Smartgen HGM9580 User manual

HGM9580 Bus Tie Bus Parallel Unit
USER MANUAL
Smartgen Technology

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: +86-371-67988888/67981888
+86-371-67991553/67992951
+86-371-67981000(overseas)
Fax: 0086-371-67992952
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
2014-02-16
1.0
Original release

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This manual is suitable for HGM9580 bus tie bus parallel unit 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 a procedure or practice, which could result in injury to personnel or
loss of life if not followed correctly.

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CONTENTS
1OVERVIEW.......................................................................................................5
2PERFORMANCE AND CHARACTERISTICS...................................................6
3SPECIFICATION...............................................................................................7
4OPERATION.....................................................................................................8
4.1 INDICATOR LIGHT .........................................................................................................8
4.2 PUSHBUTTONS .............................................................................................................9
4.3 LCD DISPLAY ...............................................................................................................10
4.3.1 MAIN DISPLAY..........................................................................................................10
4.3.2 USER MENU AND PARAMETERS SETTING MENU ...............................................10
4.4 AUTO OPERATION.......................................................................................................13
4.5 MANUAL OPERATION..................................................................................................14
5PROTECTIONS...............................................................................................15
5.1 WARNING ALARMS......................................................................................................15
5.2 TRIP ALARM.................................................................................................................16
6WIRING CONNECTION ..................................................................................17
7SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS...............................20
7.1 CONTENTS AND SCOPES OF PARAMETERS............................................................20
7.2 ENABLE DEFINITION OF PROGRAMMABLE OUTPUT PORTS..................................24
7.2.1 DEFINED COMBINATION OUTPUT .........................................................................26
7.3 DEFINED CONTENTS OF PROGRAMMABLE INPUT PORTS (ALL ACTIVEWHEN
CONNECT TO GRAND (B~))....................................................................................................27
8TYPICAL DIAGRAM.......................................................................................29
9TYPICAL APPLICATION................................................................................30
10 INSTALLATION ..............................................................................................31
11 USB.................................................................................................................32
12 FAULT FINDING.............................................................................................33

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1 OVERVIEW
HGM9580 Bus Tie Bus Parallel Unit is designed for manual/auto parallel system which composed
by multi-way bus and multi-way bus. It allows automatic parallel running function. It fit with LCD
display, graphic display, optional Chinese, English and other languages interface, and it is reliable
and easy to use.
HGM9580 Bus Tie Bus Parallel Unit controls a bus breaker which can control the controller to
synchronize the two ways buses via MSC CAN if the synchronization requirements have satisfied.
The powerful 32-bit Microprocessor contained within the unit allows for precision parameters
measuring, fixed value adjustment, time setting and set value adjusting and etc..Majority
parameters can be configured from front panel, and all parameters can be configured by USB
interface (or RS485) to adjust via PC. It can be widely used in all types of automatic genset
parallel system with compact structure, simple connections and high reliability.

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2 PERFORMANCE AND CHARACTERISTICS
With ARM-based 32-bit SCM, high integration of hardware and more reliable;
480x272 TFT 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 panel and pushbuttons for better operation in high/low temperature environment;
RS485 communication port enables remote control, remote measuring, remote
communication via ModBus protocol.
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 and frequency of Bus 1/Bus 2.
Bus 1 Bus 2
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)
Synchronization parameters:Voltage Difference Between Bus 1 and Bus 2, Frequency
Difference Between Bus 1 and Bus 2, Phase Difference Between Bus 1 and Bus 2;
All output ports are relay output;
Parameter setting: parameters can be modified and stored in internal EEPROM 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;
Widely power supply range DC(8~35)V, suitable to different starting battery voltage
environment;
Event log, real-time clock function;
All parameters used digital adjustment, instead of conventional analog modulation with
normal potentiometer, more reliability and stability;
IP55 waterproofness level can be achieved with the help of rubber-ring gasket between shell
and control panel.
Metal fixing clips enable perfect in high temperature environment;
Modular design, self extinguishing ABS plastic shell, pluggable terminal, built-in mounting,
compact structure with easy installation;

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3 SPECIFICATION
Parameter
Details
Working Voltage
DC8. 0V to 35. 0V, continuous power supply
Overall Consumption
<4W (Standby mode: ≤2W)
AC Input:
3 Phase 4 Wire
3 Phase 3 Wire
Single Phase 2 Wire
2 Phase 3 Wire
AC15V - AC360V (ph-N)
AC30V - AC620V (ph- ph)
AC15V - AC360V (ph-N)
AC15V - AC360V (ph-N)
Alternator Frequency
50Hz/60Hz
Flexible Relay Output 1
7A DC28V power supply output
Flexible Relay Output 2
7A DC28V power supply output
Flexible Relay Output 3
7A DC28V power supply output
Flexible Relay Output 4
7A AC250V volts free output
Flexible Relay Output 5
7A AC250V volts free output
Flexible Relay Output 6
7A AC250V volts free output
Flexible Relay Output 7
16A DC28V power supply output
Flexible Relay Output 8
16A DC28V power supply output
Case Dimensions
266mm x 182mm x 45mm
Panel Cutout
214mm x 160mm
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
0.95kg

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4 OPERATION
4.1INDICATOR LIGHT
NOTE: Selected light indicators description:
Warning indicator and Alarm indicator:
Alarm Type
Warning Indicator
Alarm Indicator
Warning
Slow flashing
Slow flashing
Trip Alarm
Off
Fast flashing
Running indicator: It is light on when both of bus 1 and bus 2 are normal; off when either of them
is abnormal.
Bus 1 normal light:It is light on when bus 1 is normal; off when bus 1 is abnormal.
Bus 2 normal light:It is light on when bus 2 is normal; off when bus 2 is abnormal.

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4.2PUSHBUTTONS
Alarm Reset
If alarm occurs, pressing the button can reset this alarm.
Manual Mode
Press this key and controller enters in Manual mode.
Auto Mode
Press this key and controller enters in Auto mode.
Mute
Alarming sound off.
Lamp test
Press this key can test the lamp is normal or not (lamp
test).
Close
Can control bus to switch on in Manual mode.
Open
Can control bus to switch 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) Pressing and holding for more than 3 seconds enters
parameter setting menu;
2) In settings menu confirms the set value.
Exit
1) Return to main menu;
2) Return to previous menu in setting menu.
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 PD information in the controller page of
“ABOUT” to us.

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4.3LCD DISPLAY
4.3.1 MAIN DISPLAY
Main screen show pages; use to scroll the pages and to scroll the screen.
★Main Screen, including as below,
Bus 1: voltage, frequency, active power, reactive power
Bus 2: voltage, frequency, active power, reactive power
Some status
★Status, including as below,
Module status, ATS status
★SNYC, including as below,
Voltage difference, frequency difference, angle difference, MSC status
★Alarm
Display all alarm information (warning alarm, trip alarm).
★Event log
Make records about all events (trip alarm, power on events and Bus switch events) and the real
time when events occur.
★Others, including,
Time and Date, input/output ports status.
★About, including,
Issue time of software and hardware version, product PD number.
4.3.2 USER MENU AND PARAMETERS SETTING MENU
Press key for more than 3s to enter into user manual.
★Parameter
After entering the correct password (factory default password is 00318) you can enter parameter
settings screen.
★Language
Selectable Chinese, English and others (default: Espanol)
Parameter setting including as following,
★Battery setting
★Bus settings
★Breaker settings
★Input port settings
★output port settings

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★Module settings
★Synchronization settings
Example:
Return
Battery setting
Bus setting
> Close Delay
> Open Delay
Form1: Use to scroll settings,
to enter settings (form 2), to exit
settings menu.
Breaker setting >
Input setting
Output setting
Module setting
Synchronization setting
Return
Battery setting
Bus setting
>Close Delay
Form 2: Use to scroll settings,
to enter settings, to return to
previous menu. (form 1)
> Open Delay
Breaker setting >
Input setting
Output setting
Module setting
Synchronization setting
Return
Battery setting
Bus setting
> Close Delay
Form 3: Use to scroll settings,
to contirm settings (form 4), to
return to previous menu. (form 1)
> Open Delay
Breaker setting >
Input setting
Output setting
Module setting
Synchronization setting
> Close Delay
00003
Form 4:Press to enter settings
(form 5), to return to previous menu.
(form 6).
> Open Delay

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> Close Delay
00003
Form 5: Press to change cursor position,
are used for changing cursor value,
to confirm setting (form 4), to exit setting
(form 4).
> Open Delay
> Close Delay
00003
Form 6: Use to scroll settings. to
enter settings (form 4), to return to previous
menu. (form 1).
> Open Delay

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4.4AUTO OPERATION
Auto mode is selected by pressing the button; a LED besides the button will illuminate to
confirm the operation.
1. When remote start input is active:
a) If either of the two buses is deactivate, then bus close signal will be initiated and the bus will be
paralleled with the other bus;
b) If both of Bus 1 and Bus 2 are active, the controller will adjust frequency and voltage to
synchronize bus with bus; when synchronism requirements has been achieved, bus close
signal will be initiated and the bus will be paralleled with the other bus.
2. When remote start input is deactivate, then bus open relay activate and the bus split from the
other bus.
Note: The bus voltage is regarded as active if it has exceeded the dead bus voltage (the dead
bus voltage is configurable); otherwise, it is regarded as deactivate.

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4.5MANUAL OPERATION
Manual mode is selected by pressing the button; a LED besides the button will illuminate
to confirm the operation.
1. Press button:
If either of the two buses is deactivate, then bus close signal will be initiated and the bus will be
paralleled with the other bus.
If both of Bus 1 and Bus 2 are active, the controller will adjust frequency and voltage to
synchronize bus with bus; when synchronism requirements has been achieved, bus close
signal will be initiated and the bus will be paralleled with the other bus.
2. Press button, then bus open relay activates and the bus split from the other bus.

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5 PROTECTIONS
5.1 WARNING ALARMS
Warnings are not shutdown alarms and do not affect the operation of the gen-set. Warning alarms
does not lead to shutdown. Warning alarms types are as follows:
No
Type
Description
1
Battery Over Volt
When the controller detects that the battery voltage has exceeded
the pre-set value, it will initiate a warning alarm.
2
Battery Under Volt
When the controller detects that the battery voltage has fallen
below the pre-set value, it will initiate a warning alarm.
3
Bus Breaker Fail
When the controller detects that the bus close status is not
configured in the input port, it will initiate a warning alarm.
4
Digital Input
When the digit input port is set as User Configured and the action
select “Warn”, it will initiate a warning alarm.
5
Fail to sync
When the controller does not detect synchronization signal within
the pre-set synchronization time, it will initiate a warning alarm.
6
Min Sets Not
Reached
When the controller detects fewer modules on the MSC link than
the minimum number configured in the unit, it will initiate a warning
alarm. There are 2 possible reasons: a) Communication line
between the controllers disconnects, which interrupts
communication.
b) Other parallel gen-sets controllers have not been powered on.

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5.2TRIP ALARM
On initiation of the trip condition the controller will de-energize the ‘Close Generator’ Output
without stop the generator.
Trip alarm as following,
No
Type
Description
1
Digital Input
When the digit input port is set as User Configured and the action
select “Trip”, it will initiate a trip alarm.
2
Fail to sync
When the controller does not detect synchronization signal within
the pre-set synchronization time, it will initiate a trip alarm.
3
Bus Breaker Fail
When the controller detects that the bus breaker is failed, it will
initiate a trip alarm.
4
MSC Too Few Sets
When the controller detects fewer modules on the MSC link than
the minimum number configured in the unit, it will initiate a trip
alarm. There are 2 possible reasons: a) Communication line
between the controllers disconnects, which interrupts
communication.
b) Other parallel gen-sets controllers have not been powered on.
5
Bus 1 Phase
Sequence Wrong
When the controller detects a bus 1 phase rotation error, it will
initiate a trip alarm.
6
Bus 2 Phase
Sequence Wrong
When the controller detects a bus 2 phase rotation error, it will
initiate a trip alarm.
7
MSC ID Error
When the controller detects the same ID on the MSC Bus, it will
initiate a trip alarm.
8
Volt Bus Error
When the controller detects that the genset has already closed but
there is no voltage on bus, it will initiate a trip alarm.

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6 WIRING CONNECTION
HGM9580 controller’s rear as following:
Description of terminal connection:
NO.
Functions
Cable
Size
Remark
1
DC input B-
2.5mm2
Connected with negative of starter battery.
2
DC input B+
2.5mm2
Connected with positive of starter battery. If wire
length is over 30m, better to double wires in
parallel. Max. 20A fuse is recommended.
3
COM Output 7,8
2.5mm2
Connected with B+.
4
Aux. output 7
1.5mm2
B+ is supplied by 3 point, rated 16A.
5
Aux. output 8
1.5mm2
B+ is supplied by 3 point, rated 16A.
6
Aux. output 1
1.5mm2
B+ is supplied by 2 point,
rated 7A.
Details see form 2.
7
Aux. output 2
1.5mm2
B+ is supplied by 2 point,
rated 7A.
8
Aux. output 3
1.5mm2
B+ is supplied by 2 point,
rated 7A.
9
Reserved
/
This is reserved terminals, do not connect to wire.
10
Aux. input 1
1.0mm2
Ground connected is
active (B-)
Details see form 3.
11
Aux. input 2
1.0mm2
Ground connected is
active (B-)
12
Aux. input 3
1.0mm2
Ground connected is
active (B-)

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NO.
Functions
Cable
Size
Remark
13
Aux. input 4
1.0mm2
Ground connected is
active (B-)
14
Aux. input 5
1.0mm2
Ground connected is
active (B-)
15
Aux. input 6
1.0mm2
Ground connected is
active (B-)
16
Input COM
/
17-18
Reserved
/
This is reserved terminals, do not connect to wire.
19
Aux. input 7
1.0mm2
Ground connected is
active (B-)
Details see form 3.
20
Aux. output 4
1.5mm2
Normally close outputs,
rated 7A.
Details see form 2.
21
Public points of relay
22
Normally open outputs,
rated 7A.
23
MSC1 CAN
/
Impedance-120Ω shielding wire is recommended,
its single-end earthed.
24
MSC1 CAN H
0.5mm2
25
MSC1 CAN L
0.5mm2
26
MSC2 CAN
/
Impedance-120Ω shielding wire is recommended,
its single-end earthed.
27
MSC2 CAN H
0.5mm2
28
MSC2 CAN L
0.5mm2
33
RS485
/
Impedance-120Ω shielding wire is recommended,
its single-end earthed.
34
RS485+
0.5mm2
35
RS485-
0.5mm2
36
Aux. output 5
2.5mm2
Normally close outputs,
rated 7A.
Details see form 2.
37
2.5mm2
Normally open outputs,
rated 7A.
38
2.5mm2
Public points of relay
39
Aux. output 6
2.5mm2
Normally open outputs,
rated 7A.
40
2.5mm2
Public points of relay
41
Bus 2 A-phase voltage
sensing input
1.0mm2
Connected to A-phase of Bus 2 (2A fuse is
recommended).
42
Bus 2 B-phase voltage
sensing input
1.0mm2
Connected to B-phase of Bus 2 (2A fuse is
recommended).
43
Bus 2 C-phase voltage
sensing input
1.0mm2
Connected to C-phase of Bus 2 (2A fuse is
recommended).
44
Bus 2 N-wire input
1.0mm2
Connected to N-wire of Bus 2.
45
Bus 1 A-phase voltage
sensing input
1.0mm2
Connected to A-phase of Bus 1 (2A fuse is
recommended).
46
Bus 1 B-phase voltage
sensing input
1.0mm2
Connected to B-phase of Bus 1 (2A fuse is
recommended).

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NO.
Functions
Cable
Size
Remark
47
Bus 1 C-phase voltage
sensing input
1.0mm2
Connected to C-phase of Bus 1 (2A fuse is
recommended).
48
Bus 1 N-wire input
1.0mm2
Connected to N-wire of Bus 1.
NOTE: USB ports in controller rear panel are configurable parameter ports, user can directly
program controller via PC.

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7 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS
7.1CONTENTS AND SCOPES OF PARAMETERS
Form 1
No.
Items
Parameters
Defaults
Description
Battery Setting
1
Rated Voltage
(0-60.0)V
24.0
Standard for checking battery
over/under voltage.
2
Over Voltage
(0-200)%
120%
Setting value is rated voltage’s
percentage, return value (default:
115%) and delay value (default: 60s)
can be set.
3
Under Voltage
(0-200)%
85%
Setting value is rated voltage’s
percentage, return value (default: 90%)
and delay value (default: 60s) can be
set.
Bus Setting
1
AC System
(0~3)
0
0: 3P4W; 1: 3P3W;
2: 2P3W; 3: 1P2W.
2
Volt. Trans.(PT)
(0-1)
0
0: Disable; 1:Enable
Switch Setting
1
Close Time
(0~20.0)s
5.0
Pulse width of switch on. When it is 0,
means output constantly.
2
Open Time
(0~20.0)s
3.0
Pulse width of switch off.
Module Setting
1
Power On Mode
(0~1)
0
0: Manual mode 1: Auto mode
2
Module Address
(1~254)
1
Controller’s address during remote
sensing.
3
Stop Bit
(0~1)
0
0: 2 stop bits; 1: 1 stop bit
4
Language
(0~2)
0
0: Simplified Chinese 1: English
2: Others
5
Password
(0~65535)
00318
For entering advanced parameters
setting.
Flexible Input Ports
Flexible Input Port 1
1
Contents Setting
(0~50)
28
Remote OnLoad. See form 3
2
Active Type
(0~1)
0
0: Closed to active
1: Open to active
Flexible Input Port 2
1
Contents Setting
(0~50)
0
User defined. See form 3
2
Active Type
(0~1)
0
0: Closed to active
1: Open to active
3
Arming
(0~2)
2
0: From paralleling 1: Always 2:Never
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