Smartgen HGM9120 User manual

HGM9120 Genset AMF Controller
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]
0086-371-67991553/67992951
0086-371-67981000(overseas)
Fax: [phone]
Web: www.smartgenindia.in
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.
Applications for the copyright holder‟s written permission to reproduce any part of this
publication should be addressed to Smartgen Technology at the address above.
Any reference to trademarked product names used within this publication is owned by their
respective companies.
Smartgen Technology reserves the right to change the contents of this document without
prior notice.

Software Version
Date
Version
Note
2014-04-14
1.0
Original release
This manual is suitable for HGM9120 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
1OVERVIEW..............................................................................................................................................6
2PERFORMANCE AND CHARACTERISTICS..............................................................................7
3SPECIFICATION................................................................................................................................. 10
4OPERATION..........................................................................................................................................11
4.1 INDICATOR LIGHT........................................................................................................................... 11
4.2 KEYFUNCTIONS.............................................................................................................................12
4.3 LCD DISPLAY...................................................................................................................................14
4.3.1 Main Display.......................................................................................................................... 14
4.3.2 Parameters Setting Menu...................................................................................................... 16
4.4 AUTO START/STOP OPERATION...................................................................................................18
4.5 MANUALSTART/STOPOPERATION..............................................................................................19
4.6 SWITCH CONTROLPROCEDURES...............................................................................................20
4.6.1 HGM9120 Switch Control Procedures.................................................................................. 20
5 PROTECTION..............................................................................................................22
5.1 WARNINGS ......................................................................................................................................22
5.2 SHUTDOWNALARM........................................................................................................................24
5.3 TRIPAND STOPALARM..................................................................................................................26
5.4 TRIPALARM.....................................................................................................................................27
6WIRINGS CONNECTION............................................................................................. 28
7SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS ......................31
7.1 CONTENTSAND SCOPES OF PARAMETERS ..............................................................................31
7.2 ENABLE DEFINITION OF PROGRAMMABLE OUTPUTPORTS....................................................40
7.2.1 Custom Period Output........................................................................................................... 44
7.2.2 Custom Combined Output..................................................................................................... 44
7.3 DEFINED CONTENTS OF CONFIGURABLE INPUT PORTS (ALLACTIVEWHEN CONNECTTO
GRAND (B-)) ...........................................................................................................................................46
7.4 SELECTION OF SENSORS.............................................................................................................48
7.5 CONDITIONS OF CRANK DINSCONNECTSELECTION...............................................................49

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8PARAMETERS SETTING............................................................................................ 50
9SENSORS SETTING ...................................................................................................51
10 COMMISSIONING........................................................................................................52
11 TYPICAL APPLICATION .............................................................................................53
12 INSTALLATION............................................................................................................ 54
13 GSM SHORT MESSAGE ALARM AND REMOTE CONTROL.................................... 56
13.1 GSM SHORTMESSAGEALARM ..............................................................................................56
13.2 GSM SHORTMESSAGE REMOTE CONTROL ........................................................................56
14 FAULT FINDING ..........................................................................................................58

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1OVERVIEW
HGM9120 genset controller is used for genset automation and monitor control system of
single unit to achieve automatic start/stop, data measure, alarm protection and “three
remote”(remote control, remote measuring and remote communication); especially for
auto mains failure (AMF) system composed by generator and mains. This module also can
be used as auto start module or engine control module.
HGM9120 genset 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
adjusted and monitored using PC (via Link port).It can be widely used in a number of
automatic genset control system with compact structure, simple connections and high
reliability.

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2PERFORMANCE AND CHARACTERISTICS
♦AMF (Automatic Mains Failure) function; also can be used as a single genset auto start
module by shielding mains signal or as an engine control module simply by shielding
generator signal in parameter setting interface.
♦With ARM-based 32-bit SCM, highly integrated hardware, new reliability level.
♦132x64 LCD with backlight; English interface.
♦Improved LCD wear-resistance and scratch resistance due to hard screen acrylic;
♦Silicon panel and pushbuttons for better operation in high/low temperature environment;
♦Equipped with RS232/GSM communication port. “Three remote”(remote control, remote
measuring and remote communication) function will be implemented if it is used as
monitoring port (use MODBUS RTU protocol), while SMS (Short Message Service)
function will be implemented if it is used as GSM port (GSM MODEM must be fitted,
SG361 module produced by Smartgen is recommended.) 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.
♦Suitable for 3-phase 4-wire, 3-phase 3-wire, single phase 2-wire, and 2-phase 3-wire
systems with voltage 120/240V and frequency 50/60Hz;
♦Collects and shows 3-phase voltage, current, power parameter and frequency of
generator or mains.
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)
Phase sequence Phase sequence
Frequency Hz Frequency Hz
Load
Current IA, IB, IC, IE
Each phase and total active power kW
Each phase and total reactive power Kvar
Each phase and total apparent power kVA
Each phase and average power factor PF
Accumulate total generator power kWh, kVarh, kVAh
♦For Mains, controller has over and under voltage, over and under frequency, loss of

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phase and phase sequence wrong detection functions; For generator, controller has
over and under voltage, over and under frequency, loss of phase, phase sequence
wrong, over and reverse power, over current functions;
♦Earth current detection function (earth fault protection);
♦There are 7 analog sensors, among which 5 are fixed sensors (temperature, oil pressure,
liquid level, oil temperature and canopy temperature) and other 2 are configurable
sensors (can be set as temperature sensor, oil pressure sensor or fuel level sensor);
♦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 gen-set, ATS(Auto Transfer Switch) control with
perfect failure 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 (with the exception of
scheduled start/stop and alternative configured function only) can be adjusted using
front panel of the controller and all of them can be modified using PC via Link port.
♦More kinds of curves of temperature, oil pressure, fuel level can be used directly and
users can define the sensor curves using front panel by themselves;
♦Multiple crank disconnect conditions (speed sensor, oil pressure, generator frequency)
are optional;
♦Power on mode can be set (stop mode, manual mode and auto mode can be chosen);
♦PLC (programmable logic controller) function allows the controller can be
flexibly applied to complex applications;
♦Be applicable to high voltage units; voltage transformer can be externally connected with
AC voltage input ports.
♦Sampling frequency range: 10Hz~600Hz; It can be used not only in conventional

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50/60Hz units, but also in 400Hz units.
♦Widely power supply range DC(8~35)V, suitable to different starting battery voltage
environment;
♦100 pieces event logs; real-time clock; scheduled start & stop generator (can be set as
start genset once a day/week/month whether with load or not); scheduled not start (this
function can be set in the evening to prevent disturbing the residents);
♦Can be used as an indicating instrument (indicate and alarm are enable only, relay is
inhibited );
♦With maintenance function. Actions (warning and shutdown) can be set when
maintenance time out;
♦Fuel usage protection. Fuel consumption rate can be set to monitor the fuel usage.
♦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, anti-flaming ABS plastic enclosure, pluggable connection terminals and
embedded installation way; compact structure with easy mounting.

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3SPECIFICATION
Items
Contents
Operating Voltage
DC8.0V to DC35.0V, Continuous Power Supply.
Power Consumption
<3W (standby ≤0.9W)
Alternator Input Range
3-Phase 4-Wire
3-Phase 3-Wire
Single-Phase 2-Wire
2-Phase 3-Wire
AC15V - AC 360V (ph-N)
AC30V - AC620V (ph-ph)
AC15V - AC360V (ph-N)
AC15V - AC360V (ph-N)
Alternator Frequency
50Hz /60Hz
Speed sensor voltage
1.0V to 24.0V (RMS)
Speed sensor Frequency
10,000 Hz (max.)
Start Relay Output
7 A DC28V at supply output
Fuel Relay Output
7 A DC28V at supply output
Shutdown Alarm Output
7 A DC28V at supply output
Common Alarm Output
7 A DC28V at supply output
Mains Close Output
7A AC250V voltage free output
Gen Close Output
7A AC250V voltage free output
Programmable Relay Output (1)
7 A DC28V at supply output
Programmable Relay Output (2)
7A AC250V voltage free output
Case Dimension
237mm x 172mm x 45.8mm
Panel Cutout
214mm x160mm
C.T. Secondary
5A rated
Working Conditions
Temperature: (-25~+70)°C; Humidity: (20~93)%RH
Storage Condition
Temperature: (-25~+70)°C
Protection Level
IP55 Gasket
Insulating Intensity
Apply AC2.2kV voltage between high voltage terminal
and low voltage terminal;
The leakage current is not more than 3mA within 1min.
Net Weight
0.72kg