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HGM9120 Genset Controller

HGM9120 Genset Controller Version: 1.0 2014-04-14 Page 9 of 58

50/60Hz units, but also in 400Hz units.

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Widely power supply range DC(8~35)V, suitable to different starting battery voltage

environment;

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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);

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Can be used as an indicating instrument (indicate and alarm are enable only, relay is

inhibited );

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With maintenance function. Actions (warning and shutdown) can be set when

maintenance time out;

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Fuel usage protection. Fuel consumption rate can be set to monitor the fuel usage.

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Waterproof security level IP55 due to rubber seal installed between the controller

enclosure and panel fascia;

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Metal fixing clips enable perfect in high temperature environment;

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Modular design, anti-flaming ABS plastic enclosure, pluggable connection terminals and

embedded installation way; compact structure with easy mounting.

Summary of Contents for HGM9120

Page 1: ...HGM9120 Genset AMF Controller USER MANUAL Smartgen Technology ...

Page 2: ...tion 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...

Page 3: ...on 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 ...

Page 4: ... SWITCH CONTROL PROCEDURES 20 4 6 1 HGM9120 Switch Control Procedures 20 5 PROTECTION 22 5 1 WARNINGS 22 5 2 SHUTDOWN ALARM 24 5 3 TRIP AND STOP ALARM 26 5 4 TRIP ALARM 27 6 WIRINGS CONNECTION 28 7 SCOPES AND DEFINITIONS OF PROGRAMMABLE PARAMETERS 31 7 1 CONTENTS AND SCOPES OF PARAMETERS 31 7 2 ENABLE DEFINITION OF PROGRAMMABLE OUTPUT PORTS 40 7 2 1 Custom Period Output 44 7 2 2 Custom Combined Ou...

Page 5: ...04 14 Page 5 of 58 8 PARAMETERS SETTING 50 9 SENSORS SETTING 51 10 COMMISSIONING 52 11 TYPICAL APPLICATION 53 12 INSTALLATION 54 13 GSM SHORT MESSAGE ALARM AND REMOTE CONTROL 56 13 1 GSM SHORT MESSAGE ALARM 56 13 2 GSM SHORT MESSAGE REMOTE CONTROL 56 14 FAULT FINDING 58 ...

Page 6: ...ailure 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 moni...

Page 7: ...essage 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 s...

Page 8: ...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 ...

Page 9: ...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 ...

Page 10: ...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...

Page 11: ...HGM9120 Genset Controller HGM9120 Genset Controller Version 1 0 2014 04 14 Page 11 of 58 4OPERATION 4 1 INDICATOR LIGHT HGM9120 ...

Page 12: ...tor 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...

Page 13: ...utton 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 ...

Page 14: ...age 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 No...

Page 15: ...op 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 ...

Page 16: ...ing 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 shu...

Page 17: ...m 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 valu...

Page 18: ... 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 W...

Page 19: ...d 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 5 MANUAL 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...

Page 20: ...le 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...

Page 21: ...nable there is alarming signal 2 If input port is not configured as Close Mains Auxiliary Mains load is transferred into generator load after switch off and transfer interval delay generator switch on The way to transfer generator load to mains load is as same as above NOTE When using ATS of no interposition switch off detecting should SELECT Disable When using ATS of having interposition switch o...

Page 22: ...value it will send warn signal 9 Fail to Stop When generator not stops after the stop delay is over it will send warn signal 10 Charge Alt Fail When controller detects the charger voltage is lower than the set value it will send warn signal 11 Battery Over Voltage When controller detects the battery voltage is higher than the set value it will send warn signal 12 Battery Under Voltage When control...

Page 23: ...he temperature is higher than the set value it will send warn signal 31 Low Canopy Temp Warn When controller detects the temperature is lower than the set value it will send warn signal 32 Flexible Sensor 1 Open When controller detects the sensor is open circuit and the action select warn it will send warn signal 33 Flexible Sensor 1 High When controller detects the sensor value is higher than the...

Page 24: ...g of start times controller will send a stop signal 10 Over Current When controller detects the current value is higher than the set value it will send a stop signal 11 Maintenance Due When count down time is 0 and the action select Shutsown it will send a stop alarm signal 12 Reverse Power Shutdown When controller detects reverse power value power is negative is lower than the set value and the r...

Page 25: ...ller detects the sensor value is lower than the min set value it will send stop signal 26 Flexible Sensor 2 Open When controller detects sensor is open circuit and the action select shutdown it will send a stop signal 27 Flexible Sensor 2 High When controller detects the sensor value is higher than the max set value it will send stop signal 28 Flexible Sensor 2 Low When controller detects the sens...

Page 26: ...egative is lower than the set value and the action select trip and stop it will send a trip and stop signal 4 Over Power When controller detects the over power value power is positive is higher than the set value and the action select trip and stop it will send a trip and stop signal 5 Digital Input Ports When digital input port is set as trip and stop and the action is active it will send a trip ...

Page 27: ...he action select trip it will send a trip signal 3 Over Power When controller detects the over power value power is positive is higher than the set value and the action select trip it will send a trip signal 4 Digital Input Ports When digital input port is set as trip and the action is active it will send a trip signal 5 Earth Fault When the Earth current detection is enabled if the controller det...

Page 28: ... in parallel Max 20A fuse is recommended 3 Emergency stop 2 5mm2 Connected with B via emergency stop button 4 Fuel relay output 1 5mm2 B is supplied by 3 terminal rated 7A 5 Start relay output 1 5mm2 B is supplied by 3 terminal rated 7A Connected to starter coil 6 Common Shutdown Alarm Output 1 5mm2 B is supplied by 2 terminal rated 7A Details see form 2 7 Common Alarm Output 1 5mm2 B is supplied ...

Page 29: ...rm 2 21 Public points of relay 22 Normally open output rated 7A 23 Mains Close Input 1 0mm2 Normally close output rated 7A Details see form 2 24 1 0mm2 Normally open output rated 7A 25 1 0mm2 Public points of relay 26 Gen Close Input 1 0mm2 Normally open output rated 7A 27 1 0mm2 Public points of relay 28 Mains A phase voltage sensing input 1 0mm2 Connected to A phase of mains 2A fuse is recommend...

Page 30: ...following installation instruction 41 Aux sensor 1 1 0mm2 Connected to temperature oil pressure or fuel level sensors Details see form 4 42 Aux sensor 2 1 0mm2 43 Canopy Temperature Sensor 1 0mm2 Connected to canopy temperature sensor 44 Oil temperature sensor 1 0mm2 Connected to oil temperature sensor 45 Oil pressure sensor 1 0mm2 Connected to oil pressure sensor 46 Temperature sensor 1 0mm2 Conn...

Page 31: ...ay from mains normal to abnormal 6 Volt Trans PT 0 1 0 0 Disable 1 Enable 7 Over Voltage 0 200 120 Setting value is mains rated voltage s percentage return value and delay value can be set 8 Under Voltage 0 200 80 9 Over Frequency 0 200 114 Setting value is mains rated frequency s percentage return value and delay value can be set 10 Under Frequency 0 200 90 11 Loss of Phase 0 1 1 0 Disable 1 Enab...

Page 32: ...tween over of ETS hold delay and stopped when ETS Hold output time is not 0 13 After Stop Time 0 3600 s 0 Time between genset stopped and standby Engine Setting 1 Engine Type Conventional genset not J1939 2 Flywheel Teeth 10 300 118 Tooth number of the engine for judging of starter separation conditions and inspecting of engine speed See the Installation Instructions 3 Rated Speed 0 6000 RPM 1500 ...

Page 33: ...e used alone and simultaneously to separating the start motor and genset as soon as possible 17 Disconnect Generator Freq 0 200 24 When generator frequency higher than the set value starter will be disconnected See the Installation Instructions 18 Disconnect Engine Speed 0 200 24 When generator speed higher than the set value starter will be disconnected See the Installation Instructions 19 Discon...

Page 34: ...lue is percentage of generator rated volt Delay value can be set 9 Under Volt Shutdown 0 200 80 10 Over Freq Shutdown 0 200 114 Setting value is percentage of generator rated freq Delay value can be set 11 Under Freq Shutdown 0 200 80 12 Over Volt Warn 0 200 110 Setting value is percentage of generator rated volt Delay value and return value can be set 13 Under Volt Warn 0 200 84 14 Over Freq Warn...

Page 35: ...Pulse width of mains generator switch on When it is 0 means output constantly 3 Open Time 0 20 0 s 3 0 Pulse width of mains generator switch off 4 Check Time 0 20 0 s 5 0 Time of detecting switch auxiliary contacts after transferred 5 Warn Enable 0 1 0 0 Disable 1 Enable 6 Check Enable 0 1 0 0 Disable 1 Enable 7 Enable Immediate Mains Dropout 0 1 1 0 Disable 1 Enable Module Setting 1 Power on Mode...

Page 36: ...re higher than this value Detecting only after safety delay is over The delay value and return value can be set 5 Low Temp Warn 0 1 0 0 Disable 1 Enable Oil Pressure Sensor 1 Curve Types 0 15 7 SGX See form 4 2 Open Circuit Action 0 2 0 0 Warn 1 Shutdown 2 No action 3 Low OP Shutdown 0 1000 kPa 103 Shutdown when oil pressure lower than this value Detecting only after safety delay is over The delay...

Page 37: ...p Shutdown 0 300 º C 98 Shutdown when sensor temperature higher than this value Detecting only after safety delay is over The delay value can be set 4 High Temp Warn 0 300 º C 95 Warn when sensor temperature higher than this value Detecting only after safety delay is over The delay value and return value can be set 5 Low Temp Warn 0 1 0 0 Disable 1 Enable Flexible Sensor 1 1 Flexible Sensor 1 Sett...

Page 38: ...own 2 Trip and stop 3 Trip 4 Indication 4 Active Delay 0 20 0 s 2 0 Time from detecting active to confirm 5 Description LCD display detailed contents when the input is active Remote Start Input 1 Contents Setting 0 1 0 0 Closed to active 1 Open to active Flexible Input Port 1 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 3 2 0 ...

Page 39: ...ng 0 3 2 0 From safety on 1 From starting 2 Always 3 Never 4 Active Actions 0 4 2 0 Warn 1 Shutdown 2 Trip and stop 3 Trip 4 Indication 5 Active Delay 0 20 0 s 2 0 Time from detecting active to confirm 6 Description LCD display detailed contents when the input is active Flexible Output Ports Flexible Output Port 1 1 Contents Setting 0 239 1 User defined period output default output is in preheatin...

Page 40: ...tdown trips Can be connected annunciator externally When alarm mute configurable input port is active it can remove the alarm 19 Louver Control Action in genset starting and disconnect when genset stopped completely 20 Fuel Pump Control It is controlled by fuel pump of level sensor s limited threshold 21 Heater Control It is controlled by heating of temperature sensor s setting bound 22 Cooler Con...

Page 41: ...pen when pre set ETS delay is over 39 Reserved 40 Reserved 41 Reserved 42 Reserved 43 Crank Success Close when detects a successful start signal 44 Generator OK Action when generator is normal 45 Generator Available Action in period of generator ok to hi speed cooling 46 Mains OK Action when mains normal 47 Reserved 48 Common Alarm Action when genset common warning common shutdown common trips ala...

Page 42: ...er frequency Warn Action when generator over frequency warning 110 Gen over frequency Shut Action when generator over frequency shutdown alarm 111 Gen Over Volt Warn Action when generator over voltage warning 112 Gen Over Volt Shut Action when generator over voltage shutdown 113 Gen Under Freq Warn Action when generator low frequency warning 114 Gen Under Freq Shut Action when generator low freque...

Page 43: ...0 Config1 High Warn 151 Config1 Low Warn 152 Config1 High Shut 153 Config1 Low Shut 154 Config2 High Warn 155 Config2 Low Warn 156 Config2 High Shut 157 Config2 Low Shut 158 Oil Temperature High Warn Action when high oil temperature warning 159 Oil Temperature Low Warn Action when low oil temperature warning 160 Oil Temperature High Shutdown Action when high oil temperature shutdown 161 Reserved 1...

Page 44: ...output time 2s Output time 3s Condition output contents output port 1 is active Close when condition output active inactive close when active disconnect when inactive Output port 1 active after enter starts time and delay 2s this defined period output is outputting after 3s stop outputting Output port 1 inactive defined output period is not outputting 7 2 2 CUSTOM COMBINED OUTPUT Defined combinati...

Page 45: ...condition output S2 is active inactive close when active disconnect when inactive Contents of probably condition output S3 output port 3 is active Close when probably condition output S3 is active inactive close when active disconnect when inactive When input port 1 active or input port 2 active if input port 3 is active Defined combination output is outputting If input port 3 inactive Defined com...

Page 46: ... trip alarm when input is active 4 Reserved 5 Lamp Test All LED indicators are illuminating when input is active 6 Panel Lock All buttons in panel is inactive except and there is in the left of first row in LCD when input is active 7 Reserved 8 Idle Control Mode Under voltage frequency speed protection is inactive 9 Inhibit Auto Stop In Auto mode during generator normal running when input is activ...

Page 47: ...Connected sensor digital input 28 Reserved 29 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 Note Dedicated remote start input port is fitted If active it is remote start on load input port 30 Aux Manual Start In Manual mode when input active genset will ...

Page 48: ...8 Alternative Config2 49 Alternative Config3 50 Reserved 7 4 SELECTION OF SENSORS Form4 No Description Remark 1 Temperature Sensor Oil Temperature Sensor Canopy Temperature Sensor 0 Not used 1 Custom Res Curve 2 Custom 4 20mA curve 3 VDO 4 CURTIS 5 VOLVO EC 6 DATCON 7 SGX 8 SGD 9 SGH 10 PT100 11 15 Reserved Defined resistance s range is 0 6KΩ default is SGX sensor 2 Pressure Sensor 0 Not used 1 Cu...

Page 49: ... recommend that engine oil pressure should be using with speed sensor and generator frequency together in order to make the starter motor is separated with engine immediately and can check crank disconnect exactly 2 Speed sensor is the magnetic equipment which be installed in starter for detecting flywheel teeth 3 When set as speed sensor must ensure that the number of flywheel teeth is as same as...

Page 50: ...the condition of too high as well as too low will happen NOTE When setting the warning alarm please set the correct return value otherwise maybe there is abnormal alarm When setting the maximum value the return value must less than set value When setting the minimum value the return value must over set value NOTE Please set the generator frequency value as low as possible when cranking in order to...

Page 51: ...sensor curves and using sensor user can adjust it in curve type 3 When input the sensor curve X value resistor must be input from small to large otherwise mistake occurs 4 If select sensor type as None sensor curve is not working 5 If corresponding sensor has alarm switch only user must set this sensor as None otherwise maybe there is shutdown or warning 6 The headmost or backmost values in the ve...

Page 52: ...then press stop to reset controller 6 Recover the action of stop engine start e g Connect wire of fuel valve press start button again genset will start If everything goes well genset will normal run after idle running if idle run be set During this time please watch for engine s running situations and AC generator s voltage and frequency If abnormal stop genset running and check all wires connecti...

Page 53: ...GM9120 Genset Controller Version 1 0 2014 04 14 Page 53 of 58 11TYPICAL APPLICATION HGM9120 typical application diagram Note Fuse F1 min 2A max 20A Fuse F2 max 32A Users should select suitable fuse depend on practical application ...

Page 54: ...troller s normal working 2 Speed Sensor Input NOTE Speed sensor is the magnetic equipment which be installed in starter and for detecting flywheel teeth Its connection wires to controller should apply for 2 cores shielding line The shielding layer should connect to No 16 terminal in controller while another side is hanging in air The else two signal wires are connected to No 17 and No 18 terminals...

Page 55: ...ame time the phases of current transformer and input voltage must correct Otherwise the current of collecting and active power maybe not correct NOTE ICOM port must be connected to negative pole of battery WARNING When there is load current transformer s secondary side prohibit open circuit 5 Withstand Voltage Test CAUTION When controller had been installed in control panel if need the high voltag...

Page 56: ...rs as following No SMS Orders Pass back Information Description 1 SMS GENSET GENSET ALARM When genset is shutdown alarm status of genset SYSTEM IN STOP MODE GENSET AT REST At rest status in stop mode SYSTEM IN MANUAL MODE GENSET AT REST At rest status in manual mode SYSTEM IN AUTO MODE GENSET AT REST At rest status in Auto mode SYSTEM IN STOP MODE GENSET IS RUNNING Running status in stop mode SYST...

Page 57: ...ed 8 SMS PERMIT START PERMIT START OK Discharge the inhibit start signal NOTE Its national and area s cods must be added e g China 8613666666666 NOTE When sending orders users need to follow SMS orders in above form and all the letters must be capital NOTE Pass back information from SMS DETAIL including working mode mains voltage generator voltage load current mains frequency generator frequency a...

Page 58: ... emergency stop input Check whether the circuit is open Low oil pressure alarm after crank disconnect Check the oil pressure sensor and its connections High water temp alarm after crank disconnect Check the temperature sensor and its connections Shutdown Alarm in running Check related switch and its connections according to the information on LCD Check programmable inputs Crank not disconnect Chec...

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