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

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4OPERATION
4.1INDICATOR LIGHT
HGM9120

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4.2KEY FUNCTIONS
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/Test mode.
Manual Mode
Press this key and controller enters in Manual
mode.
Auto Mode
Press this key and controller enters in Auto mode.
Mute/Reset
Alarm
Alarming sound off; If there is trip alarm, pressing
the button at least 3 seconds can reset this alarm.
Gen Close/Open
Can control generator to switch on or off in manual
mode.
Mains Close/Open
Can control generator to switch on or off in manual
mode.
Up/Increase
1) Screen scroll; 2) Up cursor and increase
value in setting menu.
Down/Decrease
1) Screen scroll; 2) Down cursor and decrease
value in setting menu.
Left
1) Screen scroll; 2) Left move cursor in setting
menu.
Right
1) Screen scroll; 2) Right move cursor in setting
menu.
Set/Confirm
1. Press the button will enter into parameter
configuration menu;
2. In settings menu confirms the set value.
Exit
1. Returns to the main menu;
2. In settings menu returns to the previous menu.
NOTE: In manual mode, pressing and simultaneously will force
generator to crank. Successful start will not be judged according to crank disconnect
conditions, operator will have to crank the starter motor manually; when operator decides

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that the engine has fired, he/she should release the button and start output will be
deactivated, safety on delay will start.
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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4.3LCD DISPLAY
4.3.1 MAIN DISPLAY
Main screen shows pages; use to scroll the pages and to scroll the screen.
★Status, including as below,
Genset status, mains status, and switch close/open status
★Engine, including as below,
Speed, engine temperature, engine oil pressure, liquid (fuel) level, canopy temperature, oil
temperature, Configure Sensor 1, Configure Sensor 2, battery voltage, charger voltage,
accumulated run time, accumulated start times.
★Gen, including as below,
Phase voltage, Line voltage, frequency, phase sequence
★Mains, including as below
Phase voltage, Line voltage, frequency, phase sequence
★Load, including as below,
Current, each phase and total active power (positive and negative), each phase and total
reactive power (positive and negative), each phase and total apparent power, each phase
and average power factor (positive and negative), accumulated energy (kWh, kvarh, kVAh)
and earth current.
Note: When only mains switch on indicator lights, count active and inactive power,
apparent power, power factor, but accumulate electric energy. Counting the generator active
and reactive power, apparent power, power factor, and accumulate electric energy under
other conditions.
NOTE: Power factor shows as following,
Remark:
P stands for active power
Q stands for inactive power

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Note:
1. Input active power, generator or mains supply electricity to load.
2. Output active power, load supply electricity to generator or mains.
3. Input reactive power, generator or mains send reactive power to load.
4. Output reactive power, load send reactive power to generator or mains.
★Alarm:
◙Event log
Records all start/stop events (shutdown alarm, trip and stop alarm, manual /auto start or stop)
and the real time when alarm occurs.
Others, including,
Time and Date, count down time for maintenance, input/output ports status.
◙About, including,
Issue time of software and hardware version
Example:
Engine-Speed
1500 r/min
Manual Mode
Power
Factor
Conditions
Active
Power
Inactive
Power
Remark
COS>0L
P>0,Q>0
Input
Input
Load is inductive resistance.
COS>0C
P>0,Q<0
Input
Output
Load is capacitance resistance.
COS<0L
P<0,Q>0
Output
Input
Load equal to one under excitation
generator
COS<0C
P<0,Q<0
Output
Output
Load equal to one over excitation
generator.
Gen-Phase Voltage
L1 220V
L2 220V
L3 220V
Battery Undervolts

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4.3.2 PARAMETERS SETTING MENU
Parameter setting Including as following,
★Mains settings
★Timer settings
★Engine settings
★Generator settings
★Load settings
★Switch settings
★Analog sensor settings
★Input port settings
★Output port settings
★Module settings
★Scheduling and maintenance settings
★GSM settings
Example,
Advanced Parameters
>Mains Setting
>Timer Setting
>Engine Setting
Form1: Use to scroll settings, to enter
settings (Form 2), to exit settings menu.
>Generator Setting
Generator
> Return
Form 2:
Use to scroll settings (Form 3); Select”Return”
and press back to previous menu(Form 1) back
to previous menu.(Form 1 )
> AC System
> Poles
> Rated Voltage
Generator
>Under voltage shutdown
>Over freq shutdown
>Under freq shutdown
Form 3:
Use to scroll settings. confirm setting (Form
4), back to previous menu (Form 1).
>Over voltage warn

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Over Voltage Warn
Enable choice: Disable
Set value: 00110%
Return value: 00108%
Delay: 00005
Form 4:
Enter setting menu (Form 5)‚ back to previous
menu (Form 3).
Over Voltage Warn
Form 5:
Use to scroll settings (Form 6)‚ confirm
setting(Form 7)‚ exit setting (Form 4).
Enable choice: Disable
Set value: 00110%
Return value: 00108%
Delay : 00005
Over Voltage Warn
Form 6:
Use to scroll settings (Form 5), confirm setting
(Form 7), exit setting (Form4).
Enable choice: Enable
Setting value: 00110%
Return value: 00108%
Delay : 00005
Over Voltage Warn
Enable choice: Enable
Setting value: 00110%
Return value: 00108%
Delay: 00005
Form 7:
Press to change cursor position, are used
for changing cursor value, Confirm setting, exit
setting (Form 4).
Over Voltage Warn
Enable choice：Disable
Setting value: 00110%
Return value: 00108%
Dealy: 00005
Form 8:
Press to change cursor position, are used
for changing cursor value, Confirm setting (Form 4),
exit setting (Form 4).
NOTE: Pressing for a long time will exit setting directly during setting.

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4.4AUTO 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. HGM9120: When Mains is abnormal (over and under voltage, over and under frequency,
loss of phase, phase sequence wrong), it enters into mains “abnormal delay” and LCD
display count down time. When mains abnormal delay is over, it enters into “start delay”;
it also enters into this mode when “remote start on load” is active.
2. Start Delay timer is shown on Status page of LCD.
3. When start delay is over, preheat relay outputs (if this be configured), “preheat start
delay XX s” is shown at the bottom line of LCD.
4. When preheat delay is over, fuel relay outputs 1s and then start relay output; if engine
crank fails during “cranking time”, the fuel relay and start relay deactivated and enter into
“crank rest time” to wait for next crank.
5. If engine crank fails within setting times, the controller sends Fail to Start signal and Fail
To Start message appears on LCD alarm page.
6. In case of successful crank attempt, “safety on timer”starts. During this period, low oil
pressure, high water temperature, under speed, charge failure alarms are disabled. As
soon as this delay is over, “start idle delay” is initiated (if configured).
7. During “start idle delay”, under speed, under frequency, under voltage alarms are
inhibited. When this delay is over, “warming up delay” starts (if configured).
8. When “warming up delay” is over, if generator state is normal, its indicator will be
illuminated. If voltage and frequency has reached on-load requirements, the closing relay
will be energised, generator will accept load, generator power indicator will illuminated,
and generator will enter Normal Running state; if voltage and frequency are abnormal,
the controller will initiate shutdown alarm (alarm type will be displayed on LCD alarm
page).
NOTE: In case of “Remote Start (off Load)”, the procedure is the same, except for step
NO. 8: the closing relay will NOT be energised, generator will NOT accept load.
Stopping Sequence:
1. HGM9120, when mains return normal during gen-set running, enters into mains voltage
“Normal delay”. When mains normal delay are over, enter into “stop delay”; also can be

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into this mode when “remote start on load” is inactive.
2. When stop delay is over, close generator relay is un-energized; generator enters into
“cooling down time”. After “transfer rest time”, close mains relay is energized; mains will
accept load; generator indicator extinguish while mains indicator lights.
3. Idle relay is energized as soon as entering “stop idle delay” (if configured).
4. If enter “ETS hold delay”, ETS relay is energized. Fuel relay is deactivated and decides
whether generator is stopped or not automatically.
5. Then enter gen-set “Fail to stop time”, auto decides whether generator is stopped or not
automatically.
6. Enter “after stop time” (if configured) as soon as generator stops. Otherwise, controller
will send “Fail to stop” alarm. (If gen-set stopped successfully after warning of “Failed to
Stop”, it will enter “after stop time” and remove alarm)
7. Enter “generator at rest” as soon as “after stop time” is over.
4.5MANUAL START/STOP OPERATION
1. MANUAL START: Press , controller enters into Manual mode and its indicator
lights. Press to start generator, can automatically detect crank disconnected, and
generator accelerates to high-speed running automatically.With high temperature, low oil
pressure, over speed and abnormal voltage during generator running, controller can
protect genset to stop quickly. Press can control the switch to close or open in
manual mode. (Please refer to No.3~8 of Auto start operation for detail procedures,
care should be taken that the switch close/open ways are different).
2. MANUAL STOP: Press can stop the running generators. (please refer to
No.2~7 of Auto stop operation for detail procedures).
NOTE: In “manual mode”, the procedures of ATS please refer to ATS procedure of
generator in this manual.

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4.6SWITCH CONTROL PROCEDURES
4.6.1 HGM9120 SWITCH CONTROL PROCEDURES
Manual transfer procedures
When controller is in Manual mode, the switch control procedures will start through manual
transfer procedures.
Users can control the loading transfer of ATS via pressing button.
A. If “Open breaker detect” is “SELECT Disable”
Press generator switch on or off key , if generator has taken load, will send unload
signal; if taken no load, generator will send load signal; if mains has taken load, mains will
unload, and then generator will take load after “open delay”has expired.
Press mains switch on or off key , if mains has taken load, will send unload signal; if
taken no load, mains will send load signal; if generator has taken load, generator will
unload, and then mains will take load after “open delay”has expired.
B. If “Open breaker detect” is “SELECT Enable”
To transfer load from mains to generator need to press mains switch off key firstly.
After switch off delay, press generator switch on key ,and generator will take load
(there is no action when pressing switch on key directly).
The way to transfer from generator to mains is as same as above.
Auto transfer procedures:
When controller is in AUTO mode, switch control procedures will start through automatic
transfer.
1. If input port is configured as Close Mains Auxiliary
A. If “Open breaker detect” is “SELECT Enable”
When transferring load from mains to generator, controller begins detecting “fail to
transfer”, then the open delay and transfer rest delay will begin. When detecting time out,
if switch open failed, the generator will not switch on, otherwise, generator switch on.
Detecting “fail to transfer”while generator switch on.When detecting time out, if switch on
fail, it is need to wait for generator to switch on. If transfer failed and warning “SELECT
Enable”, there is alarming signal whatever switch on or off failure.
The way to transfer from generator load to mains load is as same as above.
B. If “Open breaker detect” is “SELECT Disable”