Smartgen HGM9420N User manual

HGM9420N_HGM9420LT
GENSET CONTROLLER
USER MANUAL
SMARTGEN (ZHENGZHOU) TECHNOLOGY CO.,LTD.

Chinese trademark
English trademark
SmartGen —make your generator smart
SmartGen Technology Co., Ltd.
No.28 Jinsuo Road
Zhengzhou City
Henan Province
P. R. China
Tel: [phone]
0086-(0)371-67991553/67992951
0086-(0)371-67981000(overseas)
Fax: [phone]
Web: www.smartgen.com.cn
www.smartgen.cn
Email: [e-mail]
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.
Table 1 Software Version
Date
Version
Note
2019-12-10
1.0
Original release.

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Table 2 Symbol Instruction
Symbol
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 a procedure or practice, which could result in injury to personnel or loss of life
if not followed correctly.

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CONTENTS
1 OVERVIEW......................................................................................................................................... 6
2 PERFORMANCE AND CHARACTERISTICS.................................................................................... 7
3 SPECIFICATION............................................................................................................................... 10
4 OPERATION..................................................................................................................................... 12
4.1 INDICATOR LAMP.................................................................................................................. 12
4.2 PUSHBUTTONS...................................................................................................................... 13
4.3 LCD DISPLAY ......................................................................................................................... 14
4.3.1 MAIN DISPLAY ................................................................................................................... 14
4.3.2 USER MENU AND PARAMETER SETTING...................................................................... 16
4.4 AUTO START/STOP OPERATION......................................................................................... 18
4.4.1 ILLUSTRATION................................................................................................................... 18
4.4.2 AUTOMATIC START SEQUENCE..................................................................................... 18
4.4.3 AUTOMATIC STOP SEQUENCE....................................................................................... 19
4.5 MANUAL START/STOP OPERATION.................................................................................... 19
5 CONTROLLER SWITCH CONTROL PROCEDURES..................................................................... 20
5.1 SWITCH CONTROL PROCEDURE FOR SYNC TRANSFER DISABLED............................ 20
5.1.1 MANUAL TRANSFER PROCESS ...................................................................................... 20
5.1.2 AUTOMATICTRANSFER PROCEDURE............................................................................ 20
5.2 SWITCH CONTROL PROCEDURE FOR SYNCHRONOUS TRANSFER ENABLED .......... 21
5.2.1 MANUAL TRANSFER PROCEDURE................................................................................. 21
5.2.2 AUTO SWITCHING PROCESS.......................................................................................... 22
6 PROTECTIONS................................................................................................................................ 25
6.1 WARNING ALARMS................................................................................................................ 25
6.2 BLOCK ALARMS..................................................................................................................... 32
6.3 TRIP ALARM........................................................................................................................... 38
6.4 TRIP AND STOP ALARMS..................................................................................................... 43
6.5 SHUTDOWN ALARMS............................................................................................................ 50
7 WIRING CONNECTION ................................................................................................................... 56
8 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS.......................................... 59
8.1 CONTENTS AND SCOPES OF PARAMETERS.................................................................... 59
8.2 ENABLE DEFINITION OF PROGRAMMABLE OUTPUT PORTS......................................... 77
8.2.1 DEFINITION OF DIGITAL OUTPUT PORTS...................................................................... 77
8.2.2 DEFINED PERIOD OUTPUT.............................................................................................. 85
8.2.3 DEFINED COMBINATION OUTPUT.................................................................................. 85
8.3 DEFINED CONTENTS OF PROGRAMMABLE INPUT PORTS............................................ 86
8.4 SELECTION OF SENSORS.................................................................................................... 89
8.5 CONDITIONS OF CRANK DISCONNECT SELECTION........................................................ 90
9 PARAMETERS SETTING................................................................................................................. 90
10 CYCLE START ................................................................................................................................. 91
11 SENSOR SETTING .......................................................................................................................... 91

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12 COMMISSIONING............................................................................................................................ 93
13 TYPICAL APPLICATION.................................................................................................................. 94
14 NEL TRIP DESCRIPTION................................................................................................................ 96
15 DUMMY LOAD CONNECTION........................................................................................................ 97
16 OIL CONSUMPTION ILLUSTRATION............................................................................................. 98
17 ETHERNET PORT............................................................................................................................ 98
18 HOST USB PORT............................................................................................................................. 99
19 INSTALLATION................................................................................................................................. 99
19.1 SGE02 EXPANSION MODULE............................................................................................... 99
19.1.1 4G ANTENNA PORT ...................................................................................................... 99
19.1.2 GPS ANTENNA PORT.................................................................................................... 99
19.1.3 SIM CARD INSTALLATION.......................................................................................... 100
19.2 CASE DIMENSIONS AND CUTOUT SIZE........................................................................... 100
20 SMS MESSAGE ALARM AND REMOTE CONTROL.................................................................... 102
20.1 SMS MESSAGE ALARM....................................................................................................... 102
20.2 SMS MESSAGE REMOTE CONTROL................................................................................. 102
21 CONNECTIONS OF CONTROLLER AND J1939 ENGINE........................................................... 103
21.1 CUMMINS ISB/ISBE.............................................................................................................. 103
21.2 CUMMINS QSL9 ................................................................................................................... 103
21.3 CUMMINS QSM11 (IMPORT)............................................................................................... 104
21.4 CUMMINS QSX15-CM570.................................................................................................... 104
21.5 CUMMINS GCS-MODBUS.................................................................................................... 105
21.6 CUMMINS QSM11 ................................................................................................................ 105
21.7 CUMMINS QSZ13................................................................................................................. 105
21.8 DETROIT DIESEL DDEC III/IV ............................................................................................. 106
21.9 DEUTZ EMR2........................................................................................................................ 106
21.10 JOHN DEERE........................................................................................................................ 106
21.11 MTU MDEC............................................................................................................................ 107
21.12 MTU ADEC(SMART MODULE)............................................................................................ 107
21.13 MTU ADEC (SAM MODULE)................................................................................................ 107
21.14 PERKINS............................................................................................................................... 108
21.15 SCANIA.................................................................................................................................. 108
21.16 VOLVO EDC3........................................................................................................................ 108
21.17 VOLVO EDC4........................................................................................................................ 109
21.18 VOLVO-EMS2 ....................................................................................................................... 109
21.19 YUCHAI ................................................................................................................................. 110
21.20 WEICHAI................................................................................................................................ 110
22 FAULT FINDING............................................................................................................................. 111
23 APPENDIX...................................................................................................................................... 112

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1 OVERVIEW
HGM9420N_HGM9420LT genset controller is used for automatic control of single genset to realize
automatic start/AMF/synchronous transfer/cloud monitoring. This series of controller integrates
digitalization, intelligence, and network technology. It fits with LCD graphic display, optional Chinese,
English and other languages interface, and it is reliable and easy to use.
HGM9420N_HGM9420LT genset controller applies 32-bit microprocessor technology, realizing
precise measuring of many parameters, value adjusting, and timing, threshold adjusting etc. functions. A
majority of parameters can be adjusted from the front panel. All parameters can be adjusted via USB or
RS485 port on PC. Controller fits with SAE J1939 port, which can communicate with multiple ECU
(ENGINE CONTROL UNIT) units with J1939. With compact structure, simple wiring, and high reliability,
it can be used in various genset automation systems.
HGM9420N_HGM9420LT genset controller can connect with SGE02-4G network communication
expansion module, which can make genset connected with Internet. After controller is logged in cloud
server, it can upload the data information (includes: GPS positioning site, altitude etc.) at real time to the
corresponding cloud server. Users can monitor and check genset running status and event log at real
time by mobile APP (IOS or Android), or PC similar terminal device. Network communication module has
SMS message function.

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2 PERFORMANCE AND CHARACTERISTICS
HGM9420N_HGM9420LT: fits Mains-Gen power monitoring for Mains/Gen automatic transfer control
(AMF). It is used for single unit automation system formed by one Mains and one Genset. Mains can be
disabled by disabling mains parameters for single unit automation. By remote start signal genset auto
start and stop can be controlled. Mains can be enabled only by setting mains parameters to realize
mains parameter only display; by remote start signal genset auto start and stop can be controlled.
Synchronous transfer function can be enabled to realize Gen and Mains synchronous transfer function.
Main characteristics are as below:
—240x128 LCD with backlight, multilingual interface (including English, Chinese or other languages)
which can be chosen at the site, making commissioning convenient for factory personnel; For other
languages language package needs to be written by PC software;
—Language packages include: Simplified Chinese, Traditional Chinese, English, Spanish, Portuguese,
Russian, Arabic, Turkish, Thai, French, Polish, German, Italian, Dutch;
—2 RS485 and 1 RJ45 Ethernet communication port, "4 remotes" (remote control, remote measuring,
remote communicating, and remote adjusting) can be realized by MODBUS protocol;
—1 Fn function key, can be set to other function on the panel, or Fn key function;
—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 of Mains/Gen, 3-phase current, frequency, load power and
Gen voltage harmonic parameters;
Mains
Line voltage Uab, Ubc, Uca
Phase voltage Ua, Ub, Uc
Frequency Hz
Phase sequence
Gen
Line voltage Uab, Ubc, Uca
Phase voltage Ua, Ub, Uc
Frequency Hz
Phase sequence
Harmonic wave 1-21 times harmonic content waveform distortion
Load
Current Ia, Ib, Ic
Each phase and total active power P
Reactive power Q
Apparent power S
Power factor PF
Gen total energy kWh, kvarh, kVAh
Earth current A
Unbalanced current A

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Load output percentage (active power/rated power)x100%
Average load of current run kW
Total energy of current run kWh
Average load of last time kW
Historical max average load kW
—Mains has over voltage, under voltage, over frequency, under frequency, loss of phase, reverse
phase sequence function; Gen has over voltage, under voltage, over frequency, under frequency, over
current, over power, reverse power, loss of phase, reverse phase sequence, unbalanced voltage high,
waveform distortion high, earth fault, unbalanced current high, power factor low, loss of excitation
detection function;
—Synchronous transfer enabled parameters: voltage difference of Gen and Mains, frequency
difference of Gen and Mains, phase angle difference of Gen and Mains;
—Collect precisely various parameters of engine:
Temperature Unit: °C/°F
Oil pressure Unit: kPa/psi/bar
Fuel Level Unit: %
Speed Unit: r/min (RPM)
Battery voltage Unit: V
Charger D+ voltage Unit: V
Total run time max 65535 hours
Total start times max 65535 times
—Control and protection function: automatic start/stop of the diesel genset, ATS(Auto Transfer Switch)
control and perfect fault indication and protection function etc.;
—Parameter setting function: parameters can be modified by users and cannot be lost even in case of
power outage; most of them can be adjusted from the front panel of the controller and all of them can be
modified on PC by USB, RS485 port, or RJ45 Ethernet port;
—3 fixed analogue sensor inputs (temp., oil pressure, fuel level);
—3 configurable sensors can be set to temp., pressure, or level sensor;
—Oil pressure sensor, level sensor, flexible sensor 1, flexible sensor 2 inputs can directly connect
resistance, voltage, or current sensor; other sensor inputs can connect resistance sensor; if voltage or
current type sensors need to connect, please notify us before order;
—Multiple temp., pressure, and fuel level sensor curves can be used directly, and custom sensor
curve can be done;
—Multiple crank disconnect conditions (speed, engine oil pressure, gen frequency) are optional;
—Wide power supply range DC(8~35)V, suitable for different starting battery voltage environment;
—Event log, real-time clock, scheduled start & stop function (allowing to start the genset once a
day/week/month with load or not); cyclic start function of two gensets is fitted;
—Alarm data record function, which allows to record the genset data of 5 alarms;

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—A USB Host port, where U flash of FAT32 format can be inserted, can put controller configured
parameters to the controller, or save controller parameters to the U flash; Historical data can be saved;
—Accumulative total run time of A and B and total electric energy of A and B; Users can reset it as 0
and re-accumulative the value, making convenience for users to count the total value as they wish;
—Heater, cooler and fuel pump control functions;
—Applicable for water pump genset; it can also be used as an indicating instrument (only indication,
alarm, no action for relays);
—Maintenance function; 3 groups of maintenance parameters, maintenance time, pre-alarm A time,
pre-alarm B time, pre-alarm time due action, and maintenance time due action can be set;
—By judging DC voltage, auto charging start function can be realized;
—Through CAN (2) port or RS485 (2) port cyclic start function of two gensets can be realized; master
run time and backup run time can be set;
—Through CAN port, AIN24, AIN26-M02, AIN8, DIN16A and DOUT16B expansion module and
BAC150CAN charger can be connected;
—By setting oil tank volume and oil consumption curve, residue fuel, residue run time and real-time oil
consumption can be displayed;
—Monitoring data communication protocol address is customizable by users;
—PLC function is fitted;
—By connecting SGE02-4G module, wireless network can connect with cloud server;
—By connecting SGE02-4G module, SMS function can be realized; when alarms occur, it can
automatically send alarm information to the pre-set 5 phone numbers; messages are also able to control
genset and check genset status;
—By connecting SGE02-4G module, GPS positioning function can be realized to obtain genset
location;
—Genset data can be uploaded at changing by applying network data communication protocol of
JSON format; at the same time network flow are extremely reduced by using compression algorithm;
when alarms occur, it can immediately upload data to the server;
—IP65 waterproof level is achieved with the help of rubber-ring gasket between shell and control
fascia;
—Metal fixing clips employed to fix the controller and make it perform better under high temperature
environment; Modular structure design, self-extinguishing ABS plastic shell, pluggable terminal, built-in
mounting, compact structure with easy installation;

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3 SPECIFICATION
Table 3 Technical Specification
Parameter
Details
Working Voltage
Range: DC8V - DC35V continuous, DC reverse connection protection
Resolution: 0.1V
Accuracy: 1%
Overall Consumption
<7W (Standby mode: ≤2.5W)
AC Voltage
Phase voltage
Range: AC15V - AC360V (ph-N)
Resolution: 0.1V
Accuracy: 0.5%
Wire voltage
Range: AC30V - AC620V (ph- ph)
Resolution: 0.1V
Accuracy: 0.5%
AC Frequency
Range: 5Hz -75Hz
Resolution: 0.01Hz
Accuracy: 0.1Hz
AC Current
Rated: 5A
Range: 0A –10A
Resolution: 0.1A
Accuracy: 1%
Speed Sensor
Voltage Range: 1. 0 V - 24 V (RMS)
Frequency Range: 5Hz –10000Hz
Charger(D+) Voltage
Range: DC0V - DC60V continuous
Resolution: 0.1V
Accuracy: 1%
DC Voltage
Range: DC0V-DC100V
Resolution: 0.1V
Accuracy: 1%
Analog Sensor
Resistor Input
Range: 0Ω- 6000Ω
Resolution: 0.1
Accuracy: 1Ω(below 300Ω)
Voltage Input
Range: 0 V - 10V
Resolution: 0.001V
Accuracy: 1%
Current Input
Range: 0 mA - 20mA
Resolution: 0.01mA