User Manual
Contents
1. 11 13 OVERALL DEMENJPNSWREE 11 HGM160 160HC Control Module ISSUE 2011 12 22 Version 2 2 Page 3 of 11 HGM160 160HC Generator Control Module 1 SUMMARY HGM160 160HC 1 an engine control module designed to start and stop the engine via a key switch and pushbuttons on the front panel When detecting faults low oil pressure high water cylinder temperature auxiliary alarm over speed it will disconnect fuel relay and energize to stop LED annunciator displays the faults which can offer real and effective alarm information HGM160HC adds hours counter based on HGM160 other functions are as the same 2 PERFORMANCE AND CHARACTERISTICS Wide range of DC supply With low oil pressure high water cylinder temperature over speed protection and indication With charge failure warning An auxiliary shutdown alarm signal Speed signal comes from generator frequnecy LED displays various alarm states Built in dial switch to select iii 50Hz 60Hz frequency SOH See the picture With ETS function Modular structure design ABS plastic case plug in installation compact structure with small volume advanced SCU control stable performance and convenient operation 3 SPECIFICATION Working Voltage DC8 0V to 35 0V continuous Standby 12V 0 12W 24V 0 24W Power Consumption Working 12V 0 5W 24V 1W Alternator Voltage Inpu2. Garman When over speed temperature high pressure low auxiliary shutdown alarm and HGM160 160HC Control Module ISSUE 2011 12 22 Version 2 2 Page 5 of 11 HGM160 160HC Generator Control Module fail to start and fail to stop alarms occur it flashes Genset accumulated run hours Max 99999 9 Hours Counter 4 2 Descriptions of Working Modes Stop Position O 1 During genset normal running turn the key to stop position fuel relay disconnects and is energized to stop 2 When a fault alarm occurs turn the key to stop position to remove the alarm 3 When genset at rest turn key to stop position controller will be in low power consumption standby mode 4 Press stop least 1 ETS output Once release this button ETS output is disconnected Manual Position 5 Turn the key to manual position preheat outputs After crank disconnect preheat output is inhibited 6 Turn the key to manual position Press Okey after fuel outputs 1second starter is energized to output and engine cranks When gens frequency is over 15Hz or start key is released starter is de energized and crank disconnect 7 If crank disconnect signal is not detected press stop keyDat least 1 second ETS output Once release this button ETS output is disconnected 8 If crank disconnect signal is detected press stop least 1 second ETS disconnects after Output 30s or disconnects a
3. 5 HGM160 160HC Automatic Generator Control Module User Manual Smartgen Technology HGM160 160HC Generator Control Module Smartgen Smartgen Technology Co Ltd No 28 Jinsuo Road Zhengzhou Henan Province P R China Tel 0086 37 1 67988888 6 7981888 0086 371 67991553 67992951 67992952 0086 371 67981000 National Free Tel 4000318139 Fax 0086 371 67992952 67981000 Web http Awww smartgen com cn http www smartgen cn Email sales smartqen com 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 hechnology at the address above Any reference to trademarked product names used within this publication is owned by their respective companies Smartgen Technology reserves the rightto change the contents of this document without prior notice Software Version 2006 11 02 Original release 2010 06 30 Change over speed time from 3s to 1 5s 2011 06 13 24 Change pame of the company Smartgen electronics to Smartgen Technology Modify Typical Application Correct the descriptions of Preheat key HGM160 160HC Control Module ISSUE 2011 12 22 Version 2 2 Page
4. Check starting battery 11HGM170RE RELAY EXPANSION MODULE HGM170RE is modular structure which can be fixed various guides with compact structure small size and easy installation Expansion circuits output Crank not disconnect 1 Fuel relay 30A output voltage B coil powers0 9W 2 Start relay 30A output voltage B coil powers0 9W Stop relay 30A output voltage B coil powers0 9W 4 Auxiliary relay 30A passive output coil powers0 9W Terminals Description items gt o Description Start relay control connect to ground Start relay output B output Fuel control connect to ground battery positive Battery negative FUEL OUT Fuel relay output B output Battery negative GND AUX CTRL Auxiliary relay control connect to ground AUX OUT1 1 AUX OUT Auxiliary relay output free contact normally opens 2 STOP CTRL Stop relay control connect to ground 6 8 Stop relay output B output _9_ HGM160 160HC Control Module ISSUE 2011 12 22 Version 2 2 Page 10 of 11 HGM160 160HC Generator Control Module 12TYPICAL WIRING DIAGRAM Generator 5 r a a a F 2A 5 pa Al i 5 z 4 Be 10 HGM160 CONTROLLER 13 FUEL OUT Preheat STOP OUT DC32V30A AUX1 OUT DC32V 30A AC250V 30A AUX2 OUT 13OVERALL DEM EMONS OF 70 46 Note When ordering please specify 1
5. 2 of 11 HGM160 160HC Generator Control Module CONTENTS Y u Oe 4 2 PERFORMANCE AND CHARACTERISTICS 4 BS PECIFIC ANION asa us 4 4 PANELZOPERA TION 5 A1 Keys ICOM u 5 4 2 Descriptions Of Working Modes 6 5 ALARM AND PROTEC TION 6 lt 7 7 COMMISSIONING m 7 7 8 TYPICAL APPLICATION 8 9 CASE DIMENSIONS Panel Cutout 78 2 9 9 1 Battery Voltage 9 9 2 Output and Expansion Relay 2 9 9 3 Withstand Voltage 9 10 FAULT P SRK NE uyu L uuu uuu u u uuu uu 9 11 HGM170RE RELAY 10 12 TYPICAL WIRING DIAGRAM
6. 2V or 24V HGM160 160HC Control Module ISSUE 2011 12 22 Version 2 2 Page 11 of 11
7. et will start After the setting times controller will send fail to start signal press stop key to reset the controller 6 Recover the action of stop engine start e g Connect wire of fuel valve press start button again genset will start If everything goes well genset will enter into normal running During this period please watch for engine s running situations and AC voltage and frequency If abnormal stop genset running and check all connections according to this manual 7 lfthere are any other questions please contact Smartgen s service 8 TYPICAL APPLICATION LC S 3 Alternator 2 F 2A s N 10 14 HGM160 CONTROLLER ee TT Preheat Output Stop Output HGM160 160HC Control Module ISSUE 2011 12 22 Version 2 2 Page 8 of 11 HGM160 160HC Generator Control Module 9 CASE DIMENSIONS Panel Cutout 78 mm 66mm 9 High Engine Temp Input 8 Low Oil Pressure Input 7 Alternate Charger WL D 6 Aux Shutdown Input 5 Gens L A NC Gens N 2 ES Stop Output Bi 2061 0907 72mm N iE N Wm w N ig N m s i 77mm 84mm 9 1 Battery Voltage Input HGM160 160HC be applicable to range of 8 35 VDC battery voltage battery negative must be reliability connected to engine shell The connection of controller power supply and B to battery poles sh
8. fter genset at rest for 10 seconds 5 ALARM AND PROTECTION gt Low Oil Pressure After crank disconnect detecting begins after delay 10s Alarm to shutdown gt High Temperature After crank disconnect detecting begins after delay 10s Alarm to shutdown gt Over Speed Detect when crank disconnect Over speed lasts for 1 5s alarm to shutdown gt Charge failure Detect after start delay 10s Warn not shutdown gt Auxiliary Stop Alarm Detect in Manual position do not detect in stop position Alarm to shutdown HGM160 160HC Control Module ISSUE 2011 12 22 Version 2 2 Page 6 of 11 HGM160 160HC Generator Control Module gt Fail to Start under normal condition fail to start within 3 times gt Fail to Stop Stop signal has initiated for 30s but genset not stop gt Common Alarm when over speed high temperature low OP auxiliary stop alarm fail to Start fail to stop alarm occur alarm annunciator will illuminate When controller sends the alarm pressing stop reset the alarm Note When charge failure occurs pressing will stop the engine 6 CONNECTIONS Terminals description 1 DC Power Supply B Connect to start battery negative Connect to start battery positive If more than 30 DC Power Supply B meter use 2 wires to parallel Recommended 20A fuse 3 Fuel Relay Output Fuel output B external connect to fuel relay 4 Start Relay Output Start output B external connect to sta
9. ould not be less than 2 5mm if float charger is fitted please directly connect the charger output wire to battery poles and then separately connect the wirings from the battery poles to the power supply output of the controller in case that the charger_will interfere with the normal operation of the controller 9 2 Output and Expansion Relay All output of the controller is relay contacts output if there is need to expand output relays please expand follow current diode in both ends of the relay coil when extended relay coil links DC or increase resistance and capacitance loop when extended relay coil links AC inorder to prevent interference with the controller or other equipments 9 3 Withstand Voltage Test When the controller has been installed in the control panel if you want to have withstand voltage test please disconnect all terminals in the controller lest high voltage damages the controller 10 FAULT FINDING Check starting batteries Check controller connection wirings Check DC fuse Controller no response with power HGM160 160HC Control Module ISSUE 2011 12 22 Version 2 2 Page 9 of 11 HGM160 160HC Generator Control Module Check if the engine temperature Is too high Genset shutdown Check the genset AC voltage Check DC fuse crank disconnect after crank disconnect Check fuel circuit and its connections Check starting battery Check speed sensor and its connections Refer to engine manual
10. rt relay Pre Heat Output 15mm Pre heating output If engine has fired pre heat is disabled ar Connect to ground Charge Connect to alternator WL D terminal When Input Charge fails the indicator on the front panel will illuminate indication only not shutdown Oil pressure signal input Active when connect to Detection Input to GND Enabled after delay 10s Input detecting crank disconnect and speed protection NC External connect to ALT N phase volt output for 12 Gens Neutral Input detecting crank disconnect and speed protection 13 ETS Output gt When stop signal is initiated after outputting 30s P or genset al rest it will disconnect NC 7 COMMISSIONING Please make the under procedures checking before commissioning 1 Check all the connections are correct and wires diameter is suitable 2 Ensure that the controller DC power has insurance controller s positive and negative HGM160 160HC Control Module ISSUE 2011 12 22 Version 2 2 Page 7 of 11 HGM160 160HC Generator Control Module connected to start battery are correct 3 Auxiliary alarm input is connected to start battery negative via normal close contact of emergency stop button and insurance 4 Take proper action to prevent engine to crank disconnect e g Remove the connection wire of fuel valve If checking is OK energize start battery 5 Set controller into Manual mode press start button gens
11. t 15VAC VA h N Pow C 360VAC ph N Alternator Rated Freq 50 60Hz Over Speed Freq 114 of rated freq Condition Crank Disconnect 1Amp DC28V relay output GND 1 DC28V relay output GND HGM160 160HC Control Module ISSUE 2011 12 22 Version 2 2 Page 4 of 11 Generator voltage 215VAC and frequency 215Hz HGM160 160HC Generator Control Module Temperature 30 70 Humidity 20 90 Temperature 40 80 C IP55 when waterproof rubber gasket added between controller and its panel IP42 when waterproof rubber gasket not added between controller and its panel Object among input output power Insulation Intensity Quote standard IEC688 1992 Test way AC1 5kV 1m 3mA leakage current Protection Level 4 PANEL OPERATION 4 1 Keys and Icons gt keys Can stop the running genset Can reset alarm when an alarm occurs Stop Reset In Stop Mode pressing this key at least 3s can test panel indicators Lamp Test Manual In Manual Mode pressing this key can start genset In Stop Mode this key is inactive Preheat In Manual Mode press this key to output preheat signal In Manual Mode and Stop Mode this key is active Icons L High Temperature When engine stops for high temperature illuminates When engine stops for low oil pressure illuminates Over Speed When engine over speed it illuminates Charge Failure When engine failed to charge it illuminates
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