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HGMS61 Genset Controller User Manual Page 35 of 47

11

TYPICAL APPLICATION

Fig.5 – HGMS61 Typical Application Diagram

Fig.6 – HGMS61CAN Typical Application Diagram

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Summary of Contents for HGMS61

Page 1: ...HGMS61 SPLIT TYPE GENSET CONTROLLER USER MANUAL HGMS61D Display Module HGMS61M Master Control Module SMARTGEN ZHENGZHOU TECHNOLOGY CO LTD ...

Page 2: ...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 co...

Page 3: ...ts 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 ...

Page 4: ...61M CONTROLLER PANEL 17 6 2 HGMS61D CONTROLLER REAR PANEL 20 7 PARAMETER RANGE AND DEFINITION 20 7 1 PARAMETER CONTENT AND RANGE TABLE 20 7 2 PROGRAMMABLE OUTPUT 1 4 TABLE 26 7 3 PROGRAMMABLE INPUT 1 4 TABLE 28 7 4 SENSOR SELECTION 30 7 5 CONDITIONS OF CRANK DISCONNECT 31 8 PARAMETER SETTING 32 9 SENSOR SETTING 33 10 COMMISSIONING 33 11 TYPICAL APPLICATION 35 12 INSTALLATION 36 12 1 FIXING CLIPS 3...

Page 5: ...8 DETROIT DIESEL DDEC III IV 41 13 9 DEUTZ EMR2 42 13 10 JOHN DEERE 42 13 11 MTU ADEC SMART MODULE 42 13 12 MTU ADEC SAM MODULE 43 13 13 PERKINS 43 13 14 SCANIA 43 13 15 VOLVO EDC3 44 13 16 VOLVO EDC4 44 13 17 VOLVO EMS2 45 13 18 YUCHAI 45 13 19 WEICHAI 46 14 FAULT FINDING 47 ...

Page 6: ...d low efficiency and improve the production efficiency of the control cabinet It can be widely used in various types of automatic control system 2 PERFORMANCE AND CHARACTERISTICS HGMS61 HGMS61D HGMS61M HGMS61CAN HGMS61D HGMS61MCAN Display Module HGMS61D Master Control Module HGMS61M HGMS61MCAN HGMS61D Display control module HGMS61M MPU interface suitable for ESC controlled engines HGMS61MCAN CAN B...

Page 7: ...and protection functions With ETS idle speed control pre heat control speed droop raising control all of them are relay output Parameter setting allow users to modify setting the parameters cannot be lost even when power off Most of parameters can be set from the front panel all parameters can be adjusted via USB interface or RS485 interface of PC A variety of temperature pressure and fuel level s...

Page 8: ...ge Range 1 0V 24V RMS Frequency Range 5Hz 10000Hz Charger D Voltage Range DC0V DC60V continuous power supply Resolution 0 1V Accuracy 1 Analog Sensor Resistance input Range 0Ω 6000Ω Resolution 0 1Ω Accuracy 1Ω below 300Ω Fuel Relay Output 10A DC30V DC supply output relay output pluggable Start Relay Output 10A DC30V DC supply output relay output pluggable Digital Output 1 7A DC24V DC supply output...

Page 9: ... installation category over voltage category III 300V pollution class 2 altitude 3000m Overall Dimensions HGMS61D 209mm x 167mm x 45mm Panel Installation HGMS61M 248mm x 158mm x 64mm Cabinet Installation Panel Cutout HGMS61D 186mm x 141mm Working Condition Temperature 25 70 ºC Relative Humidity 20 93 RH Storage Condition Temperature 30 80 ºC Protection Level HGMS61 D IP65 HGMS61M IP20 Insulation I...

Page 10: ... Manual Press this key to set the module as Manual mode Auto Press this key to set the module as Auto mode Close Can control gens to switch on in Manual mode Open Can control gens to switch off in Manual mode Set Confirm Press this key to enter menu interface Shift cursor to confirm in parameters setting menu Up Increase Screen scroll Up cursor or increase value in setting menu Down Decrease Scrol...

Page 11: ...arning Slow flashing 1time per second Shutdown Fast flashing 5 times per second Note Status indicator won t illuminate when genset is in standby mode flashes 1 time per second in start or stop process and always illuminates when runs normally for J1939 engines press start key in auto mode or stop mode ECU power will output and status indicator always illuminates ...

Page 12: ...harge are disabled As soon as this delay is over genset will enter into Start Idle Delay if configured g During start idle delay alarms of under speed under frequency under voltage are disabled As soon as this delay is over genset will enter into Warming Up Delay if configured h When Warming Up Delay is over the indicator will illuminate if gens is normal If voltage and frequency of engine reach t...

Page 13: ... and then the controller enters safety delay 5 PROTECTION 5 1 WARNINGS When controller detects the warning signal the controller only alarms but not stop Table 7 Controller Warning Alarms No Warnings Description 1 Loss Of Speed Signal When the speed of genset is 0 and speed loss delay is 0 controller will send warning alarm signal and it will be displayed on LCD 2 Gen Over Current When the current...

Page 14: ...l send warning alarm signal and it will be displayed on LCD 12 High Temp When the water cylinder temperature of genset is higher than threshold and Enabled High Temp Stop Inhibited or Input High Temp Stop Inhibited is active controller will send warning alarm signal and it will be displayed on LCD 13 Low Oil Pressure When the oil pressure of genset is less than threshold and Enabled Low Oil Pressu...

Page 15: ... alarm signal and it will be displayed on LCD 6 Loss Of Speed Signal Shutdown When rotate speed is 0 and delay is not 0 controller will send a stop alarm signal and it will be displayed on LCD 7 Genset Over Voltage Shutdown When genset voltage is higher than threshold controller will send a stop alarm signal and it will be displayed on LCD 8 Genset Under Voltage Shutdown When genset voltage is und...

Page 16: ... of user setting and maintenance action is set as shutdown when genset starts controller will send shutdown alarm signal and it will be displayed on LCD Maintenance alarm can be reset by setting the maintenance parameters with the password 19 Input Port Shutdown When external input is active controller will send shutdown alarm signal and it will be displayed on LCD 20 Over Power Shutdown When the ...

Page 17: ...ctive B 7 Aux Relay Input 2 1 0mm2 Ground connection is active B 8 Aux Relay Input 3 1 0mm2 Ground connection is active B 9 Aux Relay Input 4 1 0mm2 Ground connection is active B 10 Temp Sensor Input Connect to temperature sensor 11 Oil Pressure Sensor Input Connect to pressure sensor 12 Level Sensor Input Connect to level sensor 13 Sensor Common 1 0mm2 Controller inside has been connected to B 14...

Page 18: ...r B 27 CT A Phase Monitoring Input 1 5mm2 Externally connect to CT secondary coil Rated 5A 28 CT B Phase Monitoring Input 1 5mm2 Externally connect to CT secondary coil Rated 5A 29 CT C Phase Monitoring Input 1 5mm2 Externally connect to CT secondary coil Rated 5A 30 CT Sensor Common 1 5mm2 Refer to installation instructions 31 UOUTPUT 1 0mm2 Generator U phase monitoring input will output after th...

Page 19: ... power 3 GND 2 5mm2 The controller inside has connected to B 4 MP2 Speed Output 0 5mm2 The controller inside has connected to B 5 NC 7 ACT2 2 5mm2 Connect to ACT2 terminal of ESC 8 NC 10 ACT1 2 5mm2 Connect to ACT1 terminal of ESC 11 NC 6 Aux Output 2 1 5mm2 Relay Common Rated 10A volt free output Connect to idle control terminal of ESC 9 N O Output 12 N C Output Connector C Connect to Charger 1 C...

Page 20: ...ct to master controller HGMS61M Connect to shielded cable to Terminal 4 GND 2 RXD 0 5mm2 3 NC 4 GND 1 5mm2 Negative post of controller power 5 B 1 5mm2 6 B 1 5mm2 Positive post of controller power 7 PARAMETER RANGE AND DEFINITION 7 1 PARAMETER CONTENT AND RANGE TABLE Table 11 Parameter Content and Range No Items Range Default Description 1 Start Delay 0 3600 s 1 Time from mains abnormal or remote ...

Page 21: ... Stop Idle Time 0 3600 s 0 Idle running time when genset stop 12 ETS Solenoid Hold 0 120 s 0 Stop electromagnet s power on time when genset is stopping 13 Fail to Stop Delay 0 120 s 20 If ETS Solenoid Hold set as 0 it is the time from end of idle delay to genset at rest if not 0 it is from end of ETS solenoid delay to genset at rest 14 Switch Close Delay 0 0 10 0 s 5 0 Mains or generator s switch ...

Page 22: ... be sent only suites for temperature sensor except for high temp pressure alarm signal inputted by programmable input port 24 Low Oil Pressure Shutdown 0 400 kPa 103 When engine oil pressure sensor value is under this value Low Oil Pressure alarm is sending out This value only judged after the end of safety delay When the value is 0 warning alarm won t be sent only suites for oil pressure sensor e...

Page 23: ... 2 Factory default Energized to stop See Table 12 37 Relay Output 2 0 28 3 Factory default Idle control See Table 12 38 Relay Output 3 0 28 5 Factory default Gens closed See Table 12 39 Relay Output 4 0 28 6 Factory default Reserved See Table 12 40 Digital Input 1 Set 0 23 1 Factory default High temperature alarm input See Table 13 41 Digital Input 1 Active 0 1 0 Factory default close 42 Digital I...

Page 24: ... 61 AC System 0 3 0 0 3P4W 1 2P3W 2 1P2W 3 3P3W 62 Temp Sensor Curve Type 0 14 8 SGX See Table 14 63 Pressure Sensor Curve Type 0 14 8 SGX See Table 14 64 Fuel Level Sensor Curve Type 0 7 3 SGD See Table 14 65 Generator Poles 2 64 4 Number of magnetic poles used for calculating rotating speed of generator without speed sensor 66 Temp Sensor Open Circuit Action 0 2 1 0 Not used 1 Warning 2 Shutdown...

Page 25: ...0 2 0 0 Default Theme 1 OEM Plant Theme 2 Terminal Users Theme 81 Fuel Output Time 1 60 s 1 It is the time of the genset fuel output during power on 82 Manual Mode ATS 0 1 0 0 Key Switch 1 Auto Switch 83 Speed Raise Pulse 0 20 0 s 0 2 It is the speed up pulse output time when the unit enters the high speed warming up 84 Speed Drop Pulse 0 20 0 s 0 2 It is the speed drop pulse output time when the ...

Page 26: ...ure is lower than pre set threshold controller sends warning signal only and not shutdown Note3 If default password 0318 isn t changed it doesn t need to input when configuring parameters via PC software if the password is changed for the first time via PC software it needs to input password in password window Note4 Between input correct password and LCD back light haven t got dark input parameter...

Page 27: ...el warning is active disconnect when the fuel level over the close threshold and the low fuel level warning input is disabled 12 High Speed Control Output when it enters into warming up time and disconnect after cooling 13 Auto Mode The controller is in Auto Mode 14 Shutdown Alarm Output when shutdown alarm occurs 15 Audible Alarm When shutdown alarm and warn alarm audible alarm is set as 300s In ...

Page 28: ...nal is active genset will immediately alarm to shutdown 5 WTH Cooling Stop During engine running and the input is active if high temperature occurs controller will stop after high speed cooling when the input is disabled controller will stop immediately 6 Generator Closed Auxiliary Connect to auxiliary port of gen load breaker 7 Reserved 8 Inhibit WTH Stop When it is active high oil temperature st...

Page 29: ...9 Alarm Mute Can prohibit Audible Alarm output when input is active 20 Idle Control Mode In this mode under voltage under frequency and under speed are not protected 21 60Hz Select It is used for J1939 engine with CANBUS port when input is active frequency is 60Hz 22 Raise Speed Pulse If engine type is common J1939 when input is active engine target speed will increase 5RPM 23 Drop Speed Pulse If ...

Page 30: ...sor 2 Pressure Sensor 0 Not used 1 User Defined Resistance Type 2 VDO 10Bar 3 SGH 4 SGD 5 CURTIS 6 DATCON 10Bar 7 VOLVO EC 8 SGX 9 User Defined 4 20mA 10 User Defined 0 5V 11 Digital Closed 12 Digital Open 13 VDO 5Bar 14 Reserved Defined input resistance range is 0Ω 6000Ω factory default is SGX sensor 3 Fuel Level Sensor 0 Not used 1 User Defined Resistance Type 2 SGH 3 SGD 4 User Defined 4 20mA 5...

Page 31: ...ect as soon as possible b Speed sensor is a magnetic device installed on the engine body to test the number of flywheel teeth c When choosing speed ensure the number of flywheel teeth is the same as the preset otherwise over or under speed shutdown may occur d If generator has no magnetic pickup sensor don t choose speed item otherwise Fail to Start or Loss of Speed Signal shutdown will occur e If...

Page 32: ...e over voltage and under voltage will occur at the same time 3 The over speed threshold must be greater than under speed threshold otherwise over speed and under speed will occur at the same time 4 Set frequency value after crank disconnect as low as possible in order to disconnect starter quickly 5 Programmable input 1 4 cannot be set as the same items otherwise it cannot realize correct function...

Page 33: ...perature pressure and fuel level will be display as in LCD If there is no pressure sensor but only has low pressure alarm switch then you must set pressure sensor as Not used otherwise oil pressure low alarm shutdown may appear Can set several points of forehand or backmost as the same ordinate as the following picture Fig 4 Sensor Curve Diagram Table 16 Conventional Pressure Unit Conversion Table...

Page 34: ...to Start signal then press stop to reset controller Recover actions of preventing engine to disconnect crank e g Connect wire of fuel value press start button again genset will start If everything goes well genset will normally run after idle running if configured During this period watch for engine s running situations and voltage and frequency of alternator If there is abnormal stop genset and c...

Page 35: ...HGMS61 Genset Controller User Manual Page 35 of 47 11 TYPICAL APPLICATION Fig 5 HGMS61 Typical Application Diagram Fig 6 HGMS61CAN Typical Application Diagram ...

Page 36: ...ixing clip screw turn anticlockwise until it reaches proper position Pull the fixing clip backwards towards the back of the module ensuring four clips are inside their allotted slots Turn the fixing clip screws clockwise until they make contact with the panel Note 0 27N m 2 75kgf cm torque is recommended to tighten the fixing clips 12 2 OVERALL DIMENSION AND PANEL CUTOUT Unit mm Fig 9 HGMS61D Case...

Page 37: ...6 At full speed output voltage range is 1 24 V AC RMS 12VAC is recommended rated speed During installing make the speed sensor contact the flywheel firstly then pour out 1 3 laps finally lock nut on the sensor 2 Output And Expansion Relay Caution All the outputs of controller are relay contact output If need to expand relay please add freewheeling diode in both ends of relay coil when expansion re...

Page 38: ...ication shielding line connect to ECU terminal only CAN H SAE J1939 signal Using impedance 120Ω connecting line CAN L SAE J1939 return Using impedance 120Ω connecting line Engine type CUMMINS ISB 13 2 CUMMINS QSL9 Suitable for CM850 engine control mode Table 19 50 Pins Connector Terminals of controller 50 pins connector Remark Programmable output port 1 39 Set configurable output 1 as Fuel Relay O...

Page 39: ... connect to ECU terminal only CAN H A Using impedance 120Ω connecting line CAN L B Using impedance 120Ω connecting line Engine type CUMMINS ISB 13 4 CUMMINS QSX15 CM570 It is suitable for CM570 engine control module Engine type is QSX15 Table 23 50 Pins Connector Terminals of controller 50 pins connector Remark Programmable output1 38 Oil spout switch Set configurable output 1 as Fuel Relay Output...

Page 40: ... coil directly Table 26 D SUB Connector 06 Terminals of controller D SUB connector 06 Remark 20 CAN communication shielding line connect to ECU terminal only RS485 21 Using impedance 120Ω connecting line RS485 18 Using impedance 120Ω connecting line Engine type CUMMINS QSK Modbus CUMMINS QST MODBUS CUMMINS QSX MODBUS 13 6 CUMMINS QSM11 Table 27 Engine OEM Connector Terminals of controller OEM conn...

Page 41: ...ing 19 connect to 41 for 0 1s during high speed warming of controller via external expansion relay CAN communication shielding line CAN H 1 Using impedance 120Ω connecting line CAN L 21 Using impedance 120Ω connecting line Engine type Common J1939 13 8 DETROIT DIESEL DDEC III IV Table 29 Engine CAN Connector Terminals of controller CAN port of engine Remark Programmable output1 Expand 30A relay ba...

Page 42: ...ammable output1 G J Set configurable output 1 as Fuel Relay Output Start relay output D CAN communication shielding line CAN H V Using impedance 120Ω connecting line CAN L U Using impedance 120Ω connecting line Engine type JOHN DEERE 13 11 MTU ADEC SMART MODULE It is suitable for MTU engine with ADEC ECU8 and SMART module Table 32 ADEC X1 port Terminals of controller ADEC X1port Remark Programmabl...

Page 43: ...is suitable for ADEM3 ADEM4 engine control mode Engine type is 2306 2506 1106 and 2806 Table 36 Connector Terminals of controller Connector Remark Programmable output1 1 10 15 33 34 Set configurable output 1 as Fuel Relay Output Start relay output Connect to starter coil directly CAN communication shielding line CAN H 31 Using impedance 120Ω connecting line CAN L 32 Using impedance 120Ω connecting...

Page 44: ...cting line CAN L 2 Using impedance 120Ω connecting line Engine type VOLVO Note When this engine type is selected preheating time should be set to at least 3 seconds 13 16 VOLVO EDC4 Suitable engine types are TD520 TAD520 optional TD720 TAD720 optional TAD721 TAD722 and TAD732 Table 40 Connector Terminals of controller Connector Remark Programmable output1 Expanded 30A relay and relay offers batter...

Page 45: ...line Engine type VOLVO EMS2 Note When this engine type is selected preheating time should be set to at least 3 seconds 13 18 YUCHAI It is suitable for BOSCH common rail pump engine Table 42 Engine 42 Pins Port Terminals of controller Engine 42 pins port Remark Programmable output1 1 40 Set configurable output 1 as Fuel Relay Output Connect to engine ignition lock Start relay output Connect to star...

Page 46: ...44 Engine Port Terminals of controller Engine port Remark Fuel relay output 1 40 Set configurable output 1 as Fuel Relay Output Connect to engine ignition lock Start relay output 1 61 CAN communication shielding line CAN H 1 35 Using impedance 120Ω connecting line CAN L 1 34 Using impedance 120Ω connecting line Engine type GTSC1 ...

Page 47: ... and connections High Temp Alarm After Crank Disconnect Check temperature sensor and connections Shutdown Alarm During Running Check switch and connections according to information on LCD Check configurable inputs Crank Disconnect Failure Check connections of fuel solenoid Check starting battery Check speed sensor and its connections Refer to engine manual Starter Inoperative Check connections of ...

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