HGM6100K INSTRUCTION
Contents
1. When preheat relay is over oil relay is outputting 1s and then start relay output if genset fails in starting during cranking time the oil and start relays stop outputting and enters into crank rest time and wait for next attempt If genset fails in starting within setting attempt times the fourth line of LED will in black and start failed alarm will be displayed on it Whatever times to start genset successfully it will enter into safety on time During this period alarms of low oil pressure hi temperature under speed charge fail and Aux input been configured are inactive As soon as this delay is over genset will enter into start idle delay if this be configured During start idle delay alarms of under speed under frequency under voltage are inactive As soon as this delay is over genset will enter into warming up time delay if this be configured When warming up time delay is over gens status indicator is light if gens normal If alternator s voltage frequency meets to requirement of load gens will close and relay is outputting then genset will enter into normal running with load and gens indicator is light if genset voltage and frequency is abnormal controller will alarm and stop engine gens alarming is displayed LCD Sequence of Auto Stop a HGM6120KC When Mains recovery during genset running enters into mains voltage normal delay and its indicator light af2. Note 2 if set as lower oil pressure to prohibit stop or set programmable port as lower oil pressure prohibits stop and this port is active when lower oil pressure values lower than set of lower oil pressure value or lower oil pressure alarm input is active controller send warning signal of higher temperature only and not stop 7 2 PROGRAMMABLE OUTPUT 1 4 TABLE TABLE 2 Num Content Description 0 Not used Output is no use when select this Common alarm The designated programmable output relay will energize when any warning or shutdown fault circuit has been activated HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 19 of 31 HGM6100K Series Genset Controller Num Content Description ETS solenoid hold The designated programmable output relay will energize when a stop signal has been activated The output will remain energized for pre set timer once the engine has come to a complete stop then de energizes Idle control The designated programmable output relay will energize when the idle delay is not zero The output contact would typically be connected to the idle run input control of an electronic governor Preheat control The designated programmable output relay will energize during the preheat delay timer period and also energize until the engine receive a crank success signal The preheat output is typically used for an
3. ISSUE 2012 12 01 Version 1 8 Page 21 of 31 HGM6100K Series Genset Controller Num Content Description out of limits condition occurring If this input is active and a remote start signal mains failure occurs the HGM6110 20K will not give a start command to the generator If this input signal is then removed the HGM6110 20K will operate as if a remote start mains failure has occurred starting and loading the generator This function can be used to give an AND function so that a generator will only be called io start if the mains fails and another condition exists which requires the generator to run If the Auto start Inhibit signals become active once more it will be ignored until the module has returned the mains supply on load and shutdown 7 4 SENSOR SELECTION TABLE 4 Num Content Description Temperature Sensor O Not used 1 Defined Res Type 2 VDO 3 SGH Huanghe sensor 4SGD DongKang sensor 5 CURTIS 6 DATCON 7 VOLVO EC 8 SGX 9 Reserved Defined input resistance range is 0 6000Q factory default is SGX Pressure Sensor 0 Not used 1 Defined Res Type 2 VDO 10Bar 3 SGH Huanghe sensor 4 SGD DongKang sensor 5 CURTIS 6 DATCON 10Bar 7 VOLVO EC 8 SGX 9 Reserved Defined input resistance range is 0 6000Q factory default is SGX Fuel Level Sensor O Not used Defined curve input 1 Defined Res Type resistance range
4. SS condition select WS e Table 5 lt When engine speed is over 64 p 0 6000 RPM 360 than this point starter will disconnect j disconnect When generator frequency 65 Freq disconnect 10 30 Hz 14 is over than this point starter will disconnect When engine oil pressure is 66 OP disconnect 0 400 kPa 200 over than this point starter will disconnect HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 18 of 31 HGM6100K Series Genset Controller Num Parameter Range Default Description Hiah on Default when temperature 67 sgleci p 0 1 0 is higher alarm to stop P Details see Note1 Low OP prohibit Default when oil pressure 68 Zani 0 1 0 is lower alarm to stop Details see Note2 0 3phase 4wire Single 3 phases 1 j SS input select 2phase 3wire 9 aphace sewing 2 1phase 2wire 70 Select temp 0 9 08 SGX sensor 74 Select press 0 9 08 SGX sensor 72 Select liquid 0 5 03 SGD level sensor Number of magnetic poles 73 Number of Poles 2 32 04 used for calculating rotating speed of generator without speed sensor Note 1 if set as higher temperature to prohibit stop or set programmable port as higher temperature prohibits stop and this port is active when temperature value is higher than set of higher temperature value or higher temperature alarm input is active controller send warning signal of higher temperature only and not stop
5. and to stop The alarms are displayed in LCD Stop alarms as following 1 Emergency Stop When controller detected emergency stop signal it will HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 10 of 31 HGM6100K Series Genset Controller send a stop alarm signal and it will be displayed in LCD When controller detected the temperature of 2 High Temp water cylinder is higher than set it will send a stop alarm alarm signal and it will be displayed in LCD When controller detected oil pressure is lower than set Lower OP Gg f o 3 aarm for alarming it will send a stop alarm signal and it will be displayed in LCD When controller detected genset speed is over than set Over speed Bee delet nner 4 Ha for alarming it will send a stop alarm signal and it will be displayed in LCD When controller detected genset speed is under than Under speed Soe eae a i 5 aain set for alarming it will send a stop aarm signal and it will be displayed in LCD When controller detectedgenset speed is 0 or delay is Speed signal rete Gg 6 iost alani not O it will senda stop alarm signal and it will be displayed in LCD When controller detected genset voltage is over than 7 Gens over set for alarming it will send a stop alarm signal and it voltage will be displayed in LCD When controller detected genset voltage is under 8 Gens under than set for alarmmg IL will send a s
6. as 0 controller will send warning alarm signal and it will be displayed in LCD When controller detected the currentof genset is over Gens Over than threshold and over current delay set as 0 Current controller will send warning alarm signal and it will be displayed in LCD When generator not stops after the stop relay is over 3 Failed To Stop controller will send warning alarm signal and it will be displayed in LCD When controller detected the oil level of genset is lower than threshold or low oil level warn input is active controller will send warning alarm signal and it will be displayed in LCD When controller detected the voltage of genset charger 5 Charge Alt Fail is lower than threshold controller will send warning alarm signal and it will be displayed in LCD When coniroller detected the voltage of genset battery is lower than threshold controller will send warning 4 Low oil level Battery Low ores alarm signal and it will be displayed in LCD When controller detected the voltage of genset battery 7 Men High is higher than threshold controller will send warning Voltage alarm signal and it will be displayed in LCD When controller detected the warning of low water level 8 Low water level input is active controller will send warning alarm signal and it will be displayed in LCD 5 2 SHUTDOWN ALARM When controller detected shutdown alarm it will send signal to break off
7. engine starting aid such as glow plugs Closed Gens Switch generator breaker on Closed Mains Switch mains breaker on HGM6120KC Open ATS Switch breaker off The output delay is 3 seconds Raise speed In the process of warm up when he entered the suction suck time for high speed warm up delay time Raise speed auxiliary input effective disconnect Drop speed Enter into stop idling process or to ETS solenoid stop when alarm stop sucked and suck time to stop idling delay time Drop speed when the auxiliary active disconnect 10 Generator run output Outputting when genset in normal running and disconnected after speed is lower than start successful speed value 11 Fuel pump control When the fuel level lower than the set threshold to open the fuel pump or input a low oil level warning enter active pull when the fuel level over than that set off the fuel pump and the input threshold of the low oil level warning off when input is inactive open 12 High speed control Outputting when genset enters into Warming Up and disconnected after Cooling Down is over 13 System in automatic mode The controller work in automatic mode HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 20 of 31 HGM6100K Series Genset Controller Num Content Description 14 Shutdown alarm Output when shutdown alarm occurs It w
8. nothing otherwise may appear oil pressure low alarm shutdown Can set up several point offforehand or several point of backmost ordinate the same The following picture kPa 800 700 600 7 500 400 300 200 100 32 64 96 128160192 224 Q2 omh HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 25 of 31 HGM6100K Series Genset Controller Common units conversion table 1N m pa 1kgf cm 1bar 1b in psi 1Pa 1 1 02x10 1x10 1 45x10 1kgf cm 9 8x104 1 0 98 14 2 bar 1x10 1 02 1 14 5 1psi 6 89x10 7 03x10 6 89107 1 10 COMMISSIONING Before operation inspections that are recommended as follows should be carried out a Check and assure that all connections are correct and that diameter of line is suitable b The DC power supply of controller is equipped with fuse and the positive supply Ve and negative supply Ve connected with battery are connected correctly c The emergency stop input is connected with the positive supply Ve of the battery through the NC terminal and use of emergency stop button d The suitable operation should be taken to prevent the engine from crank success such as dismantling the connection of fuel check and assure that it is correct then connect with battery select manual mode the controller will execute program e Press down the starting button on the panel of controller the engine wi
9. 8 17 configurable input item of automatic inhibit start and an option active connecting with B or B for all input port Add High speed control option in output ports Add prohibit stop when High temperature low oil pressure in programmable parameters Revise range of sensor curve input 1 6 2011 04 12 Add Russian and five programmable output port options 1 7 2012 07 05 Modify parameters Modify some details Add Portuguese shutdown alarm output port 1 27 2010 04 20 1 5 2010 12 09 1 8 2012 12 1 HGM6100K Series Genset Controller O N 10 11 12 13 CONTENT SUMMARY EE 4 PERFORMANCE AND CHARACTERISTICS annann 4 SPEGIFIGATION EE 6 OPERATION KEE 7 dA KEY FUNCTION eiert eeben 7 4 2 AUTOMATIC OPERATION e 88 Qb 7 4 3 MANUAL OPERATION REESEN 9 PROTECTION ccccacc caccacaci cic E E D 10 5 1 WADNING EE Wf A S 10 5 2 SHUTDOWN ALARM JB bh 2 10 CONNECTING TERMINAL EN 12 PARAMETER RANGE AND DEFINE ee 14 7 1 PARAMETERS TABLE TAB WW 14 7 2 PROGRAMMABLE OUTPUT 124 TABLE TABLE 21 19 7 3 PROGRAMMABLE DIGIT INPUT 1 5 TABLE ALL IS VALID WHEN CONNECT GRAND B TABLE 2 21 7 4 SENSOR SELECTION TABLE Ai 22 7 5 CONDITIONS OF CRANK SUCCEED TABLE Si 23 id VC al 24 SENSQR Smee G TION EE 25 old Tell IC 26 TYPICAMWAPPLICATION wc cel crete cei eee eats 27 INSTALEATION ME 29 FAULT EE lege eeh eal tee 30 HGM6100K Series
10. C ph N 15V AC 360 V AC ph N Frequency 50Hz 60 Hz Magnetic AC voltage 1 0V to 24V effective value Magnetic AC Frequency 10 000 Hz max Start Relay Output 16 Amp DC28V at supply voltage Fuel Relay Output 16 Amp DC28V at supply voltage Auxiliary Relay Output 1 7 Amp DC28V Auxiliary Relay Output 2 7A 250VAC passive Auxiliary Relay Output 3 16A 250VAC passive Auxiliary Relay Output 4 16A 250VAC passive Overall Dimensions 209mm x 153mm x 55mm Panel cutoff 186mm x 141mm C T Secondary 5A rated Operating Temp Range Temperature 25 70 C Humidity 20 90 Storage Condition Temperature 30 80 C Protective Level IP55 when waterproof rubber ring added between controller and its panel IP42 when waterproof rubber ring not have between controller and its panel Insulation Intensity Object among in input output power Quote standard IEC688 1992 Test way AC1 5 kV 1min 3mA leakage current Weight 0 71kg HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 6 of 31 4 OPERATION HGM6100K Series Genset Controller 4 1 KEY FUNCTION Can stop generator under mode of Manual Auto Can reset alarming under Stop Stop Reset To test panel Indicators are OK or not pressing this key at least 3 seconds During stopping process pr
11. Genset Controller other equipment 4 Alternating current input HGM6100K series controller to external input current transformer electric current transformer side must be 5A while the current transformers for phases and the phase of the input voltage must be correct otherwise the current and sampling the active power may be incorrect Note A ICOM must connect battery anode power controllers B When the load current the transformer secondary side is strictly open circuit 5 Pressure test When the controller has been installed in the control panel if you will please put pressure test controller terminals all disconnected lest high pressured into and damaged controller 13 FAULT FINDING Symptom Possible Remedy Generator inoperative Check thebattery and wiring to the unit Check the DC supply Check the DC fuse Generator shutdown Check water cylinder temperature whether or not too high Check AC generator voltage Check the DC fuse Emergency shutdown If an Emergency shutdown switch is not fitted ensure that a positive is connected to the emergency shutdown input Check emergency shutdown switch is functioning correctly Check wiring is not open circuit Low oil Pressure alarm after crank success Check engine oil pressure Check oil pressure switch sensor and wiring Check configured polarity if applicable is correct High Temp alarm after crank success C
12. Genset Controller ISSUE 2012 12 01 Version 1 8 Page 3 of 31 HGM6100K Series Genset Controller 1 SUMMARY HGM6100K series Genset controller integrating digital intelligent and network techniques is used for automatic control system of diesel generator It can carry out functions including automatic start stop data measure and alarm protective The controller uses LCD display optional Chinese English Spanish Russian and Portuguese display interface with operation easy and reliable HGM6100K series Genset controller uses micro processing technique which can carry out precision measure constant value adjustment timing and threshold setting and etc functions It can be widely used in all types of generatonautomatic control system for compact structure advanced circuits simple connections and high reliability can be widely applied to various types of generating units automation system 2 PERFORMANCE AND CHARACTERISTICS m HGM6100K controller has four types HGM6110K 6110KC Automatic Start Module it controls generator to start stop by remote start signal HGM6120K 6120KC Based on HGM6110K 6110KC and add mains AC monitoring Mains Generator automatic switching control functions AMF especially suitable for the automation system composed by Mains and Generator Note1 HGM6110KC 6120KC with RS485 interface HGM6110K 6120K without RS485 interface Note2 And then take HGM6110KC 6120KC with text as an example to describe Using
13. RS485 port A 0 5mm Use only 1200 RS485 approved cable 37 RS485 port B 0 5mm 38 Auxiliary input 4 1 0mm Switch to ve Reference HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 13 of 31 39 Auxiliary input 5 1 0mm Switch to ve HGM6100K Series Genset Controller table 3 40 Common port 1 0mm Auxiliary input common port Note LINK interface in back is as a parameter programming interface by PC to programmable controller via SG72 adapter 7 PARAMETER RANGE AND DEFINE All parameters of HGM6100K series are as following 7 1 PARAMETERS TABLE TABLE 1 Num Parameter Range Default Description 4 Mains ne 0 3600 s 10 normar delay Mains transient delay Suited for ATS automatic 2 Mains volt 0 3600 s 5 transfer switch abnormal delay When mains voltage is under than the point mains 3 Mains under volt 30860 v jeg eet ee ee When the point is zero mains under voltage are disabled When mains voltage is over than the point mains over 4 Mains over volt 30 360 V 276 voltage are active When the point is 360V mains over voltage are disabled It s the delay from mains is 5 Transfer Switch 0 99 9 s 10 opened to generator closing interval or from generator is opened to mains closing It s the delay from remote 6 Start delay 0 3600 s ME i ee mains is failure to start generator It s the delay f
14. Smartgen HGM6100K Series Genset Controller USER MANUAL Saa jee hil o lo lel le lo lo a L lt lt a G d L _ o lol lelle lo le Smartgen Technology Smartgen Smartgen Technology Co Ltd No 28 Jinsuo Road Zhengzhou Henan Province P R China Tel 0086 371 67988888 67981888 0086 371 67991553 67992951 0086 371 67981000 overseas Fax 0086 371 67992952 Web http www smartgen com cn http www smartgen cn Email sales smartgen cn All rights reserved No part of this publication may bereproduced 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 Electronics at the address above Any reference to trademarked product names used within this publication is owned by their respective companies Smartgen electronics reserves the right to change the contents of this document without prior notice Software Version Version Date Note 1 0 2009 10 10 Original release 14 2010 04 07 Add a typical wiring diagram and an AUX INPUT4 38 Pin and an AUX INPUT5 39 Pin and an Earth wire 40 Pin Add a language of Spanish Modify the panel cutout size and the operation temperature range Add a configurable output item of fuel pump control and a 1 4 2010 0
15. age environment battery anode musi be reliable connect engine shell B and B controller power battery anode and cathode connections is not less than 2 5 if there was the float electrical please put the charger output wire directly to battery is negative and from the battery is connected to the anode separately on the power input positive controller to prevent the normal operation of the controller battery charger interference Speed sensorinput Speed sensor is installed in the engine block of magnetic device testing flywheel teeth it should be used with the controller of attachment 2 core shielding line shielding layer on the 16th pin controller the other end terminal the other two are respectively in signal controller and meet the terminals 15th and 16th pin At full soeed sensor output voltage range should be in 1 24VAC RMS recommend voltage for 12VAC in the rated speed When the velocity sensor can be installed to contact the flywheel spinning sensor first then pour out 1 3 laps finally will lock nut on the sensor Output and relays Controller for all output relay contacts output if need to expand relays please will expand relay coil free wheeling diode increased ends when extended relay coil links DC or increase resistance and capacitance loop when extended relay coil links AC in order to prevent interference controller or HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 29 of 31 HGM6100K Series
16. ameters This can be applied to the pump set if not choose magnetic pickup sensor the speed signal will come from the generating AC signal HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 23 of 31 HGM6100K Series Genset Controller 8 PARAMETER SETTING After controller powered on press Q to enter into the parameters setting menu 1 Set Parameters 2 Information 3 Set Languages m Set parameters When entering password entering 1234 can set the item 1 to 38 inthe table parameters table Table 1 entering 0318 can set all items NOTE a When the controller type is HGM6110KC you will not have a table with a 1 5 the programmable output 1 4 will have no power of some mains switch output b Please modify the parameters such as crank disconnect input and output configuration various time etc in standby mode otherwise it might alarm shutdown or other abnormal behavior c The over voltage threshold must be greater than the under voltage threshold otherwise both will occur at the same time over voltage and under voltage situation d The over speed threshold must be greater than under speed threshold otherwise you will receive both the over speed and under speed e As far as possible set the frequency crank disconnect to lower numerical in order to quickly crank disconnect when crank success f Configurable input port 1 5 cannot set for the same items otherwise cannot appear correct fun
17. can protect genset to stop quickly detail procedures please refer to No 4 9 of Auto start operation Under Manual Test MO 8 genset with load is decided by Mains is normal or not lf mains are normal loading switch is never transferred while mains are abnormal loading switch is transferred into gens side Under Manual Test w after genset runs well in high speed no matter mains is normal or not loading switch must be transferred into gens side HGM6110KC Auto starts mode is activeywhen ws and its indicator is illuminating Then press to start generator it can automatic detect start successfully and gensetautomatic accelerates to Hi speed running If there is Hi temperature low oil level and voltage abnormal during diesel genset running controller can protect genset to stop quickly detail procedures please refer to No 4 9 of Auto start operation After genset runs well in High speed controller will send signal of gens close Manual stop press can shut down the running genset detail procedures please refer to No 3 7 of Auto stop operation HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 9 of 31 HGM6100K Series Genset Controller 5 PROTECTION 5 1 WARNING When controller detects the warning signal only alarm and not stop genset The alarms are displayed in LCD Warnings as following When controller detected the speed of gensetris 0 and 1 Lost of speed speed lost delay set
18. ction configurable output 1 4 can be set for the same item g If need to shutdown after cooling please set any one configurable input as stop after cooling then connect this input with GND Information LCD will display the controller software version issue date Note Press the key Dui display the states of switching input 5 whether or not active HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 24 of 31 HGM6100K Series Genset Controller Set language User may set display interface language as Chinese English Spanish Russian and Portuguese Note Press the key will exit setting interface at any time 9 SENSOR SELECTION When the choice sensor the sensor to standard curve will call lffactory set temperature sensor for SGH 120 degrees resistance type sensor curve for SGH 120 degrees resistance type 120 degrees Celsius elected SGD type resistively curve for temperature sensor SGD curve If use standard sensor with the curve can differ option item sensor curve input after adjusting adjustment can be determined according to save When the input sensor curve X resistance must be in accordance with the order of big from small otherwise will enter errors When the sensor is choosing nothing the sensor curves no affection LCD display temperature or pressure for If there is no pressure Sensor only low pressure alarm switch it must be alarm settings for pressure sensor
19. ess this again Cam stop generator immediately a Start To start genset under Manual or Auto mode Manual Pressing this key will set the module into manual mode Weeer Pressing this key will set the module into automatic mode Pressing and controller is Under manual testing Running with MORR gt j load Under this mode genset will run with load automatic when gens are normal HGM6110KC without Set Confirm Enters into Set menu after pressing this and can shift cursor to confirm Gi Page up Screen pages turning increase Shift cursor and increase its position no in setting Gei Page down Screen pages turning decrease Shift cursor and decrease its position no in setting 4 27AUTOMATIC OPERATION This mode is activated by pressing the LED indicator is illuminating beside the button confirms this action Sequence of Auto Start HGM6100K Series Genset Controller HGM6120KC When Mains is abnormal over and under voltage or miss phase enters into mains abnormal delay and LCD display count down time When mains abnormal delay is over enter into start delay HGM6110KC entries into start delay as soon as Remote Start is input valid Count down of start delay is displayed in LCD When start delay is over preheat relay is outputting if be equipped preheat start delay XX s is displayed in LCD ISSUE 2012 12 01 Version 1 8 Page 7 of 31 HGM6100K Series Genset Controller
20. heck engine temperature Check switch sensor and wiring Check configured polarity if applicable is correct Shutdown fault operates Check relevant switch and wiring of fault indicated on LCD display Check configuration of input HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 30 of 31 HGM6100K Series Genset Controller Symptom Possible Remedy Crank no success Check wiring of fuel solenoid Check starting batteries Check speed sensor and its connections Refer to engine manual Crank failure Check wiring of fuel solenoid Check fuel Check battery supply Check battery supply is present on the Fuel output of the module Check the speed sensing signal is presenton the 6100K series inputs Refer to engine manual Unit operation but ATS Check ATS Check the connection between the ATS and the controller RS485 communication abnormal Check wiring Check COM ports set correctly Check the A and B RS485 line is reversed Check of RS485 conversion module Check the PC communications port is damaged Suggest that the A and B lines of the 485 network should be terminated at each end wita 1200 resistor HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 31 of 31
21. ill self locking until alarm reset 15 Reserved 16 Reserved 17 Reserved 7 3 PROGRAMMABLE DIGIT INPUT 1 5 TABLE ALL IS VALID WHEN CONNECT GRAND B TABLE 3 Num Content Description 0 Not used 1 High Temp alarm input After the end of the delay in the safe 2 Low OP alarm input operation ifthe signal is active generator will immediately alarm shutdown 3 Auxiliary warn input Auxiliary warn alarm digital input 4 Auxiliary shutdown When power on if active generator will stop alarm input immediately During engine running if the engine occur high temperature shutdown when the input is 5 Stop after cooled active the engine will first initiate cooling delay hand then stop else will stop immediately 6 Se closed meg The input state of generator closed 7 SC Weed ete The input state of Mains closed 8 Higher temp stop When it is active prohibit stop when higher prohibit temperature Details see Note1 Oilpressure lower stop When it is active prohibit stop when oil 9 S prohibit pressure lower Details see Note2 10 Remote start input 11 Low Fuel Level warn 12 Low coolant level warn 13 Low Fuel Level shutdown 14 Low coolant level shutdown This input is used to provide an over ride 15 Automatic start Inhibit function to prevent the 6100K from starting the generator in the event of a remote start mains HGM6100K Series Genset Controller
22. is 2 SGH 3 SGD 0 6000Q factory default is SGD HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 22 of 31 HGM6100K Series Genset Controller Num Content Description 4 Reserved 1 5 Reserved 2 7 5 CONDITIONS OF CRANK SUCCEED TABLE 5 Num Content 0 Magnetic pickup sensor 1 Generator 2 Magnetic pickup sensor Generator 3 Magnetic pickup sensor Oil pressure 4 Generator Oil pressure 5 Generator Magnetic pickup sensor Oil pressure 1 2 3 4 The crank disconnect condition has three kinds th magnetic pickup sensor and the generator voltage can be used alone the oil pressure must be used with the magnetic pickup sensor and the generatorivoltage the purpose is to make the starter and the engine to disconnect as soon as possible Magnetic pickup sensor is installed in the engine block number of magnetic device testing flywheel When choosing magnetic pickup sensor ensure engine flywheel teeth setting otherwise may appear over speeding shutdown or loss speed shutdown If the generator is not magnetic pickup sensors please don t choose corresponding otherwise this will occur fail to start or loss of speed alarm and shuidown If the generator has no oil pressure sensor please don t choose corresponding If the generator starting conditions has not be selected the controller will not measure and display the relative par
23. ll crank after starts have been carried out according to setting crank numbers the controllerssends the signal that indicates crank failure Press the Stop Reset key to make the controller resetting f Restore the measure that prevents the engine from crank success such as restoring the connection of fuel press down the starting button again the engine will crank if crank is normal the generator will operate from idle operation if idle has been set to normal operation In the meantime observe the operation situation of engine and the voltage and frequency of the AC HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 26 of 31 HGM6100K Series Genset Controller generator If there is abnormal stop the generator then check connections of each part according to this handbook Select automatic state through front panel then switch on the mains voltage the controller switches over ATS if it exist to mains on load after pass through the mains normal delay after cooling time and then shut down to go into standby state until the mains is abnormal again After the mains is abnormal again the Generator will automatically crank into normal operation state and then close generator relay control the ATS to switch transfer to generator on load If the situation is notssame as described above check the connection of control part of the ATS according to this handbook If there are other questions please contac
24. microprocessor as a core symbol LCD with backlight display the five languages display Chinese English Spanish Russian and Portuguese key touch operation Have a RS485 port with Modus communication protocol Adapt to 3phase 4wires single phase 2wires or 2phase 3 wires 120 240V 50 60Hz AC power system Measure and display 3 phase voltage 3 phase current frequency power etc parameter of Mains and Gens Mains Gens Line voltage Uab Ubc and Uca Line voltage Uab Ubc and Uca HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 4 of 31 HGM6100K Series Genset Controller Phase voltage Ua Ub and Uc Phase voltage Ua Ub and Uc Frequency HZ Frequency HZ Load Power Current IA IB IC Active power KW Inactive power KVar Apparent power KVA Power factor Cos Accumulate total gens power kWh Mains have over voltage under voltage loss phase function Gens have over voltage under voltage over frequency under frequency over current function Precision measure and display parameters about Engine Temp WT C F both are display Oil pressure OP kPa Psi Bar all be display Fuel oil level FL unit Speed SPD RPM unit Voltage of Battery VB V unit Voltage of Charger VD V unit Hour count HC can accumulate Max 999999 hours Starting up can accumulate Max 999999 times Control protection Automatic crank stop of diesel engine load transfer ATS control and com
25. nd 24 Under speed 0 6000 RPM 1200 hold great than 10 seconds generator under speed is active HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 15 of 31 HGM6100K Series Genset Controller Num Parameter Range Default Description 25 Over speed 0 6000 RPM 1710 When the engine speed is over than the point and hold great than 2 seconds generator over speed is active 26 Gens under freq 0 75 0 Hz 45 0 When generator freq is low than the point generator low frequency and hold great than 10 seconds is active 27 Gens over freq 0 75 0 Hz 57 0 When generator freq is over than the point and hold great than 2 seconds generator over frequency is active 28 High temperature 80 140 9C 98 When engine temperature sensor value is over than this point and remain for 2 seconds send out shutdown alarm When the value is 140 send out warning alarm It s suited for engine temperature sensor only 29 Low oil pressure 0 400 kPa 103 When engine oil pressure sensor value is under than this point and remain for 2 seconds send out shutdown alarm When the value is zero send out warning alarm it s suited for oil pressure sensor only 30 Low Fuel Level 0 100 10 When fuel level sensor value is under than this point and remain for 10 seconds send out warning alarm 31 Lose s
26. p threshold ene SS 10 seconds the output signal to open fuel pump When the fuel level higher Fuel pump off f than the set value and for 40 threshold 0 100 E te seconds the output fuel pump off signal 41 Digit Output1 set 0 17 2 Energized to stop 42 DigiE NIPU 2 0 17 3 Idle control set HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 17 of 31 HGM6100K Series Genset Controller Num Parameter Range Default Description 43 GE QUIGUE 3 0 17 5 Close gens 44 7 St 4 0 17 6 Close mains 45 Aux inputi 0 15 1 High Temperature input 46 Aux input1 valid 0 1 0 Factory default is closed EEN 0 20 0 s 2 0 delay 48 Aux input2 0 15 2 Low Oil Pressure input 49 Aux input2 valid 0 1 0 Factory default is closed le 0 20 0 s 2 0 delay 51 Aux input3 0 15 10 Remote start input 52 Aux input3 valid 0 1 0 Factory defaultis closed ee EES 0 20 0 s 2 0 delay 54 Aux input4 0 15 11 Low fuel level warn 55 Aux input4 valid 0 1 0 Factory default is closed Sef ER 0 20 0 s 2 0 delay 57 Aux input5 0 15 12 Low coolant level warn 58 Aux input5 valid 0 1 0 Factory default is closed Ee E EEN 0 20 0 s 2 0 delay 0 Stop mode 60 E power 0 2 0 1 Manual mode 2 Auto mode 61 Module address 1 254 1 62 Passwords set 0 9999 1234 Crank success Setting item is given in
27. peed delay 0 20 0 s 5 0 When speed is zero and remain for the delay send out shutdown alarm When the delay is zero send out warning alarm HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 16 of 31 HGM6100K Series Genset Controller Num Parameter Range Default Description During generator is running when charge alternator WL D voltage is under 32 Charge fail volt 0 30 V 6 0 than this point and remain for 5 seconds generator will warning alarm When generator battery voltage is over fan the i hold f 2 33 Battery over volt 12 40 V 33 0 paint and JI WW seconds battery over voltage signal is active It s a warning alarm When generator battery voltage is under than the 34 Battery under 4 30 V 8 0 point and hold for 20 volt seconds battery under voltage signal is active It s a warning alarm 35 CT rate 5 6000 5 500 Current transformer rate 36 Full load current 5 6000 A Mad ains or generator set maximum rated current Over ee When the load current is 37 50 130 120 over than the point the over percentage CR current delay is initiated When load current is over than the point and hold 38 Over current 0 3600 s 1296 great than the timer send delay out over current signal When the delay is zero over current is disabled When the fuel level lower Open Fuel o than the set value and for ee Pum
28. pletely faults display protection With ETS idle control pre heat control raises speed control functions and all types of them are belong to relay output Parameters setting Allow user to modify setting and store them by inside internal FLASH memory the parameters can not be lost even with power off All of parameters can be set not only from the front panel but by PC via SG72 an adaptor USB LINK RS485 module or through RS485 port via PC Most of temperature pressure oil level sensor can be directly used and also user can define sensor curve by themselves Multiple crank disconnection conditions can be selected Speed sensor oil pressure gens Power supply range is wide 8 35 VDC accommodating to different starting battery voltage environments All parameters use digital modulation abandoning analog modulation using HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 5 of 31 HGM6100K Series Genset Controller conventional electronic potentiometer more reliability and stability Modular configuration design Flame Retardant ABS plastic shell inserted type connection terminals installation 3 SPECIFICATION flush type installation compact structure easy Operating Voltage DC8 0V to 35 0V Continuous Power Consumption lt 3W Standby mode lt 2W AC voltage Input Range 3 Phase 4 Wire 2 Phase 3 Wire Single phase 2 Wire 15V AC 360 V AC ph N 15V AC 360 V A
29. rom remote 7 Stop delay 0 3600 s 1 start signal is inactive or mains is normal to stop generator HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 14 of 31 HGM6100K Series Genset Controller Num Parameter Range Default Description When engine start no success most of cranking 8 Number of crank 1 10 times 3 ee When teat setting crank numbers controller send out start fail signal 9 Preheat time 0 300 s 0 The starter adds the time of nO Grani ime SES the electricity each time 11 Crank rest time 3 60 s 10 12 Safe run time 1 60 s 10 13 Start idle time 0 3600 s 0 14 Warming up time 0 3600 s 10 15 Cooling time 3 3600 s 10 16 Stop idle time 0 3600 s 0 17 ETS solenoid 0 120 s 20 It s the delay for energizing hold to stop 18 Fail to stop delay 0 120 s 0 Mains or Generator switch 19 ATS close time 0 10 s Mg losing pulse wiati When it IS zero output is continuous 20 Flywheel teeth 10 300 118 Gens abo gia A 10 0 delay When generator voltage is over than the point 22 Gens overvolt 30 360 V eee active When the point is 360V generator over voltage is disabled When generator voltage is under than the point 23 Gens under volt 30 360 V foe We eee active When the point is 30V generator under voltage is disabled When the engine speed is under than the point a
30. round battery ve 15 Magnetic pickup ve S ST EE 16 Magnetic pickup ve onnect to Magnetic Pickup device Connecting water cylinder 17 Temp sensor input temperature resistance type anderen sensor F e table 4 18 Oil pressure input Connect to oil pressure sensor 19 Liquid level input Connect to liquid Level sensor 20 Auxiliary input 1 1 0mm Switch to ve ee Reference 21 Auxiliary input 2 1 0mm Switch to ve table 3 22 Auxiliary input 3 1 0mm Switch to ve 23 CT Secondary for A 1 5mm ec n of A monitoring CT 24 CT Secondary for B 1 5mN d to secondary of B monitoring 25 CT Secondary for C PN o Ga to secondary of C monitoring 26 CT secondary gt ome to secondary of all monitoring common CT s 27 Generator A voltage 10 Connect to Generator A output monitoring AMM Recommend 2A fuse 28 Generator B voltage 10 Connect to Generator B output monitoring AMM Recommend 2A fuse 29 Gen rator C voltage 1 0 Connect to Generator C output monitoring sina Recommend 2A fuse Generator Neutral Connect to generator neutral 30 1 0mm input terminal AC 31 Mains A voltage 1 0 Connect to mains A output monitoring wen Recommend 2A fuse 32 Mains B voltage 1 0 Connect to mains B output monitoring GT Recommend 2A fuse Mains C voltage Connect to mains C output 33 DER 1 0mm monitoring Recommend 2A fuse 34 Mains Neutral input 1 0mm Connect to mains neutral terminal 35 RS485 port common 0 5mm 36
31. s following 15 16 17 18 19 20 21 22 38 39 20 e op E LCD CONTRAST ADJUST AUX INPUTS Description of terminal blocks connection GENS VOLTAGE MAINS VOLTAGE R S ET NI ouma 29 22 25 26 IA IB IC ICOM eed elt U V W N2 BEE CONTROLLER Co bis PROGRAM PORT RS485 GND RS485 CURRENT ISOLATION RATED 5A DC Plant Supply input System DC negative input Battery 1 2 5mm ve Negative System DC positive input Battery 2 SE SW input 2 5mm Positive Recommended Maximum Fuse 20A 3 Emenf fcy Ma input 2 5mm Plant Supply ve Also supplies fuel amp start outputs Plant Supply ve from pin 3 d Fuel relay output 1 5mm 16 Amp rated Plant supply ve Connect to 5 Start relay output 1 5mm from pin 3 16 Amp starter starting rated coil Plant Supply ve 6 Auxiliary relay output 1 1 5mm from pin 2 7 Amp rated 7 Closed output 7 DE EN Amp rated table 2 8 Auxiliary relay output 2 1 5mm Relay common point Open output 7 Amp 9 rated 10 Auxiliary relay output 3 2 5mm Free volt contacts HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 12 of 31 11 HGM6100K Series Genset Controller 12 16 Amp rated 13 Auxiliary relay output 4 2 5mm 14 a ENEE port 1 0mm Do not connect to g
32. t the technical personnel of Smartgen immediately 11 TYPICAL APPLICATION GENS HGM6110KC Typical wiring diagram 35 A SG72 Module srd 2 penn L1 BEPA reng S e BEER Te H 1 d HII e AUX OUTPUT2 ME t AUX OUTPUTA 77 AE 8 9 12 13 30 29 28 27 23 24 25 14 17 18 19 1516 20 21 22 38 39 40 6 LEVEL CHARGER D AUX OUTPUT1 D I ES N N Qa HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 27 of 31 HGM6100K Series Genset Controller HGM6120KC Typical wiring diagram LOAD S Ss N og Jj SWITCH1 SWITCH2 MAINS GENS lA z lt C Zz O 3 AUX OUTPUT2 17 18 19 1516 AUX INPUT2 AUX OUTPUT COOLANT TEMP OIL PRESSURE GENSET MAINS INPUT 26 27 30 34 31 Single phase 2 wires R N MAINS INPUT 27 28 30 34 32 31 2 phase 3 wires Note Recommend that the output of crank and Fuel expand high capacity relay HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 28 of 31 HGM6100K Series Genset Controller 12 INSTALLATION The controller is designed to panel installation mode and it is fixed by clamps when it is installed The overall dimension and panel tapping dimension are given as follows 1 2 3 50 mm 5mm CUT OFF bi 186mm 153mm 139 mm 141mm Battery voltage input HGM6100K series controller can be applicable to 8 35 VDC battery volt
33. ter Mains normal be confirmed Start delay is beginning HGM6110KC genset enters into stop delay as soon as Remote Start putting is inactive As soon as stop delay is over genset enters into High Speed cooling delay Mains are close and breaker is disconnected After switch rest time delay mains are Close and relay is output as well as with loading Gens indicator is dark while mains light Idle relay has power and outputs as soon as entering stop idle relay If this been configured When enters ETS relay ETS relay has power and outputs Oil relay s output is disconnected When genset enters stop time automatic to decide whether generator is stopped or not When genset will enter into over stop time as soon as genset is stopped If genset failed to stop and controller will alarm stop failed will be displayed in LCD HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 8 of 31 HGM6100K Series Genset Controller 4 3 MANUAL OPERATION 1 HGM6120KC Auto starts mode is active when press and its indicator is illuminating press then controller under Manual Test Mode and its indicator is illuminating Under the both modes press qp to start genset and it can automatic detect start successfully and accelerate to Hi speed running If there is Hi temperature low oil level and voltage abnormal during diesel genset running controller
34. top alarm signal voltage and it will be displayed in LCD When controller detected genset current is over than 9 Gens over set for alarming or delay is not O it will send a stop current alarm signal and it will be displayed in LCD During the start attempt times if genset start failed it 10 Start failed will send a stop alarm signal and it will be displayed in alarm LCD When controller detected genset frequency is over than Over frequency E e e 11 SZ set for alarming it will send a stop alarm signal and it will be displayed in LCD When controller detected genset frequency is under Under a 12 ae alarm than set for alarming it will send a stop alarm signal 9 y and it will be displayed in LCD 13 Gens failed When controller detected genset frequency is 0 it will alarm send a stop alarm signal and it will be displayed in LCD When controller detected genset oil lever lower input is Oil level lower f SE f Eege 14 RES active it will send a stop alarm signal and it will be displayed in LCD When controller detected genset water level lower input Water level f SE ae 15 is active it will send a stop alarm signal and it will be lower alarm displayed in LCD HGM6100K Series Genset Controller ISSUE 2012 12 01 Version 1 8 Page 11 of 31 6 Connecting terminal HGM6100K Series Genset Controller HGM6110KC compared with HGM6120KC is less a Mains three phase AC input terminal The HGM6110KC and HGM6120KC backplane is a
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