USER MANUAL
Contents
1. 37 HSC960 Genset Controller Version 1 0 2015 05 21 Page 3 of 37 SmartGen Z FOREWORD J N Chinese trademark 5 r t Ge n English trademark SmartGen make your generator smart 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 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 publication is owned by their respective companies omartgen Technology reserves the right to change the contents of this document without prior notice HSC960 Genset Controller Version 1 0 2015 05 21 Page 4 of 37 SmartGen Table 1 Software Version 2014 06 10 Original release Table 2 Clarification of notation used within this publication A OTE Highlights an essential element of a procedure to ensure correctness T Indicates2. 20 8 PARAMETERS E38 72 30 8 1 UEF o WM AME 30 amy PARAMEBBRSUBETWUNG 30 3 ih LP CMM 30 ST MEN 6 ico c 30 85 WAD CONTRAST REGULATION 30 9 SENSOR ee ee tne eee eee eee eee ete mee ee ee ere eee eee ree ete nee LL ee eee eee eee een 31 10 COMMISSIONING iiie 32 11 TYPICAL cae 32 12 THE CONNECTION BETWEEN CONTROLLER 5 34 13 FIXING CLIPS 35 14 OVERALL DIMENSION AND PANEL 35 15 MATTERS NEED ATTENTION OF INSTALLATION cc ceeeeeee nennen 36 BAPTEHY VOETAGE 2 36 15 2 SPEED SENSOR INPUT iet hoe iet hehe 36 15 3 OUTPUT AND EXPANSION 22 2 0044222222 22221 36 15 4 AG CURRENT 36 15 5 WITHDRAW VOLTAGE TEST smosso 36 HSC960 Genset Controller Version 1 0 2015 05 21 Page 2 of 37 SmartGen Z HSC960 Genset Controller User Manual 16 FAULT
3. SmartGen 5 960 GENSET CONTROLLER USER MANUAL ZHENGZHOU SMARTGEN TECHNOLOGY CO LTD SmartGen 2 HSC960 Genset Controller User Manual CONTENT FOREWORD 25222 demens MIN MEE 4 1 OVERVIEW eee meee nee ere nen DEED DID II I 6 2 PERFORMANCE AND 5 5 2222 121 7 2 SPECIFICATION 9 ME 2 71 m 10 41 KEY FUNCTIONS cicer pp pes co a 10 42 INDICATOR 11 43 AUTO STARTSTOP OPERATION iii aE NEEE EEEE 12 AsO AMUSTPAUON e A E E A E N AER 12 4 3 2 Automatic Start 5 22 12 4 3 3 Automatic Stop 2 12 4 3 4 Manual start stop 13 5 PROTECTION 9 14 51 WARNINGS A sss 14 5 2 SHUTDOWN ALARM 22999 15 6 WIRINGS CONNECTION dB BP MA eoo n nenne nana aa ner rere errans 17 7 SCOPES AND DEFINITIONS OF CONFIGURABLE PARAMETERS
4. CAUTION Expand relay must used generator closed outputs HSC960 Genset Controller Version 1 0 2015 05 21 Page 33 of 37 SmartGen 12 THE CONNECTION BETWEEN CONTROLLER AND GENSET Cylinder emperature Sensor Position Feedback DC Motor Oil Pressure Sensor Power Acquisition Figure 5 Connection Diagram HSC960 Genset Controller Version 1 0 2015 05 21 Page 34 of 37 SmartGen 2 13 FIXING CLIPS INSTALLATION Controller is panel built in design it is fixed by clips when installed Withdraw the fixing clip screw turn anticlockwise until it reaches proper position Pull the fixing clip backwards towards the back of the module ensuring two clips are inside their allotted slots Turn the fixing clip screws clockwise until they are fixed on the panel A Note Care should be taken not to over tighten the screws of fixing clips Figure 6 Fixing Clips 14 OVERALL DIMENSION AND PANEL CUTOUT CUT OUT 186 22 771 Figure 7 Dimension And Cutout HSC960 Genset Controller Version 1 0 2015 05 21 Page 35 of 37 141 SmartGen 15 MATTERS NEED ATTENTION OF INSTALLATION 15 1 BATTERY VOLTAGE INPUT HSC960 controller can suit for widely range of battery voltage DC 8 35 V Negative of battery must be connected with the engine shell The diameter of wire which from power supply to battery must be over 2 5mm If floating charge
5. RATED 5A ENGINE TEMP OIL PRESSURE FUEL LEVEL NPUT 1 NPUT 2 INPUT 3 NPUT 5 AUX AUX AUX AUX Figure 2 Back Panel Table 7 Description of terminal connection 2 Remarks Size 1 Connected with negative of starter battery 25 mm Connected with positive of starter battery Max 20A fuse is recommended m c Connected with via emergency stop button 4 DEO Fuel relay output is supplied by 3 terminal rated 16A E Start relay output B is supplied by 3 terminal rated 16A Connected to starter coil 9 Always open output rated 7A Free contact always open rated Details see free contact output Table 9 5 mm HSC960 Genset Controller Version 1 0 2015 05 21 Page 17 of 37 1 5 mm Common terminal ideas for power HSC960 Genset Controller User Manual mme Connected with charger starters D WL CHARGER D 1 0 mm terminals Being hang up lf there is no this terminal Connected to U phase of generator 2A fuse is 15 Gens AC Voltage U 1 0 mm P 9 l recommended Connected to V phase of generator 2A fuse is 16 AC Voltage V 1 0 mm P 9 l recommended Connected to W phase of generator 2A fuse is 17 Gens AC Voltage W 1 0 mm P 9 l recommended Gens AC Voltage N2 Connected to N phase of generator DC12V Negative Connected with Tps DC DC12V Positive engine for power supply DC Gens Negative Connected with Tps DC DC
6. low fuel level signal Only alarm not shutdown If the set value is 0 only warning and not to shutdown the generator During generator is normal running when alternator D WL voltage has fallen below the set value and remains for 5s It will initiate a shutdown alarm signal When battery voltage has exceeded the set value and remains for 20s It will 12 40 V 33 0 initiate a warning alarm signal Only warning and not to shutdown the generator When battery voltage has fallen below the set value and remains for 20s It will initiate a warning alarm signal Only warning and not to shutdown the generator 5 6000 5 500 External connecting Rating Current 5 6000 A 500 Using for calculation of over current When gens current has exceeded this Over Current 50 130 120 range the over current delay will initiate When current has exceeded the pre set value and last for pre set time it will be Low Oil Pressure 0 400 kPa 103 55 ES gt gt Low Fuel Level 0 100 96 Loss of Speed 0 20 0 s Signal Charge Alt Failure Warning 25 26 O NO N Co Co CO amp CO NO Co NO O O 9 CO lt Battery Over NO Co Voltage Warning Battery Under 4 30 V Voltage Warning Over Current 0 3600 s 1296 Delay judged to over current When delay is set to Os it will only warn not shutdown When fuel level is lower than the pre set value and last for 10s it w
7. preheat control and raise speed drop speed control in addition they are all relay output Parameter setting parameters can be modified while write in EEPROM storage and cannot be lost even in case of power outage all parameters can be configured from front panel or by configurable port 5672 must be fitted and RS485 port to adjust via PC Multiple crank disconnect conditions speed sensor oil pressure generating are optional Widely power supply range DC 8 35 V suitable to different start battery voltage environment All parameters used digital adjustment instead of conventional analog modulation with normal potentiometer more reliability and stability Fixed with metal clips HSC960 Genset Controller Version 1 0 2015 05 21 Page 7 of 37 ky SmartGen Modular design self extinguishing ABS plastic enclosure pluggable connection terminals and embedded installation way compact structure with easy mounting HSC960 Genset Controller Version 1 0 2015 05 21 Page 8 of 37 SmartGen 3 SPECIFICATION Table 3 Parameters 010000 Operating Voltage DC8 0V to DC35 0V Continuous Power Supply Power Consumption ANODY SA P Working lt 8W When driving stepper motor is regulating Alternator Input Range 3 Phase 4 Wire AC15V AC360V ph N AC15V AC360V ph N Single Phase 2 Wire AC15V AC360V ph N 3 Phase 3 Wire AC620V ph ph 2 Phase 3 Wire Aux
8. 0 100 pe the genset is started HSC960 Genset Controller Version 1 0 2015 05 21 Page 24 of 37 When the value of external aux sensor has exceeded this value it will initiate warn alarm When the value of external aux sensor has exceeded this value it will initiate shutdown alarm N O1 N OD See teil When the value of external aux sensor has fallen below this value it will initiate warn alarm When the value of external aux sensor has fallen below this value it will initiate shutdown alarm 78 SmartGen m Offer standard to adjust idle speed 900 The rising speed rate during the Idle Slope 0 6000 10 process of genset change idle running status into rated speed running status is idle running gt Idle Speed 0 6000 r min 0 6000 r min 1 3000 The regulated gain when the genset is 89 Window i 1000 min 200 rumning in rated speed 90 WindowGai 1000 3000 1100 04000 0 92 Gain 04000 0 The regulated gain of throttle position 0 Defined temperature sensor 1 Defined pressure sensor 2 Defined level sensor 3 Defined aux sensor Chose the sensor which needs setting then input resistance value corresponding value of each point It needs to input 8 points Note 1 if high temperature inhibit is configured or set auxiliary input as inhibit high temperatur
9. a procedure or practice which if not strictly observed could result in CAUTION damage or destruction of equipment Indicates error operation may cause death serious injury and significant WARNING Property damage HSC960 Genset Controller Version 1 0 2015 05 21 Page 5 of 37 SmartGen 1 OVERVIEW HSC960 genset controllers integrate digitization intellectualization and network technology which are used for gas genset automation and monitor control system of single unit to achieve automatic start stop data measure alarm protection three remote remote control remote measuring and remote communication and speed regulation The controller adopts large liquid crystal display LCD and selectable Chinese and English interface with easy and reliable operation HSC960 genset controllers adopt micro processor technology with precision parameters measuring fixed value adjustment time setting and set value adjusting and etc All parameters can be configured from front panel or by configurable port and also can be configured by RS485 communication interface to adjust and monitor via PC It can be widely used in all types of automatic genset control system with compact structure advanced circuits simple connections and high reliability HSC960 Genset Controller Version 1 0 2015 05 21 Page 6 of 37 SmartGen 2 PERFORMANCE AND CHARACTERISTICS HSC960 used for single automation systems it regulates the speed simply by
10. configured please firstly connect output wires of charger to battery s positive and negative directly then connect wires from battery s positive and negative to controller s positive and negative input ports in order to prevent charge disturbing the controller s normal working 15 2 SPEED SENSOR INPUT 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 17 terminal in controller while another side is hanging in air The else two signal wires are connected to No 17 and No 18 terminals in controller The output voltage of speed sensor should be within AC 1 24 V effective value during the full speed AC12V is recommended in rated speed When install the speed sensor let the sensor is spun to contacting flywheel first then port out 1 3 lap and lock the nuts of sensor at last 15 3 OUTPUT AND EXPANSION RELAY All outputs of controller are relay contact output type If need to expand the relays please add freewheel diode to both ends of expand relay s coils when coils of relay has DC current or add resistance capacitance return circuit when coils of relay has AC current in order to prevent disturbance to controller or others equipment 15 4 AC CURRENT INPUT The current input of HSC960 Controller must be connected with external common reactance whose secondary current m
11. into its standby mode Otherwise fail to stop alarm is initiated and the corresponding alarm information is displayed on LCD HSC960 Genset Controller Version 1 0 2015 05 21 Page 12 of 37 SmartGen 4 3 4 Manual start stop operation a MANUAL START Manual mode is selected by pressing the 0 button a LED besides the button will illuminate to confirm the operation then press 4 button to start the genset can detect crank disconnect condition and generator accelerates to high speed running automatically With high temperature low oil pressure over speed and abnormal voltage during generator running controller can protect genset to stop quickly please refer to No 3 8 of Automatic Start Sequence for detail procedures Pressing o button the genset will be on load after the genset is normal running b MANUAL STOP Press can stop the running generators please refer to No 2 6 of Automatic Stop Sequence for detail procedures HSC960 Genset Controller Version 1 0 2015 05 21 Page 13 of 37 SmartGen 5 PROTECTION 5 1 WARNINGS Warnings are not shutdown alarms and do not affect the operation of the genset Warning alarms does not lead to shutdown and the alarm information will be displayed on the LCD Table 5 Warning alarms types are as follows When the controller detects the speed is 0 and the Loss of Speed oignal delay is set as 0 it will initiate a warning alarm and the alarm information will be displayed on
12. the LCD When the controller detects the speed is 0 and the Generating Overcurrent delay is set as O it will initiate a warning alarm and the alarm information will be displayed on the LCD After the ETS delay Fail to Stop delay has expired if the genset stop Preso nn it will initiate a warning alarm and the alarm information will be displayed on the LCD When the controller detects that there is Low Fuel Level input it will eai a warning alarm and the alarm information will be displayed on the LCD When the controller detects that the charger voltage has fallen below Charge Alt Fail the pre set value it will initiate a warning alarm and the alarm information will be displayed on the LCD When the controller detects that the battery voltage has fallen below the pre set value it will initiate a warning alarm and the alarm information will be displayed on the LCD When the controller detects that the battery voltage has exceeded the pre set value it will initiate a warning alarm and the alarm information will be displayed on the LCD When the low water level is set as warning and active it will initiate a warning alarm and the alarm information will be displayed on the LCD Temperature When the sensor didn t connect to correct port it will initiate a warning oensor Open alarm and the alarm information will be displayed on the LCD Oil Pressure When the sensor didn t connect to correct port it will initiate a warning oensor Open ala
13. 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 connection according to this manual Select the AUTO mode from controller s panel connect remote start signal genset will be started automatically and into normal running then controller send signal to close generator QCut off remote start signal genset will be stopped automatically the Open Generator signal will be send out If not like this please check ATS wires connection of control according to this manual lf there is any other question please contact Smartgen s service 11 TYPICAL APPLICATION U PPF L1 ete ee 2 lt 27 e pe N N AUX OUTPUT2 E aux OUTPUT4 11 AUX OUTPUT1 7 8 9 lt 9 12 13 18 17 16 15 43 44 45 46 5672 IET v 34 35 36 37 383921 22 23 24 25 26 19 F FTL 254 Electronic Throttle Electronic Throttle Power Supply Figure 4 Typical Application Diagram AUX INPUT1 T2 AUX INPUT3 AUX INPUT4 AUX INPUT5 MOTOR MOTOR VREF DC12V DC12V AUX INPU UJ I 2 CRANK FUEL CHARGER D a COOLANT TEMP HSC960 Genset Controller Version 1 0 2015 05 21 Page 32 of 37 SmartGen CAUTION Expand relay with high capacity in start and fuel output is recommend
14. 0 factory default is SGX 4 Reserved 5 Reserved Pressure Sensor Fuel Level Sensor Table 12 Conditions of crank dinsconnect selection Gen frequency 3 Speed sensor Oil Prese 000 4 Gen trequency Ol Pressures OOO 5 Speed sensor Gen frequency Ol Pressure a There are 3 conditions to make starter disconnected with engine that is speed sensor generator frequency and oil pressure Speed sensor and generator frequency can be used separately oil pressure needs speed sensor and generator frequency simultaneously for cooperation in order to make the starter motor is separated with engine immediately and can check crank disconnect exactly HSC960 Genset Controller Version 1 0 2015 05 21 Page 28 of 37 SmartGen b Speed sensor is the magnetic equipment which be installed in starter for detecting flywheel teeth c When set as speed sensor must ensure that the number of flywheel teeth is as same as setting otherwise over speed shutdown or under speed shutdown may be caused d If genset without speed sensor please don t select corresponding items otherwise start fail or loss speed signal maybe caused e If genset is without oil pressure sensor please don t select corresponding items f If not select generator frequency in crank disconnect setting controller will not collect and display the relative power quantity can be used in water pump set if not select speed senso
15. Gens Positive engine Suppl ositive pole for Position Positive position sensor Connected to the signal of forward direction the Connected to Tps Position Negative 1 0 mm supply negative pole for position sensor Connected to the signal of reverse direction the Position Signal2 1 0 mm larger the aperture of Tps is the lower the signal Position Signal 1 0 mm larger the aperture of Tps is the higher the signal voltage is voltage is Connected with Speed sensor shielding line is MP2 has already 0 5 mm P 9 recommended ignal Connected to resistance Sensor of water Temp Input 1 0 mm temperature or cylinder temperature Details see Table 11 Connected to resistance 31 Pressure Input 1 0 mm sensor Connected to oil pressure resistance sensor HSC960 Genset Controller Version 1 0 2015 05 21 Page 18 of 37 SmartGen resistance sensor Ground connected is active B Diai Ground connected is Digit Input2 1 0 mm active B Ground connected is Digit Input3 1 0 mm Details see form 10 active B Digit Input4 1 0 mm Ground connected is eani active B Ground connected is active B RS485 COM shielding wire recommended its single end earthed 1 5 mm External connected to CT secondary coil Rated 5A External connected to CT secondary coil Rated External connected to CT secondar
16. adjust the throttle opening via the driving stepper motor auto start stop of the unit are performed with the help of remote signal Key characteristics 132x64 LCD with backlight multilingual interface including Chinese and English pushbutton operation Sulitable for 3 phase 4 wire 3 phase 3 wire single phase 2 wire and 2 phase 3 wire systems with voltage 120 240V and frequency 50 60Hz Collects and shows 3 phase voltage current power parameter and frequency of generator Generator Line voltage Uab Ubc and Uca Phase voltage Ua Ub and Uc Frequency Hz Current IA IB IC Active Power kW Reactive Power Apparent Power Power Factor PF Electric Energy kWh For generator controller has over and under voltage over and under frequency over current functions Speed regulation function via Driving Stepper Motor Precision measure and display parameters about Engine Temperature WT C F display simultaneously Oil Pressure OP kPa Psi bar display simultaneously Fuel Level FL unit Speed SPD r min unit Battery Voltage VB V unit Charger Voltage VD V unit Hour count HC can accumulate to max 65535 hours otart times can accumulate to max 65535 times Protection automatic start stop of the genset ATS Auto Transfer Switch control with perfect failure indication and protection function ETS Energize to Stop idle control
17. bnormal functions However the auxiliary output 1 4 can be set as same items lf need to shut down after cooling please set any digital input as WTH STOP by cool then connect this input port to ground sounaly 8 3 INFORMATION LCD will display software version issue date of the controller A Note In this interface press will display the auxiliary inputs and outputs status 8 4 LANGUAGE Chinese and English interface can be selected 8 5 LCD CONTRAST REGULATION Simultaneously press and Q or e can adjust contrast in order to make LCD more distinct The range of regulation is 0 7 Note In setting process press in any time will break the parameter setting off and return back to main interface HSC960 Genset Controller Version 1 0 2015 05 21 Page 30 of 37 SmartGen 9 SENSOR SELECT When reselect sensors the sensor curve will be transferred into the standard value For example if temperature sensor is SGH 120 resistor type its sensor curve is SGH 120 resistor if select the SGD 120 resistor type the temperature sensor curve is SGD curve When there is difference between standard sensor curves and using sensor user can chose Defined sensor and input defined sensor curve When input the sensor curve X value resistor must be input from small to large otherwise mistake If select sensor type None temperature pressure and fuel level which LCD dis
18. e situation the controller WTH STOP by cool will first cool down the generator and then stop it if the signal is deactivated and a high temperature situation occurs the controller will shut down the gen set without cooling down Generator Closed input Inhibit igh When it is active high temperature shutdown will be prohibited Table8Note 1 Inhibit Low Oil Pressure When it is active low oil pressure shutdown will be prohibited Table8Note 2 Hemote Start Fuel Level Shutdown Coolant Level Shutdown 2 In Auto mode if this input is active whether remote start signal activates or not the controller will not give a start command to Inhibit Start Auto the generator If generator is normal running stop command won t be executed When this input is deactivated genset will automatically start or stop Shutdown input s HSC960 Genset Controller Version 1 0 2015 05 21 Page 27 of 37 SmartGen mtm 7 HSC960 Genset Controller User Manual Table 11 SENSOR SELECTION 0 None 1Defined Resistance 2 VDO 3 SGH 4 SGD The range of Defined Resistance is 5 CURTIS 0 600090 factory default is SGX 6 DATCON 7 VOLVO EC 8 SGX 9 Reserved 0 None 1Defined Resistance 2 VDO 10bar 3 SGH 4 SGD The range of Defined Resistance is 5 CURTIS 0 600090 factory default is SGX 6 DATCON 10bar 7 VOLVO EC 8 SGX 9 Reserved 0 None 1Defined Resistance 2 SGH The range of Defined Resistance is 3 SGD 0 60009
19. e stop and 82 83 84 85 this input is active when temperature is higher than the preset value or high temperature alarm input is active controller will send warning signal only and not stop the unit Note 2 if low oil pressure inhibit is configured or set auxiliary input as inhibit low oil pressure stop and this input is active when oil pressure is lower than the preset value or low oil pressure alarm input is active controller will send warning signal only and not stop the unit Note 3 if 3P3W is selected maximum shutdown threshold of Gens Over Voltage be set as 620V when select others maximum shutdown threshold can be set as 360V HSC960 Genset Controller Version 1 0 2015 05 21 Page 25 of 37 SmartGen Table 9 Enable definition of programmable output ports Not Used Output port is deactivated when Not Used is selected Include all shutdown alarms and warning alarms When there is Common Alarm warning alarm only it is not self lock when a shutdown alarm occurs it is self lock until the alarm is reset Suitable for genset with electromagnet and will active after stop idle delay It is deactivated when the ETS Solenoid delay 2 Energized to Stop expires Used for engine which has idles Close before starting and open Idle Control in warming up delay Close during stop idle delay and open when stop is completed Close when the generator enters into Warm
20. ected When the generator frequency has Disconnect Freq 10 0 30 0 Hz 14 0 exceeded the set value starter will be disconnected 61 Disconnect OP m9 S S m f Disc Condition 9 S O1 O1 O CO HSC960 Genset Controller Version 1 0 2015 05 21 Page 23 of 37 SmartGen ideas for power 2222 5 960 Genset Controller User Manual Inhibit W TH 63 Inhibit OPL Engine Temp Curve gt Factory default High Temp Shutdown When high temperature occurs shutdown alarm is active Table8 Note1 Factory default when low oil pressure 62 occurs shutdown alarm 15 active Table8 Note2 0 3P4W 1 2P3W 2 1P2W 3 3P3W The gain is regulated during the genset is idle running 0 Indicate 1 Warn 2 Shutdown Oil Pressure Curve 7 Fuel Level Curve Generator Poles Temp S Open Action 0 OP S Open Action OD 0 Indicate 1 Warn 2 Shutdown Used to set the intermission of maintenance time 0 Negative 1 Warn 2 Shutdown N Maintenance When maintenance action is set to Negative the alarm will reset 0 Not used 1 Temp sensor 2 Pressure sensor 3 Level sensor ve Action Aux Sensor1 E Aux Sensor1 Curve Aux S 1 H Warn 0 1000 Aux S 1 H 0 1000 Shutdown 77 Aux S 1 L Warn 0 1000 Aux S 1L 0 1000 Shutdown The throttle opening before the genset 15 starting The initial opening of the throttle after Crank Disc Angle
21. f the driving stepper motor will govern the speed allowing Low Oil Pressure High Temperature Under speed Charge Alternator Failure and auxiliary inputs be configured to stabilise without triggering the fault As soon as this delay is over start idle delay is initiated if configured g During start idle delay under speed under frequency under voltage alarms are inhibited When this delay is over warming up delay is initiated if configured h After the warming up delay if generator status is normal its indicator will be illuminated If generator voltage and frequency have reached on load requirements then the generator close relay will be energized genset will take load generator power indicator will illuminate and generator will enter into Normal Running status If voltage or frequency is abnormal the controller will initiate shutdown alarm alarm information will be displayed on LCD 4 3 3 Automatic Stop Sequence a When the Remote Start signal is removed the Stop Delay is initiated b Once this stop delay has expired the Cooling Delay is then initiated Moreover the generator indicator is extinguished c During Stop Idle Delay if configured idle relay is energized d 5 Solenoid Hold delay begins ETS relay is energized while fuel relay is de energized e Fail to Stop Delay begins complete stop is detected automatically f When generator is stop completely generator is placed
22. gain will return to main interface HSC960 Genset Controller Version 1 0 2015 05 21 Page 10 of 37 SmartGen 4 2 INDICATOR LIGHT Figure 1 Indicator Light HSC960 Genset Controller Version 1 0 2015 05 21 Page 11 of 37 SmartGen 4 3 AUTO START STOP OPERATION 4 3 1 Illustration Auto mode is selected by pressing the button a LED besides the button will illuminate to confirm the operation 4 3 2 Automatic Start Sequence a When Remote Start is active Start Delay timer is initiated b Start Delay countdown will be displayed on LCD c When start delay is over preheat relay energizes if configured preheat delay XX s information will be displayed on LCD d After the above delay the Fuel Relay is energized and then one second later the throttle of the driving stepper motor will rotate as the pre set angle and then the Start Relay is engaged The engine is cranked for a pre set time If the engine fails to fire during this cranking attempt then the fuel relay and start relay are disengaged for the pre set rest period crank rest time begins and wait for the next crank attempt e Should this start sequence continue beyond the set number of attempts the start sequence will be terminated the fourth line of LCD display will be highlighted with black and Fail to Start fault will be displayed f In case of successful crank attempt the Safety On timer is activated and the throttle o
23. iliary Relay Output 2 Nr Nr Temperature 25 70 C Humidity 20 93 RH otorage Condition Temperature 25 70 C Protection Level IP55 Gasket Apply AC2 2kV voltage between high voltage terminal Insulating Intensity and low voltage terminal The leakage current is not more than 3mA within 1min Net Weight 0 56kg HSC960 Genset Controller Version 1 0 2015 05 21 Page 9 of 37 SmartGen 4 OPERATION 4 1 KEY FUNCTIONS Table 4 Button Description COL L efi tion Stop running generator in Auto Manual mode Reset alarm if alarm Stop Reset occurs During stopping process press this button again to stop generator immediately s Start genset in Manual Test mode Manual Mode Pressing this key will set the module into Manual mode Auto Mode Pressing this key will set the module into AUTO mode ra Lamp Test Pressing this key will test the lamp if it is working In manual mode it can be controlled to close In manual mode it can be controlled to open In parameter setting interface press this key will shift cursor or o Set Confirm P 9 y confirm setting value Scrolls the screen up Shift the cursor up or increase the set value in Up Increase parameter setting menu scrolls the screen down Shift the cursor down or decrease the Down Decrease value in parameter setting menu Menu Pressing this key will enter into menu interface pressing this button a
24. ill initiate a fuel pump on signal Fuel Pump On 0 100 25 HSC960 Genset Controller Version 1 0 2015 05 21 Page 22 of 37 A SmartGen Fuel Pump Off 0 100 When fuel level is higher than the pre set value and last for 10s it will initiate a fuel pump off signal a 00 WA Factory default Cooling Liquid Level Warn Factory default Close to active 0 Stop Mode pssssaetessus I 5 Am Am es Nr Nr igi igi y Digit Input2 Set 0 16 Digit Input2 Act 0 1 Digit Input2 Delay 0 20 0 s Digit Input3 Set 0 16 Digit Input3 Act 0 1 Digit Input3 Delay 0 20 0 s Digit Input4 Set 0 16 y y 3 3 3 3 4 4 4 4 4 4 4 4 4 4 Digit Input4 Act 0 1 Digit Input4 Dela 0 20 0 s Digit Input5 Set Digit Input5 Act Digit Input5 Dela Power On Mode 6 Slave Address 1 254 7 0 9999 i 0 16 0 1 6 7 8 9 0 1 4 5 6 7 8 9 50 51 52 53 54 0 20 0 s 55 0 2 1 Manual Mode 2 Auto Mode 1 Communication address of controller There are 2 conditions of disconnecting starter with engine Generating Magnetic Sensor and Oil Pressure Each condition can be used alone and simultaneously to separating the start motor and genset as soon as possible When the engine speed has exceeded Disconnect Speed 0 3000 r min 360 the value starter will disconn
25. ing Up delay close Raise Speed time warming up delay while open when Aux Raise Speed input is active Close when the generator enters into Stop Idle delay Energized Drop Speed to Stop delay close time Stop Idle delay while open when Aux Drop Speed input is active HO Generator un 4 Action when genset is normal running while deactivated when 10 Generator Run engine speed is lower than the crank disconnect speed Close when fuel level is lower than the Fuel Pump On value or when low fuel level warning input is active Open when fuel level 11 Fuel Pump Control is higher than the Fuel Pump Off and low fuel level warning input is deactivated Close when the generator enters into Warming Up delay while 12 High Speed Control 9 J P y open after cooling delay ae Resev S HSC960 Genset Controller Version 1 0 2015 05 21 Page 26 of 37 SmartGen Table 10 Defined contents of configurable input ports All active when connect to grand Bespln 0 NotUsed 2 High Temperature Input If these signals are active after safety on delay shutdown alarm Low Oil Pressure Input will be immediately initiated Warn Input Only warning and not shutdown if this input is active Shutdown alarm will be immediately initiated if this input is active When the genset is running normally and this signal is activated if there is a high temperatur
26. itiate a shutdown alarm and the alarm information will be displayed on the LCD When the controller detects that there is Low Oil Pressure input and the shutdown is allowed it will initiate a shutdown alarm and the alarm information will be displayed on the LCD When the controller detects that the generator speed has exceeded the Over Speed pre set value it will initiate a shutdown alarm and the alarm information will be displayed on the LCD When the controller detects that the generator speed has fallen below Under Speed the pre set value it will initiate a shutdown alarm and the alarm information will be displayed on the LCD When the controller detects the speed is 0 and the Loss of Speed Signal delay is NOT set as O it will initiate a shutdown alarm and the alarm information will be displayed on the LCD When the controller detects that the generator voltage has exceeded the Gen Over Volt pre set value it will initiate a shutdown alarm and the alarm information will be displayed on the LCD Gem Mer When the controller detects that the generator voltage has fallen below the pre set value it will initiate a shutdown alarm and the alarm Volt information will be displayed on the LCD When the controller detects that the generator current has exceeded the pre set value and the Overcurrent Stop Threshold delay is NOT set as 0 it will initiate a shutdown alarm and the alarm information will be displayed on the LCD If the e
27. ngine does not fire after the pre set number of attempts it will Fail To Start initiate a shutdown alarm and the alarm information will be displayed on the LCD When the controller detects that the generator frequency has exceeded Gen Over Freq the pre set value it will initiate a shutdown alarm and the alarm information will be displayed on the LCD When the controller detects that the generator frequency has fallen below the pre set value it will initiate a shutdown alarm and the alarm Freq information will be displayed on the LCD When the controller detects the generator frequency is 0 it will initiate i shutdown alarm and the alarm information will be displayed on the LCD HSC960 Genset Controller Version 1 0 2015 05 21 Page 15 of 37 Emergency Stop High Temperature Low Oil Pressure Loss of Speed Signal Gen Over Current O NO SmartGen Low Fuel Level Low Water evel Dl 16 Open 17 Oil Sensor Open Aux Sensor 5 960 Genset Controller User Manual Description When the controller detects that the fuel level is lower than the set value or there is Low Fuel Level input it will initiate a shutdown alarm and the alarm information will be displayed on the LCD When the controller detects that there is Low Water Level input it will initiate a shutdown alarm and the alarm information will be displayed on the LCD When the sens
28. or didn t connect to correct port it will initiate a shutdown alarm and the alarm information will be displayed on the LCD When the sensor didn t connect to correct port it will initiate a shutdown alarm and the alarm information will be displayed on the LCD When the genset working time has exceeded the maintain time moreover the maintain action has been set to shutdown it will initiate a shutdown alarm and the alarm information will be displayed on the LCD When the maintain action is negative the alarm resets When the Tps feedback signal failed it will initiate a shutdown alarm and the alarm information will be displayed on the LCD When the controller detects that the aux sensor has exceeded the pre set value it will initiate a shutdown alarm and the alarm information will be displayed on the LCD When the controller detects that the aux sensor has fallen below the pre set value it will initiate a shutdown alarm and the alarm information will be displayed on the LCD HSC960 Genset Controller Version 1 0 2015 05 21 Page 16 of 37 SmartGen 6 WIRINGS CONNECTION oeleleeleeleeeleelee o lolelelelieliolie 5 14 gt CRANK 16A AUX OUTPUT 7A 7A250VAC 7A250VAC 7A 250VAC CHARGER D Electronic Throttle N m n O lt lt AUX OUTPUT 3 AUX OUTPUT 4 RS485 ISOLATION CURRENT ZU16 1207
29. plays will be If there is no pressure sensor only pressure low alarm switch user must set the sensor as None otherwise maybe pressure low alarm shutdown occurs The headmost or backmost values in the vertical coordinates can be set as same as below 32 64 96 128 160192 224 2 omh Figure 3 Sensor Curve Table 13 Common unit conversion table Unt gom bar pin psi 6 89x10 7 03x10 6 89x10 HSC960 Genset Controller Version 1 0 2015 05 21 Page 31 of 37 SmartGen 10 COMMISSIONING Please make the under procedures checking before commissioning Ensure all the connections are correct and wires diameter is suitable Ensure that the controller DC power has fuse controller s positive and negative connected to start battery are correct Take proper action to prevent engine to crank disconnect e g Remove the connection wire of fuel valve If checking is OK make the start battery power on choose manual mode and controller will executive routine Set controller under manual mode press start button genset will start After the setting times as setting controller will send signal of Start Fail then press stop to reset controller 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
30. r in crank disconnect setting the rotating speed displayed in controller is calculated by generator signal HSC960 Genset Controller Version 1 0 2015 05 21 Page 29 of 37 SmartGen 8 PARAMETERS SETTING 8 1 MENU ITEMS Start the controller then MK 3 enter into the parameters setting menu see fig 1 below a Set Parameters b Information c Language 8 2 PARAMETERS SETTING When entering password interface input password 1234 can set parts of the parameter items in Form 8 and input password 0318 can set all of the parameter items in Form 8 If there is need to set more parameters e g Voltage Current Calibration please contact the factory CAUTION Please change the controller parameters when generator is in standby mode only g Crank disconnect conditions selection auxiliary input auxiliary output various delay otherwise shutdown and other abnormal conditions may happen Over voltage set value must be higher than under voltage set value otherwise over voltage and under voltage condition may occur simultaneously Over speed set value must be higher than under speed set value otherwise over speed and under speed condition may occur simultaneously Please set the generator frequency value as low as possible when cranking in order to make the starter be separated quickly as soon as possible Auxiliary input 1 5 could not be set as same items otherwise there are a
31. rm and the alarm information will be displayed on the LCD When the genset working time has exceeded the maintain time Maintain Time Over moreover the maintain action has been to alarm it will initiate a warning alarm and the alarm information will be displayed on the LCD When the controller detects that the aux sensor has exceeded the O Loss of Speed Signal Generating Overcurrent Warn Battery Under Voltage Battery Over Voltage Low Water Level N C A Co 2 Co O Aux Sensor Over pre set value it will initiate a warning alarm and the alarm information will be displayed on the LCD When the controller detects that the aux sensor has fallen below the Aux Sensor Under value it will initiate a warning alarm and the alarm information will be displayed on the LCD HSC960 Genset Controller Version 1 0 2015 05 21 Page 14 of 37 SmartGen 5 2 SHUTDOWN ALARM When controller detects shutdown alarm it will send signal to open breaker and shuts down generator Besides the alarm information will be displayed on the LCD Table 6 Shutdown alarms as following Description When the controller detects that there is Emergency Stop input it will initiate a shutdown alarm and the alarm information will be displayed on the LCD When the controller detects that there is High Temperature input and the shutdown is allowed it will in
32. set stop Maximum crank times of crank Start Attempts 1 10 times 3 attempts When reach this number controller will send start failure signal Power on time of heater plug before Pre heat Delay 0 300 s dis starter is powered up Cranking Time 3 60 s 8 Power on time of starter The waiting time before second power Crank Rest Time 3 60 s 10 k up when engine start fail Alarms for low oil pressure high temperature under speed under Safety On Delay 1 60 s 10 ed frequency voltage charge alt failure are inactive Idle running time of genset when Start Idle Time 0 3600 s 9 starting Warming Up Time 0 3600 s Js 10 Js A SmartGen When generator voltage has exceed the set value and the Gen abnormal delay has expired Over Voltage shutdown alarm is active When set the value as 620V the controller does not detect over voltage signal When generator voltage has fallen 88 7 Gens Over Volt 30 620 V below the set value and the Gen abnormal delay has expired Gen 18 Gens Under 30 620 V Under Voltage shutdown alarm 15 active When set the value as 30V the controller does not detect under voltage signal When engine speed has fallen below the set value for 10s Under Speed Under Speed 0 6000 r min 1000 4 x shutdown alarm is active It will initiate shutdown alarm signal When engine speed has exceed the set value for 2s O
33. ter no response Check starting batteries DC Motor Reverse Cross the connections of throttle and DC motor Check the speed sensor voltage is no less than 2V when GOV is out of control cranking Check the connections of throttles Check the switch Switch no action Genset OK Check the connections of controller and switch Check the connections Check the setting of COM Check the wire and wire B of RS485 is reverse or not Check the communication port of PC is broke or not Adding a 1200 resistance between port and B of 5485 of controller is commanded RS485 Communication Fail HSC960 Genset Controller Version 1 0 2015 05 21 Page 37 of 37
34. ust be 5A meanwhile the phase and voltage of common reactance must be correct otherwise the sampling current and active power may be incorrect A Note ICOM must be connected to battery controller negative pole A Note When there is load current the common reactance secondary side mustn t be open 15 5 WITHDRAW VOLTAGE TEST When controller had been installed in control panel if need the high voltage test please disconnect controller s all terminal connections in order to prevent high voltage into controller and damage it HSC960 Genset Controller Version 1 0 2015 05 21 Page 36 of 37 SmartGen 16 FAULT FINDING Table 14 finding Symptoms Possible Solutions Check starting batteries Controller no response with power Check controller connection wirings Check DC fuse Check the water cylinder temperature is too high or not Genset shutdown Check the genset AC voltage Check DC fuse Low oil pressure alarm after crank Check the oil pressure sensor and its connections disconnect High water temp alarm after crank Check the temperature sensor and its connections disconnect Check related switch and its connections according to the Shutdown Alarm in running information on LCD Check auxiliary input ports Check fuel oil circuit and its connections Check starting batteries Check speed sensor and its connections Fail to start Refer to engine manual Check starter connections otar
35. ver Speed shutdown Over Speed 0 6000 r min 4200 ia T alarm is active It will initiate a shutdown alarm signal When generator frequency has fallen below the set value but Not equal to 0 for 10s Under Frequency shutdown alarm is active It will initiate a shutdown 21 22 Gens Over Freq 0 75 0 Hz 23 Gens Under Freq 0 75 0 Hz alarm signal When generator frequency has exceeded the set value for 2s Over 68 0 Frequency shutdown alarm is active It will initiate a shutdown alarm signal When temperature of external sensor is higher than this value it will send high temperature signal This value is only judged after safety delay and only judge to temperature sensor connecting with external port When this value is 140 it will not send high temperature signal Only send signal to temperature sensor not including alarm signal of digital input port High Temperature 80 140 C mr HSC960 Genset Controller Version 1 0 2015 05 21 Page 21 of 37 SmartGen ideas for power HSC960 Genset Controller User Manual l When pressure of external sensor is lower than this value the delay will initiate This value is only judged after safety delay When this value is O it will not send low oil pressure signal Only send signal to pressure sensor not including alarm signal of digital input port When the level value is fallen below this value and last for 10s it will not send
36. y coil Rated 5A Details see installation instructions NOTE LINK interface is parameters configured interface that can be programmed by PC using an SG72 Digit 5 1 0 mm adapter HSC960 Genset Controller Version 1 0 2015 05 21 Page 19 of 37 SmartGen 7 SCOPES AND DEFINITIONS OF CONFIGURABLE PARAMETERS No Table 8 Contents and scopes of parameters Start Delay Warming time between genset switch on and high speed running Radiating time before genset stop after Cooling Time 3 3600 Stop Idle Time 0 3600 0 Idle running time when genset stop Stop electromagnets power on time 2 ETS Hold Time 0 120 s 20 4 ed when genset is stopping Time between ending of genset idle delay and stopped when ETS time is 13 Fail to Stop 0 120 s set as 0 Time between ending of ETS hold delay and stopped when ETS time is not O When it is 0 means output constantly Tooth number of the engine for judging of starter crank disconnect conditions Flywheel Teeth 1 300 118 l and inspecting of engine speed See the installation instructions GenVolt The alarm delay of generator over 16 0 20 0 s 10 0 y 9 9 AbnormTime voltage and under voltage HSC960 Genset Controller Version 1 0 2015 05 21 Page 20 of 37 7707 Time from remote start signal is active 0 3600 s 1 to start genset Time from remote start signal is Stop Delay 0 3600 s deactivated to gen
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