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HGM8110DC-2 GENSET CONTROLLER USER MANUAL

HGM8110DC-2 Genset Controller 2020-02-20 Version 1.0 Page 11 of 69

Items

Contents

pollution class 2, altitude 3000m;

Case Dimension

242mm x186mm x53mm

Panel Cutout

214mm x160mm

CT Secondary Current

5A rated

Working Conditions

Temperature: (-40~+70)°C; Relative Humidity: (20~93)%RH

Storage Condition

Temperature: (-45~+80)°C

Protection Level

IP65: when rubber seal installed between the controller enclosure

and panel fascia.

Insulating Intensity

Apply AC2.2kV between high volt terminal and low volt terminal;

The leakage current is not more than 3mA within 1min.

Net Weight

0.85kg

Summary of Contents for HGM8110DC-1

Page 1: ...HGM8110DC 2 GENSET CONTROLLER USER MANUAL SMARTGEN ZHENGZHOU TECHNOLOGY CO LTD...

Page 2: ...ny 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 per...

Page 3: ...ights 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 Indi...

Page 4: ...8110DC 2 SWITCH CONTROL PROCEDURES 18 6 PROTECTION 19 6 1 WARNINGS 19 6 2 SHUTDOWN ALARM 22 6 3 TRIP AND STOP ALARM 25 6 4 TRIP ALARM 26 7 WIRINGS CONNECTION 27 8 SCOPES AND DEFINITIONS OF PROGRAMMABL...

Page 5: ...2 CUMMINS QSL9 60 14 3 CUMMINS QSM11 import 61 14 4 CUMMINS QSX15 CM570 61 14 5 CUMMINS GCS MODBUS 62 14 6 CUMMINS QSM11 62 14 7 CUMMINS QSZ13 62 14 8 DETROIT DIESEL DDEC III IV 63 14 9 DEUTZ EMR2 63...

Page 6: ...electromagnetic interference Controller is pluggable terminal structure which is very convenient for product maintenance and upgrade and update Controller can display Chinese English and other various...

Page 7: ...able 3 Models Comparison Models HGM8110DC HGM8110DC 2 Display VFD DC Monitoring Mains Monitoring None None Input Number 8 8 Output Number 8 8 Sensor Number 5 5 Earth Current Schedule Function RS485 ET...

Page 8: ...on of ECU machine but also control starting up shutdown raising speed and speed droop via CANBUS port controller with CANBUS interface is needed Suitable for 3 phase 4 wire 3 phase 3 wire single phase...

Page 9: ...pressure generator 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 generator functi...

Page 10: ...r Frequency 10 000 Hz max Start Relay Output 16 A DC28V at supply output Fuel Relay Output 16 A DC28V at supply output Programmable Relay Output 1 7A DC28V supply output Programmable Relay Output 2 7A...

Page 11: ...t 214mm x160mm CT Secondary Current 5A rated Working Conditions Temperature 40 70 C Relative Humidity 20 93 RH Storage Condition Temperature 45 80 C Protection Level IP65 when rubber seal installed be...

Page 12: ...Manual mode Manual Mode Press this key and put controller in Manual mode Auto Mode Press this key and put controller in Auto mode Alarm Mute Remove alarm sound If there is trip alarm pressing the butt...

Page 13: ...Default password is 00318 operator can change the password to prevent others changing advanced configurations randomly Please remember the password clearly after change In case that you forget it plea...

Page 14: ...sor 2 battery voltage charger voltage accumulated run time accumulated start times user A and user B accumulated start times NOTE If engine information are read by J1939 via CAN BUS port then Engine p...

Page 15: ...an enter parameter settings screen Language Selectable Chinese English and others default Espanol Test Run On load off load and custom commissioning are optional Custom commissioning can be configured...

Page 16: ...riod 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 sp...

Page 17: ...s into manual mode and its indicator is light on Press to start generator it can automatically detect crank disconnect and generator accelerates to high speed running automatically If high water tempe...

Page 18: ...tch on transfer failure starts to detect at the same time of close output When detecting time is out if switch on failed it will wait for switch on Otherwise switch on is completed If transfer failure...

Page 19: ...tects the frequency of AC genset is lower than the set value it will send warn signals 6 AC Over Voltage Active always When controller detects the voltage of AC genset is higher than the set value it...

Page 20: ...en controller detects the switch on and off fail and the action select enable it will send warn signals 20 DC Over Voltage Active Always When controller detects the voltage of DC genset is higher than...

Page 21: ...send warn signals 32 Flexible Sensor 1 Low Active from start idle to stop idle When controller detects the sensor value is lower than the min set value it will send warn signals 33 Flexible Sensor 2...

Page 22: ...he frequency value of AC genset is lower than the set value it will send stop signals 7 AC Over Voltage Active always When controller detects the voltage value of AC genset is higher than the set valu...

Page 23: ...alue and the reverse power action select shutdown it will send stop signals 20 Temp Sensor Open Active always When controller detects sensor is open circuit and the action select shutdown it will send...

Page 24: ...detects the sensor value is higher than the max set value it will send stop signals 30 Flexible Sensor 2 Low Active from start idle to stop idle When controller detects the sensor value is lower than...

Page 25: ...select trip and stop it will send a trip and stop signals 4 AC Over Power Active always When controller detects the over power value of AC genset power is positive is higher than the set value and the...

Page 26: ...tive always When controller detects the over power value of AC genset power is positive is higher than the set value and the action select trip it will send a trip signals 4 DC Over Current Active alw...

Page 27: ...ositive of starter battery If wire length is over 30m better to double wires in parallel Max 20A fuse is recommended 3 Emergency stop 2 5mm2 Connected with B via emergency stop button 4 Fuel relay out...

Page 28: ...nnect Terminal 23 and Terminal 24 at using 24 ECU CAN H 0 5mm2 25 ECU CAN L 0 5mm2 26 CAN2 Internal Resistance Impedance 120 shielding wire is recommended its single end earthed 120 resistor is connec...

Page 29: ...nstruction 52 Earth Current 1 5mm2 External connected to secondary coil of current transformer rated 5A 53 1 5mm2 54 Aux Input 8 1 0mm2 Ground connected is active B Details see Table 15 55 Aux sensor...

Page 30: ...as the standard for load power 6 CT Ratio 10 6000 A 20mA 400 Ratio of the external connected DC current transformer 7 Rated Power 10 6000 kW 100 It is rated power for DC generator which is used as the...

Page 31: ...alarm value and this delay is expired 12 Over Current 0 Disable 1 Enable 1 Alarm is detected after enabled not detected if it is disabled 0 200 110 Set value is DC generator rated voltage s percentag...

Page 32: ...ng time before genset stop after it unloads 10 Stop Idle Time 0 3600 s 0 Idle running time when genset stop 11 ETS Solenoid Hold 0 3600 s 20 The time of powering up the electromagnet during stop proce...

Page 33: ...entage of rated speed start alarm handle when it is above this value 0 200 108 Set value is percentage of rated speed when alarm is active and speed is below return value alarm can be cleared automati...

Page 34: ...enabled not detect alarms when disabled 0 60 0 V 8 0 Set value is percentage of charger voltage During genset normal running process start alarm handle when charger D WL voltage is below this value 0...

Page 35: ...d and does not enter the normal running period when the generator voltage is less than the load voltage 5 Rated Frequency 10 0 600 0 Hz 50 0 To offer standards for detecting of over under load frequen...

Page 36: ...er Volt Warn 0 Disable 1 Enable 1 Start to detect alarms when it is enabled not detect alarms when disabled 0 200 110 Set value is percentage of AC Gen rated voltage start alarm handle when it is abov...

Page 37: ...lay time is expired 16 Loss of Phase 0 1 1 0 Disable 1 Enable 17 Phase Sequence Wrong 0 1 1 AC Load 1 Current Transform 5 6000 A 5A 500 The ratio of external CT 2 Rated Current 5 6000 A 500 Generator...

Page 38: ...0 200 110 Set value is percentage of AC Gen rated power when power is negative and above this value start alarm handle 0 200 105 Set value is percentage of AC Gen rated power when alarm is active powe...

Page 39: ...It is detected only after Safety On Delay is over 0 3600 s 3 Alarm starts when temp reaches alarm value and this delay time is expired 4 High Warning 0 Disable 1 Enable 1 Start to detect alarms when...

Page 40: ...1000 kPa 124 When external oil pressure value is below this value oil pressure low warning alarm is issued It is only detected after Safety On Delay is over 0 1000 kPa 138 When oil pressure low alarm...

Page 41: ...ontents Setting 0 55 27 Low Oil Pressure Shutdown See Table 15 2 Active Type 0 1 0 0 Closed to Activate 1 Open to Activate Digital Input Port 4 1 Contents Setting 0 55 0 User Configured See Table 15 2...

Page 42: ...to Activate 1 Open to Activate Digital Input Port 8 1 Contents Setting 0 55 0 User Configured See Table 15 2 Active Type 0 1 0 0 Closed to Activate 1 Open to Activate 3 Arming 0 3 0 0 From safety on...

Page 43: ...Period 2 3 Custom Period 3 4 Custom Period 4 5 Custom Period 5 6 Custom Period 6 7 Custom Combined 1 8 Custom Combined 2 9 Custom Combined 3 10 Custom Combined 4 11 Custom Combined 5 12 Custom Combin...

Page 44: ...d wait to stop running time 38 Energise to Stop Used for engines with ETS electromagnet Close when stop idle is over and open when pre set ETS delay is over 39 Speed Drop Pulse Act for 0 1s when contr...

Page 45: ...when input port 7 is active 76 Digital Input 8 Active Act when input port 8 is active 77 80 Reserved 81 96 Expand Digital Input 1 16 Act when expand input port is active 97 98 Reserved 99 Emergency St...

Page 46: ...enerator over voltage 127 DC Over Current Act when controller detects DC generator over current 128 DC Over Power Act when controller detects DC generator over power 129 138 Reserved 139 High Temperat...

Page 47: ...176 Exp1 Ch18 Low Shut 177 Exp1 Ch18 Low Warn 178 Exp1 Ch19 High Shut 179 Exp1 Ch19 High Warn 180 Exp1 Ch19 Low Shut 181 Exp1 Ch19 Low Warn 182 Exp1 Ch20 High Shut 183 Exp1 Ch20 High Warn 184 Exp1 Ch2...

Page 48: ...02 20 Version 1 0 Page 48 of 69 No Type Description 231 At Manual Mode Act when system is in Manual mode 232 Reserved 233 At Auto Mode Act when system is in Auto mode 234 Generator Load 235 Reserved 2...

Page 49: ...parts OR condition output S1 or S2 and AND condition output S3 S1 or S2 is TRUE while S3 is TRUE Defined combination output is outputting S1 and S2 are FALSE or S3 is FALSE Defined combination output...

Page 50: ...indicators are illuminated when input is active 6 Panel Lock All buttons in panel are inactive except navigation and exit buttons and there is on the right of first row in LCD when input is active 7 W...

Page 51: ...9 Remote Start Off Load In Auto mode when input is active genset can be started automatically and NOT take load after genset normal running when input is inactive genset will stop automatically 30 Man...

Page 52: ...1 User Configured Resistance 2 User Config 4 20 mA Curve 3 User Config 0 5V Curve 4 VDO 10Bar 5 CURTIS 6 VOLVO EC 7 DATCON 10Bar 8 SGX 9 SGD 10 SGH 11 VDO 5Bar 12 DATCON 5Bar 13 DATCON 7Bar 14 SUSUKI...

Page 53: ...tor and engine separate as soon as possible b Speed sensor is the magnetic equipment installed on engine body to detect flywheel teeth number c When speed is selected please ensure engine flywheel tee...

Page 54: ...r minimum set value in case that the condition of too high as well as too low will happen 2 When warning alarms are set please set return value correctly otherwise alarm may not work normally At setti...

Page 55: ...used sensor user can adjust it in curve type When input the sensor curve X value resistor must be input from small to large otherwise mistake occurs If select sensor type as None sensor curve is not...

Page 56: ...ng is OK make the start battery power on choose manual mode and controller will execute routine Set controller under manual mode press start button genset will start If start fails after pre set start...

Page 57: ...ion 1 0 Page 57 of 69 12 TYPICAL APPLICATION Fig 4 HGM8110DC 2 Typical Application Diagram NOTE B fuse minimum 2A and maximum 20A Emergency fuse maximum 32A Customers should select appropriate fuse ba...

Page 58: ...pply 2 core shielding line The shielding layer should connect to No 16 terminal in controller while another side is hanging in air The other two signal wires are connected to No 17 and No 18 terminals...

Page 59: ...is load current transformer s secondary side is prohibited to have open circuit 13 6 WITHSTAND VOLTAGE TEST CAUTION When controller has been installed in control window if it needs voltage withstand t...

Page 60: ...communication shielding line connect with ECU terminal only CAN H SAE J1939 signal Impedance 120 connecting line is recommended CAN L SAE J1939 return Impedance 120 connecting line is recommended Engi...

Page 61: ...C CAN communication shielding line connect with ECU terminal only CAN H A Using impedance 120 connecting line CAN L B Using impedance 120 connecting line Engine type Cummins ISB 14 4 CUMMINS QSX15 CM5...

Page 62: ...SX Modbus 14 6 CUMMINS QSM11 Table 29 Engine OEM Connector Terminals of controller OEM connector of engine Remark Fuel relay output 38 Start relay output Connect with starter coil directly CAN GND CAN...

Page 63: ...TZ EMR2 Table 32 F Connector Terminals of controller F connector Remark Fuel relay output Expand 30A relay battery voltage of 14 is supplied by relay Fuse is 16A Start relay output Connect to starter...

Page 64: ...tput X1 34 X1 Terminal 33 connected to negative of battery Table 36 ADEC X4 Connector Terminals of controller SMART X4 port Remark CAN GND X4 3 CAN communication shielding line connect to controller s...

Page 65: ...ctor Remark Fuel relay output 3 Start relay output Connect to starter coil directly CAN GND CAN communication shielding line connect with controller s terminal only CAN H 9 Using impedance 120 connect...

Page 66: ...CAN H 12 Using impedance 120 connecting line CAN L 13 Using impedance 120 connecting line Engine type VolvoEDC4 14 18 VOLVO EMS2 Volvo Engine types are TAD734 TAD940 TAD941 TAD1640 TAD1641 and TAD1642...

Page 67: ...20 connecting line Table 46 Engine 2 Pin Connector Battery Engine 2 pins Remark Battery negative 1 Wire diameter 2 5mm2 Battery positive 2 Wire diameter 2 5mm2 Engine type BOSCH 14 20 WEICHAI It is su...

Page 68: ...able or via switchboard The communication between the controller and monitoring equipment is carried out by using TCP ModBus protocol NOTE In this connection mode controller parameters can be set Smar...

Page 69: ...Check programmable inputs Crank not disconnect Check fuel oil circuit and its connections Check starting batteries Check speed sensor and its connections Refer to engine manual Starter no response Che...

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