature, Engine Oil Pressure
★Engine 1#, including as below,
Liquid (Fuel) Level, Controller Voltage, Charger Voltage, Configure Analog 1
NOTE: If connected with J1939 engine via CANBUS port, this page also includes: coolant
pressure, coolant level, fuel temperature, oil pressure, inlet temperature, exhaust temperature,
turbo pressure, total fuel consumption and so on.(different engine with different parameters)
★Acc. Information, including as below,
Total Running Time, Total Start Times, Maintenance Due
★Alarm：
Display all of alarm information.
NOTE: For ECU alarms and shutdown alarms, if the alarm information is displayed,
check engine according to it, otherwise, please check the manual of generator according to
SPN alarm code.
★Press can enter into menu interface to viewing the following items: event log;
input/output ports status; Issue time of software and hardware version; Time and Date
★Event Log, including as below,
Records all start/stop events (shutdown alarm, trip and stop alarm, manual /auto start or stop)
and the real time when alarm occurs.
4.2.2. PARAMETERS SETTING MENU
Parameters setting including as following,
★Charge Settings

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★Timer settings
★Engine settings
★Load settings
★ATS settings
★Analog sensor settings
★Input port settings
★Output port settings
★Module settings
★Scheduling and maintenance settings
★GSM settings
Example:
Advanced Parameters
Form 1:
Use to scroll settings, to enter settings (form
2), to exit settings menu.
> Charge
> Timer
> Engine
> Load
Charge
> Return
Form 2:
Use to scroll settings (form 3); select “return” and
press to return to previous menu (form 1), or press
to return to previous menu (form 1).
> 1# Bat Rated Voltage
>2# Bat Rated Voltage
> 1# Battery Num
Charge
> Charge Stop Current
> Float Charge Volt
> Nominal Voltage
Form 3:
Use to scroll settings, to confirm settings (form
4), to return to previous menu. (form 1)
> Charge OC
Charge OC
Sel：Disable
Set Value：00110%
Return Value：00108%
Delay：00005
Form 4:
Use to enter settings (form 5), to scroll settings,
to return to previous menu. (form 3)

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Charge OC
Form 5:
Use to scroll settings (form 6), to enter settings
(form 7), to exit settings menu. (form 4)
Sel：Disable
Set Value：00110%
Return Value：00108%
Delay：00005
Charge OC
Form 6:
Use to scroll settings (form 5), to enter settings
(form 7), to exit settings menu. (form 4)
Sel：Disable
Set Value：00110%
Return Value：00108%
Delay：00005
Charge OC
Sel：Enable
Set Value：00110%
Return Value：00108%
Delay：00005
Form 7:
Use to scroll settings (form 5), to enter settings,
to exit settings menu. (form 4)
Charge OC
Sel：Disable
Set Value：00110%
Return Value：00108%
Delay：00005
Form 8:
Use to scroll settings, to enter settings (form 4),
to exit settings menu. (form 4)
NOTE: Long time pressing can exit setting directly during setting.

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4.3. AUTO START/STOP OPERATION
Auto mode is selected by pressing the button; a LED besides the button will illuminate to
confirm the operation.
Starting Sequence:
1. When the accumulator voltage has fallen below the “Charge Start Voltage” or when
“Remote Start (with load)” is active, “Start Delay” timer is initiated. “Start Delay”
countdown will be displayed on LCD display;
2. When start delay is over, preheat relay energizes (if configured), “preheat delay XXs”
information will be displayed on LCD display;
3. After the above delay, the Fuel Relay (if configured) is energized, and then one second
later, the Start Relay is engaged. The engine is cranked for a pre-set time. If the engine
fails to fire during this cranking attempt then the fuel relay and start relay are disengaged
for the pre-set rest period; “crank rest time” begins and wait for the next crank attempt.
4. Should this start sequence continue beyond the set number of attempts, the start
sequence will be terminated, and Fail to Start fault will be displayed on LCD display.
5. In case of successful crank attempt, the “Safety On” timer is activated, allowing Low Oil
Pressure, High Temperature, Under speed and Charge Alternator Failure inputs to
stabilise without triggering the fault. As soon as this delay is over, “Waiting For Load”
delay is initiated.
6. If the on-load requirements have been reached, then the generator close relay will be
energized and the constant-current charge status is settled. The generator will regulate
GOV/AVR voltage automatically according to the charging current; If the GOV/AVR
voltage has reached its maximum value while the charging current is lower than the
“Rated Charge Current”, Charge Fault alarm will be initiated.
NOTE: Charge Stop Mode：Charge Current + Volt. The accumulator charges the
genset with the preset rated charging current (charge type: constant current). When the
accumulator voltage has exceeded the “constant voltage value”, enter into the “Constant
Voltage Charge” status. During the “Constant Voltage Charge” status, the accumulator
charges the genset with its minimum charging current as soon as the minimum value is
reached. After the accumulator voltage has reached the “Charge Stop Voltage”, the
charging is finished and the genset is enter into “Stop Mode”.
Charge Stop Mode：Charge Delay. The accumulator charges the genset with the preset
rated charging current (charge type: constant current). When the accumulator voltage has

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exceeded the “constant voltage value”, enter into the “Constant Voltage Charge” status
and this status will last for preset time.
Automatic Stop Sequence,
1) When the genset is charged or when the “Remote Start” signal is removed, the Stop
Delay is initiated. Once this “stop delay” has expired, the Generator Breaker will open and
the “Cooling Delay” is then initiated.
2) After the “Cooling Delay”, "Fail to Stop Delay" begins, fuel relay is de-energized, complete
stop is detected automatically.
3) When generator is stop completely, “After stop” delay will be initiated. Otherwise, fail to
stop alarm is initiated and the corresponding alarm information is displayed on LCD
display. (If generator is stop successfully after “fail to stop” alarm has initiated, “After stop”
delay will be initiated and the alarm will be removed).
4) Generator is placed into its standby mode after its “After stop” delay.

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4.4. MANUAL START/STOP OPERATION
1 Manual mode is selected by pressing the button; a LED besides the button will
illuminate to confirm the operation; Then press button to start the generator, it can
automatically judge crank success and accelerate to high speed running. If high
temperature, low oil pressure, over speed and abnormal voltage occur during genset
running, controller can effectively protect genset to stop (detail procedures please refer to
No.2~6 of Auto Start Sequence). If generator is normal, users can energize “Gen Close
Relay” manually via button or adjust engine speed manually via button in
order to let the accumulator is charged.
2 Manual stop: pressing key can shut down the running genset. (detail procedures
please refer to No.2~4 of Auto Stop Sequence)
NOTE: Manual start/stop operations are used for Test only.

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5 SWITCH CONTROL PROCEDURES
5.1 ACCUMULATOR/GENSET PRIORITY SYSTEM:
Charging：Igen = Iacc + Iload；
Non-charging：Igen = 0，Iacc = -Iload；
Charging：Iacc = Igen - Iload；
Non-charging：Iacc = -Iload；

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Charging：Iload = Igen - Iacc；
Non-charging：Iacc = xxx，Iload = xxx，Igen = 0；
Accumulator Priority System: In Auto mode, K2 and K3 are always close. When the
accumulator voltage has fallen below the Charge Start Volt, the genset will be started
according to the preset sequence. If the on-load requirements have been reached, K1 Close
relay will activate to charge the accumulator.
Genset Priority System: In Auto mode, K1 and K3 are always close. When the accumulator
voltage has fallen below the Charge Start Volt, the genset will be started according to the
preset sequence. If the on-load requirements have been reached, K2 Close relay will activate
to charge the accumulator. If Genset failure occurs, K2 Close relay will activate and the
Accumulator will take load.

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5.2 TWO ACCUMULATOR PRIORITY SYSTEM
1# Acc Charging：Iacc1 = Igen;
1# Acc on-load：Iacc1 = -Iload;
2# Acc Charging：Iacc2 = Igen;
2# Acc on-load：Iacc2 = -Iload;
1. Accumulator Switching Mode: Gap
1# Accumulator take load (K4 is closed)；When the 1# accumulator voltage has fallen below
the Charge Start Volt, K4 open relay will active, after 10s delay, 2# Accumulator take load (K5
is closed). During the above transfer process, the load is disconnect; The genset will be
started according to the preset sequence to charge the 1# Accumulator (K1 is closed).
Same procedures as above when 2# Accumulator transfer to 1# Accumulator.
2. Two Accumulator Switching Mode: Continuous
1# Accumulator take load (K4 is closed)；When the 1# accumulator voltage has fallen below
the Charge Volt, 2# accumulator voltage will be recorded and the genset voltage detection
begins; The genset will be started according to the preset sequence; When the genset
voltage rise to 1# accumulator voltage, K2 close relay will active and genset takes load. After
1s delay, K4 open relay will active. Adjust the genset voltage to reach to 2# accumulator
voltage, then 2# accumulator takes load (K5 is closed), K2 open relay active. After 1s delay,
K1 close relay active to charge the 1# accumulator．
Same procedures as above when 2# Accumulator transfer to 1# Accumulator.
NOTE：All above switch actions can be implemented when the controller is in Auto mode.
MANUAL TRANSFER PROCEDURES:
Accumulator Priority: K2 and K3 are always close. Press button，if generator have taken
load (K1 Close)，will output unload signal (K1 Open)；if taken no load (K1 Open)，generator
will output load signal (K1 Close)；
Generator Priority: K1 and K3 are always close. Press button，if Accumulator have taken